Note: Descriptions are shown in the official language in which they were submitted.
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A component for an article for use in an aerosol provision system
Technical Field
The present disclosure relates to a component for an article for use in or as
a
combustible aerosol provision system, an article for use in or as a
combustible aerosol
provision system and a method for forming a component for an article for use
in or as a
combustible aerosol provision system.
Background
Certain tobacco industry products produce an aerosol during use, which is
inhaled by a
user. For example, cigarettes form an aerosol through combustion of tobacco
material.
Such tobacco industry products commonly include mouthpieces through which the
aerosol passes to reach the user's mouth.
Summary
In accordance with embodiments described herein, according to a first aspect,
there is
provided a component for an article for use in or as a combustible aerosol
provision
system, the component comprising a body of material extending in a
longitudinal
direction, wherein the body of material comprises crimped sheet material
formed
having a crimp pattern comprising a series of substantially parallel ridges
and grooves,
wherein the average spacing between adjacent ridges is greater than about 0.3
mm and
wherein the average density of said body of material is between about 0.1 and
about
0.25 mg/mm3.
In accordance with embodiments described herein, according to a second aspect,
there
is provided component for an article for use in or as a combustible aerosol
provision
system, the component comprising a body of material extending in a
longitudinal
direction, wherein the body of material comprises crimped sheet material
formed
having a crimp pattern comprising a series of substantially parallel ridges
and grooves,
wherein the crimp amplitude is less than about 0.7 mm and wherein the average
density of said body of material is between about 0.1 and about 0.25 mg/mmi.
In accordance with embodiments described herein, according to a third aspect,
there is
provided an article for use in or as a combustible aerosol provision system,
the article
comprising an aerosol generating material and a downstream portion downstream
of
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the aerosol generating material, the downstream portion comprising a component
according to the first or second aspect above.
In accordance with embodiments described herein, according to a fourth aspect
there is
provided a combustible aerosol provision system comprising an article
according to the
third aspect above.
In accordance with embodiments described herein, according to a fifth aspect
there is
provided a method for forming a component for an article for use in a
combustible
io aerosol provision system, the method comprising applying a crimp pattern
to a sheet
material, the crimp pattern comprising a series of substantially parallel
ridges and
grooves, wherein the average spacing between adjacent ridges is greater than
about 0.3
mm, and forming said sheet material into a body of material, wherein the
average
density of said body of material is between about 0.1 and about 0.25 mg/mm3.
In accordance with embodiments described herein, according to a sixth aspect
there is
provided a method for forming a component for an article for use in a
combustible
aerosol provision system, the method comprising applying a crimp pattern to a
sheet
material, the crimp pattern comprising a series of substantially parallel
ridges and
grooves, wherein the crimp amplitude is less than about 0.7 mm and forming
said sheet
material into a body of material, wherein the average density of said body of
material is
between about 0.1 and about 0.25 mg/mm3.
Brief Description of the Drawings
Embodiments of the invention will now be described, by way of non-limiting
examples
only, with reference to the accompanying drawings, in which:
Figure 1 is a side-on cross sectional view of an article for use with an
aerosol provision
device, the article including a body of material formed from a sheet material;
Figure 2A is a cross-sectional end view of the body of material of the article
of Figure 1,
along the line A-A of Figure 1;
Figure 2B is a side-on view of the sheet material forming the body of material
of Figure
2A;
Figure 3 is a side-on cross sectional view of an article for use with an
aerosol provision
device;
Figure 4 is a side-on cross sectional view of an article for use with an
aerosol provision
device;
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Figure 5 is a side-on cross sectional view of an article for use with an
aerosol provision
device; and
Figure 6 is a side-on cross sectional view of a multiple length rod for
manufacture of a
body of material of the article of Figure 5.
Detailed Description
According to the present disclosure, an "aerosol provision system" includes
both
combustible aerosol provision systems and non-combustible aerosol provision
systems.
io According to the present disclosure, a "combustible" aerosol
provision system is one
where a constituent aerosol-generating material of the aerosol provision
system (or
component thereof) is combusted or burned during use in order to facilitate
delivery of
at least one substance to a user.
In some embodiments, the delivery system is a combustible aerosol provision
system,
such as a system selected from the group consisting of a cigarette, a
cigarillo and a
cigar.
In some embodiments, the disclosure relates to a component for use in a
combustible
aerosol provision system, such as a filter, a filter rod, a filter segment, a
tobacco rod, a
spill, an aerosol-modifying agent release component such as a capsule, a
thread, or a
bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.
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 substance to be delivered comprises an active
substance.
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
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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 or be derived from one or
more
botanicals or constituents, derivatives or extracts thereof. As used herein,
the term
"botanical" includes any material derived from plants including, but not
limited to,
io 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. 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, 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, Memtha 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.
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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 selected
from rooibos and fennel.
In some embodiments, the substance to be delivered comprises a flavour.
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,
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
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.
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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
io 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.
Aerosol-generating material is a material that is capable of generating
aerosol, for
example when heated, irradiated or energized in any other way. Aerosol-
generating
material may, for example, be in the form of a solid, liquid or gel which may
or may not
contain an active substance and/or flavourants. In some embodiments, the
aerosol-
generating material may comprise an "amorphous solid", which may alternatively
be
referred to as a "monolithic solid" (i.e. non-fibrous). In some embodiments,
the
amorphous solid may be a dried gel. The amorphous solid is a solid material
that may
retain some fluid, such as liquid, within it. In some embodiments, the aerosol-
generating material may for example comprise from about 50wt%, 6owt% or 70wt%
of
amorphous solid, to about 90vvt%, 95vvt% or mowt% of amorphous solid.
The aerosol-generating material may comprise one or more active substances
and/or
flavours, one or more aerosol-former materials, and optionally one or more
other
functional material.
The aerosol-former material may comprise one or more constituents capable of
forming
an aerosol. In some embodiments, 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
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benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid,
myristic acid, and
propylene carbonate.
The one or more other functional materials may comprise one or more of pH
regulators, colouring agents, preservatives, binders, fillers, stabilizers,
and/or
antioxidants.
The material may be present on or in a support, to form a substrate. The
support may,
for example, be or comprise paper, card, paperboard, cardboard, reconstituted
io material, a plastics material, a ceramic material, a composite material,
glass, a metal, or
a metal alloy. In some embodiments, the support comprises a susceptor. In some
embodiments, the susceptor is embedded within the material. In some
alternative
embodiments, the susceptor is on one or either side of the material.
A consumable is an article comprising or consisting of aerosol-generating
material, part
or all of which is intended to be consumed during use by a user. A consumable
may
comprise one or 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.
An aerosol-modifying agent is a substance that is configured to modify the
aerosol
generated, for example by changing the taste, flavour, acidity or another
characteristic
of the aerosol. The aerosol-modifying agent may be provided in an aerosol-
modifying
agent release component, that is operable to selectively release the aerosol-
modifying
agent
The aerosol-modifying agent may, for example, be an additive or a sorbent. The
aerosol-modifying agent may, for example, comprise one or more of a
flavourant, a
colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for
example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in
powder,
thread or granule form. The aerosol-modifying agent may be free from
filtration
material.
Articles, for instance those in the shape of rods, are often named according
to the
product length: "regular" (typically in the range 68 ¨ 75 mm, e.g. from about
68 mm to
about 72 mm), "short" or "mini" (68 mm or less), "king-size" (typically in the
range 75 -
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91 mm, e.g. from about 79 mm to about 88 mm), "long" or "super-king"
(typically in the
range 91 ¨ 105 mm, e.g. from about 94 mm to about 101 mm) and "ultra-long"
(typically in the range from about no mm to about 121111111).
They are also named according to the product circumference: "regular" (about
23 ¨ 25
mm), "wide" (greater than 25 mm), "slim" (about 22 - 23 mm), "demi-slim"
(about 19
- 22 mm), "super-slim" (about 16 ¨ 19 mm), and "micro-slim" (less than about
16 mm).
Accordingly, an article in a king-size, super-slim format will, for example,
have a length
io of about 83 mm and a circumference of about 17 mm.
Each format may be produced with mouthpieces of different lengths. The
mouthpiece
length will be from about 3 omm to 50 mm. A tipping paper connects the
mouthpiece
to the aerosol generating material and will usually have a greater length than
the
mouthpiece, for example from 3 to io mm longer, such that the tipping paper
covers
the mouthpiece and overlaps the aerosol generating material, for instance in
the form
of a rod of substrate material, to connect the mouthpiece to the rod.
Articles and their aerosol generating materials and mouthpieces described
herein can
be made in, but are not limited to, any of the above formats.
The terms 'upstream' and 'downstream' used herein are relative terms defined
in
relation to the direction of mainstream aerosol drawn though an article or
device in
use.
The filamentary tow material described herein can comprise cellulose acetate
fibre tow.
The filamentary tow can also be formed using other materials used to form
fibres, such
as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL),
poly(1-4
butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate)(PBAT),
starch
based materials, cotton, aliphatic polyester materials and polysaccharide
polymers or a
combination thereof. The filamentary tow may be plasticised with a suitable
plasticiser
for the tow, such as triacetin where the material is cellulose acetate tow, or
the tow may
be non-plasticised. The tow can have any suitable specification, such as
fibres having a
'Y' shaped or other cross section such as 'X' shaped, filamentary denier
values between
2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per
filament
and total denier values of 5,000 to 50,000, for example between 10,000 and
.40,000.
