Note: Descriptions are shown in the official language in which they were submitted.
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A combustion retarding material and uses thereof
Field
The invention relates to a combustion retarding material comprising a
combustion
retarding salt and an amorphous solid material. It also relates to consumables
comprising the combustion retarding material, and non-combustible aerosol
provision
systems comprising such consumables. The invention further relates method for
manufacturing the combustion retarding material and the use of a combustion
retarding salt and an amorphous material to retard combustion.
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
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.
Summary
According to a first aspect of the invention, there is provided a combustion
retarding
material comprising a combustion retarding salt and an amorphous solid
material.
In some embodiments, the combustion retarding salt is an alkali metal salt,
optionally
selected from the group consisting of: sodium chloride, potassium chloride,
sodium
bromide, potassium bromide, and combinations thereof.
In some embodiments, the combustion retarding salt is incorporated in the
amorphous
solid material.
In some embodiments, the combustion retarding salt is applied to the amorphous
solid
material.
In some embodiments, the combustion retarding material comprises from about 3
wt
to about 6o wt% of the combustion retarding salt (dry weight basis).
According to a second aspect of the invention, there is provided a consumable
comprising a combustion retarding material according to the first aspect.
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In some embodiments, the consumable further comprises an aerosol-generating
material.
In some embodiments, the combustion retarding material at least partially
surrounds
the aerosol-generating material.
In some embodiments, the consumable further comprises a wrapper.
In some embodiments, the combustion retarding material is distributed within
the
aerosol-generating material.
In some embodiments, the aerosol-generating material comprises tobacco
material. In
some embodiments, the tobacco material is cut rag tobacco.
In some embodiments, the consumable comprises a binder.
In some embodiments, the consumable is rod shaped.
According to a third aspect of the invention, there is provided a non-
combustible
aerosol provision system comprising a consumable according to the second
aspect.
According to a fourth aspect of the invention, there is provided a method for
manufacturing the material according to the first aspect, wherein the
combustion
retarding salt is incorporated into or added to the amorphous solid material.
In some embodiments, a solution or suspension comprising the combustion
retarding
salt is applied to the amorphous solid material.
In some embodiments, the combustion retarding salt is added during the
manufacture
of the amorphous solid material.
According to a fifth aspect of the invention, there is provided use of the
material
according to the first aspect for retarding combustion of a consumable for use
in a non-
combustible aerosol provision system.
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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 side-on cross sectional view of a first embodiment of a
consumable for use
with a non-combustible aerosol provision device comprising the combustion
retarding
material;
Figure 2 is a side-on cross sectional view of a second embodiment of a
consumable for
use with a non-combustible aerosol provision device comprising the combustion
retarding material;
Figure 3 is a perspective illustration of a non-combustible aerosol provision
device for
generating aerosol from the aerosol-generating material of the consumables of
Figure 1
or Figure 2.
Detailed Description
The present invention relates to a combustion retarding material comprising at
least
one combustion retarding salt and an amorphous solid material.
Combustion retarding salt
The salt used herein is a chemical compound consisting of an ionic assembly of
cation
and anions. The salts used herein are those whose anion and/or whose cation
may be
effective in retarding combustion. In some embodiments, the salt is an
inorganic salt.
In some embodiments, the salt is a halide salt, i.e. has a halide anion. In
some
embodiments, the salt is a chloride salt or a bromide salt. The presence of
high
concentrations of chloride or bromide has been shown to retard combustion, as
discussed further below.
In some embodiments, the salt may be an alkali metal salt, i.e. has an alkali
metal
cation. In some embodiments, the salt has an alkaline earth metal cation. In
some
embodiments, the salt has a zinc cation or an iron cation, such as a ferric or
ferrous
cation. In some embodiments, the salt has an ammonium cation or a phosphonium
cation.
In some embodiments, the salt may be an alkali metal halide, such as sodium
chloride
or potassium chloride. The salt may be an alkaline earth metal halide, such as
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magnesium chloride, calcium chloride. The salt may be another metal halide,
such as
zinc chloride or sodium bromide.
In some embodiments, the salt has a carboxylate anion. For example, the salt
may be
an alkali metal carboxylate, such as potassium citrate, potassium succinate,
potassium
malate, potassium acetate, potassium tartrate, potassium oxalate, sodium
citrate,
sodium succinate, sodium acetate, or sodium malate.
In other embodiments, the salt has an anion selected from: borate, carbonate,
phosphate, sulphate or sulphamate.
Factors that may influence the selection of salt will include, for example,
melting point,
which will preferably be at least 450 C. In some embodiments, the salt is
soluble in
water. In some embodiments, the salt is selected to provide a desired pH to
the
material it is added to. In some embodiments, the salt will not significantly
change the
pH of the material
In some embodiments, sodium chloride (NaCl) is the salt used. It has been
demonstrated that amorphous solid material with a high chloride content is
difficult to
combust. Further, sodium chloride is neutral, highly soluble and does not
affect pH of
the amorphous solid material.
The combustion retarding salt may be one salt or a combination of any number
of salts
disclosed herein or known in the all:, and is referred to as "combustion
retarding salt"
herein. The combustion retarding salt(s) may be advantageously selected to
give the
combustion retarding material desired characteristics.
In some embodiments, the combustion retarding salt selected may have one or
more
advantageous properties, such as: inertness, solubility in a precursor liquid,
solubility
or distribution in the amorphous solid or precursor material to the amorphous
solid,
density or other properties known in the art.
In some embodiments, the combustion retarding salt comprises, consists
essentially of,
or consists of sodium chloride, potassium chloride, sodium bromide and/or
potassium
bromide.
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Depending on the combustion retarding or other physical properties desired,
the
components of the salt may be in free base form, salt form, or as a complex,
or as a
solvate. The combustion retarding salt may be of any density and any
crystalline
structure.
In some embodiments, the combustion retarding salt is incorporated into or
added to
the amorphous solid material dissolved in a solvent or liquid carrier. In some
embodiments, the combustion retarding salt is suspended in a liquid carrier.
The
solvent or liquid carrier may be an aqueous or organic liquid, and may be
polar or non-
_ro polar depending on its suitable application.
The liquid carrier or precursor solvent may be advantageously selected to be
readily
removed during the manufacture of the combustion retarding material to leave
the
combustion retarding salt in or on the amorphous solid material.
In some embodiments, the liquid carrier is a mixture of liquids, including
aqueous
liquid (water) and non-aqueous liquid (e.g. glycerol). Upon removal of the
water
following application of the salt, the glycerol will be retained in the
amorphous solid
material, where it offers flexibility and assists in aerosol formation upon
heating.
The amorphous solid material
The combustion retarding material comprises an "amorphous solid material",
which
may alternatively be referred to as a "monolithic solid" (i.e. non-fibrous).
