Note: Descriptions are shown in the official language in which they were submitted.
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Tobacco constituent releasing components
Technical Field
The invention relates to tobacco constituent releasing components for
inclusion in an
aerosol provision device, such as an apparatus for heating smokeable material
to
volatilise at least one component of the smokeable material, the tobacco
constituent
releasing component including tobacco particles, optionally in an agglomerated
structure. The invention also relates to apparatus including the tobacco
constituent
releasing components and to methods of manufacturing the tobacco constituent
io releasing components.
Background
Smoking articles such as cigarettes, cigars and the like burn tobacco during
use to
create tobacco smoke. Attempts have been made to provide alternatives to these
/5 articles by creating products that release compounds without combusting.
Examples of
such products are so-called "heat not burn" products or tobacco heating
devices or
products, which release compounds by heating, but not burning, smokeable
material.
It is also known to include flavours in smoking articles to add specific
desirable flavours
20 to the aerosol generated by the smoking article. This has been achieved
in a variety of
different ways, including the use of crushable capsules that contain flavour
compositions.
Summary
25 According to a first aspect of the invention, there is provided a
tobacco constituent
releasing component for inclusion in an aerosol provision device, the tobacco
constituent releasing component having an agglomerated structure formed from a
precursor composition comprising tobacco particles, wherein the pH of the
precursor
composition has been adjusted to a basic pH.
In some embodiments the pH is increased by the addition of one or more bases
or a
basic buffer system.
Alternatively, there is provided a tobacco constituent releasing component for
inclusion
in an aerosol provision device, the tobacco constituent releasing component
comprising
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tobacco particles and one or more bases or a basic buffer system, the tobacco
constituent releasing component having a basic pH.
In some embodiments the one or more base is selected from the group consisting
of
hydroxides, carbonates and hydrogen carbonates. In some embodiments the one or
more base is selected from the group consisting of: potassium hydroxide,
sodium
hydroxide, sodium carbonate and sodium bicarbonate.
In some embodiments the pH of the precursor composition is at least about 7.5.
In some embodiments the tobacco particles have an average diameter no greater
than
3 mm, no greater than 1 mm, no greater than 0.5 mm, or no greater than 0.3 mm.
In some embodiments one or more aerosol forming agent is included. In some
is embodiments the aerosol forming agent is selected from the group
consisting of
glycerol, propylene glycol and glyceryl triacetate.
In some embodiments one or more binder is included. In some embodiments the
one
or more binder is selected from the group consisting of: thermoreversible
gelling
.. agents, such as gelatin; starches; polysaccharides; pectins; celluloses;
cellulose
derivatives, such as carboxymethylcellulose; and alginates.
In some embodiments one or more flavour-modifier is included.
In some embodiments the precursor composition is granulated or spheronised to
form
the agglomerated structure.
In some embodiments the precursor composition is extruded to form the
agglomerated
structure.
In some embodiments the components are in the form of granules.
In some embodiments the components have an elongated or rod-shaped form.
In some embodiments the components have a cross sectional shape to increase
the
surface area of the tobacco constituent releasing component.
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According to a second aspect of the invention, there is provided an aerosol
provision
device comprising a tobacco constituent releasing component according to the
first
aspect of the invention.
In some embodiments the device is a tobacco heating product comprising a
tobacco
segment which is to be heated to volatilise constituents, and optionally
including a filter
or filter element.
In some embodiments the device is a Hybrid product comprising a tobacco
segment
which is to be heated to volatilise constituents, and a liquid which is to be
heated to
form a vapour, and optionally including a filter or filter element.
In some embodiments the tobacco constituent releasing component is located in
a filter
/5 or filter element of the device. In some embodiments one or more tobacco
constituent
releasing components are surrounded by filter material in the filter or filter
element. In
other embodiments one or more tobacco constituent releasing components are
located
in a cavity of a multi-segment filter.
In some embodiments one or more tobacco constituent releasing components are
located in the tobacco segment. In some embodiments the tobacco segment
consists of
one or more tobacco constituent releasing components.
In some embodiments the device is a Hybrid product comprising a tobacco
segment
which is to be heated to volatilise constituents, and a liquid which is to be
heated to
form a vapour, wherein one or more tobacco constituent releasing components
are
located in the tobacco segment and wherein the tobacco segment is heated by
the
vapour. In some embodiments, the liquid is a nicotine-free liquid. In some
embodiments, the device includes a means for heating the liquid to form a
vapour, but
does not include a separate means for heating the smokeable material.
According to a third aspect of the invention, there is provided a method of
manufacturing a tobacco constituent releasing component, comprising preparing
a
precursor composition comprising tobacco particles; adjusting the pH of the
precursor
composition to a basic pH; and treating said precursor composition to form an
agglomerated structure.
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In some embodiments the precursor composition is granulated or spheronised to
form
the agglomerated structure.
In some embodiments the precursor composition is extruded to form the
agglomerated
structure. In some embodiments the extruded agglomerate is cooled during or
after
extrusion. In some embodiments the extrusion creates inner channels within the
extruded agglomerate.
io According to a fourth aspect of the invention, there is provided an
apparatus for heating
smokeable material to volatilise at least one component of the smokeable
material, and
a nicotine-free liquid which is to be heated to form a vapour, wherein the
smokeable
material comprises tobacco particles having a basic pH, and wherein the
smokeable
material is heated by the vapour.
In some embodiments the apparatus includes a means for heating the liquid to
form a
vapour, but does not include a separate means for heating the smokeable
material.
In some embodiments the pH is increased by the addition of one or more bases
or a
basic buffer system.
In some embodiments the pH of the tobacco particles is at least about 7.5.
In some embodiments the tobacco particles have an average diameter no greater
than
3 mm, no greater than 1 mm, no greater than 0.5 mm, or no greater than 0.3 mm.