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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 the figures described herein, like reference numerals are used to
illustrate equivalent
io features, articles or components.
Figure 1 is a side-on cross sectional view of an article 1 for use as a
combustible aerosol
provision system, for instance a cigarette.
The article 1 includes a cylindrical rod of aerosol generating material 3, in
the present
case tobacco material, and a downstream portion, in the present case referred
to as a
mouthpiece 2, connected to the aerosol generating material 3 such that it is
downstream of the aerosol generating material 3. The aerosol generating
material 3
provides an aerosol when combusted.
The aerosol generating material 3, also referred to herein as an aerosol
generating
substrate 3, comprises at least one aerosol-former material. In the present
example,
the aerosol-former material is glycerol. In alternative examples, the aerosol-
former
material can be another material as described herein or a combination thereof,
for
instance propylene glycol.
In the present example, the mouthpiece includes a tubular portion 4a, in the
present
example formed by a hollow tube, also referred to as a cooling element. The
mouthpiece
2, in the present example, includes a component including a body of material 6
downstream of the tubular portion 4a. In the present example, the body of
material 6 is
adjacent to and in an abutting relationship with the tubular portion 4a. The
body of
material 6 and tubular portion 4a each define a substantially cylindrical
overall outer
shape and share a common longitudinal axis.
In the present example, the body of material 6 of the component is formed from
sheet
material which is crimped. In the present example, the body of material
comprises
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crimped sheet material formed having a crimp pattern comprising a series of
substantially parallel ridges and grooves, and the average spacing between
adjacent
ridges is greater than about 0.3 mm. In addition, in the present example, the
crimp
amplitude is less than about 0.7 mm. In other examples, the sheet material can
include
either an average spacing between adjacent ridges of greater than about 0.3 mm
or a
crimp amplitude of less than about 0.7 mm. Alternatively or in addition, the
crimp
amplitude can be between about o.7mm and about 1.2mm. In any of these
examples,
the average density of said body of material can be between about 0.1 and
about 0.25
mg/mm3.
The crimp amplitude (also known as "crimping factor") refers to the depth of
the
grooves the crimping forms in the sheet material forming the body. That is,
crimping
the sheet material produces a plurality of peaks and troughs in the sheet
material when
viewed from a first side of the sheet material, as shown in Figure 2B, wherein
the crimp
amplitude 'A' is the depth of the troughs, measured from their peak. The
crimping may
form a `Zig-Zag' formation or another shape. In some embodiments, adjacent
grooves
of the crimped sheet material are spaced by a distance, or have a pitch 'P',
in the range
of 0.3 to 2 mm and, preferably, in the range of 0.4 to 1 mm. In some
embodiments,
adjacent grooves of the crimped sheet material are spaced by a distance of at
least 0.4
mm or at least 0.5, o.6, 0.7 or o.8 mm. In some embodiments, adjacent grooves
of the
crimped sheet material 10 are spaced by a distance of at most 1.5 mm, and
preferably,
at most, 1.4, 1.3, 1.2, 1.1 or 1.0 mm. For instance, the sheet material can
have a crimp
with a crimp amplitude of less than distance of 500 pm and spacing between
peaks (or
troughs) of at least 300 pm, at least 400 mn or at least 500 pm.
In some embodiments, the sheet material 10 is heated as it is crimped. For
example, the
sheet material 10 may be passed between crimping rollers, wherein one or both
of the
crimping rollers is heated.
Advantageously, sheet material, for instance paper, having the above crimp
pitch
and/or amplitude has been found to exhibit improved performance when used in
components of aerosol provision systems. In particular, these relatively low
levels of
crimp pitch and amplitude surprisingly result in a body of material having a
lower
pressure drop compared to bodies formed from sheet material with higher levels
of
crimping.
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In the present example, the density of the body of material 6 is about 0.19
mg/mm3. In
some embodiments, the body 6 has a density of at least 0.1 mg/mm3, 0.12 mg/mm3
or
0.15 mg/mm3. Alternatively or in addition, the body of material 6 can have a
density of
less than about 0.3 mg/mm3, less than about 0.25 mg/mm3 or less than about
0.22
mg/mm3. Advantageously, the density of the body of material can be between
about
0.15 mg/mm3 and about 0.25 mg/mm3. These values include any additives included
within the body of material 6. Before being crimped and formed into the body
of
material, the sheet material can have a density of between about 0.2 and 0.5
mg/mm3,
for instance about 0.25, 0.30 or 0.35 mg/mm3.
In some embodiments, the sheet material comprises fibres having a length in
the range
2 Min to 6 mm. Such fibres have the benefit that they result in a material
which is less
likely to absorb and hold an aerosol former (e.g. glycerol, as in the present
example)
and/or an aerosol-modifying agent (e.g. menthol). Hence, a body of material
including
such fibres may allow a greater amount of aerosol former and/or aerosol-
modifying
agent to pass through the body of material to the user's mouth. In some
embodiments,
the body of material comprises fibres having a length in the range 2 mm to 5
mm, 2 Min
to 4 mm, or 2 111111 to 3 MM.
The body of material can comprise fibres having one or more of the following
lengths:
about 2 111111, about 2.5 mm, about 3 mm, about 3.5 mm, about 4 mm, about 4.5
mm,
about 5 mm, about 5.5 mm and about 6 mm.
The fibre length can be measured in accordance with an appropriate standard
and the
fibre lengths set out above can be the length-weighted mean value of fibre
lengths.
Selection of appropriate fibre lengths can be made based, for instance, on the
source of
material, such as the type of wood, used to provide pulp for the sheet
material paper
production process. The fibre length can be, for instance, selected based on
the form of
cellulosic material used to form the sheet material. For instance, species of
pine
generally result in wood pulp having an average fibre length in the range of
about
3.mm to 4.4mm , whereas species of ash may result in wood pulp having an
average
fibre length between about 1.05mm and 1.20MM. The average fibre length in the
sheet
material can, for instance, be determined by scanning electron microscopy or
other
techniques known to those in the art. At least 70% of the fibres, for
instance, can have
a length in the range 2 MIT1 to 6 mm, or at least 80% or 90%.
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In alternative embodiments, the article 1 can be adapted, for instance by
removal of the
tubular portion 4a and/or adjustment of the level of aerosol former material.
The body of material 6 may be formed from a continuous web of sheet material
6A. In
the present example, the sheet material 6A is gathered to form the body of
material 6 is
a similar manner to a 'crepe filter'. The sheet material 6A may be
manufactured using a
CIJ-20 filter making machine manufactured by Decoufle (TM). However, a skilled
person will appreciate that other machines may be used to manufacture the body
of
material 6.
In the present example, the sheet material 6A comprises cellulose. In the
present
example, the sheet material 6A is paper.
In some embodiments, the continuous web of sheet material 6A has a width of at
least
6o mm, at least 70 mm, at least 8o mm, at least 90 mm, at least loo mm, at
least no
mm, or at least 120 mm.
In some embodiments, the continuous web of sheet material 6A has a width of at
most
240 mm, at most 230 mm, at Most 220 MM, at Most 210 HIM, at Most 200 Min or at
most 190 MM.
In some embodiments, the sheet material has a width in the range of 120 Mtn to
200
mm, in the range of 150 mm to 190 mm, in the range of 160 mm to 190 mm, or in
the
range of 16o mm to 18o mm.
The sheet material can have a thickness of between about 50 and about 100 pm,
or
between about 6o and about 90 um. In one example, the sheet material is paper
having
a thickness of between 60 and 70 um and a basis weight of between 30 and 40
grams/m2.
The sheet material 6A may additionally or alternatively comprise a different
material.
For example, in some embodiments the sheet material 6A comprises reconstituted
tobacco that is formed into a sheet material 6A that is arranged to form the
body of
material 6. The reconstituted tobacco comprises cellulose. In another
embodiment (not
shown), the reconstituted tobacco is manufactured into a uniform plug of
material that
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forms the body 6. The reconstituted tobacco may optionally be paper
reconstituted
tobacco.
In some embodiments, the sheet material 6A comprises paper with a basis weight
in the
range of 15 gm to 8o gsm, or in the range of 20 gsm to 50 gsm.
In some embodiments, the sheet material 6A has a basis weight of at least 15
gsm, at
least 20 gsm, at least 25 gsm or at least 30 gsm.
io In some embodiments, the sheet material has a basis weight of loo gsm or
less, 90 gsm
or less, 8o gsm or less or 70 gsm or less. Preferably, the sheet material has
a basis
weight of 6o gsm or less, 50 gsm or less, or 40 gsm or less.
In some embodiments, the sheet material has a basis weight in the range of 20
gsm to
40 gsm, in the range of 24 gsm to 36 gsm, or in the range of 30 gsm to 40 gsm.
The body of material 6 is wrapped in a first plug wrap 7. In the present
example, the
tubular portion 4a and body of material 6 are combined using a second plug
wrap 9
which is wrapped around both sections. A tipping paper 5 is wrapped around the
full
length of the mouthpiece 2 and over part of the rod of aerosol generating
material 3 and
has an adhesive on its inner surface to connect the mouthpiece 2 and rod 3.
In the present example, the tubular portion 4a is formed from a plurality of
layers of
paper which are parallel wound, with butted seams, to form a hollow tube. In
the
present example, first and second paper layers are provided in a two-ply tube,
although
in other examples 3, 4 or more paper layers can be used forming 3, 4 or more
ply tubes.
Other constructions can be used, such as spirally wound layers of paper,
cardboard
tubes, tubes formed using a papier-mâché type process, moulded or extruded
plastic
tubes or similar.