In some
embodiments, the amorphous solid material may be a dried gel. The amorphous
solid
is a solid material that may retain some fluid, such as liquid, within it.
The amorphous solid material may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%,
5
wt%, to wt%, 15 wt%, 20 wt% or 25 wt% to about 6o wt%, 50 wt%, 45 wt%, 40 wt%
or
wt% of a gelling agent (all calculated on a dry weight basis). For example,
the
30 amorphous solid may comprise 1-50 wt%, 5-45 wt%, 10-40 wt% or 20-
35 wt% of a
gelling agent. In some embodiments, the gelling agent comprises a
hydrocolloid.
In some embodiments, the gelling agent comprises one or more compounds
selected
from the group comprising alginates, pectins, starches (and derivatives),
celluloses (and
35 derivatives), gums, silica or silicones compounds, clays,
polyvinyl alcohol and
combinations thereof. For example, in some embodiments, the gelling agent
comprises
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one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl
cellulose,
carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose,
acacia
gum, fumed silica, PDMS, sodium silicate, kaolin and polyvinyl alcohol. In
some cases,
the gelling agent comprises alginate and/or pectin, and may be combined with a
setting
agent (such as a calcium source) during formation of the amorphous solid. In
some
cases, the amorphous solid may comprise a calcium-crosslinked alginate and/or
a
calcium-crosslinked pectin.
In some embodiments, the gelling agent comprises alginate. In a preferred
embodiment, the alginate is present in the amorphous solid in an amount of
from 1-30
wt% of the amorphous solid (calculated on a dry weight basis). In some
embodiments,
alginate is the only gelling agent present in the amorphous solid. In other
embodiments, the gelling agent comprises alginate and at least one further
gelling
agent, such as pectin.
In some embodiments the combustion retarding material may comprise an
amorphous
solid which may include gelling agent comprising carrageenan.
Suitably, the amorphous solid may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%,
3
wt%, 5 wt%, 7 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt% or 40% to
about
75 wt%, 70 wt%, 65 wt%, 6o wt%, 55 wt% or 50 wt% of an aerosol-former material
(all
calculated on a dry weight basis). For example, the amorphous solid may
comprise 5-
10 wt%, 20-70 wt%, 40-60 wt% or 50-60 wt% of an aerosol-former material.
As used herein, the aerosol-former material may comprise one or more of
glycerine,
glycerol, propylene glycol, diethylene glycol, triethylene glycol,
tetraethylene glycol, 1,3-
butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate,
a diethyl
suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate,
benzyl phenyl
acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene
carbonate.
In some cases, the aerosol-former material comprises one or more compound
selected
from erythritol, propylene glycol, glycerol, vegetable glycerine (VG),
triacetin, sorbitol
and xylitol. In some cases, the aerosol-former material comprises, consists
essentially
of or consists of glycerol.
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The aerosol-former material may act as a plasticiser. For example, the
amorphous solid
material may comprise 0.5-40 wt%, 3-35 wt% or 10-25 wt% of an aerosol-former
material. In some cases, the aerosol-former material comprises one or more
compound
selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol and
xylitol. In
some cases, the aerosol-former material comprises, consists essentially of or
consists of
glycerol. The inventors have established that if the content of the
plasticiser is too high,
the amorphous solid material may absorb water resulting in a material that
does not
create an appropriate consumption experience in use. The inventors have
established
that if the plasticiser content is too low, the amorphous solid material may
be brittle
_ro and easily broken. The plasticiser content specified herein provides an
amorphous
solid flexibility which allows the amorphous solid sheet to be wound onto a
bobbin,
which is useful in manufacture of aerosol-generating articles.
In some embodiments, the amorphous solid material is a hydrogel and comprises
less
than about 20 wt% of water calculated on a wet weight basis. In some cases,
the
hydrogel may comprise less than about 15 wt%, 12 wt% or 10 wt% of water
calculated
on a wet weight basis. In some cases, the hydrogel may comprise at least about
1 wt%, 2
wt% or at least about 5 wt% of water (WINB).
The combustion retarding material
In some embodiments, the combustion retarding material comprises a combination
of
an amorphous solid material and a combustion retarding salt, as discussed
herein.
In some embodiments, the proportion of combustion retarding salt in the
combustion
retarding material may be advantageously selected for its combustion retardant
properties. Suitably, the combustion retarding material may comprise from
about 3
wt%, 15 wt%, 20 wt%, 25 Wt %, 30 WC%, 35 wt%, 40 wt%, 45 wt%, or from about 50
wt%
to about 90 wt%, 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt% or to about 60 wt% of
the
combustion retarding salt (all calculated on a dry weight basis).
In some embodiments, the combustion retarding salt is incorporated into the
amorphous solid material. This means that the combustion retarding salt is
included
within the amorphous solid composition. For example, during the preparation of
the
amorphous solid material, a liquid precursor of the amorphous solid material
is mixed
with combustion retarding salt. This distributes the combustion retarding salt
throughout the resultant amorphous solid material. In some embodiments, the
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distribution of the combustion retarding salt is even throughout the amorphous
solid
and this may be advantageous as the combustion retarding effect is effective
across all
of the material. The combustion retarding salt may be added in the form of a
solution
or suspension. Alternatively, the combustion retarding salt may be added to
the liquid
precursor in solid form, for example in particulate form, such as a powder.
In other embodiments, the combustion retarding salt is added or applied to the
amorphous solid material. For example, once the amorphous solid material has
been
prepared, a solution or suspension comprising the combustion retarding salt is
applied
ro to the surface of the amorphous solid material, to deposit the
combustion retarding salt
on the surface of the amorphous solid material.
In some embodiments, the amorphous solid material is contacted with a solution
or a
suspension comprising the combustion retarding salt. This technique may be
used to
form a coating of salt on the surface of the amorphous material. This
technique may be
repeated multiple times to form one or more layers of the combustion retarding
salt. In
some embodiments, different combustion retarding salts may be incorporated in
the
one or more coatings and/or in the amorphous solid material. This may provide
a
specific combustion-retarding profile.
In some embodiments, a solution or suspension of the combustion retarding salt
may
be sprayed directly onto the amorphous solid. This is advantageous because the
layer of
the inorganic solid may be evenly distributed over the amorphous solid. This
process
may also be repeated to provide a desired thickness of the layer of combustion
retarding salt, which is a further advantage. The layers of the combustion
retarding salt
may comprise the same salt or different salts. Additionally, the proportion of
the
combustion retarding salt in the carrier liquid or solvent may be altered to
provide a
layer on the amorphous solid material with desired properties. In such
embodiments,
the proportion of the combustion retarding salt in the solvent or carrier
liquid may
comprise from about 1 wtcY0, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about
60
wt%, 50 wt%, 45 wtO, 40 wt% or 35 wt% of the combustion retarding salt (all
calculated on a dry weight basis).