Brief Description of the Drawings
Embodiments of the invention will now be described, by way of example only,
with
reference to accompanying drawings, in which:
Figure 1 is a flow chart showing key steps of a process according to
embodiments of the
present invention;
Figures 2a, 2b and 2c show examples of nozzle designs for forming extruded
agglomerates having inner channels, whilst Figures 2d and 2e show how such
nozzles
may be used to shape the extruded agglomerates;
Figure 3 is a photograph of some extruded agglomerates, showing different
cross-
sectional geometries forming inner channels;
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Figure 4a shows an example of a die used to produce granules by extrusion,
whilst
Figure 4h shows how such a die may be used to form the extruded agglomerates;
Figure 5 is a schematic representation of some extruded granules;
Figure 6 is a schematic cross-sectional view of a tobacco heating product for
heating
smokeable material to volatilise at least one component of the smokeable
material
including a tobacco constituent releasing component;
Figure 7 is a schematic view of a Hybrid device for heating smokeable material
to
volatilise at least one component of the smokeable material including a
tobacco
constituent releasing component; and
/o Figure 8 is a schematic cross-sectional view of an example of a
cartridge containing
multiple tobacco constituent releasing components.
Detailed Description
The invention relates to tobacco constituent releasing components that are
formed
/5 from tobacco particles. These components are able to release tobacco
constituents
including flavours and nicotine, for example when heated.
At least some of the released constituents are directly derived from the
tobacco
particles used to form the components. In some embodiments, further materials
may
20 be added to the components for release. These further materials may, for
example, also
comprise tobacco constituents added to supplement those directly derived from
the
tobacco particles. Alternatively or in addition, the further materials added
to the
components for release may not be derived from tobacco. For example, the
components may also, in some embodiments, carry and release other flavours,
25 including those not derived from tobacco.
In some embodiments, the tobacco constituent releasing components are
agglomerated
structures. This means that they are a mass or cluster formed by fusing or
adhering
multiple particles to one another. The constituent particles include tobacco
particles.
30 In some embodiments, particles of other materials may also be included.
pH adjustment
In some embodiments, the agglomerated structures are formed from a precursor
composition comprising tobacco particles, wherein the pH of the precursor
35 composition has been adjusted to a basic pH. For example, the pH may be
adjusted to
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at least about 7.5. The pH may be adjusted by the addition of one or more
bases.
Alternatively, the pH may be adjusted by the use of a buffer solution.
In some embodiments, the tobacco constituent releasing component comprises
tobacco
particles and one or more bases or a basic buffer system, so that the tobacco
constituent
releasing component has a basic pH. For example, the pH may be at least about
7.5.
The purpose of adjusting the pH of the tobacco particles and/or of the
precursor
composition is to provide the tobacco constituents in a chemical form which
means that
io they are readily released from the releasing component, and/or they are
readily
transferred to the aerosol generated by the smoking article. Adjusting the pH
of
tobacco changes the natural balance of those acid-base reactions that bind
certain
classes of chemicals within the tobacco. For example, in natural tobacco leaf,
nicotine
tends to bind with organic acids that are present in the leaf and hence is
more stable
is and less likely to volatilise when exposed to mild heat. If the pH of
the leaf is raised,
this reduces the nicotine's natural association with the acids. Such unbound
of "free"
nicotine is more volatile. The same principle applies to other chemical
equilibria within
tobacco.
20 In some embodiments, the pH of the precursor composition is adjusted to
at least about
7.5, at least about 8, at least about 8.5, at least about 9, at least about
9.5 or at least
about 10. In some embodiments, the pH is adjusted to no higher than about 14,
no
higher than about 13.5, no higher than about 13, no higher than about 12.5, no
higher
than about 12, no higher than about 11.5, no higher than about 11, no higher
than about
25 10.5 or no higher than about 10. In some embodiments, the pH of the
precursor
composition is adjusted to from about 8 to about 10, or from about 8.5 to
about 9.5.
In some embodiments, the pH of the tobacco constituent releasing component is
at
least about 7.5, at least about 8, at least about 8.5, at least about 9, at
least about 9.5 or
30 at least about 10. In some embodiments, the pH is no higher than about
14, no higher
than about 13.5, no higher than about 13, no higher than about 12.5, no higher
than
about 12, no higher than about 11.5, no higher than about 11, no higher than
about 10.5
or no higher than about 10. In some embodiments, the pH of the tobacco
constituent
releasing component is adjusted to from about 8 to about 10, or from about 8.5
to about
35 9.5.
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In some embodiments, the pH is adjusted to from about 7.5 to about 10, or from
about
8 to about 9, or to about 8.5, about 9, about 9.5 or about 10.
In some embodiments, the base used to adjust the pH is a hydroxide or a
carbonate.
Hydroxides used may be monoacidic bases, diacidic bases or triacidic bases.
Suitable
bases include, for example, potassium hydroxide, calcium hydroxide, silver
hydroxide,
ammonium hydroxide, magnesium hydroxide, sodium carbonate, sodium bicarbonate
(also known as sodium hydrogen carbonate), and potassium carbonate.
/o The base may be added to the precursor composition in the form of a
liquid, such as an
aqueous or non-aqueous solution or suspension, or in the form of a solid, such
as a
powder.
The precursor composition comprises a mixture of tobacco particles and a pH
adjuster.
/5 In embodiments where the tobacco particles and pH adjuster are dry, for
example
where the base is in the form of a dry powder, the pH of the precursor
composition will
be adjusted (compared to the pH of the tobacco particles without the pH
adjuster) once
water is added to the composition.
20 As used herein, the pH of the precursor composition or of the tobacco
constituent
releasing component refers to the pH once water is added to the composition or
component where the composition or component is dry.
In some embodiments, the buffer system used to adjust the pH is a mixture of a
weak
25 base and its conjugate acid. Suitable buffer systems include, for
example, ones having a
pH of at least about 7.5, at least about 8, at least about 8.5 or at least
about 9. In some
embodiments, the pH of the buffer system is from about 8 to about 10, or from
about
8.5 to about 9.5. Suitable buffer systems include, for example, those based on
ammonia, carbonates or hydroxides, with suitable counterions. An example of a
30 specific buffer system is a mixture of ammonia and ammonium chloride.
Tobacco particles
The tobacco particles present in the precursor composition have a size small
enough to
ensure that multiple such particles can be agglomerated to form tobacco
constituent
35 releasing components having desired dimensions based upon their intended
use.
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Smaller tobacco particles have a greater surface area to volume ratio and they
may
therefore exhibit enhanced release of tobacco constituents compared to
particles of
larger sizes.