In some embodiments, the tubular portion has a wall thickness of at least
about 150 pm
and up to about 2 mm, between 200 pm and 1.5 mm, or between 250 pm and 1 mm.
In
the present example, the tubular portion has a wall thickness of about 300
p.m. The
"wall thickness" of the tubular portion corresponds to the thickness of the
wall of the
tubular portion in a radial direction. This may be measured, for example,
using a
caliper.
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The article 1 has a ventilation level of about 75% of the aerosol drawn
through the
article. In alternative embodiments, the article can have a ventilation level
of between
50% and 80% of aerosol drawn through the article, for instance between 65% and
75%.
Ventilation at these levels helps to slow down the flow of aerosol drawn
through the
mouthpiece 2 and thereby enable the aerosol to cool sufficiently before it
reaches a
downstream end 2b of the mouthpiece 2. The ventilation is provided directly
into the
mouthpiece 2 of the article 1. In the present example, the ventilation is
provided into
the tubular portion 4a, which has been found to be particularly beneficial in
assisting
io with the aerosol generation process. The ventilation is provided via
first and second
parallel rows of ventilation holes 12, in the present case formed as laser
perforations, at
positions 13.925 mm and 14.625 mm respectively from the downstream, mouth-end
2b
of the mouthpiece 2. These ventilation holes 12 pass though the tipping paper
5, second
plug wrap 9 and tubular portion 4a. In alternative embodiments, the
ventilation can be
provided into the mouthpiece at other locations. For example, the ventilation
may be
provided into the body of material 6.
Alternatively, the ventilation can be provided via a single row of ventilation
holes, for
instance laser perforations, into the portion of the article in which the
tubular body 4a
is located. This has been found to result in improved aerosol formation, which
is
thought to result from the airflow through the ventilation holes being more
uniform
than with multiple rows of ventilation holes, for a given ventilation level.
In some examples, the aerosol generating material 3 described herein is a
first aerosol
generating material and the tubular portion 4a may include a second aerosol
generating
material. In one example, wall 4b of tubular portion 4a comprises the second
aerosol
generating material. For example, the second aerosol generating material can
be
disposed on an inner surface of wall 4b of the tubular portion 4a.
The second aerosol generating material comprises at least one aerosol former
material,
and may also comprise at least one aerosol modifying agent, or other sensate
material.
The aerosol former material and/or aerosol modifying agent can be any aerosol
former
material or aerosol modifying agent as described herein, or a combination
thereof.
As the aerosol generated from aerosol generating material 3, referred to
herein as the
first aerosol, is drawn through the tubular portion 4a of the mouthpiece, heat
from the
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first aerosol may aerosolise the aerosol forming material of the second
aerosol
generating material, to form a second aerosol. The second aerosol may comprise
a
flavourant, which can be any of the flavourants described herein, and which
may be
additional or complementary to the flavour of the first aerosol.
Providing a second aerosol generating material on the tubular body 4a can
result in
generation of a second aerosol which boosts or complements the flavour or
visual
appearance of the first aerosol.
io In the present example, the article 1 has an outer circumference
of about 21 mm (i.e. the
article is in the demi-slim format). In some embodiments, the article 1 has a
rod of
aerosol generating material having a circumference greater than 19 mm.
The outer circumference of the mouthpiece 2 is substantially the same as the
outer
circumference of the rod of aerosol generating material 3, such that there is
a smooth
transition between these components. In the present example, the outer
circumference
of the mouthpiece 2 is about 20.8 mm.
In some examples, the tipping paper 5 comprises citrate, such as sodium
citrate or
potassium citrate. In such examples, the tipping paper 5 may have a citrate
content of
2% by weight or less, or i% by weight or less. Reducing the citrate content of
the
tipping paper 5 is thought to assist with reducing the charring effect which
may occur
during use.
In the present example, the tipping paper 5 extends 5 mm over the rod of
aerosol
generating material 3 but it can alternatively extend between 3 mm and 10 mm
over the
rod 3, or between 4 mm and 6 mm, to provide a secure attachment between the
mouthpiece 2 and rod 3. The tipping paper 5 can have a basis weight which is
higher
than the basis weight of plug wraps used in the article 1, for instance a
basis weight of
40 gsm to 80 gsm, or between 50 gsm and 70 gsm, and in the present example 58
gsm.
These ranges of basis weights have been found to result in tipping papers
having
acceptable tensile strength while being flexible enough to wrap around the
article 1 and
adhere to itself along a longitudinal lap seam on the paper. The outer
circumference of
the tipping paper 5, once wrapped around the mouthpiece 2, is about 21 MM.
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In some embodiments, the first plug wrap 7 has a basis weight of less than 50
gsm, for
instance between about 20 gsm and 40 gsm. However, it should be recognised
that the
basis weight of the first plug wrap 7 may be higher to increase the hardness
of the
mouthpiece. For instance, the basis weight of the first plug wrap 7 may be at
least 50
gsm, at least 6o gsm, at least 70 gsm, at least 8o gsm, at least 90 gsm or at
least 100
gsm. In some embodiments, the basis weight of the first plug wrap 7 is in the
range of
50 gsm to no gsm, or in the range of 6o gsm to loo gsm.
In some embodiments, the first plug wrap 7 has a basis weight of at least 20
gsm or at
io least 30 gsm. In some embodiments, the first plug wrap 7 has a basis
weight of at most
120 gsm, no gsm or wo gsm. In some embodiments, the first plug wrap 7 has a
basis
weight in the range of 20 gsm to 120 gsm, or in the range of 30 to loo gsm.
In some embodiments, the first plug wrap 7 has a thickness of between 30 pm
and 6o
pm, or between 35 ?Jill and 45 um. However, it should be recognised that the
thickness
weight of the first plug wrap 7 may be higher to increase the hardness of the
mouthpiece. In some embodiments, for example, the thickness of the first plug
wrap 7
may be at least 40 microns, 50 microns, 60 microns, 70 microns, 80 microns, 90
microns or wo microns. In some embodiments, the thickness of the first plug
wrap 7 is
in the range of 40 microns to 120 microns, or in the range of 50 to 100
microns.
In some embodiments, the first plug wrap 7 is a non-porous plug wrap, for
instance
having a permeability of less than loo Coresta units, for instance less than
50 Coresta
units. However, in other embodiments, the first plug wrap 7 can be a porous
plug wrap,
for instance haying a permeability of greater than 200 Coresta Units.
In some embodiments, the length of the body of material 6 is less than about
20 mm. In
the present example, the length of the body of material 6 is about 12 MM.
In some embodiments, the axial length of the body of material 6 is in the
range of 10
mm to 20 mm.
In some embodiments, an aerosol-former material is applied to the body of
material 6.
For example, the aerosol-former material may be applied to the sheet material
6A prior
to the sheet material 6A being folded to form the body of material 6. The
aerosol-
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former material may be sprayed on to the sheet material 6A or applied by a
brush or by
dipping the sheet material 6A in aerosol-former material.
In some embodiments, 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. For instance, the aerosol-former material can comprise triacetin
and/or
triethyl citrate.
In some embodiments, at least 0.02 mg of aerosol-former material is applied to
the
body of material per 1mm axial length of the body of material. In some
embodiments,
at least 0.03 mg, at least 0.04 mg or at least 0.05 mg of aerosol-former
material is
applied to the body of material per 1 mm axial length of the body of material.
In some embodiments, 0.5 mg or less of aerosol-former material is applied to
the body
of material per 1 mm axial length of the body of material. In some
embodiments, 0.4
mg or less or 0.3 mg or less of aerosol-former material is applied to the body
of material
per 1 mm axial length of the body of material.
At least some of the aerosol-former material is combined with the aerosol as
it passes
through the body of material 6 and helps to make the aerosol feel less dry
within the
user's mouth.
In some embodiments, the body of material 6 has an outer volume of at least
115 mm3.
In the present example, the body of material 6 is generally cylindrical and
thus has a
generally cylindrical outer volume. It should be recognised that in other
embodiments
the body of material 6 may have an outer volume that is smaller than 115 mm3.
In the present example, the width Wi of the body of material 6 (which in the
present
example corresponds to the diameter of the body of material 6) is about 6.36
mm and
the axial length Li of the body of material 6 is 12 mm. Thus, the outer volume
of the
body of material 6 is about 381 mm3.
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It has been found that a body of material 6A comprising cellulose and having a
volume
of at least 115mm3 helps to remove moisture from aerosol generated by the
aerosol
generating material 3 as the aerosol passes through the body of material 6A of
the
mouthpiece 2. That is, the cellulose containing sheet material 6A absorbs
water from
the aerosol. Removing moisture from the aerosol makes the aerosol feel cooler
in the
user's mouth.
In some embodiments, the body of material 6 has a volume of at least 19 mm3
per mm
axial length of the body of material, at least 25 mm3 per mm axial length, or
at least 30
mm3 per mm axial length. For instance, if the body of material 6 has a volume
of 19
mm3 per mm axial length, and a length Li of 10 mm, then the volume of the body
of
material would be 190 mm3.
A larger volume of body of material 6A will generally be more effective at
removing
moisture from the aerosol. In some examples, the outer volume of the body of
material
6 is at least 200 mm3, at least 300 mm3, at least 400 mm3, at least 500 mm3,
at least
600 mm3, at least 700 mm3, at least 8o0 mm3, at least 900 mm3 or at least l000
mm3.
