Note: Descriptions are shown in the official language in which they were submitted.
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A Component for An Article
Technical Field of the Invention
The present invention relates to a component for a non-combustible aerosol
provision
article, and a method of forming the component.
Background of the Invention
Certain delivery systems produce an aerosol during use, which is inhaled by a
user. For
example, tobacco heating devices heat an aerosol-generating substrate such as
tobacco
io to form an aerosol by heating, but not burning, the substrate. Such
delivery systems
commonly include a heating device with a heating element, which, when heated,
heat
the aerosol-generating substrate to release an aerosol.
Summary of the Invention
In accordance with embodiments of the invention, in a first aspect there is
provided a
component for a non-combustible aerosol provision article for use in a non-
combustible aerosol provision system, the component comprising: a core section
extending longitudinally; and an outer section extending longitudinally
comprising an
aerosol-generating substrate which surrounds the core section and is
configured to
generate aerosol when heated; wherein the core section comprises a first
material
configured to receive a heating element.
In some embodiments, the core section and the outer section may be formed
coaxially.
In some embodiments, the core section may comprise a tube having a cavity, the
cavity
being configured to receive a heating element.
In some embodiments, the cavity may extend the full length of the core
section.
In some embodiments, the tube may be configured to maintain a gap from a
heating
element, when a heating element is inserted into the tube.
In some embodiments, an inner surface of the tube may be embossed, the
embossed
portion being configured to minimise contact with a heating element when a
heating
element is inserted into the tube.
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In some embodiments, the tube may have a hardness in the range of about 50% to
about 98%.
In some embodiments, the first material forming the core section may be paper.
In some embodiments, the core section may comprise a loose gathered sheet.
In some embodiments, the loose sheet may be gathered to form a central column
of
material.
In some embodiments, the first material forming the loose sheet may be at
least one of
a paper material, bandcast tobacco, paper reconstituted tobacco, or an
amorphous solid
material.
In some embodiments, the first material may be a paper material which is
porous.
In some embodiments, the porosity of the first material may be the range of
about 50
Coresta units to about l0000 Coresta units.
In some embodiments, the first material may comprise at least one active
substance,
and/or aerosol modifying substance, and/or flavour.
In some embodiments, the first material may comprise a coating configured to
provide
an aerosol.
In some embodiments, the aerosol-generating substrate may comprise a plurality
of
elongate strips extending substantially parallel to one another in the
longitudinal
direction.
In some embodiments, the aerosol-generating substrate may be crimped,
optionally to
a depth in the range of about 20 urn to about 1mm.
In some embodiments, the component may be an aerosol-generating component of a
non-combustible aerosol provision system.
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In another aspect of the invention, there is provided an article comprising a
component.
In another aspectof the invention, there is provided a method of forming a
component
for a non-combustible aerosol provision article, the method comprising:
providing an
assembly comprising a sheet of aerosol-generating substrate and a first
material;
arranging the sheet of aerosol-generating substrate and the first material
into a
component such that the sheet of aerosol generating substrate forms an outer
section,
which surrounds a core section formed by the first material.
In some embodiments, the first material and the aerosol-generating substrate
may be
formed coaxially.
The method may further comprise the step of gathering the aerosol-generating
material
around the first material to form a coaxial rod.
In some embodiments, the step of gathering may comprise providing a stream of
aerosol-generating material to a gatherer, and gathering the stream of aerosol-
generating material around the first material.
In some embodiments, the step of gathering may comprise providing a plurality
of
streams of aerosol-generating material to a gatherer, the plurality of streams
of aerosol-
generating material being located at various positions around the first
material.
In some embodiments, providing the assembly may comprise the step of providing
a
pre-formed tube of first material.
In some embodiments, providing the assembly may comprise the step of providing
a
sheet of first material, and forming a tube from the sheet of first material.
In some embodiments, providing the assembly may comprise the step of providing
adhesive on the sheet of first material, and drying the adhesive before
gathering the
aerosol-generating substrate around the first material.
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In some embodiments, providing the assembly may comprise the step of providing
a
sheet of first material and gathering the sheet material together with the
sheet of
aerosol-generating material to form a coaxial rod.
Brief Description of the Drawings
Embodiments of the invention will now be described, by way of example only,
with
reference to the accompanying drawings, in which:
Fig. 1 shows a side on cross-sectional view of an article;
Fig. 2 shows a side on cross-sectional view of an article;
Fig. 3 shows a side on cross-sectional view of a component of an article;
Fig. 4 shows an end view of a component of an article;
Fig. 5 shows a side on cross-sectional view of a component of an article;
Fig. 6 shows a schematic view of an apparatus for forming a component of an
article;
and
Fig. 7 shows a schematic view of an apparatus for forming a component of an
article.
Detailed Description
The present invention relates to an article for consumable for use in a
delivery system.