In addition, the size of the tobacco particles (and of other particles in the
precursor
composition) will have an effect on the porosity and density of the
agglomerated
structures and tobacco constituent releasing components. Thus, the size of the
tobacco
particles may be selected to produce a more porous agglomerated structure,
which will
have an impact on the release of the tobacco constituents. Thus, the size of
the tobacco
/o particles is another factor that may be adjusted in order to influence
the release of
tobacco constituents, in particular where the agglomerated structure is made
by
granulation as opposed to extrusion.
The preferred size of the tobacco particles may also depend upon the method
used to
/5 form the agglomerated structures. For example, extrusion processes can
be sensitive to
the size of the particles within the composition being extruded. Specifically,
in some
embodiments where the precursor composition is extruded to form the
agglomerated
structure, it may be desirable for the particles in the precursor composition,
including
the tobacco particles, to have an average particle size of no greater than
about 3 mm, of
20 no greater than 1 mm, of no greater than about 0.5 mm, or to have an
average particle
size of no greater than about 0.3 mm, when measured by sieving.
In some embodiments, it may be desirable for the tobacco particles in the
precursor
composition and/or in the tobacco constituent releasing component to have an
average
25 particle size of no greater than about 3 mm, of no greater than 1 mm, of
no greater than
about 0.5 mm, or to have an average particle size of no greater than about 0.3
mm,
when measured by sieving. In some embodiments, the average particle size is
within
the range of about 0.1 to about 3 mm, of about 0.1 to about 1 mm, of about 0.1
to about
0.5 mm, of about 0.1 to about 0.4 mm, or in the range of about 0.2 to about
0.3 mm. In
30 some embodiments, at least about 90% of the particles of the precursor
composition
will have a particle size within the range of about 0.1 to about 3 mm, or of
about 0.1 to
about 1 m, or of about 0.1 to about 0.5 mm. In some embodiments, at least
about 90%
of the tobacco particles of the precursor composition will have a particle
size within the
range of about 0.1 to about 3 mm, or of about 0.1 to about 1 mm, or of about
0.1 to 0.5
35 mm. In some embodiments, none of the particles in the precursor
composition have a
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particle size greater than 5 mm, greater than 4 mm, greater than 2 mm, greater
than 1.5
mm, or greater than about 1 mm.
Particles of the desired size may be formed by grinding, shredding, cutting or
crushing
tobacco material. Suitable machinery to create such tobacco particles
includes, for
example, shredders, cutters, or mills, such as hammer mills, roller mills or
other types
of commercially available milling machinery. The size of the tobacco particles
is
selected to provide particles which can be readily prepared from a variety of
different
types of tobacco material, which can be formed into agglomerated structures
using the
/o processes described herein and having the properties described herein,
and which
provide a source of tobacco constituents that are readily released.
Without wishing to be bound by any one particular theory, it is speculated
that the
chopping of the tobacco to form the tobacco particles enhances the release of
tobacco
/5 constituents including volatile flavours and aromatic constituents, as
well as nicotine.
The increased surface area of the tobacco particles is also thought to aid
volatilisation.
The smaller tobacco particles also improve the homogeneity of agglomerated
structures
formed therefrom together with other components.
20 The tobacco material used to form the tobacco particles may be any type
of tobacco and
any part of the tobacco plant, including tobacco lamina, stem, stalk, ribs,
scraps and
shorts or mixtures of two or more thereof. Suitable tobacco materials include
the
following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental
tobacco, or
blends of tobacco materials, optionally including those listed here. The
tobacco may be
25 expanded, such as dry-ice expanded tobacco (DIET), or processed by any
other means.
In some embodiments, the tobacco material may be reconstituted tobacco
material.
The tobacco may be pre-processed or unprocessed, and may be, for instance,
solid
stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any
combination thereof. The tobacco material may be fermented, cured, uncured,
toasted,
30 or otherwise pre-treated.
Additional components of precursor composition
The tobacco constituent releasing components having an agglomerated structure
are
formed from a precursor composition comprising tobacco particles.
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In some embodiments, the precursor composition and/or the tobacco constituent
releasing component does not include a binder or binding additive. In other
embodiments, the precursor composition comprises a binder or binding additive.
The
binding additive may be selected to assist in the formation of an agglomerated
structure
by helping to adhere the tobacco particles to each other and to other
components in the
composition. Suitable binding additives include, for example, thermoreversible
gelling
agents such as gelatin, starches, polysaccharides, pectins, alginates, wood
pulp,
celluloses, and cellulose derivatives such as carboxymethylcellulose.
io In some embodiments, the precursor composition and/or the tobacco
constituent
releasing component further comprises a diluent. The diluent may be in solid
or liquid
form. In some embodiments, the diluent is inert or substantially inert.
In some embodiments, the agglomerated structure formed from the precursor
is composition may have an increased surface area by including in the
precursor
composition particles of an inert filler material. Suitable inert fillers may
be porous or
non-porous.
In some embodiments, the precursor composition and/or the tobacco constituent
20 releasing component further comprises at least one aerosol forming agent
which may
be, for instance, a polyol aerosol generator or a non-polyol aerosol
generator, preferably
a non-polyol aerosol generator. It may be a solid or liquid at room
temperature, but
preferably is a liquid at room temperature. Suitable polyols include sorbitol,
glycerol,
and glycols like propylene glycol or triethylene glycol. Suitable non-polyols
include
25 monohydric alcohols, high boiling point hydrocarbons, acids such as
lactic acid, and
esters such as diacetin, triacetin, triethyl citrate or isopropyl myristate. A
combination
of aerosol forming agents may be used, in equal or differing proportions.
Glycerol and
propylene glycol are particularly preferred.
30 In some embodiments, the the precursor composition and/or tobacco
constituent
releasing components may include a flavour-modifier, to modify the flavour
provided
by the tobacco particles or to add flavour. In some embodiments, the flavour-
modifier
may be included in the precursor composition. Alternatively or in addition,
the flavour-
modifier may be added to or applied to the agglomerated structure. Flavour-
modifiers
35 include, for example, casing materials, as well as "flavour" and
"flavourant" materials
which, where local regulations permit, may be used to create a desired taste
or aroma in
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a product for adult consumers. They may include extracts (e.g., licorice,
hydrangea,
Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol,
Japanese
mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple,
Drambuie,
bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery,
cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil,
vanilla,
lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage,
fennel,
piment, ginger, anise, coriander, coffee, or a mint oil from any species of
the genus
Mentha), flavour enhancers, bitterness receptor site blockers, sensorial
receptor site
activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose,
acesulfame
potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose,
fructose,
sorbitol, or mannitol), and other additives such as charcoal, chlorophyll,
minerals,
botanicals, or breath freshening agents. They may be imitation, synthetic or
natural
ingredients or blends thereof. They may be in any suitable form, for example,
oil,
liquid, gel, wax or powder.