In some embodiments, the combustion retarding material comprises:
¨ about 1 to about 50 wt% of a gelling agent;
- about 0.1 to about 50 wt% of an aerosol-former agent; and
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- about 3 to about 90 wt% of an combustion retarding salt;
wherein these weights are calculated on a dry weight basis.
In particular exemplary embodiments, the combustion retarding material
comprises:
- about 20 to about 30 wt% of a gelling agent;
- about 20 to about 30 wt% of an aerosol-former agent; and
- about 50 to about 60 wt% of an combustion retarding salt;
wherein these weights are calculated on a dry weight basis.
In another example, the combustion retarding material is formed from a slurry
comprising:
43 g alginate (2.7%)
loo g sodium chloride (6.3%)
50 g glycerol (3.1%)
1400 ml water (87.9%).
Once this slurry has been dried, the composition of the combustion retarding
material
will be as follows: alginate (22.3%); sodium chloride (52.1%); and 50 g
glycerol (25.6%).
In some cases, the combustion retarding material may consist essentially of,
or consist
of a combustion retarding salt, a gelling agent, an aerosol-former agent and
water.
The inventors have advantageously found that an improved article may be
produced
comprising a combustion retarding material comprising a combustion retarding
salt
and an amorphous solid, wherein the material properties (e.g. density) and
specification (e.g. thickness, length, and cut width) fall within the ranges
set out herein.
In some cases, the combustion retarding material may have a thickness of about
0.015
mm to about 1.5 mm, suitably about 0.05 mm to about 1. 5 mm or 0.05 mm to
about 1
mm. Suitably, the thickness may be in the range of about 0.1 mm or 0.15 mm to
about 1
mm, 0.5 mm or 0.3 mm. The combustion retarding material may comprise more than
one layer, and the thickness described herein refers to the aggregate
thickness of those
layers.
In some embodiments in which the combustion retarding material includes the
combustion retarding salt as a coating on the amorphous solid, the coating
layer of
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combustion retarding salt may have a thickness of about 0.01 mm to about 0.1
mm.
The combustion retarding salt coating may comprise more than one layer, and
the
thickness described herein refers to the aggregate thickness of those layers.
The thickness of the material or layers discussed herein may be measured using
a
microscope such as a scanning electron microscope (SEM), as known to those
skilled in
the art, or any other suitable technique known to those skilled in the art.
The inventors have established that if the combustion retarding material is
too thick,
io then heating efficiency can be compromised. This can adversely affect
power
consumption in use, for instance the power consumption for release of flavour
from the
amorphous solid. Conversely, if the combustion retarding material is too thin,
it can be
difficult to manufacture and handle; a very thin material can be harder to
cast and may
be fragile, compromising aerosol formation in use. In some cases, an
individual strip or
piece of combustion retarding material has a minimum thickness over its area
of about
0.015 mm. In some cases, an individual strip or piece of the amorphous solid
has a
minimum thickness over its area of about 0.05 mm or about 0.1 mm. In some
cases, an
individual strip or piece of the amorphous solid has a maximum thickness over
its area
of about 1.0mm. In some cases, an individual strip or piece of the combustion
retarding material has a maximum thickness over its area of about 0.5 mm or
about 0.3
MM.
For the avoidance of doubt, where reference is made herein to area density,
this refers
to an average area density calculated for a given strip, piece or sheet of
combustion
retarding material, the area density calculated by measuring the surface area
and
weight of the given strip, piece or sheet of combustion retarding material.
In some cases, the combustion retarding material thickness may vary by no more
than
25%, 20%, 15%, 10%, 5% or 1% across its area.
In some embodiments in which the combustion retarding material is in sheet
form, the
sheet may have any suitable area density, such as from about 30 g/m2 to about
150
g/m2. In some cases, the sheet may have a mass per unit area of about 55 g/m2
to about
135 g/m2, or about 8o to about 120 g/m2, or from about 70 to about no g/m2, or
particularly from about 90 to about no g/m2, or suitably about loo g/m2. Such
area
densities may be particularly suitable where the combustion retarding material
is
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included in an aerosol-generating article as a shredded sheet (described
further herein).
In some cases, the sheet may have a mass per unit area of about 30 to 70 g/m2,
40 to 6o
g/m2, or 25 to 6o g/m2 and may be used to wrap an aerosolisable material such
as
tobacco.
The density of the combustion retarding material has an impact on the speed at
which
heat conducts through the material, with lower densities, for instance those
below 700
mg/cc, conducting heat more slowly through the material, and therefore
enabling a
more sustained release of aerosol. The density of the combustion retarding
salt also has
ro an impact on the speed of heat conductions, as well as the
aforementioned
combustibility of the consumable.
In some examples, such as where the combustion retarding material does not
comprise
a filler, the combustion retarding material may have a tensile strength of
from 200 N/m
to 400 N/m, or 200 N/m to 300 N/m, or about 250 N/m. Such tensile strengths
may
be particularly suitable for embodiments wherein combustion retarding material
is
formed as a sheet and then shredded and incorporated into the consumable.
In some embodiments, such as where the combustion retarding material is used
in
sheet form, a filler is included to increase the tensile strength. In some
embodiments,
the combustion retarding material may have a tensile strength of at least
about 1500 or
at least about 2000 N/m and/or up to about 5000 N/m. In some embodiments, the
tensile strength may be from about 3000 to about 4000 N/m. Such tensile
strengths
may be particularly suitable for embodiments wherein combustion retarding
material is
incorporated into a consumable in sheet form, for example as a wrapper.
In some embodiments, the combustion retarding material comprises an amorphous
solid which is a hydrogel and comprises less than about 20 wt% of water
calculated on a
wet weight basis. In some cases, the hydrogel may comprise less than about 15
wt%, 12
wt% or 10 wt% of water calculated on a wet weight basis. In some cases, the
hydrogel
may comprise at least about 1 wt%, 2 wt% or at least about 5 wt% of water.
Additional components of the combustion retarding material
In some embodiments, the combustion retarding material may comprise of
additional
components, which are described herein. The additional components may be
included
in any part of the combustion retarding material. In some embodiments the
additional
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components included in the amorphous solid material and so are distributed
within the
combustion retarding material.
In some embodiments, the combustion retarding material comprises one or more
other
functional materials, which may comprise one or more of pH regulators,
colouring
agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.
In some embodiments, the combustion retarding material comprises a flavour.
The
combustion retarding material therefore has the advantage of preventing the
combustion of the flavourant and delivering a desired taste.