In some embodiments, the axial length Li of the body of material 6 is at least
4 mm, at
least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, or at
least 10
mm.
In some embodiments, the axial length Li of the body of material 6 is in the
range of 5
mm to 20 mm, 6 mm to 15 mm, or 8 mm to 14 mm.
In some embodiments, the width Wi of the body of material 6 is at least 4 mm,
at least
5 mm, at least 6 mm, at least 7 mm, at least 8 mm or at least 9 mm.
In some embodiments, the circumference of the body of material 6 is at least
16 mm, at
least 18 mm, at least 20 mm, at least 22 mm, at least 25 mm or at least 26 mm.
In some embodiments, the pressure drop across the body of material 6 is at
least 2
mmt120, at least 3 mml120, or at least 4 mmI-120. The pressure drop across the
body of
material may be at least 5 mmH20, at least 6 mmH20, at least 7 mmE120, at
least 8
mmt120, at least 9 mmH20, at least 10 mmH20 or at least ii mmH20.
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In some embodiments, the pressure drop across the body of material 6 is less
than 30
mmt120, less than 28 mmf120 or less than 25 mmt120.
In some embodiments, the pressure drop across the body of material 6 is about
20
mmH20, 23 mmH20 or 28 mmH20.
In some embodiments, the pressure drop across the body of material 6 is in the
range of
to mmH20 to 30 mmH20, or in the range of 15 mmH20 to 25 mmH20.
io In some embodiments, the pressure drop across the body of material 6 is
at least 1.0
mmt120 per mm axial length of the body of material 6. In some embodiments, the
pressure drop across the body of material 6 is at least 1.2 MMH20, 1.5 mmH20,
or 1.8
mmH20 per mm axial length of the body of material 6.
In some embodiments, the pressure drop across the body of material 6 is less
than 3.0
mmt120, 2.8 mmH20, or 2.6 mmt120 axial length of the body of material 6. In
some
embodiments, the pressure drop across the body of material 6 is less than 2.5
mmH20,
2.4 mmH20 or 2.3 mmH20 per mm of axial length of the body of material 6.
In some embodiments, the pressure drop across the body of material 6 is in the
range of
1.5 mmI-I20 to 2.5 mmH20 per mm axial length of the body of material 6, or in
the
range of 1.6 to 2.4 mmWG per mm axial length of the body of material 6.
In some of the embodiments, the mass of body of material 6 is at least 50 mg,
at least
60 mg or at least 70 mg. It has been advantageously found that providing a
higher mass
of the body of material 6 increases the amount of moisture that is absorbed
form the
aerosol. In the present example, the mass of the body of material is about 75
mg.
In some of the embodiments, the mass of body of material 6 is less than 150
mg, less
than too mg, less than 85 mg or less than 80 mg.
In some embodiments, the body of material 6 has a weight of at least 2 mg per
mm
axial length of the body of material. In some embodiments, the body of
material 6 has a
weight of at least 3 mg per mm axial length or at least 4 mg per mm axial
length.
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In the present example, the body of material 6 has a weight of about 6 mg per
mm. That
is, if the body of material 6 has an axial length Li of 12 mm, as in the
present example,
then the total mass of the body of material 6 would be about 74 mg.
In some embodiments, the body of material 6 is a solid cylindrical body of
material.
In some embodiments, the mouthpiece 2 has a hardness in the range of about 80%
to
95%, or in the range of about 85% to 90%. The hardness of the mouthpiece 2 may
be at
least 8o%, at least 81%, at least 82%, at least 83%, at least 84%, at least
85%, at least
/0 86%, at least 87%, at least 88%, at least 89%, at least 90%, at least
91% or at least 92%.
The hardness of the mouthpiece 2 may be measured according to the following
protocol. Where the hardness of a section is referred to herein, the hardness
is that as
determined by the following measurement process. Any suitable device may be
used
Is for performing the measurement, such as the Borgwaldt Hardness Tester
Hio.
Hardness is defined as the ratio between the height ho of a body and the
height hi of
the body under a defined load, stated as a percentage of ho. Hardness may be
expressed
as:
Hardness = (M/ho) xioo
For an individual body, or a body contained in a multi-section rod, the
hardness
measurement is performed at the longitudinal centre point of the body.
A load bar is used to apply the defined load to the body. The length of the
load bar
should be significantly higher than that of the specimen to be measured. Prior
to the
hardness measurement, the body to be measured is conditioned according to ISO
3402
for a minimum of 48 hours, and is maintained in environmental conditions
according
to ISO 3402 during the measurement.
To perform the hardness measurement, a body is placed into the Hardness Tester
Hio,
a pre-load of 2 g is applied to the body, and after 1 s the initial height ho
of the body
under the 2 g pre-load is recorded. The pre-load is then removed and a load
bar bearing
a load of 150 g is lowered onto the sample at a rate of 0.6 mm/s, after 5 s
the height hi
of the body under the 150 g load is measured.
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The hardness of the mouthpiece is determined as the average hardness of at
least 20
mouthpieces measured according to this protocol.
The hardness of the body of material 6 circumscribed by the first plug wrap 7
(hereinafter together referred to as the "component" for the purposes of
determining
the hardness) may also be determined using the above protocol, by carefully
cutting the
article to remove the body of material 6 surrounded by the first plug wrap 7.
The
hardness of the component may be at least 8o%, at least 81%, at least 82%, at
least at
io least 83%, at least 84%, at least 85%, at least 86%, at least 87%, at
least 88%, at least
89%, at least 90%, at least 91% or at least 92%.
The expression "roundness" refers to the percentage conformity of the cross-
sectional
shape of the article/component to a perfect circle. The roundness is
calculated
according to Equation 1 below:
Rt2:1314 neSS (%) = _____________________________________ ) X WO
[Equation 1]
To determine the roundness of the article 1 the maximum external diameter "X"
of the
component is measured using a calliper and the minimum external diameter "Y"
of the
article is measured using a calliper (the diameters being perpendicular to the
central
axis of the article 1). The less deviation between the maximum external
diameter X and
minimum external diameter Y of the article 1, the higher the roundness, which
indicates
that the cross-sectional shape of the article 1 is closer to a perfect circle.
Tn some embodiments, the roundness of the article 1 is at least 90%, at least
91%, at
least 92%, at least 93%, at least 94% or at least 95%.
The hardness of the body of material 6 circumscribed by the first plug wrap 7
(hereinafter together referred to as the "component" for the purposes of
determining
the roundness) may also be determined using the above protocol, by carefully
cutting
the article to remove the body of material 6 surrounded by the first plug wrap
7.
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To determine the roundness of the body of material 6 circumscribed by the
first plug
wrap 7 (hereinafter together referred to as "the component" for the purposes
of
determining the roundness) the maximum external diameter "X" of the component
is
measured using a calliper and the minimum external diameter "Y" of the
component is
measured using a calliper (the diameters being perpendicular to the central
axis of the
component). The less deviation between the maximum external diameter X and
minimum external diameter Y of the component, the higher the roundness, which
indicates that the cross-sectional shape of the component is closer to a
perfect circle.
io In some embodiments, the roundness of the component (i.e. the roundness
of the body
of material 6 circumscribed by the first plug wrap 7) is at least 90%, at
least 91%, at
least 92%, at least 93%, at least 94% or at least 95%.
The increased roundness of the article/component helps to ensure that the
downstream
portion can be processed, as otherwise a downstream portion that is too oval
may
become jammed or misaligned in the manufacturing machinery.
The first and/or second plug wraps 7, 9 can be adhered around the component(s)
of the
article by adhesive applied to a lap seam extending longitudinally along the
first and/or
second plug wraps. The first and/or second plug wraps 7, 9 can alternatively
or in
addition be adhered directly to the underlying component(s) using an adhesive.
In
both cases, the adhesive can be selected to be a water soluble adhesive to aid
degradation of the component(s). Additionally or alternatively, the first
and/or second
plug wraps 7, 9 can themselves be formed from paper or other material having
improved degradability, for instance improved dispersibility when exposed to
water.
Biodegradability can be measured according to the procedure set out under ISO
14855.
Components as described herein can achieve a biodegradation of greater than
50% in
days when exposed to either fresh or marine water.
In some embodiments, the length of the tubular portion 4a is less than about
50 mm. In
some embodiments, the length of the tubular portion 4a is less than about 40
mm. In
some embodiments, the length of the tubular portion 4a is less than about 35
mm. In
addition, or as an alternative, the length of the tubular portion 4a is at
least about 10
mm. In some embodiments, the length of the tubular portion 4a is at least
about 15
mm.
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In some embodiments, the length of the tubular portion 4a is from about 15 mm
to
about 35 mm, from about 20 1111T1 to about 30 mm, from about 23 to about 29
mm, or
about 25 mm or about 29 mm. In the present example, the length of the tubular
portion
4a is 25 mm.
In some embodiments, the second plug wrap 9 has a basis weight of less than 50
gsm.
In some embodiments, the second plug wrap 9 has a basis weight between about
20
gsm and 45 gsm. However, it should be recognised that the basis weight of the
second
io plug wrap 9 may be higher to increase the hardness of the mouthpiece.
For instance,
the basis weight of the second plug wrap 9 may be at least 50 gsm, at least 60
gsm, at
least 70 gsm, at least 8o gsm, at least 90 gsm or at least 100 gsm. In some
embodiments, the basis weight of the second plug wrap 9 is in the range of 50
gsm to
110 gsm, or in the range of 6o gsm to loo gsm.