In some embodiments, the precursor composition and/or the tobacco constituent
releasing component further comprises a preservative. Suitable preservatives
would be
readily known to the skilled person and would include, for example, those that
are safe
for use in products producing inhalable aerosols. Examples of preservatives
that might
be used include: propylene glycol, carvacrol, thymol, L-menthol, 1,8-cineole,
phenoxyethanol, PhytoCide, sorbic acid and its salts, sodium
hydroxymethylglycinate,
ethylhexylglycerin, parabens and vitamins such as vitamin E or vitamin C.
In some embodiments, neither the precursor composition nor the tobacco
constituent
releasing component includes a gelling agent.
Form of agglomerated structures
In some embodiments, the tobacco constituent releasing components are in
particulate
form, being small, separate particles. In most embodiments, multiple particles
will be
incorporated into an apparatus in order to have the desired effect on the
aerosol of the
apparatus.
In some embodiment, the particulate tobacco constituent releasing components
have
an average size (as measured by sieving) of from about 0.5 mm to about 4 mm.
In
some embodiments, it may be preferable for the granules to have an average
size of
from about 0.7 mm to about 3 mm. Where, for example, the granules are to be
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dispersed within the filter material of a filter element (as in a Dalmatian
style filter
element), it may be preferable for the granules to have an average size of
from about 0.3
mm to about 1 mm. Where, for example, the granules are to be included in a
cavity,
such as a cavity within a filter, it may be preferable for the granules to
have an average
size of from about 0.5 mm to about 4 mm.
In other embodiments, the tobacco constituent releasing components are in
monolithic
form, being larger articles. In most embodiments, a single monolithic
component will
be incorporated into an apparatus in order to have the desired effect on the
aerosol of
io the apparatus.
In some embodiments, the monolithic components are roughly spherical or
cylindrical
in shape. They may have a diameter of from about 4 mm to about 10 mm. In some
embodiments, the diameter may be from about 5 mm to about 8 mm. Cylindrical
/5 components may additionally have a length of from about 5 mm to about 80
mm, from
about 15 mm to about 50 mm, or from about 20 mm to about 30 mm.
Forming the agglomerated structures
Figure 1 is a flow chart showing the key steps in the processes of the present
invention.
20 The tobacco starting material, which may be pre-treated or pre-
processed, is ground to
the desired particle size. The pH is adjusted, either by adding one or more
bases or by
adding a buffer solution to the tobacco particles. Any additional components
may be
added to the tobacco material. These additional components may be in liquid
form or
is solid form. Additional solid components are preferably in particulate or
powder
25 form. The additional components may be added before, during or after the
pH
adjustment step. An agglomerated structure is then formed from the resultant
precursor composition, by adhering the pH-adjusted tobacco particles and
optional
other components to form multi-particle entities.
30 In some embodiments, water may be added to the precursor composition as
a
processing aid. For example, the presence of water may help to dissolve
components of
the precursor composition, such as the pH adjusting agent and sugars, and/or
it may
assist with binding or improve agglomeration.
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In some embodiments, the agglomerated structure may be formed from the
precursor
composition by a process including one or more steps selected from the group
consisting of granulation, extrusion and spheronisation.
Granulation
Granulation of the precursor composition involves the binding or fusing
together of the
particles of the precursor composition to form larger, multi-particle entities
which are
referred to herein as agglomerated structures. The multi-particle entities
formed by
granulation are called granules and they may have various geometric shapes,
including,
/o for example, the general form of spheres, cylinders, and the like.
In one embodiment, the granulation step used is wet granulation. In wet
granulation,
granules are formed by the addition of a granulation liquid onto a powder bed.
Agitation in the system, along with the wetting of the components within the
precursor
/5 composition, results in the aggregation of the particles to produce wet
granules. The
granulation liquid may be at least partially removed by drying to provide dry
granules.
The granulation liquid may be water-based or solvent-based. Suitable
granulation
liquids include, for example, water, glycerol, ethanol and isopropanol, either
alone or in
combination. In some embodiments, the granulation liquid comprises an aerosol
20 forming agent, such as glycerol or one of the other agents mentioned
herein, and/or a
binder or binding agent. In some embodiments, no water is added to the
precursor
composition to aid granulation.
In another embodiment, the granulation step used is dry granulation. In dry
25 granulation, granules are formed without using a granulation liquid.
This type of
process has the advantage that it does not expose the precursor composition to
moisture and so there is no requirement to expose the granules to heat in
order to dry
them. Forming granules by dry granulation involves compacting and densifying
the
precursor composition, usually under high pressure.
Extrusion
Extrusion of the precursor composition involves the feeding of the precursor
composition through an orifice to produce an extruded agglomerate. The
process,
which applies pressure to the precursor composition combined with shear
forces,
results in agglomerated structures.
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Extrusion may be performed using one of the main classes of extruders: screw,
sieve
and basket, roll, ram and pin barrel extruders. A single screw or twin screw
extruder
may be used. Forming the tobacco constituent releasing components by extrusion
has
the advantage that this processing combines mixing, conditioning, homogenizing
and
molding of the precursor composition.
In some embodiments, during extrusion the free-flowing precursor composition
is
exposed to elevated pressure and temperature and is forced though an orifice,
such as a
shaping nozzle or die, to form an extruded agglomerate. In some embodiments,
the
/o extruded agglomerate has a rod-like form and/or it may be cut into
segments of a
desired length as it exits the orifice. A rod-like extruded agglomerate may
subsequently
be cut into segments of desired length.
In some embodiments, the precursor composition comprising tobacco particles is
/5 exposed to temperatures from about 4.0 C to about 150 C, or from about
80 C to about
130 C, or from about 60 C to about 95 C within the extruder. In some
embodiments,
including those using double extrusion, the precursor composition is exposed
to
temperatures from about 70 C to about 95 C within the extruder. In some
embodiments, including those using single extrusion, the precursor composition
is
20 exposed to temperatures from about 60 C to about 80 C within the
extruder. The
composition may be exposed to pressures (immediately before the die or nozzle)
ranging from about 2 bar to about loo bar, or from about 5 bar to about 60
bar,
depending on the design of the die or nozzle being used.