In some embodiments, the combustion retarding material may comprise up to
about
8o wt%, 70 wt%, 6o wt%, 55 wt%, 50 wt% or 45 wt% of a flavour. In some cases,
the
combustion retarding material may comprise at least about 0.1 wt%, 1 wt%, 10
wt%, 20
wt%, 30 wt%, 35 wt% or 40 wt% of a flavour (all calculated on a dry weight
basis).
For example, the combustion retarding material may comprise 1-80 wt%, 10-80
wt%,
20-70 wt%, 30-60 wt%, 35-55 wt% or 30-45 wt% of a flavour. In some cases, the
flavour comprises, consists essentially of or consists of menthol.
In some embodiments, the flavourant is included in the aerosol-generating
material.
Flavour provided in the amorphous solid material may be more stably retained,
resulting in a more consistent flavour profile between consumables as
disclosed herein.
As used herein, the terms "flavour" and "flavourant" refer to materials which,
where
local regulations permit, may be used to create a desired taste, aroma or
other
somatosensorial sensation in a product for adult consumers. They may include
naturally occurring flavour materials, botanicals, extracts of botanicals,
synthetically
obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice
(liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile,
fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise),
cinnamon,
turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red
berry,
cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical
fruit, papaya,
rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus
fruits,
Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint,
lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood,
bergamot,
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geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla,
lemon oil,
orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine,
ylang-
ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint
oil from any
species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass,
rooibos, flax,
ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as
green tea or
black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano,
paprika,
rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro,
myrtle, cassis,
valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil,
chive,
carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers,
bitterness
io 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, liquid such as an oil, solid such as
a powder,
or gas.
In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint.
In some embodiments, the flavour comprises flavour components of cucumber,
blueberry, citrus fruits and/or redberry. In some embodiments, the flavour
comprises
eugenol. In some embodiments, the flavour comprises flavour components
extracted
from tobacco. In some embodiments, the flavour comprises flavour components
extracted from cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to
achieve a somatosensorial sensation which are usually chemically induced and
perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in
addition to
or in place of aroma or taste nerves, and these may include agents providing
heating,
cooling, tingling, numbing effect. A suitable heat effect agent may be, but is
not limited
to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited
to
eucolyptol, WS-3.
The amorphous solid may be made from a gel, and this gel may additionally
comprise a
solvent, included at 0.1-50 wt%. However, the inventors have established that
the
inclusion of a solvent in which the flavour is soluble may reduce the gel
stability and the
flavour may crystallise out of the gel. As such, in some cases, the gel does
not include a
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solvent in which the flavour is soluble. In some embodiments, solvent may be
removed
by evaporation prior to the inclusion of a flavour.
In some cases, the combustion retarding material may additionally comprise an
emulsifying agent, which emulsified molten flavour during manufacture. For
example,
the combustion retarding material may comprise from about 5 wt% to about 15
wt% of
an emulsifying agent (calculated on a dry weight basis), suitably about 10
wt%. The
emulsifying agent may comprise acacia gum (gum arabic) or guar gum.
In some embodiments, the emulsifying agent is included in the amorphous solid
material.
In some embodiments, and where local regulations permit, the combustion
retarding
material may comprise an active substance. In some embodiments, the combustion
retarding material does not comprise an active substance.
In some embodiments, the active substance is included in the amorphous solid
material.
The active substance as used herein may be a physiologically active material,
which is a
material intended to achieve or enhance a physiological response. The active
substance
may for example be selected from nutraceuticals, nootropics, psychoactives.
The active
substance may be naturally occurring or synthetically obtained. The active
substance
may comprise for example nicotine, caffeine, taurine, theine, vitamins such as
B6 or
B12 or C, melatonin, cannabinoids, or constituents, derivatives, or
combinations
thereof. The active substance may comprise one or more constituents,
derivatives or
extracts of tobacco, cannabis or another botanical.
In some embodiments, the active substance comprises nicotine. In some
embodiments,
the active substance comprises caffeine, melatonin or vitamin B12.
As noted herein, the active substance may comprise one or more constituents,
derivatives or extracts of cannabis, such as one or more cannabinoids or
terpenes.
As noted herein, the active substance may comprise or be derived from one or
more
botanicals or constituents, derivatives or extracts thereof. As used herein,
the term
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"botanical" includes any material derived from plants including, but not
limited to,
extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen,
husk, shells or
the like. Alternatively, the material may comprise an active compound
naturally
existing in a botanical, obtained synthetically. The material may be in the
form of
liquid, gas, solid, powder, dust, crushed particles, granules, pellets,
shreds, strips,
sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise,
hemp, cocoa,
cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax,
ginger,
ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate,
orange skin,
papaya, rose, sage, tea such as green tea or black tea, thyme, clove,
cinnamon, coffee,
_ro aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg,
oregano,
paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower,
vanilla,
wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro,
bergamot,
orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram,
olive,
lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry,
ginseng,
theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab
or
any combination thereof. The mint may be chosen from the following mint
varieties:
Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita
citrata
c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha
longifolia,
Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha
suaveolens
In some embodiments, the active substance comprises or is derived from one or
more
botanicals or constituents, derivatives or extracts thereof and the botanical
is tobacco.
In some embodiments, the active substance comprises or derived from one or
more
botanicals or constituents, derivatives or extracts thereof and the botanical
is selected
from eucalyptus, star anise, cocoa and hemp.
In some embodiments, the active substance comprises or derived from one or
more
botanicals or constituents, derivatives or extracts thereof and the botanical
is selected
from rooibos and fennel.
In some cases, the total content of active substance and/or flavour in the
combustion
retarding material may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20
Wt%, 25
wt% or 30 wt%. In some cases, the total content of active substance and/or
flavour may
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be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt% or 40 wt% (all
calculated
on a dry weight basis).
In some embodiments and where local regulations permit, the combustion
retarding
material additionally comprises plant material or tobacco material and/or
nicotine.
In some cases, the combustion retarding material may comprise 5-60 wt%
(calculated
on a dry weight basis) plant material and/or tobacco material and/or nicotine
and/or
tobacco extract. In some cases, the combustion retarding material may comprise
from
about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 70 wt%, 6o wt%,
50
wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis)
plant
material and/or tobacco material and/or nicotine and/or tobacco extract.
In some cases, the combustion retarding material may comprise 5-60 wt%
(calculated
on a dry weight basis) plant material and/or tobacco material and/or nicotine
and/or
tobacco extract. In some cases, the combustion retarding material may comprise
from
about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 70 wt%, 60 wt%,
50
wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis)
plant
material and/or tobacco material and/or nicotine and/or tobacco extract. In a
preferred
embodiment of the invention, the combustion retarding material may comprise 5-
60
wt% (calculated on a dry weight basis) plant material and/or tobacco material
and/or
nicotine and/or tobacco extract.