As used herein, the term "delivery system" is intended to encompass systems
that
deliver at least one substance to a user, and includes:
combustible aerosol provision systems, such as cigarettes, cigarillos, cigars,
and
tobacco for pipes or for roll-your-own or for make-your-own cigarettes
(whether based
on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco,
tobacco
substitutes or other smokeable material); and
non-combustible aerosol provision systems that release compounds from an
aerosol-generating material without combusting the aerosol-generating
material, such
as electronic cigarettes, tobacco heating products, and hybrid systems to
generate
aerosol using a combination of aerosol-generating materials.
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.
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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, or
an aerosol-
modifying agent release component.
According to the present disclosure, a "non-combustible" aerosol provision
system is
_ro one where a constituent aerosol-generating material of the aerosol
provision system (or
component thereof) is not combusted or burned in order to facilitate delivery
of at least
one substance to a user.
In some embodiments, the delivery system is a non-combustible aerosol
provision
system, such as a powered non-combustible aerosol provision system.
In some embodiments, the non-combustible aerosol provision system is an
electronic
cigarette, also known as a vaping device or electronic nicotine delivery
system (END),
although it is noted that the presence of nicotine in the aerosol-generating
material is
not a requirement.
In some embodiments, the non-combustible aerosol provision system is a hybrid
system to generate aerosol using a combination of aerosol-generating
materials, one or
a plurality of which may be heated. Each of the aerosol-generating materials
may be, for
example, in the form of a solid, liquid, or gel and may or may not contain
nicotine. In
some embodiments, the hybrid system comprises a liquid or gel aerosol-
generating
material and a solid aerosol-generating material. The solid aerosol-generating
material
may comprise a plant-based material, for example, tobacco or a non-tobacco
product.
Typically, the non-combustible aerosol provision system may comprise a non-
combustible aerosol provision device and a consumable for use with the non-
combustible aerosol provision device.
In some embodiments, the disclosure relates to consumables comprising aerosol-
generating material and configured to be used with non-combustible aerosol
provision
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devices. These consumables are sometimes referred to as articles throughout
the
disclosure.
In some embodiments, the non-combustible aerosol provision system may comprise
an
area for receiving the consumable, an aerosol generator, and aerosol
generation area, a
housing, a mouthpiece, a filter, and/or an aerosol-modifying agent.
In some embodiments, the consumable for use with the non-combustible aerosol
provision device may comprise aerosol-generating material, an aerosol-
generating
io material storage area, an aerosol-generating material transfer
component, an aerosol
generator, an aerosol generation area, a housing, a wrapper, a filter, a
mouthpiece,
and/or an aerosol-modifying agent.
In some embodiments, the substance to be delivered may be an aerosol-
generating
material or a material that is not intended to be aerosolised. As appropriate,
either
material may comprise one or more active constituents, one or more flavours,
one or
more aerosol-former materials, and/or one or more other functional materials.
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
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,
extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen,
husk, shells or
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the like. Alternatively, the material may comprise an active compound
naturally
existing in a botanical, obtained synthetically. The material may be in the
form of
liquid, gas, solid, powder, dust, crushed particles, granules, pellets,
shreds, strips,
sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise,
hemp, cocoa,
cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax,
ginger,
ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate,
orange skin,
papaya, rose, sage, tea such as green tea or black tea, thyme, clove,
cinnamon, coffee,
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.
In some embodiments, the active substance comprises or derived from one or
more
botanicals or constituents, derivatives or extracts thereof and the botanical
is selected
from rooibos and fennel.
In some 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
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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,
ro 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.
In some embodiments, the flavour comprises menthol, spearmint and/or
peppermint.
In some embodiments, the flavour comprises flavour components of cucumber,
blueberry, citrus fruits and/or redberry. In some embodiments, the flavour
comprises
eugenol. In some embodiments, the flavour comprises flavour components
extracted
from tobacco. In some embodiments, the flavour comprises flavour components
extracted from cannabis.
In some embodiments, the flavour may comprise a sensate, which is intended to
achieve a somatosensorial sensation which are usually chemically induced and
perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in
addition to
or in place of aroma or taste nerves, and these may include agents providing
heating,
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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
_ro 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 90wt%, 95wt% or wowt% of amorphous solid.
In some embodiments, the amorphous solid comprises: 1-6o wt% of a gelling
agent;
0.1-50 wt% of an aerosol-former agent; and 0.1-80 wt% of a flavour; wherein
these
weights are calculated on a dry weight basis.
In some further embodiments, the amorphous solid comprises: 1-50 wt% of a
gelling
agent; 0.1-50 wt% of an aerosol-former agent; and 30-60 wt% of a flavour;
wherein
these weights are calculated on a dry weight basis.