In some embodiments, the second plug wrap 9 has a basis weight of at least 10
gsm, at
least 15 gsm, at least 20 gsm or at least 25 gsm.
In some embodiments, the second plug wrap 9 has a basis weight of less than 40
gsm,
less than 35 gsm or less than 30 gsm.
In some embodiments, the second plug wrap 9 has a basis weight in the range of
10 to
40 gsm, in the range of 15 to 35 gsm, in the range of 20 to 30 gsm, or in the
range of 25
to 30 gsm. In some embodiments, the basis weight of the second plug wrap 9 is
about
27 gsm.
In some embodiments, the second plug wrap 9 has a thickness of between 30 !_im
and
60 .tm, or between 35 !_tni and 45 Kn. However, it should be recognised that
the
thickness of the second plug wrap 9 may be higher to increase the hardness of
the
mouthpiece. In some embodiments, for example, the thickness of the second plug
wrap
9 may be at least 40 microns, at least 50 microns, at least 6o microns, at
least 70
microns, at least 8o microns, at least 90 microns or at least loo microns. In
some
embodiments, the thickness of the second plug wrap 9 is in the range of 40
microns to
120 microns, or in the range of 50 microns to loo microns.
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In some embodiments, the second plug wrap 9 is a non-porous plug wrap having a
permeability of less than loo Coresta Units, for instance less than 50 Coresta
Units.
However, in alternative embodiments, the second plug wrap 9 can be a porous
plug
wrap, for instance having a permeability of greater than 200 Coresta Units.
The mouthpiece 2 of the article 1 comprises an upstream end 3a adjacent to the
aerosol
generating substrate 3 and a downstream end 2b distal from the aerosol
generating
substrate 3.
io The pressure drop or difference (also referred to as resistance
to draw) across the
mouthpiece, for instance the part of the article 1 downstream of the aerosol
generating
material 3, is less than about 40 mml120. Such pressure drops have been found
to
allow sufficient aerosol, including desirable compounds such as flavour
compounds, to
pass through the mouthpiece 2 to the consumer. In some embodiments, the
pressure
drop across the mouthpiece 2 is less than about 20 mmH2O. In some embodiments,
particularly improved aerosol has been achieved using a mouthpiece 2 having a
pressure drop of less than 15 mmt120, for instance about 6 mmH20, about 10
mmH2o
or about 14 mmH20. Alternatively or additionally, the mouthpiece pressure drop
can
be at least 3 mm1-120, at least 4 mm1-120 or at least 5 mmH20. In some
embodiments,
the mouthpiece pressure drop can be between about 5 mml-120 and 20 mmH20 or
between 5 mmI120 and 15 mmH20. These values enable the mouthpiece 2 to slow
down the aerosol as it passes through the mouthpiece 2 such that the
temperature of
the aerosol has time to reduce before reaching the downstream end 2b of the
mouthpiece 2.
In the present example, the aerosol generating material 3 is wrapped in a
wrapper 10.
The wrapper 10 can, for instance, be a paper or paper-backed foil wrapper. In
the
present example, the wrapper 10 is substantially impermeable to air. In
alternative
embodiments, the wrapper 10 has a permeability of less than loo Coresta Units,
or less
than 60 Coresta Units. It has been found that using low permeability wrappers,
for
instance having a permeability of less than 100 Coresta Units, or less than 6o
Coresta
Units, results in an improvement in the aerosol formation in the aerosol
generating
material 3. Without wishing to be bound by theory, it is hypothesised that
this is due to
reduced loss of aerosol compounds through the wrapper 10. The permeability of
the
wrapper 10 can be measured in accordance with ISO 2965:2009 concerning the
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determination of air permeability for materials used as cigarette papers,
filter plug
wrap and filter joining paper.
In the present embodiment, the wrapper in comprises aluminium foil. Aluminium
foil
has been found to be particularly effective at enhancing the formation of
aerosol within
the aerosol generating material 3. In the present example, the aluminium foil
has a
metal layer having a thickness of about 6 um. In the present example, the
aluminium
foil has a paper backing. However, in alternative arrangements, the aluminium
foil can
be other thicknesses, for instance between 4 vim and 16 um in thickness. The
io aluminium foil also need not have a paper backing, but could have a
backing formed
from other materials, for instance to help provide an appropriate tensile
strength to the
foil, or it could have no backing material. Metallic layers or foils other
than aluminium
can also be used. The total thickness of the wrapper is between 20 vim and 6o
um, or
between 30 um and 50 um, which can provide a wrapper having appropriate
structural
integrity and heat transfer characteristics. The tensile force which can be
applied to the
wrapper before it breaks can be greater than 3,000 grams force, for instance
between
3,000 and 10,000 grams force or between 3,000 and 4,500 grams force.
In some examples, the wrapper lo surrounding the aerosol generating material 3
has a
high level of permeability, for example greater than about i000 Coresta Units,
or
greater than about 1500 Coresta Units, or greater than about 2000 Coresta
Units. The
permeability of the wrapper 10 can be measured in accordance with ISO
2965:2009
concerning the determination of air permeability for materials used as
cigarette papers,
filter plug wrap and filter joining paper.
The wrapper io may be formed from a material with a high inherent level of
permeability, an inherently porous material, or may be formed from a material
with
any level of inherent permeability where the final level of permeability is
achieved by
providing the wrapper io with a permeable zone or area. Providing a permeable
wrapper io provides a route for air to enter the article. The wrapper lo can
be provided
with a permeability such that the amount of air entering through the rod of
aerosol
generating material is relatively more than the amount of air entering the
article
through the ventilation holes 12 in the mouthpiece. An article having this
arrangement
may produce a more flavoursome aerosol which may be more satisfactory to the
user.
In some embodiments, the aerosol generating material 3 is provided as a
cylindrical rod
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of aerosol generating material. Irrespective of the form of the aerosol
generating
material, it can have a length of about 10 mm to 100 mm. In some embodiments,
the
length of the aerosol generating material is in the range about 25 mm to 50
mm, in the
range about 30 mm to 45 mm, or in the range about 30 mm to 40 mm.
The volume of aerosol generating material 3 provided can vary from about 200
mm3 to
about 4300 mm3, from about 500 mm3 to 1500 mm3, or from about 1000 mm3 to
about
1300 mm3.
/0 The mass of aerosol generating material 3 provided can be
greater than 200 mg, for
instance from about 200 mg to 400 mg, from about 230 mg to 360 mg, or from
about
250 mg to 360 mg.
In some embodiments, the aerosol generating material or substrate is formed
from
tobacco material as described herein, which includes a tobacco component.
In the tobacco material described herein, the tobacco component may contain
paper
reconstituted tobacco. The tobacco component may also contain leaf tobacco,
extruded
tobacco, and/or bandcast tobacco.
The aerosol generating material 3 can comprise reconstituted tobacco material
having a
density of less than about 700 milligrams per cubic centimetre (mg/cc).
The tobacco material 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 1.7mm). In some embodiments, 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 1.4mm) or at least 20 cuts per inch (about 7.9 cuts per cm,
equivalent to
a cut width of about 1.27mm). In one example, the cut rag tobacco has a cut
width of 22
cuts per inch (about 8.7 cuts per cm, equivalent to a cut width of about
1.15mm). The
cut rag tobacco may have a cut width at or below 40 cuts per inch (about 15.7
cuts per
cm, equivalent to a cut width of about 0.64mm). Cut widths between 0.5 mm and
2.0
mm, for instance between o.6 mm and 1.5 mm, or between 0.6 mm and 1.7mm have
been found to result in tobacco material which is suitable in terms of surface
area to
volume ratio, particularly when heated, and the overall density and pressure
drop of the
substrate 3. The cut rag tobacco can be formed from a mixture of forms of
tobacco
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material, for instance a mixture of one or more of paper reconstituted
tobacco, leaf
tobacco, extruded tobacco and bandcast tobacco. In some embodiments, the
tobacco
material comprises paper reconstituted tobacco or a mixture of paper
reconstituted
tobacco and leaf tobacco.
In the tobacco material described herein, the tobacco material may contain 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
io 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 the tobacco material, or in an amount of from ito 10% by
weight
of the composition. In some embodiments, the filler component is absent.
In the tobacco material described herein, the tobacco material contains an
aerosol-
former material. In this context, an "aerosol-former material" is an agent
that promotes
the generation of an aerosol. An aerosol-former material may promote the
generation
of an aerosol by promoting an initial vaporisation and/or the condensation of
a gas to
an inhalable solid and/or liquid aerosol. In some embodiments, an aerosol-
former
material may improve the delivery of flavour from the aerosol generating
material. In
general, any suitable aerosol-former material or agents may be included in the
aerosol
generating material of the invention, including those described herein. Other
suitable
aerosol-former materials include, but are not limited to: a polyol such as
sorbitol,
glycerol, and glycols like propylene glycol or triethylene glycol; a non-
polyol such as
monohydric alcohols, high boiling point hydrocarbons, acids such as lactic
acid,
glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol
diacetate,
triethyl citrate or myristates including ethyl myristate and isopropyl
myristate and
aliphatic carboxylic acid esters such as methyl stearate, dimethyl
dodecanedioate and
dimethyl tetradecanedioate.
The aerosol-former material may be included in any component, for example any
tobacco component, of the tobacco material, and/or in the filler component, if
present.
Alternatively or additionally the aerosol-former material may be added to the
tobacco
material separately. In either case, the total amount of the aerosol-former
material in
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the tobacco material can be as defined herein.