In some cases, there may be no nicotine in the combustion retarding material
other
than that which is provided from the tobacco material or the tobacco extract.
In some embodiments the combustion retarding material comprises no tobacco
material but does comprise nicotine. In some such cases, the combustion
retarding
material may comprise from about 1 wt%, 2 wt%, 3 wt% or 4 wt% to about 20 Wt%,
18
wt%, 15 wt% or 12 wt% (calculated on a dry weight basis) nicotine. For
example, the
combustion retarding material may comprise 1-20 wtO, 2-18 wt% or 3-12 wt%
nicotine.
In some embodiments, the combustion retarding material comprises a filler. In
some
embodiments, the filler is included in the amorphous solid material.
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In some embodiments, the combustion retarding material comprises less than 60
wt%
of a filler, such as from 1 wt% to 6o wt%, or 5 wt% to 50 wt%, or 5 wt% to 30
wt%, or 10
wt% to 20 WtO.
In other embodiments, the combustion retarding material comprises less than 20
Anft%,
suitably less than 10 wt% or less than 5 wt% of a filler. In some cases, the
amorphous
solid material comprises less than 1 wt% of a filler, and in some cases,
comprises no
filler.
io The filler, if present, may comprise one or more inorganic filler
materials in addition to
the combustion retarding salt(s), such as calcium carbonate, perlite,
vermiculite,
diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulphate,
magnesium carbonate, and suitable inorganic sorbents, such as molecular
sieves. The
filler may comprise one or more organic filler materials such as wood pulp,
cellulose
and cellulose derivatives. In particular cases, the combustion retarding
material
comprises no calcium carbonate such as chalk.
In particular embodiments which include filler, the filler is fibrous. For
example, the
filler may be a fibrous organic filler material such as wood pulp, hemp fibre,
cellulose or
cellulose derivatives. Without wishing to be bound by theory, it is believed
that
including fibrous filler in the combustion retarding material may increase the
tensile
strength of the material.
In some embodiments, the combustion retarding material does not comprise
tobacco
fibres.
In some examples, such as where the combustion retarding material comprises a
filler,
combustion retarding material may have a tensile strength of from 600 N/m to
900
N/m, or from 700 N/m to 900 N/m, or around 800 N/m. Such tensile strengths may
be particularly suitable for embodiments wherein the combustion retarding
material is
included in an aerosol-generating article as a rolled sheet, suitably in the
form of a tube
or a rod.
Consumables
A consumable is an article comprising aerosol-generating material, part or all
of which
is intended to be consumed during use by a user. A consumable may comprise one
or
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more other components, such as an aerosol-generating material storage area, an
aerosol-generating material transfer component, an aerosol generation area, a
housing,
a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A
consumable
may also comprise an aerosol generator, such as a heater, that emits heat to
cause the
aerosol-generating material to generate aerosol in use. The heater may, for
example,
comprise combustible material, a material heatable by electrical conduction,
or a
susceptor. The consumable may be any shape or size that is appropriate to the
smoking
device. In a preferred embodiment of the invention, the consumable is a rod
shape.
In the present invention, the consumable comprises a combustion retarding
material as
disclosed herein. In some territories, it is necessary for the consumable to
resist
combustion and this may be enhanced by inclusion of the combustion retarding
material.
In some embodiments, the inclusion of the combustion retarding material in the
consumable means that it is not necessary to include a foil in the consumable.
Consumables can include a metal foil, such as aluminium foil, as part of the
wrapper
surrounding the aerosol-generating material to retard or prevent combustion.
In some embodiments, the combustion retarding material surrounds at least some
of
the aerosol-generating material. For example, a wrapper surrounding the
aerosol-
generating material may comprise or consist of a combustion retarding
material. The
combustion retarding material may be in the form of a sheet. One or more
layers of the
combustion retarding material may circumscribe the aerosol-generating
material.
In some embodiments, the combustion retarding material surrounds all of the
aerosol-
generating material. Where the aerosol-generating material is provided in the
form of a
rod, the combustion retarding material not only circumscribes the length of
the rod of
aerosol-generating material but also encloses the end of the rod. This may be
in the
form of the sheet being folded or otherwise extended over the end of the rod,
or a plug
of the combustion retarding material being inserted into the end of the rod.
This will
prevent the aerosol-generating material combusting if an attempt is made to
light the
consumable like a cigarette.
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As described herein, the rod of aerosol-generating material may have a first
end and a
second end. In use, the rod has a downstream end, usually connected to or
comprising
a mouthpiece and/or filter, and an upstream end, also referred to as a distal
end.
In other embodiments, the combustion retarding material is provided locally,
for
example, at the distal end of a rod of aerosol-generating material, with
little or no
combustion retarding material provided in other parts of the consumable. In
some
embodiments, the combustion retarding material is provided in greater
concentration
at a location proximal to the distal end. In some embodiments, the combustion
io retarding material is provided exclusively at a location proximal to the
distal end. The
area in which the combustion retarding material is provided may be at most
about 5%,
at most about 10%, at most about 20%, at most about 30%, at most about 40%, at
most
about 50%, or at most about 6o% of the rod from the distal end. In some
embodiments
the combustion retarding material is disposed at the distal end of the rod in
the form of
a shredded sheet. In some embodiments in which the combustion retarding
material is
shredded, said combustion retarding material may be interspersed, mixed or
otherwise
combined with the aerosol-generating material. Alternatively, the shredded
combustion
retarding material may circumscribe the aerosol-generating material. In other
embodiments, the shredded combustion retarding material is not mixed with the
aerosol-generating material, and may be in the form of a plug. The shredded
format of
the combustion retarding material has the advantage that this is well suited
to being
incorporated into the rod.
In some embodiments where the combustion retarding material is disposed at the
distal end of the rod, the combustion retarding material may be in the form of
a
gathered sheet. In some embodiments the gathered sheet is in the form of a
plug. The
gathered sheet format has the advantage that travel of salt up the rod is
reduced. A
plug of combustion retarding material may also be formed as a solid mass
comprising a
combustion retarding salt and an amorphous solid material.
In some embodiments, a portion of the aerosol-generating material, such as
tobacco,
may be replaced with the combustion retarding material. In some embodiments,
between about 5% to about 15%, or about 8% to about 12% of the weight of the
aerosol-
generating material may be replaced with the combustion retarding material.
The
combustion retarding material may be in the form of a plug. This embodiment
enjoys
the advantage of preventing the aerosol-generating material combusting if an
attempt
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is made to light the consumable like a cigarette, whilst maintaining the total
size of the
consumable or rod. This is particularly beneficial when the rod is used as
consumable
in an aerosol-generating device and can be swapped with alternative
consumable(s)
already in production.