25 In some embodiments, due to the relatively high density of the extruded
agglomerate
and the relatively open surface of the tobacco particles within it, the
tobacco constituent
releasing components formed from the extruded agglomerate exhibit good heat
transfer
and mass transfer, which has a positive impact on the release of tobacco
constituents,
such as flavours and nicotine.
In some embodiments, the extrusion may be a generally dry process, with the
precursor
composition being a dry or substantially dry material that includes tobacco
particles, as
well as optionally other particulate materials including, for example, base,
diluent, solid
aerosol forming agents, solid flavour modifiers, etc.
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In some embodiments, liquids may be added to the precursor composition during
the
extrusion process. For example, water may be added to the precursor
composition, for
example as a processing aid to assist dissolution or solubilisation of
components of the
composition, or to aid binding or agglomeration. Alternatively or
additionally, a
.. wetting agent may be added to the precursor composition.
In some embodiments, the liquid may be an aerosol forming agent such as
glycerol or
others discussed herein. When liquid is added to the precursor composition in
this
manner, the liquid is applied not only on the surface, but, as a result of the
extruder
/o .. pressure combined with the intensive mixing by high shear forces, the
extruded
agglomerate becomes impregnated with the liquid. Where the liquid is an
aerosol
forming agent, this can result in a high availability of the aerosol forming
agent in the
agglomerated product to enhance evaporation of flavour components from the
tobacco
particles and other components of the agglomerated structure, enhancing
release of
/5 tobacco constituents from the resultant extruded tobacco constituent
releasing
components.
In some embodiments, in view of the impregnation of the extruded agglomerate
with
the aerosol forming agent, greater volumes of this additive can be
incorporated into the
20 tobacco constituent releasing component than if the aerosol forming
agent were simply
being applied to the surface of the precursor composition or of the extruded
agglomerate. In some embodiments, the amount of aerosol forming agent
incorporated
into the tobacco constituent releasing component may be at least about 1% by
weight, at
least about 1.5% by weight, at least about 2% by weight, at least about 3% by
weight, at
25 least about 5%, at least about 10%, at least about 15% or at least about
20% by weight.
In some embodiments, the amount of aerosol forming agent incorporated into the
tobacco constituent releasing component may be up to about 30% by weight and
even
up to about 40% by weight. High amounts of aerosol forming agent, such as at
least
about 10% or at least about 20% by weight, may be advantageous where the
tobacco
30 constituent releasing component is to generate an aerosol in addition to
releasing the
tobacco constituents. Smaller amounts of aerosol forming agent, such as up to
about
5% by weight, may be sufficient where the tobacco constituent releasing
component's
primary function is to releasing the tobacco constituents or other flavours
carried by
the components into an existing aerosol or air flow.
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The extruded agglomerate will be shaped by the nozzle or die through which it
is forced.
In some embodiments, the extruded agglomerate is cut into pieces of desired
length.
The pieces formed in this way may be used as tobacco constituent releasing
components or they may undergo further processing.
In some embodiments, the nozzle or die is shaped to provide a solid strand of
extruded
agglomerate. For example, the extruded agglomerate may have the form of a
solid
cylindrical rod. Alternatively, the extruded agglomerate may have different
cross-
sectional shapes, including oval, polygonal (such as triangular, square,
etc.), and stars.
In some embodiments, the extruded composition is formed into a desired shape
selected to enhance or promote the release of flavour, for example by
providing a form
having a large surface area per unit volume. This large surface area may be
provided on
the outer surface of the extruded agglomerate, for example by selecting cross-
sectional
is shapes with large perimeter. Alternatively or in addition, the large
surface area may be
provided through the creation of channels within the extruded agglomerate.
In some embodiments, the nozzle is shaped to provide an extruded agglomerate
with
inner channels. These inner channels provide further surface area and can
enhance
constituent release.
Examples of some nozzle designs are shown in Figures 2a, 2b and 2c. These
nozzles 1
have orifices 2 through which the extruded composition is forced to produce an
extruded agglomerate with a cartwheel-like spoked structure. These nozzles are
used in
an extruder, as shown in Figures 2d and 2e, in which the direction of the flow
of the
material being extruded is indicated by the arrow A.
Figure 3 is a photograph of some extruded rod-shaped agglomerates, showing
different
cross-sectional geometries including inner channels. Some of these extruded
agglomerates have been made using the nozzle designs of Figures 2a, 2b and 2c.
Figure 4a shows an example of a die used to produce granules by extrusion.
This die 3
has multiple orifices 4 through which the extruded composition is forced to
produce
extruded agglomerates which exit the die in the form of a numerous solid
cylindrical
rods which are cut at the die to form extruded granules of the desired length.
The
diameter of the granules is driven primarily by the diameter of the orifice 4.
Such a die
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can be used in an extruder, and the direction of the flow of the material
being extruded
is indicated by the arrow A in Figure 4b, which includes a side view of the
die 3.
Figure 5 is a schematic representation of some extruded agglomerates in the
form of
granules.
Tobacco constituent releasing components formed from such shaped extruded
agglomerate sections have an inner channel structure which have advantageous
adjustable strand ventilation properties and a significantly enlarged inner
surface
io leading to improved heat and mass transfer. As a result, such components
exhibit
better, more uniform release of flavour by evaporation. Furthermore, the
structure
with inner channels exhibits significantly improved strength in both the
radial and axial
directions, which is beneficial for the further processing of the extruded
agglomerate,
for example when it is cut into segments.
By means of various nozzle or die designs and/or different process parameters
within
the extruder, including the temperature, pressure and shear forces, extruded
agglomerates with different physical properties may be prepared, including
different
heat transfer properties, draft resistance, and capable of producing different
aerosols
and/or of modifying aerosols being drawn through the extruded agglomerate.
In some embodiments, the extruded agglomerate is shaped upon discharge from
the
extruder. In some embodiments, the extruded agglomerate is cut to an initial
length,
for example 1 metre, and allowed to cool before then being cut into sections
of the
desired length to provide tobacco constituent releasing components of the
desired
dimensions.