The tobacco material can contain between io% and 90% by weight tobacco leaf.
The tobacco material described herein contains nicotine. The nicotine content
is from
0.5 to 1.75% by weight of the tobacco material, and maybe, for example, from
0.8 to
1.5% by weight of the tobacco material. Additionally or alternatively, the
tobacco
material contains between 10% and go% by weight tobacco leaf having a nicotine
content of greater than 1.5% by weight of the tobacco leaf. It has been
advantageously
io 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 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
from 3mg to 2omg of menthol, between 5mg and 18mg or between 8mg and thmg of
menthol. In the present example, the tobacco material comprises thmg of
menthol.
The tobacco material can contain between 2% and 8% by weight of menthol,
between
3% and 7% by weight of menthol, or 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, the use of a high volume of aerosol generating
material,
for instance tobacco material, can increase the level of menthol loading that
can be
achieved, for instance where greater than about 500 mm3 or suitably more than
about
woo mm3 of aerosol generating material, such as tobacco material, are used.
In the compositions described herein, where amounts are given in % by weight,
for the
avoidance of doubt this refers to a dry weight basis, unless specifically
indicated to the
contrary. Thus, any water that may be present in the tobacco material, or in
any
component thereof, is entirely disregarded for the purposes of the
determination of the
weight %. The water content of the tobacco material described herein may vary
and
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may be, for example, from 5 to 15% by weight. The water content of the tobacco
material described herein may vary according to, for example, the temperature,
pressure and humidity conditions at which the compositions are maintained. The
water
content can be determined by Karl-Fisher analysis, as known to those skilled
in the art.
On the other hand, for the avoidance of doubt, even when the aerosol-former
material
is a component that is in liquid phase, such as glycerol or propylene glycol,
any
component other than water is included in the weight of the tobacco material.
However,
when the aerosol-former material is provided in the tobacco component of the
tobacco
material, or in the filler component (if present) of the tobacco material,
instead of or in
io addition to being added separately to the tobacco material, the aerosol-
former material
is not included in the weight of the tobacco component or filler component,
but is
included in the weight of the "aerosol-former material" in the weight % as
defined
herein. All other ingredients present in the tobacco component are included in
the
weight of the tobacco component, even if of non-tobacco origin (for example
non-
tobacco fibres in the case of paper reconstituted tobacco).
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 is present in the tobacco component of the tobacco
material described herein in an amount of from 10% to r00% by weight of the
tobacco
component. In embodiments, the paper reconstituted tobacco is present in an
amount
of from ro% to 8o% 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 some 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 ro% 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.
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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
io 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.
Figure 3 is a side-on cross sectional view of a further article 1', including
mouthpiece 2'
including a hollow tubular element 8. Mouthpiece 2' is substantially the same
as
mouthpiece 2 described above in relation to Figure 1, except that at the
downstream
end 2b, the mouthpiece 2' includes a hollow tubular element 8 formed from
filamentary
tow. In the present example, the tubular portion 4a, the body of material 6
and the
hollow tubular element 8 are combined using the second plug wrap 9 which is
wrapped
around all three sections. The further article 1' can be for use as a
combustible aerosol
provision system, for instance a cigarette.
The body of material 6 of the article i' of Figure 3 is similar to the body of
material 6
described above in relation to Figures i and 2. As before, the body of
material 6 is
manufactured from a sheet material comprising cellulose, for example, the
sheet
material may be paper. The sheet material is gathered to form the body of
material 6.
In the present example, the axial length Li of the body of material 6 is about
10 mm.
However, a skilled person will recognise that the body of material 6 may have
a
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different axial length Li. In some embodiments, the length Li of the body of
material 6
is less than about 20 mm or less than 15 mm. In some embodiments, the length
Li of
the body of material 6 is less than about 10 mm. In addition, or as an
alternative, the
length Li of the body of material 6 may be at least about 5 mm. In some
embodiments,
the length Li of the body of material 6 is at least about 6 mm. In some
embodiments,
the length Li of the body of material 6 is from about 5 mm to about 15 mm,
from about
6 mm to about 12 mm. In some embodiments, the length Li of the body of
material is 6
mm, 7 mm, 8 mm, 9 mm or to mm.
io The part of the mouthpiece which comes into contact with a consumer's
lips has usually
been a paper tube, which is either hollow or surrounds a cylindrical body of
filter
material. Providing a hollow tubular element 8 has advantageously been found
to
significantly reduce the temperature of the outer surface of the mouthpiece 2'
at the
downstream end 2b of the mouthpiece which comes into contact with a consumer's
mouth when the article 1' is in use. In addition, the use of the tubular
portion 4a has
also been found to significantly reduce the temperature of the outer surface
of the
mouthpiece 2' even upstream of the tubular portion 4a. Without wishing to be
bound
by theory, it is hypothesised that this is due to the tubular portion 4a
channelling
aerosol closer to the centre of the mouthpiece 2', and therefore reducing the
transfer of
heat from the aerosol to the outer surface of the mouthpiece 2'. In addition,
the body of
material 6 has been found to remove moisture from aerosol generated by the
aerosol
generating material 3 as the aerosol passes through the body of material 6A of
the
mouthpiece 2, which makes the aerosol feel cooler in the user's mouth.
In the present example, the hollow tubular element 8 is formed from
filamentary tow.
In alternative embodiments, the hollow tubular element may be formed using any
construction as described herein for the tubular portion 4a.
The "wall thickness" of the hollow tubular element 8 corresponds to the
thickness of the
wall of the tube 8 in a radial direction. This may be measured in the same way
as that of
the tubular portion. The wall thickness is advantageously greater than 0.9 mm,
and
may be 1.0 mm or greater. In some embodiments, the wall thickness is
substantially
constant around the entire wall of the hollow tubular element 8. However,
where the
wall thickness is not substantially constant, the wall thickness may be
greater than 0.9
mm at any point around the hollow tubular element 8, for instance tomm or
greater.
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The length of the hollow tubular element 8 is less than about 20 mm. In some
embodiments, the length of the hollow tubular element 8 is less than about 15
mm. In
some embodiments, the length of the hollow tubular element 8 is less than
about 10
mm. In addition, or as an alternative, the length of the hollow tubular
element 8 may
be at least about 5 mm. In some embodiments, the length of the hollow tubular
element 8 is at least about 6 mm. In some embodiments, the length of the
hollow
tubular element 8 is from about 5 mm to about 20 mm, from about 6 mm to about
10
mm, or from about 6 mm to about 8 mm. In some embodiments, the length of the
hollow tubular element 8 is 6 mm, 7 mm or 8 mm. In the present example, the
length of
io the hollow tubular element 8 is 6 mm.
The density of the hollow tubular element 8 is at least about 0.25 grams per
cubic
centimetre (g/cc), for instance at least about 0.3 g/cc. In some embodiments,
the
density of the hollow tubular element 8 is less than about 0.75 grams per
cubic
centimetre (g/cc), for instance less than o.6 g/cc. In some embodiments, the
density of
the hollow tubular element 8 is between 0.25 g/cc and 0.75 g/cc, between 0.3
g/cc and
o.6 g/cc, or between 0.4 g/cc and o.6 g/cc. In some embodiments, the density
of the
hollow tubular element 8 is about 0.5 g/cc. These densities have been found to
provide
a good balance between improved firmness afforded by denser material and the
lower
heat transfer properties of lower density material. For the purposes of the
present
invention, the "density" of the hollow tubular element 8 refers to the density
of the
filamentary tow forming the element with any plasticiser incorporated. The
density
may be determined by dividing the total weight of the hollow tubular element 8
by the
total volume of the hollow tubular element 8, wherein the total volume can be
calculated using appropriate measurements of the hollow tubular element 8
taken, for
example, using callipers. Where necessary, the appropriate dimensions may be
measured using a microscope.
The filamentary tow forming the hollow tubular element 8 may have a total
denier of
less than 45,000, for instance less than 42,000. This total denier has been
found to
allow the formation of a hollow tubular element 8 which is not too dense. In
some
embodiments, the total denier is at least 20,000, for instance at least
25,000. In some
embodiments, the filamentary tow forming the hollow tubular element 8 has a
total
denier between 25,000 and 45,000, for instance between 35,000 and 45,000. In
some
embodiments, the cross-sectional shapes of the filaments of tow are 'Y'
shaped,
although in other embodiments other cross-sectional shapes such as 'X' shaped
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filaments can be used.
The filamentary tow forming the hollow tubular element 8 may have a denier per
filament of greater than 3. This denier per filament has been found to allow
the
formation of a hollow tubular element 8 which is not too dense. In some
embodiments,
the denier per filament is at least 4, for instance at least 5. In some
embodiments, the
filamentary tow forming the hollow tubular element 8 has a denier per filament
between 4 and 10, for instance between 4 and 9. In one example, the
filamentary tow
forming the hollow tubular element 8 has an 8Y4o,000 tow formed from cellulose
io acetate and comprising 18% plasticiser, for instance triacetin.
The hollow tubular element 8 may have an internal diameter of greater than 3.0
mm.
Smaller diameters than this can result in increasing the velocity of aerosol
passing
though the mouthpiece 2' to the consumers mouth more than is desirable, such
that the
aerosol becomes too warm, for instance reaching temperatures greater than 40 C
or
greater than 45 C. In some embodiments, the hollow tubular element 8 has an
internal
diameter of greater than 3.1 mm, for instance greater than 3.5 mm or 3.6 mm.