In some embodiments, the consumable may comprise at least one ventilation area
arranged to allow external air to flow into the article. The ventilation area
may
comprise one or more ventilation apertures or perforations cut into the
wrapper to
allow ambient air to be drawn into the article. This will influence pressure
drop and can
io enhance the user's experience of the flavour properties of the
aerosol generating
material. The location of these vents and/or perforations may be between about
0.5
mm to about 10 mm, between about 1 mm to about 4 mm or between about 4mm to
about 8 mm from the distal end of the rod. The vents and/or perforations may
be of any
suitable size and/or number to adapt the flow-through of air. The size, number
and
location on the wrapper of the vents and/or perforations may be selected to
provide the
appropriate flow through of air. For example, more numerous and larger vents
and/or
perforations may introduce more air into the rod, increase the flow-through of
air and
thus provide the appropriate pressure drop.
In other embodiments, the combustion retarding material is mixed with the
aerosol-
generating material. In such embodiments, the combustion retarding material
may be
in the form of a shredded or cut sheet, mixed with the aerosol-generating
material.
The presence of the combustion retarding material distributed within the
aerosol-
generating material can reduce the tendency of the aerosol-generating material
to
combust when exposed to high temperatures and/or a flame.
In exemplary embodiments, the consumable comprises a blend of aerosol-
generating
material and combustion retarding material. For example, the blend comprises
aerosol-generating material in an amount from 50% to 98%, for instance from
80% to
95%, wherein the aerosol-generating material is for instance cut rag tobacco,
and
shredded amorphous solid material in an amount from 2% to 50%, for instance
from
5% to 20%.
In some embodiments, even mixing of the aerosol-generating material and the
combustion retarding material can be achieved when the combustion retarding
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material in sheet form is shredded. Preferably the cut width of the shredded
combustion retarding material is between 0.75 mm and 2 mm, for instance
between 1
mm and 1.5 mm. The strands of combustion retarding material formed by
shredding
may be cut width-wise, for example in a cross-cut type shredding process, to
define a
cut length for the shredded combustion retarding material, in addition to a
cut width.
The cut length of the shredded combustion retarding material is preferably at
least 5
mm, for instance at least 10 mm, or at least 20 mm. The cut length of the
shredded
combustion retarding material can be less than 60 mm, less than 50 mm, or less
than
40 mm. In some embodiments, to achieve even mixing of the shredded combustion
io retarding material with cut rag tobacco, the cut length of the shredded
a combustion
retarding material is preferably non-uniform. Although referred to as cut
length, the
length of the shreds or strips of combustion retarding material can
alternatively or
additionally be dictated by a dimension of the material determined during its
manufacture, for instance the width of a sheet of the material as
manufactured.
In some embodiments, the aerosol-generating material included in the
consumable
comprises one or more active substances and/or flavours. In some embodiments,
this
material includes tobacco or other plant derived material. When this aerosol-
generating material includes tobacco, heating this material releases volatile
tobacco
components including nicotine and flavour or aroma compounds.
In some embodiments, the aerosol-generating material comprises a plant-based
material, such as tobacco material. As used herein, the term "tobacco
material" refers
to any material comprising tobacco or derivatives or substitutes thereof. The
term
"tobacco material" may include one or more of tobacco, tobacco derivatives,
expanded
tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material
may
comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded
tobacco,
tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.
In some embodiments, the plant material is tobacco material and may be
provided in
the form of cut rag tobacco. The cut rag tobacco can have a cut width of at
least 15 cuts
per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm).
Preferably,
the cut rag tobacco has a cut width of at least 18 cuts per inch (about 7.1
cuts per cm,
equivalent to a cut width of about 1.4 mm), more preferably at least 20 cuts
per inch
(about 7.9 cuts per cm, equivalent to a cut width of about 1.27 mm). In one
example,
the cut rag tobacco has a cut width of 22 cuts per inch (about 8.7 cuts per
cm,
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equivalent to a cut width of about 1.15 mm). Preferably, the cut rag tobacco
has a cut
width at or below 40 cuts per inch (about 15.7 cuts per cm, equivalent to a
cut width of
about 0.64 mm). Cut widths between 0.5 mm and 2.0 mm, for instance between o.6
and 1.7 mm or between 0.6 mm and 1.5 mm, have been found to result in tobacco
material which is preferably in terms of surface area to volume ratio,
paiticularly when
heated, and the overall density and pressure drop of the rod of aerosol-
generating
material. The cut rag tobacco can be formed from a mixture of forms of tobacco
material, for instance a mixture of one or more of paper reconstituted
tobacco, leaf
tobacco, extruded tobacco and bandcast tobacco. Preferably the tobacco
material
io comprises paper reconstituted tobacco or a mixture of paper
reconstituted tobacco and
leaf tobacco.
The plant material, such as tobacco material, may have any suitable thickness.
The
plant material, such as tobacco material, may have a thickness of at least
about 0.145
mm, for instance at least about 0.15 mm, or at least about 0.16 mm. The plant
material
may have a maximum thickness of about 0.25 mm, for instance the thickness of
the
plant material may be less than about 0.22 mm, or less than about 0.2 mm. In
some
embodiments, the plant material may have an average thickness in the range
0.175 mm
to 0.195 mm. Such thicknesses may be particularly suitable where the plant
material is
a reconstituted tobacco material.
The tobacco material can comprise reconstituted tobacco material having a
density of
less than about 700 mg/cc, for instance paper reconstituted tobacco material.
For
instance, the aerosol-generating material comprises reconstituted tobacco
material
having a density of less than about 600 mg/cc. Alternatively or in addition,
the aerosol-
generating material can comprise reconstituted tobacco material having a
density of at
least 350 mg/cc.
In some embodiments, the aerosol-generating material contains a filler
component.
The filler component is generally a non-tobacco component, that is, a
component that
does not include ingredients originating from tobacco. The filler component
may be a
non-tobacco fibre such as wood fibre or pulp or wheat fibre. The filler
component may
also be an inorganic material such as chalk, perlite, vermiculite,
diatomaceous earth,
colloidal silica, magnesium oxide, magnesium sulphate, magnesium carbonate.
The
filler component may also be a non-tobacco cast material or a non-tobacco
extruded
material. The filler component may be present in an amount of o to 20% by
weight of
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the tobacco material, or in an amount of from 1 to 10% by weight of the
composition.
In some embodiments, the filler component is absent.
In some embodiments, the aerosol-generating material contains an aerosol-
former
material.
In some embodiments, the aerosol-former material included with the plant or
tobacco
material may be glycerol, propylene glycol, or a mixture of glycerol and
propylene
glycol. Glycerol may be present in an amount of from 10 to 20 % by weight of
the
io tobacco material, for example 13 to 16 % by weight of the composition,
or about 14% or
15% by weight of the composition. Propylene glycol, if present, may be present
in an
amount of from 0.1 to 15% by weight of the composition.