In some embodiments, the extruded agglomerate may be cooled just before or
just as it
leaves the extruder. In some embodiments, the cooling is intensive and
involves
exposing the extruded agglomerate, which will be at an elevated temperature,
for
example from about 30 C to about 100 C, or from about 40 C to about 70 C, to a
cooling means that will reduce the temperature to within a range of from about
0 C to
about 70 C, from about 0 C to about 5o C, from about 5 C to about 25 C or from
about
5 C to about 15 C. This rapid cooling of the extruded agglomerate may enhance
the
internal and external stability of the extruded agglomerate. In some
embodiments, it is
the nozzle or die that is cooled to achieve this effect.
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In some embodiments, it may be desirable to control the temperature of the
precursor
composition during extrusion, including before feeding the composition through
the
nozzle or die. This is especially the case where the precursor composition
includes
temperature sensitive components, such as aerosol forming agents such as
glycerol.
Thus, in some embodiments, extrusion of the precursor composition includes
reducing
the temperature of the precursor composition before it reaches the nozzle or
die. Such
cooling of the precursor composition may result in the formation of an
extruded
agglomerate with beneficial properties, or may improve the strand-shaping
process, for
/o example where channels are to be formed within the extruded agglomerate
strand.
In some embodiments, spheronisation is used to further process extruded
segments.
These segments are typically cylindrically-shaped and are cut or broken into
uniform
lengths following extrusion. They are then gradually transformed into
spherical shapes
is by spheronisation. This shaping occurs as a result of plastic
deformation and
spheronisation can lead to spherical agglomerated structures, often with a
nearly
uniform diameter.
Incorporation into an apparatus
20 One or more tobacco constituent releasing components may be incorporated
into an
aerosol provision device, such as an apparatus for heating smokeable material
to
volatilise at least one component of the smokeable material.
As used herein, an aerosol provision device includes vapour devices such as
25 e-cigarettes, devices for heating smokeable material such as tobacco
heating devices
and hybrid devices.
As used herein, the apparatus for heating smokeable material to volatilise at
least one
component of the smokeable material includes so-called "heat not burn"
products or
30 tobacco heating devices or products, which release compounds by heating,
but not
burning, smokeable material. It also includes other nicotine delivery products
such as
aerosol generation devices including e-cigarettes and Hybrid products, in
which a
liquid, such as a nicotine-containing liquid or a nicotine-free liquid, is
heated to form
an aerosol and this aerosol is then drawn through a smokeable material, such
as a
35 tobacco segment, picking up tobacco flavours or wherein a separate
aerosol is formed
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by heating a smokeable material. The aforementioned apparatus may be provided
with
a filter for the aerosol drawn by the user.
The tobacco constituent releasing component may be positioned within the
apparatus
or device so that the tobacco constituents that are released become entrained
in an
aerosol generated by the apparatus or device upon use, modifying the
properties of the
aerosol, for example by imparting tobacco constituents, including tobacco
flavour, to
that aerosol. Additionally or alternatively, the tobacco constituent releasing
component
may itself generate an aerosol during use, said aerosol including the released
tobacco
io constituents.
In some embodiments, an apparatus or device may be provided with a filter
having
tobacco constituent releasing component located within said filter. This may
be in
addition to or instead of the apparatus or device including other tobacco
constituent
/5 releasing components.
In some embodiments the filter or filter element may comprise a filter
material which
has a filtering effect. Suitable filter material may include, for example, tow
comprising
or consisting of cellulose acetate, polylactic acid, and/or other suitable
polymers, or the
20 filter or filter element may comprise a hard material such as plastic
with holes.
In some embodiments where multiple tobacco constituent releasing components
are
incorporated into a filter, this may be in a "Dalmatian" style filter section,
where the
tobacco constituent releasing components are dispersed throughout a fibrous
filter plug
25 material. Alternatively, the tobacco constituent releasing components
may be located
in a cavity within the filter. The cavity may, for example, be a cavity
section positioned
between two (or more) adjacent filter plugs or the cavity may be a pocket
defined within
a filter plug. In such embodiments, the tobacco constituent releasing
components may
be small in size, for example in the form of granules.
In other embodiments, a larger, single tobacco constituent releasing component
is
incorporated into a filter. For example, a single tobacco constituent
releasing
component may be embedded in a fibrous filter plug material.
Alternatively, the tobacco constituent releasing component may be incorporated
into a
multi-segment filter, the tobacco constituent releasing component itself
making up one
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of the filter segments. In such embodiments, the tobacco constituent releasing
component may have any shape or size, but it may be advantageous for the
component
to a have a cylindrical shape and the dimensions similar to or compatible with
those of
the filter segments. In some embodiments, the tobacco constituent releasing
component may be surrounded by filter material such as a layer of fibrous
filter tow, to
form a filter segment. In other embodiments, the tobacco constituent releasing
component may have the dimensions of a filter plug and it may be incorporated
into a
filter with one or more adjacent filter plugs. Alternatively, a tobacco
constituent
releasing component may be included in a cavity section positioned between two
(or
io more) adjacent filter plugs.
In some embodiments the tobacco constituent releasing component itself may be
the
filter element in the aerosol provision device, it being capable of filtering
condensates
and other particulate matter in the aerosol, before the aerosol is inhaled by
the user.
According to some embodiments, one or more tobacco constituent releasing
components are included in an aerosol provision device or apparatus for
heating
smokeable material to volatilise at least one component of the smokeable
material in
which a tobacco segment is heated but not combusted (i.e., a tobacco heating
product
or so-called Heat-not-Burn product). In some of these products, the tobacco
segment is
heated to generate an aerosol.
One option is to incorporate the one or more tobacco constituent releasing
components
in the filter of such products. In some embodiments, multiple tobacco
constituent
releasing components are incorporated into the filter of a tobacco heating
product. In
other embodiments, a single tobacco constituent releasing component is
incorporated
into the filter of a tobacco heating product.
Another option is to incorporate one or more tobacco constituent releasing
components
in the tobacco segment of such products. In some embodiments, one or more
tobacco
constituent releasing components may be incorporated into tobacco material to
form
the tobacco segment. For example, the one or more tobacco constituent
releasing
components may be dispersed within the tobacco material, such as cut tobacco
or
reconstituted tobacco, to contribute to the flavour imparted by the tobacco.