In one
embodiment, the internal diameter of the hollow tubular element 8 is about 3.9
mm.
In some embodiments, the hollow tubular element 8 comprises from 15% to 22% by
weight of plasticiser. For cellulose acetate tow, the plasticiser may be
triacetin,
although other plasticisers such as polyethelyne glycol (PEG) can be used. In
some
embodiments, the hollow tubular element 8 comprises from 16% to 20% by weight
of
plasticiser, for instance about 17%, about 18% or about 19% plasticiser.
In the present example, the tubular portion 4a is a first hollow tubular
element, and
hollow tubular element 8 is a second hollow tubular element.
In the present example, the ventilation is provided into tubular portion 4a,
as described
in relation to Figure 1. In alternative embodiments, the ventilation can be
provided into
the mouthpiece at other locations, for instance into the body of material 6 or
hollow
tubular element 8.
In the examples described above, the mouthpieces 2, 2' each comprise a single
body of
material 6. In other examples, the mouthpiece 2, 2' may include multiple
bodies of
material. The mouthpieces 2, 2' may comprise a cavity between the bodies of
material.
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In some examples, the mouthpiece 2, 2' downstream of the aerosol generating
material
3 can comprise a wrapper, for instance the first or second plug wraps 7, 9, or
tipping
paper 5, which comprises an aerosol modifying agent as described herein or
other
sensate material.
In some embodiments (not shown), the mouthpiece 2, 2' may comprise an aerosol-
modifying agent release component, that is operable to release the aerosol-
modifying
agent. In some embodiments, the aerosol-modifying agent release component may
be
io operable to selectively release the aerosol-modifying agent. As
discussed above, the
body of material 6 can comprise fibres having a length in the range 2 Mal to 6
mm,
which leads to the body of material 6 absorbing less of a certain aerosol-
modifying
agent when the aerosol-modifying agent is released from the aerosol-modifying
agent
release component.
The aerosol-modifying agent may, for example, be an additive or a sorbent. The
aerosol-modifying agent may, for example, comprise one or more of a
flavourant, a
colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for
example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in
powder,
20 thread or granule form. The aerosol-modifying agent may be free from
filtration
material.
The aerosol-modifying agent release component may be, for example, a capsule,
thread
or bead. In some embodiments, a plurality of aerosol-modifying agent release
25 components are provided, and may comprise a plurality of charcoal
particles loaded
with aerosol-modifying agent.
In some embodiments, the aerosol-modifying agent release component comprises a
thread loaded with additive. The thread may made from fibres of, for example,
cellulose
30 acetate or cotton.
In some embodiments, the aerosol-modifying release component has in the range
of 1
mg to 20 mg of aerosol-modifying agent, for instance in the range of 2 mg to
15mg of
aerosol-modifying agent.
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The aerosol-modifying agent release component, for example, a capsule, may be
located
in the body 6. The (or each) aerosol-modifying agent release component may be
combined with the sheet material 6A, for instance, being adhered thereto,
before the
sheet material 6A is formed into the body 6.
The aerosol-modifying agent release component may comprise a capsule. In some
embodiments, the aerosol-modifying agent release component comprises first and
second capsules. The first capsule is disposed in a first portion of the
aerosol-modifying
agent release component and the second capsule is disposed in a second portion
of the
io aerosol-modifying agent release component downstream of the
first portion.
The aerosol-modifying agent release component may comprise one or more
components of the article 1. In some embodiments, the first and second
capsules are
disposed in the body of material 6. In one embodiment, the aerosol-modifying
agent
release component comprises two bodies of material (not shown), wherein the
first and
second capsules are disposed in the first and second bodies respectively. In
some
embodiments, the aerosol-modifying agent release component alternatively or
additionally comprises one or more tubular elements upstream and/or downstream
of
the body or bodies of material. The aerosol generating component may comprise
the
mouthpiece 2, 2'.
In some embodiments, the second capsule is spaced from the first capsule by a
distance
of at least 7 mm, measured as the distance between the centre of the first and
second
capsules. In some embodiments, the second capsule is spaced from the first
capsule by
a distance of at least 8 mm, 9 mm or lo mm. It has been found that increasing
the
distance between the first and second capsules increases the difference
between the
first and second temperatures.
The first capsule comprises an aerosol modifying agent. The second capsule
comprises
an aerosol modifying agent which may be the same or different as the aerosol
modifying agent of the first capsule. In some embodiments, a user may
selectively
rupture the first and second capsules by applying an external force to the
aerosol-
modifying agent release component in order to release the aerosol modifying
agent
from each capsule.
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The aerosol-modifying agent of the second capsule is heated to a lower
temperature
than the aerosol-modifying agent of the first capsule due to the difference
between the
first and second temperatures.
The aerosol-modifying agents of the first and second capsules can be selected
based on
this temperature difference. For instance, the first capsule may comprise a
first aerosol
modifying agent that has a lower vapour pressure than a second aerosol
modifying
agent of the second capsule. If the capsules were both heated to the same
temperature,
then the higher vapour pressure of the aerosol modifying agent of the second
capsule
io would mean that a greater amount of the second aerosol modifying agent
would be
volatised relative to the aerosol modifying agent of the first capsule.
However, since the
second capsule is heated to a lower temperature, this effect is less
pronounced such that
a more even amount of the aerosol modifying agents of the first and second
capsules
are volatised upon breaking of the first and second capsules respectively.
In some embodiments, the first and second capsules have the same aerosol-
modifying
profiles, meaning that both capsules contain the same type of aerosol-
modifying agent
and in the same amount such that if both capsules were heated to the same
temperature and broken then both capsules would cause the same modification of
the
aerosol. However, since the first capsule is heated to a higher temperature
than the
second capsule, more of the aerosol-modifying agent of the first capsule will
be, for
example, volatised compared to the modifying agent of the second capsule and
thus will
cause a more pronounced modification of the aerosol than the second capsule.
Therefore, despite both capsules being the same, which may make the aerosol-
modifying agent release component easier and/or less expensive to manufacture,
the
user can decide whether to break the first capsule to cause a more pronounced
modification of the aerosol, or the second capsule to cause a less pronounced
modification of the aerosol, or both capsules to cause the greatest
modification of the
aerosol.
In some embodiments, the first and second capsules both comprise first and
second
aerosol modifying agents. The first aerosol modifying agent has a lower vapour
pressure than the second aerosol modifying agent. Thus, when the second
capsule is
broken, a greater proportion of the second aerosol modifying agent will be
vaporised
relative to the first aerosol modifying agent in comparison to when the hotter
first
capsule is broken during use of the system to generate aerosol. Therefore, the
same
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capsule can be used to generate different modifications of the aerosol based
on the
positon of the capsule in the first or second portion of the aerosol-modifying
agent
release component.
In some embodiments, the (or each) capsule comprises an outer shell and an
inner
core.
The shell of each capsule may be solid at room temperature. The shell may
comprise,
consist of, or essentially consist of, alginate. However, it should be
recognised that in
io alternative embodiments the shell is formed from a different material.
For example, the
shell may alternatively comprise, consist of, or essentially consist of,
gelatin,
carageenans or pectins. The shell may comprise, consist of, or essentially
consist of, one
or more of alginate, gelatin, carrageenans or pectins.
The shell of each additive capsule may be impermeable, or substantially
impermeable,
to the aerosol modifying agent agent of the core. Therefore, the shell
initially prevents
the agent of the core from escaping from the capsule. When the user desires to
modify
the aerosol, the shells of the capsules are ruptured such that the agent is
released.
In some embodiments (not shown), the (or each) capsule further comprises a
carrier
material. The carrier material may comprise, for example, gelatin.
In some embodiments, the (or each) capsule has a diameter in the range of 1 mm
to 5
mm, or in the range of 2 min to 4 mm. In some embodiments, the diameter of the
(or
each) capsule is about 3 mm. The (or each) capsule may be generally spherical.
In
other examples, other shapes and sizes of capsule can be used.
The total weight of each capsule may be in the range about 5 mg to about 50
mg, or in
the range of about 10 mg to about 30 mg. In some embodiments, each capsule has
a
weight of about 14 mg.
In some embodiments, one or more aerosol-modifying agent release components
are
included in the body of material 6, wherein the body of material 6 is formed
from a
sheet material having a basis weight of less than 40 gsm, for instance less
than 35 or 30
gsm. This helps to reduce the density of the body of material 6 to compensate
for the
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presence of the aerosol-modifying agent release component within the body 6
which
may otherwise result in an increase in the firmness of the body 6.
In some embodiments, one or more aerosol-modifying agent release components
are
included in the body of material 6, wherein the body of material 6 is formed
from a
sheet material having width of less than loo mm for instance less than go mm
or 80
mm. This helps to reduce the density of the body of material 6 to compensate
for the
presence of the aerosol-modifying agent release component within the body 6
which
may otherwise result in an increase in the firmness of the body 6.
In some embodiments, the (or each) capsule is centred on the longitudinal axis
of the
mouthpiece 2.
As discussed above, the (or each) capsule may have a core-shell structure.
That is, the
encapsulating material or barrier material creates a shell around a core that
comprises
the aerosol modifying agent. The shell structure hinders migration of the
aerosol
modifying agent during storage of the article but allows controlled release of
the aerosol
modifying agent, also referred to as an aerosol modifier, during use.