In some embodiments in which the plant material is a tobacco material, the
tobacco
material can contain between 10% and 90% by weight tobacco leaf, wherein the
aerosol-former material is provided in an amount of up to about 10% by weight
of the
leaf tobacco. To achieve an overall level of aerosol-former material between
10% and
20% by weight of the tobacco material, it has been advantageously found that
this can
be added in higher weight percentages to the another component of the tobacco
material, such as reconstituted tobacco material.
The tobacco material described herein contains nicotine. The nicotine content
is from
0.5 to 1.75% by weight of the tobacco material, and may be, for example, from
o.8 to
1.5% by weight of the tobacco material. Additionally or alternatively, the
tobacco
material contains between 10% and 90% by weight tobacco leaf having a nicotine
content of greater than 1.5% by weight of the tobacco leaf. It has been
advantageously
found that using a tobacco leaf with nicotine content higher than 1.5% in
combination
with a lower nicotine base material, such as paper reconstituted tobacco,
provides a
tobacco material with an appropriate nicotine level but better sensory
performance
than the use of paper reconstituted tobacco alone. The tobacco leaf, for
instance cut rag
tobacco, can, for instance, have a nicotine content of between 1.5% and 5% by
weight of
the tobacco leaf.
The plant or tobacco material described herein can contain an aerosol
modifying agent,
such as any of the flavours described herein. In one embodiment, the tobacco
material
contains menthol, forming a mentholated article. The tobacco material can
comprise
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from 3 mg to 20 mg of menthol, preferably between 5 mg and 18 mg and more
preferably between 8 mg and 16 mg of menthol. In the present example, the
tobacco
material comprises 16 mg of menthol. The tobacco material can contain between
2%
and 8% by weight of menthol, preferably between 3% and 7% by weight of menthol
and
more preferably between 4% and 5.5% by weight of menthol. In one embodiment,
the
tobacco material includes 4.7% by weight of menthol. Such high levels of
menthol
loading can be achieved using a high percentage of reconstituted tobacco
material, for
instance greater than 50% of the tobacco material by weight. Alternatively or
additionally, a higher level of menthol loading that can be achieved by
incorporation of
io the menthol in an aerosol-generating material comprising an aerosol
forming agent and
one or more binder and/or cross-linker
In an embodiment, the tobacco material comprises the tobacco component as
defined
herein and the aerosol-former material as defined herein. In an embodiment,
the
tobacco material consists essentially of the tobacco component as defined
herein and
the aerosol-former material as defined herein. In an embodiment, the tobacco
material
consists of the tobacco component as defined herein and the aerosol-former
material as
defined herein.
Paper reconstituted tobacco may be present in the tobacco component of the
tobacco
material described herein in an amount of from 10% to l00% by weight of the
tobacco
component. In embodiments, the paper reconstituted tobacco is present in an
amount
of from 10% to 80% by weight, or 20%. to 70% by weight, of the tobacco
component. In
a further embodiment, the tobacco component consists essentially of, or
consists of,
paper reconstituted tobacco. In preferred embodiments, leaf tobacco is present
in the
tobacco component of the tobacco material in an amount of from at least 10% by
weight
of the tobacco component. For instance, leaf tobacco can be present in an
amount of at
least 10% by weight of the tobacco component, while the remainder of the
tobacco
component comprises paper reconstituted tobacco, bandcast reconstituted
tobacco, or
a combination of bandcast reconstituted tobacco and another form of tobacco
such as
tobacco granules. Suitably, leaf tobacco can be present in an amount up to 40
% or
6o% of the tobacco material, while the remainder of the tobacco component
comprises
paper reconstituted tobacco, bandcast reconstituted tobacco, or a combination
of
bandcast reconstituted tobacco and another form of tobacco such as tobacco
granules.
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Paper reconstituted tobacco refers to tobacco material formed by a process in
which
tobacco feedstock is extracted with a solvent to afford an extract of solubles
and a
residue comprising fibrous material, and then the extract (usually after
concentration,
and optionally after further processing) is recombined with fibrous material
from the
residue (usually after refining of the fibrous material, and optionally with
the addition
of a portion of non-tobacco fibres) by deposition of the extract onto the
fibrous
material. The process of recombination resembles the process for making paper.
The paper reconstituted tobacco may be any type of paper reconstituted tobacco
that is
_ro known in the art. In a particular embodiment, the paper reconstituted
tobacco is made
from a feedstock comprising one or more of tobacco strips, tobacco stems, and
whole
leaf tobacco. In a further embodiment, the paper reconstituted tobacco is made
from a
feedstock consisting of tobacco strips and/or whole leaf tobacco, and tobacco
stems.
However, in other embodiments, scraps, fines and winnowings can alternatively
or
additionally be employed in the feedstock.
The paper reconstituted tobacco for use in the tobacco material described
herein may
be prepared by methods which are known to those skilled in the art for
preparing paper
reconstituted tobacco.
The density of the tobacco material has an impact on the speed at which heat
conducts
through the material, with lower densities, for instance those below 700
mg/cc,
conducting heat more slowly through the material, and therefore enabling a
more
sustained release of aerosol.
In the figures described herein, like reference numerals are used to
illustrate equivalent
features, articles or components.
Figure 1 is a side-on cross sectional view of a consumable or article 1 for
use in an
aerosol delivery system.
The article 1 comprises a mouthpiece segment 2, and an aerosol generating
segment 3.
The aerosol generating segment 3 is in the form of a cylindrical rod and
comprises an
aerosol-generating material 4 comprising cut rag reconstituted tobacco. The
aerosol-
generating material can be any of the materials discussed herein.
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Although described above in rod form, the aerosol generating segment 3 can be
provided in other forms, for instance a plug, pouch, or packet of material
within an
article.
The mouthpiece segment 2, in the illustrated embodiment, includes a body of
material
5 such as a fibrous or filamentary tow.
The rod-shaped consumable 1 further comprises a wrapper 6 circumscribing the
io mouthpiece segment 2 and aerosol generating segment 3. The
wrapper 6 comprises a
sheet of combustion retarding material as described herein. In the illustrated
example,
the combustion retarding material is a sheet of amorphous solid material
comprising
sodium chloride.
Figure 2 is a side-on cross sectional view of an alternative embodiment of a
consumable
or article 1 for use in an aerosol delivery system.
In this alternative embodiment, the article 1 again comprises a mouthpiece
segment 2,
and an aerosol generating segment 3. The aerosol generating segment 3
comprises a
blend 7 of aerosol-generating material and combustion retarding material.