In other
embodiments, the tobacco included in the tobacco segment of the tobacco
heating
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product consists or consists essentially of one or more tobacco constituent
releasing
components. In one embodiment, the tobacco segment heated by the tobacco
heating
product consists of or consists essentially of one or more tobacco constituent
releasing
component. The tobacco constituent releasing component may be heated directly.
Where the tobacco segment is multiple tobacco constituent releasing
components,
these may be held in a container or cartridge. At least portions of the
container or
cartridge may be permeable to air, to allow air to flow over or through the
tobacco
constituent releasing components.
/o Figure 6 shows a cross-sectional view of an example of a tobacco heating
product for
heating a smokeable material. The apparatus ii has a heating chamber 14 which
in use
contains the smokeable material to be heated and volatilised. In this
embodiment, the
smokeable material is in the form of a monolithic tobacco constituent
releasing
component 13. The smokeable material could however be multiple tobacco
constituent
/5 releasing components held in the heating chamber or provided in a
cartridge like the
one illustrated in Figure 8.
The apparatus ii of Figure 6 further has an electronics/power chamber 16 which
may,
for example, contain electrical control circuitry and/or a power source (not
shown).
20 The electrical control circuitry may include a controller, such as a
microprocessor
arrangement, configured and arranged to control the heating of the smokeable
material
via a heating element (not shown). The electrical control circuitry may in use
receive a
signal from for example a puff-actuated sensor which is sensitive to for
example
changes in pressure or changes in rate of air flow that occur upon initiation
of a draw
25 on the apparatus 11 by a user. The electrical control circuitry can then
operate so as to
cause heating of the smokeable material "on demand". Various arrangements for
a
puff-actuated sensor are available, including for example a thermistor, an
electro-
mechanical device, a mechanical device, an optical device, an opto-mechanical
device
and a micro electro mechanical systems (MEMS) based sensor. As an alternative,
the
30 apparatus may have a manually operable switch for a user to initiate a
puff.
The heating chamber 14 is contained within the housing 12. There may be a
support
and/or insulating means (not shown) positioned between the heating chamber 14
and
the housing 12, for example to assist in heat-insulating the housing 12 from
the heating
35 chamber 14, so that the housing 12 does not become hot or at least too
hot to touch
during use.
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The housing 12 includes an inlet 15 through which air is drawn into the
apparatus. The
housing 12 also includes an outlet 17 at a mouthpiece 18 of the apparatus 11.
Air is
drawn into the apparatus 11 through the inlet 15, travels through the
apparatus picking
up tobacco constituents released by the tobacco constituent releasing
component 13,
and the resulting aerosol generated by the apparatus 11 leaves the apparatus
11 through
the outlet 19 and is inhaled by the user.
According to some embodiments, one or more tobacco constituent releasing
io components are included in a so-called Hybrid product for heating
smokeable material
to volatilise at least one component of a smokeable material. In some of these
products, the tobacco segment is heated to generate an aerosol, in addition to
the
heating of a liquid, such as a nicotine-containing liquid or a nicotine-free
liquid, which
is heated by a heat source to form an aerosol or vapour. In some Hybrid
products, the
is aerosol or vapour formed from the liquid is drawn over or through the
tobacco
segment, picking up tobacco flavours. In other embodiments, the aerosol or
vapour
formed from the liquid is not drawn over or through the tobacco segment.
In Hybrid products that include a filter, one option is to incorporate the
tobacco
20 constituent releasing components in the filter of such products, in a
similar manner to
that described for tobacco heating products. In some embodiments, multiple
tobacco
constituent releasing components are incorporated into the filter of a Hybrid
product.
In other embodiments, a single tobacco constituent releasing component is
incorporated into the filter of a Hybrid product.
Where the smoking article is a so-called Hybrid product another option is to
incorporate the tobacco constituent releasing components in the tobacco
segment of
such products. In some embodiments, one or more tobacco constituent releasing
components may be incorporated into tobacco material to form the tobacco
segment.
For example, the one or more tobacco constituent releasing components may be
dispersed within the tobacco material, such as cut tobacco or reconstituted
tobacco, to
contribute to the flavour imparted by the tobacco. In other embodiments, the
tobacco
included in the tobacco segment of the Hybrid product consists of one or more
tobacco
constituent releasing components. In one embodiment, the tobacco segment in
the
Hybrid product consists of or consists essentially of one or more tobacco
constituent
releasing components.
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Figure 7 shows a cross-sectional view of an example of a Hybrid product for
heating a
smokeable material and a liquid. The apparatus 21 has a housing 22 containing
a
chamber 24 which in use contains the smokeable material to be heated and
volatilised.
In this embodiment, the smokeable material is in the form of a monolithic
tobacco
constituent releasing component 23. The smokeable material could however be
multiple tobacco constituent releasing components held in the chamber or
provided in
a cartridge like the one illustrated in Figure 8. The housing 22 also contains
a liquid
reservoir 25 containing a liquid 26 to be heated to form a vapour.
The apparatus 21 further has an electronics/power chamber 27 which may, for
example, contain electrical control circuitry and/or a power source (not
shown). The
electrical control circuitry may include a controller, such as a
microprocessor
arrangement, configured and arranged to control the heating of the smokeable
material
is and of the liquid 26 via one or more heating elements (not shown). The
electrical
control circuitry may allow the apparatus 21 to be puff-actuated, so as to
cause heating
of the smokeable material "on demand". As an alternative, the apparatus 22 may
have
a manually operable switch for a user to initiate a puff.
.. The housing 22 also includes an inlet 28 through which air is drawn into
the
apparatus. The housing 22 also includes an outlet 29 at a mouthpiece 30 of the
apparatus 21. Air is drawn into the apparatus 21 through the inlet 28, travels
through
the apparatus picking up the vapour created by heating the liquid 26 in the
liquid
reservoir 25, and tobacco constituents released by the tobacco constituent
releasing
component 23, and the resulting aerosol generated by the apparatus 21 leaves
the
apparatus 21 through the outlet 29 and is inhaled by the user.
The Hybrid device 21 shown schematically in Figure 7 represents just one
possible
configuration of such an apparatus. The relative positions of the liquid
reservoir 25
and the smokeable material chamber 24 can be changed, as can the path of the
air
flowing through the apparatus.