In some cases, the barrier material (also referred to herein as the
encapsulating
material) is frangible. The (or each) capsule is crushed or otherwise
fractured or broken
by the user to release the encapsulated aerosol modifier. Typically, one or
more of the
capsules is broken immediately prior to heating being initiated but the user
can select
when to release the aerosol modifier of said capsule. The user can then choose
to break
the other capsules a later time, for example, after heating being initiated.
The user may
choose to break said other one of the capsules once some of the aerosol has
been
released from the aerosol generating material, such that the remaining aerosol
generating material is modified by the aerosol modifying agent of another of
the
capsules. Alternatively, the user may choose to break a plurality of capsules
simultaneously.
The term "breakable capsule" refers to a capsule, wherein the shell can be
broken by
means of a pressure to release the core; more specifically the shell can be
ruptured
under the pressure imposed by the user's fingers when the user wants to
release the
core of the capsule.
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In some cases, the barrier material is heat resistant. That is to say, in some
cases, the
barrier will not rupture, melt or otherwise fail at the temperature reached at
the capsule
site during operation of the aerosol provision device. Illustratively, a
capsule located in
a mouthpiece may be exposed to temperatures in the range of 30 C to 100 C for
example, and the barrier material may continue to retain the liquid core up to
at least
about 50 C to 120 C.
In other cases, the (or each) capsule releases the core composition on
heating, for
example by melting of the barrier material or by capsule swelling leading to
rupture of
io the barrier material.
The total weight of each capsule may be in the range of about 1 mg to about
loo mg,
about 5 mg to about 60 mg, about 8 mg to about 50 mg, about 10 mg to about 20
mg, or
about 12 mg to about 18 mg.
The total weight of the core formulation may be in the range of about 2 mg to
about 90
mg, about 3 mg to about 70 mg, about 5 mg to about 25 mg, about 8 mg to about
20
mg, or about 10 mg to about 15 mg.
20 In some embodiments, the (or each) capsule comprises a core as described
above, and a
shell. The capsules may each present a crush strength from about 4.5 N to
about 40 N,
from about 5 N to about 30 N or from about 5 N to about 28 N (for instance
about 9.8
N to about 24.5 N). The capsule burst strength of each capsule can be measured
when
said capsule is removed from the body of material 6 and using a force gauge to
measure
25 the force at which the capsule bursts when pressed between two flat
metal plates. A
suitable measurement device is the Sauter FK 50 force gauge with a flat headed
attachment, which can be used to crush the capsule against a flat, hard
surface having a
surface similar to the attachment.
30 The (or each) capsule may be substantially spherical and have a diameter
of at least
about 0.4 mm, o.6 mm, o.8 mm, 1.0 mm, 2.0 aim, 2.5 ITIM, 2.8 mm or 3.0 mm. The
diameter of the (or each) capsule may be less than about 10.0 mm, 8.o mm, 7.0
mm,
6.o mm, 5.5 mm, 5.0 mm, 4.5 mm, 4.0 mm, 3.5 mm or 3.2 mm. Illustratively, the
capsule diameter may be in the range of about 0.4 mm to about 10.0 mm, about
o.8
35 111111 to about 6.o mm, about 2.5 mm to about 5.5 mm or about 2.8 mm to
about 3.2
mm. In some cases, the (or each) capsule may have a diameter of about 3.0 mm.
These
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sizes are particularly suitable for incorporation of the capsules into an
article as
described herein.
The cross-sectional area of each capsule at its largest cross sectional area
is in some
embodiments less than 28% of the cross sectional area of the portion of the
mouthpiece
2 in which the capsule is provided, for instance less than 27% or less than
25%. For
instance, for a spherical capsule having a diameter of 3.0 mm, the largest
cross
sectional area of the capsule is 7.07 mm2. For the mouthpiece having a
circumference
of 21 MM as described herein, the body of material 6 has an outer
circumference of 20.8
io mm, and the radius of this component will be 3.31 mm, corresponding to a
cross
sectional area of 34.43 mm2. The capsule cross sectional area is, in this
example, 20.5%
of the cross-sectional area of the mouthpiece 2. As another example, if a
capsule had a
diameter of 3.2mm, its largest cross sectional area would be 8.04 mm2. In this
case, the
cross sectional area of the capsule would be 23.4% of the cross sectional area
of the
body of material 6. A capsule with a largest cross sectional area less than
28% of the
cross sectional area of the portion of the mouthpiece 2 in which the capsule
is provided
has the advantage that the pressure drop across the mouthpiece 2 is reduced as
compared to capsules with larger cross sectional areas and adequate space
remains
around the capsule for aerosol to pass without the body of material 6 removing
significant amounts of the aerosol mass as it passes through the mouthpiece 2.
In some
embodiments, first and second capsules are provided, which may be the same
size or
different sizes.
Figure 4 is a side-on cross sectional view of a further article 1", including
mouthpiece
2". Mouthpiece 2" is substantially the same as mouthpiece 2 described above in
relation
to Figures iand 2. A difference is that the body of material 6 of the article
1" is located
upstream of the tubular portion 4a. The further article 1" can be for use as a
combustible aerosol provision system, for instance a cigarette.
In the present example the tubular portion 4a and body of material 6 are
combined
using the second plug wrap 9 which is wrapped around both sections.
The body of material 6 of the article 1" of Figure 4 is similar to the body of
material 6
described above in relation to Figures 1 to 3. As before, the body of material
6 is
manufactured from a sheet material comprising cellulose, for example, the
sheet
material may be paper. The sheet material is gathered to form the body of
material 6.
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The body of material 6 is disposed at the upstream end 2a of the mouthpiece
2'. The
body of material 6 is adjacent to the aerosol generating material 3.
The tubular portion 4a is disposed at the downstream end 2b of the mouthpiece
2" and
thus forms a cavity at the downstream end 2h. The tubular portion 4a is
located
downstream of the body of material 6. In the present example, the tubular
portion 4a is
immediately adjacent to the body of material 6.
io The tubular portion 4a has an axial length L2 of at least 20 mm, for
instance at least 22
mm. In the present example, the axial length L2 of the tubular portion 4a is
about 25
mm.
It has been found that the tube having an axial length L2 of at least 20 mm
results in
significant cooling of the aerosol as it passes through the tubular portion
4a. In
addition, as explained previously, the cellulose containing sheet material of
the body of
material 6 absorbs water from the aerosol. Removing moisture from the aerosol
makes
the aerosol feel cooler in the user's mouth.
In some embodiments, the tubular portion 4a comprises one or more ventilation
holes,
which also contribute to cooling of the aerosol.
In some embodiments, the tubular portion 4a is manufactured from paper.
Figure 5 is a side-on cross sectional view of a further article 1¨, including
mouthpiece
2". The mouthpiece 2" is substantially the same as mouthpiece 2 described
above in
relation to Figures 1 and 2. A difference is that that the mouthpiece 2¨
further
comprises a tubular element 20 located within the body of material 6. The
further
article 1¨ can be for use as a combustible aerosol provision system, for
instance a
cigarette.
In the present example, the tubular portion 4a and body of material 6 are
combined
using the second plug wrap 9 which is wrapped around both sections.
The body of material 6 of the article 1¨ of Figure 5 is similar to the body of
material 6
described above in relation to Figures 1 to 3. As before, the body of material
6 is
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manufactured from a sheet material comprising cellulose, for example, the
sheet
material may be paper. The sheet material is gathered to form the body of
material 6.
The tubular element 20 may be, for example, a paper or plastic tube disposed
within
the body of material 6. The tubular element 20 forms a cavity 21 within the
body of
material 6. Optionally, the tubular element 20 is located substantially
radially centrally
within the body of material 6.
In the present example, the cavity 21 extends to the downstream end 2b of the
mouthpiece 2".
In the present example, the axial length Li of the body of material 6 is about
10 mm.
However, a skilled person will recognise that the body of material 6 may have
a
different axial length Li. In some embodiments, the length Li of the body of
material 6
is less than about 15 mm. In some embodiments, the length Li of the body of
material 6
is less than about io mm. In addition, or as an alternative, the length Li of
the body of
material 6 may be at least about 5 mm. In some embodiments, the length Li of
the
body of material 6 is at least about 6 mm. In some embodiments, the length Li
of the
body of material 6 is from about 5 mm to about 15 mm, from about 6 mm to about
12
mm, or from about 6 mm to about 12 mm. In some embodiments, the length Li of
the
body of material 6 is 6 mm, 7 mm, 8 mm, 9 mm or io mm.
In some embodiments, the tubular element 20 has an axial length L3 of at least
4 mm,
for instance a length of about 5 mm.
The cavity 21 has been found to promote cooling of the aerosol. The portion 6b
of the
body of material 6 that surrounds the tubular element 21 has been found to
effectively
thermally insulate the user's lips from the heat of the aerosol. For example,
in
embodiments wherein the body of material 6 is manufactured from a sheet
material
that is arranged into the body of material, it is thought that the multiple
layers of the
sheet material of the body of material 6 help to insulate the user's lips from
the heat of
the aerosol. In some embodiments, there may optionally be gaps, for example,
air gaps,
between the layers of the sheet material that contribute to the insulating
effect.
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Also, the body of material 6 may be more readily biodegradable than
configurations
where instead a cellulose acetate tubular portion is provided at the
downstream end 2b
of the mouthpiece.
The body of material 6 may be manufactured from a multiple length rod 22, as
shown
in Figure 6, which in the present example is a four-length rod. The rod is cut
at lines C-
C to form individual bodies of material 6 each comprising a tubular element 20
with a
corresponding cavity 21.
io 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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