The rod-shaped consumable 1 further comprises a wrapper 8 circumscribing the
mouthpiece segment 2 and aerosol generating segment 3. The wrapper 8 comprises
a
sheet of paper.
Non-combustible aerosol provision systems
According to the present disclosure, a "non-combustible" aerosol provision
system is
one where a constituent aerosol-generating material of the aerosol provision
system (or
component thereof) is not combusted or burned in order to facilitate delivery
of at least
one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol
provision
system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an
electronic
cigarette, also known as a vaping device or electronic nicotine delivery
system (END),
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although it is noted that the presence of nicotine in the aerosol-generating
material is
not a requirement.
In some embodiments, the non-combustible aerosol provision system is an
aerosol-
generating material heating system, also known as a heat-not-burn system. An
example of such a system is a tobacco heating system.
In some embodiments, the non-combustible aerosol provision system is a hybrid
system to generate aerosol using a combination of aerosol-generating
materials, one or
io a plurality of which may be heated. Each of the aerosol-generating
materials may be,
for example, in the form of a solid, liquid or gel and may or may not contain
nicotine.
In some embodiments, the hybrid system comprises a liquid or gel aerosol-
generating
material and a solid aerosol-generating material. The solid aerosol-generating
material
may comprise, for example, tobacco or a non-tobacco product.
Typically, the non-combustible aerosol provision system may comprise a non-
combustible aerosol provision device and a consumable for use with the non-
combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-
generating material and configured to be used with non-combustible aerosol
provision
devices. These consumables are sometimes referred to as articles throughout
the
disclosure.
In some embodiments, the non-combustible aerosol provision system, such as a
non-
combustible aerosol provision device thereof, may comprise a power source and
a
controller. The power source may, for example, be an electric power source or
an
exothermic power source. In some embodiments, the exothermic power source
comprises a carbon substrate which may be energised so as to distribute power
in the
form of heat to an aerosol-generating material or to a heat transfer material
in
proximity to the exothermic power source.
In some embodiments, the non-combustible aerosol provision system may comprise
an
area for receiving the consumable, an aerosol generator, an aerosol generation
area, a
housing, a mouthpiece, a filter and/or an aerosol-modifying agent.
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Figure 3 shows an example of a non-combustible aerosol provision device 100
for
generating aerosol from an aerosol-generating medium/material such as the
aerosol-
generating material of a consumable 110, as described herein. In broad
outline, the
device 100 may be used to heat a replaceable article 110 comprising the
aerosol-
generating medium, for instance an article 1 as illustrated in any one of
Figures 1 or 2 or
as described elsewhere herein, to generate an aerosol or other inhalable
medium which
is inhaled by a user of the device 100. The device 100 and replaceable article
110
together form a system.
_to The device 100 comprises a housing 102 (in the form of an outer cover)
which
surrounds and houses various components of the device 100. The device 100 has
an
opening 104 in one end, through which the article 110 may be inserted for
heating by a
heating assembly. In use, the article 110 may be fully or partially inserted
into the
heating assembly where it may be heated by one or more components of the
heater
assembly.
The device 100 of this example comprises a first end member 106 which
comprises a lid
108 which is moveable relative to the first end member 106 to close the
opening 104
when no article 110 is in place. In Figure 3, the lid 108 is shown in an open
configuration, however the lid 108 may move into a closed configuration. For
example,
a user may cause the lid 108 to slide in the direction of arrow "B".
The device 100 may also include a user-operable control element 112, such as a
button
or switch, which operates the device 100 when pressed. For example, a user may
turn
on the device 100 by operating the switch 112.
The device 100 may also comprise an electrical component, such as a
socket/port 114,
which can receive a cable to charge a battery of the device 100. For example,
the socket
114 may be a charging port, such as a USB charging port.
Method of manufacture
In some embodiments, the combustion retarding salt is incorporated into or
added to
the amorphous solid material dissolved in a solvent or liquid carrier. In some
embodiments, the combustion retarding salt is a suspension in a liquid
carrier. The
solvent or liquid carrier may be an aqueous or organic liquid, and may be
polar or non-
polar depending on its suitable application. The liquid carrier or precursor
solvent may
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be advantageously selected to be volatile, so that the carrier liquid or
solvent may be
removed to leave the combustion retarding salt in or on the amorphous solid
material.
In some embodiments, the solvent or liquid carrier comprises a mixture of
water and
glycerol.
Example
Consumables with a range of different wrappers surrounding a rod of aerosol-
generating material were prepared and their combustion characteristic
compared.
Consumables comprising cut rag aerosol-generating material were prepared,
using a
variety of different wrappers.
The first wrapper used was paper, namely 24 GSM (grammes per square metre)
paper
with a porosity of 75 CU (Coresta units).
Further wrappers used were 32 GSM and 64 GSM Delfort papers.
A further wrapper used was laminated aluminium foil comprising 6.3 i_tm
thickness
lacquered aluminium foil laminated with 23.5 GSM paper with 37 i_tm thickness.
Finally, a combustion retarding material according to the present disclosure
was used,
formed from a slurry having the following make up:
43 g alginate (2.7%)
insa g sodium chloride (6.3 %)
50 g glycerol (3.1%)
1400 ml water (87.9 %)
The consumables were hand made, by inserting the combustion retarding sheet as
an
inner wrapper, and then filling the rod with tobacco.
For testing, the consumables were lit in the manner of a combustible cigarette
and
attempts were made to smoke them by puffing. The greater the combustion
resistance
of the wrapper materials, the less of the consumable was combusted.
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Tests showed that the amorphous solid material comprising sodium chloride
resisting
combustion well and performed similarly to the known combustion retardant foil
and
Delfort papers.
In addition, further combustion retarding material according to the present
disclosure
was used, formed from a slurry having the following make up:
21.5 g alginate
21.5 g wood pulp
120 g sodium chloride
_/c) 30 g glycerol
1400 ml water
The slurry was dried in an oven to form a sheet. The sheets that were obtained
did not
combust when exposed to a naked flame from a lighter.
The various embodiments described herein are presented only to assist in
understanding and teaching the claimed features. These embodiments are
provided as
a representative sample of embodiments only, and are not exhaustive and/or
exclusive.
It is to be understood that advantages, embodiments, examples, functions,
features,
structures, and/or other aspects described herein are not to be considered
limitations
on the scope of the invention as defined by the claims or limitations on
equivalents to
the claims, and that other embodiments may be utilised and modifications may
be
made without departing from the scope of the claimed invention. Various
embodiments of the invention may suitably comprise, consist of, or consist
essentially
of, appropriate combinations of the disclosed elements, components, features,
parts,
steps, means, etc., other than those specifically described herein. In
addition, this
disclosure may include other inventions not presently claimed, but which may
be
claimed in future.
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