In one embodiment, the liquid reservoir is positioned upstream of the
smokeable
material to be volatilised. Alternatively, the liquid reservoir may be
positioned
downstream of the smokeable material to be volatilised. In a yet further
arrangement,
the two sources of aerosol in the apparatus may be arranged side-by-side, etc.
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In some embodiments, the vapour produced by heating the liquid in the liquid
reservoir
flows over or through the smokeable material comprising or consisting of one
or more
tobacco constituent releasing components. In some embodiments, the elevated
temperature of the vapour causes the tobacco constituents to be released.
Alternatively
or in addition, the smokeable material may be separately heated by a heating
means.
In some embodiments, a Hybrid device is provided in which the vapour created
by
heating a liquid heats the smokeable material in order to volatilise at least
one
io component of the smokeable material. In some embodiments, the liquid is
a nicotine-
free liquid. In other embodiments, the liquid contains nicotine. Where the
smokeable
material is heated by the vapour to volatilise at least one component of the
smokeable
material, in certain embodiments the device does not include a separate means
for
heating the smokeable material. The smokeable material may comprise or consist
of at
/5 least one tobacco constituent releasing component.
In other embodiments, the vapour produced by heating the liquid in the liquid
reservoir does not flows over or through the smokeable material comprising or
consisting of one or more tobacco constituent releasing components. Rather,
this
20 vapour and the aerosol generated by heating the smokeable material only
mix after they
are both formed.
The tobacco heating products and Hybrid products described herein may, in some
embodiments, include tobacco segments in the form of containers or cartridges
25 containing one or more tobacco constituent releasing components. These
containers or
cartridges may be removable. They may replace both the chamber holding the
smokeable material and the smokeable material in the apparatus described above
with
reference to Figures 6 and 7, and in the alternative embodiments discussed.
30 Referring to Figure 8, a tobacco segment cartridge 31 is shown,
comprising a housing
32 defining a cavity within which are held one or more tobacco constituent
releasing
components according to the invention (not shown). The housing 32 may, for
example
be made from moulded plastic or the like. In order to allow air drawn through
the
device to pass into the cartridge 31 and over or through the one or more
tobacco
35 constituent releasing components and then out of the cartridge 31,
ventilation holes 33
are provided in the housing 32 of the cartridge 31. In some embodiments, the
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cartridge 31 may further comprise heating means that is heatable by a suitable
means
in order to heat the one or more tobacco constituent releasing components held
therein.
Hybrid product
An apparatus is provided for heating smokeable material to volatilise at least
one
component of the smokeable material, and a nicotine-free liquid which is to be
heated
to form a vapour, wherein the smokeable material comprises tobacco particles
having a
basic pH, and wherein the smokeable material is heated by the vapour. This is
a so-
/o called Hybrid device.
In some embodiments, the apparatus includes a means for heating the liquid to
form a
vapour, but not including a separate means for heating the smokeable material.
Thus,
the heat to volatilise at least one component of the smokeable material comes
from the
/5 vapour created by heating the nicotine-free liquid (the e-liquid, as it
is often referred to
as in such devices).
The tobacco particles are pH-adjusted. This may be achieved by adding a pH
adjuster
to the tobacco particles or to a composition including the tobacco particles.
The pH
20 may, for example, be increased by the addition of one or more bases or a
basic buffer
system. Any of the bases and buffer systems mentioned herein may be suitable.
Furthermore, the pH may be adjusted to any of the pH values or ranges
mentioned
herein.
25 In some embodiments, the tobacco particles have an average diameter no
greater than
3 mm, no greater than 1 mm, no greater than 0.5 mm, or no greater than 0.3 mm,
as
measured by sieving. Once again, the particle size may be as discussed above.
The smokeable material comprising the tobacco particles may include other
materials.
In some embodiments, the smokeable does not include a binder or binding
additive. In
other embodiments, the smokeable material comprises a binder or binding
additive.
Suitable binding additives include, for example, thermoreversible gelling
agents such as
gelatin, starches, polysaccharides, pectins, alginates, wood pulp, celluloses,
and
cellulose derivatives such as carboxymethylcellulose.
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In some embodiments, the smokeable material further comprises a diluent. The
diluent may be in solid or liquid form. In some embodiments, the diluent is
inert or
substantially inert.
In some embodiments, the smokeable material further comprises at least one
aerosol
forming agent which may be, for instance, a polyol aerosol generator or a non-
polyol
aerosol generator, preferably a non-polyol aerosol generator. It may be a
solid or liquid
at room temperature, but preferably is a liquid at room temperature. Suitable
polyols
include sorbitol, glycerol, and glycols like propylene glycol or triethylene
glycol.
io Suitable non-polyols include monohydric alcohols, high boiling point
hydrocarbons,
acids such as lactic acid, and esters such as diacetin, triacetin, triethyl
citrate or
isopropyl myristate. A combination of aerosol forming agents may be used, in
equal or
differing proportions. In some embodiments, glycerol and propylene glycol are
particularly preferred.
In some embodiments, the smokeable material may include a flavour-modifier, to
modify the flavour provided by the tobacco particles or to add flavour.
Suitable flavour-
modifiers are discussed in detail above.
In some embodiments, the smokeable material further comprises a preservative,
as
discussed above. In other embodiments, the smokeable material is free of any
preservative.
In some embodiments, the smokeable material comprises tobacco particles in the
form
of one or more agglomerated structures, as discussed in detail above.
Optionally, such
agglomerated structures may be formed by extrusion.
In order to address various issues and advance the art, the entirety of this
disclosure
shows by way of illustration various embodiments in which the claimed
invention(s)
may be practiced and provide for superior tobacco constituent releasing
components
and smoking articles. The advantages and features of the disclosure are of a
representative sample of embodiments only, and are not exhaustive and/or
exclusive.
They are presented only to assist in understanding and teach the claimed
features. It is
to be understood that advantages, embodiments, examples, functions, features,
structures, and/or other aspects of the disclosure are not to be considered
limitations
on the disclosure as defined by the claims or limitations on equivalents to
the claims,
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and that other embodiments may be utilised and modifications may be made
without
departing from the scope and/or spirit of the disclosure. Various embodiments
may
suitably comprise, consist of, or consist essentially of, various combinations
of the
disclosed elements, components, features, parts, steps, means, etc. In
addition, the
disclosure includes other inventions not presently claimed, but which may be
claimed
in future.