In some further embodiments, the amorphous solid comprises: aerosol-former
material
in an amount of from about 40 to 80 wt% of the amorphous solid; gelling agent
and
optional filler (i.e. in some examples filler is present in the amorphous
solid, in other
examples filler is not present in the amorphous solid), wherein the amount of
gelling
agent and filler taken together is from about 10 to 60 wt% of the amorphous
solid (i.e.
the gelling agent and filler taken together account for about 10 to 6o wt% of
the
amorphous solid); and optionally, active substance and/or flavourant in an
amount of
up to about 20 WM of the amorphous solid (i.e. the amorphous solid comprises
20
wt% active substance).
The amorphous solid material may be formed from a dried gel. It has been found
that
using the component proportions discussed above means that as the gel sets,
flavour
compounds are stabilised within the gel matrix allowing a higher flavour
loading to be
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achieved than in non-gel compositions. The flavour (e.g. menthol) is
stabilised at high
concentrations and the products have a good shelf life.
In some cases, the amorphous solid may have a thickness of about 0.015 mm to
about
1.5 mm. Suitably, the thickness may be in the range of about 0.0 5mm, 0.1 mm
or 0.15
mm to about 0.5 mm, 0.3 mm or 1 mm. The inventors have found that a material
having a thickness of 0.2 MM is particularly suitable in some embodiments. The
amorphous solid may comprise more than one layer, and the thickness described
herein refers to the aggregate thickness of those layers.
If the amorphous solid is too thick, then heating efficiency is compromised.
This
adversely affects the power consumption in use. Conversely, if the amorphous
solid is
too thin, it is difficult to manufacture and handle; a very thin material is
harder to cast
and may be fragile, compromising aerosol formation in use.
Suitably, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15
wt%,
wt%, 25 wt%, 30 wt% or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%
or 35 AA% of a gelling agent (all calculated on a dry weight basis). For
example, the
amorphous solid may comprise 1-60 wt%, 5-60 wt%, 20-60 wt%, 25-55 wt%, 30-50
20 wt%, 35-45 wt%, 5-45 wt%, 10-40 wt% or 20-35 IA% of a gelling agent.
The amorphous solid may comprise a gelling agent. The gelling agent may
comprise
one or more compounds selected from cellulosic gelling agents, non-cellulosic
gelling
agents, guar gum, acacia gum and mixtures thereof.
In some embodiments, the gelling agent comprises a hydrocolloid. In some
embodiments, the gelling agent comprises one or more compounds selected from
the
group comprising alginates, pectins, starches (and derivatives), celluloses
(and
derivatives), gums, silica or silicones compounds, clays, polyvinyl alcohol
and
combinations thereof. For example, in some embodiments, the gelling agent
comprises
one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl
cellulose,
carboxymethylcellulose, pullulan, xanthan gum guar gum, carrageenan, agarose,
acacia
gum, fumed silica, polydimethylsiloxane (PDMS), sodium silicate, kaolin and
polyvinyl
alcohol. In some cases, the gelling agent comprises alginate and/or pectin,
and may be
combined with a setting agent (such as a calcium source) during formation of
the
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amorphous solid. In some cases, the amorphous solid may comprise a calcium-
crosslinked alginate and/or a calcium-crosslinked pectin.
The cellulosic gelling agent can be selected from the group consisting of:
hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose,
carboxymethylcellulose (CMC), hydroxypropyl methylcellulose (HPMC), methyl
cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate
(CAB),
cellulose acetate propionate (CAP) and combinations thereof.
In some embodiments, the gelling agent comprises (or is) one or more of
hydroxyethyl
cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC),
carboxymethylcellulose, guar gum, or acacia gum.
In some embodiments, the gelling agent comprises (or is) one or more non-
cellulosic
gelling agents, including, but not limited to, agar, xanthan gum, gum Arabic,
guar gum,
locust bean gum, pectin, carrageenan, starch, alginate, and combinations
thereof. In
some embodiments, the non-cellulose based gelling agent is alginate or agar.
In some embodiments, the amorphous solid comprises alginate and pectin, and
the
ratio of the alginate to the pectin is from 1:1 to 10:1. The ratio of the
alginate to the
pectin is typically >1:1, i.e. the alginate is present in an amount greater
than the amount
of pectin. In examples, the ratio of alginate to pectin is from about 2:1 to
8:1, or about
3:1 to 6:1, or is approximately 4:1.
In some embodiments, the amorphous solid comprises filler in an amount of from
ito
wt% of the amorphous solid, such as 5 to 25 wt%, or 10 to 20 wt%. In examples,
the
amorphous solid comprises filler in an amount greater than 1 wt%, 5 wt%, or 8
wt% of
the amorphous solid. In examples, the amorphous solid comprises filler in an
amount
less than 4 ovvt%, 30 wt%, 201A71%, 151/171%, 12Wt% 10W1%, 5wt%, or ivvt% of
the
30 amorphous solid. In other examples, the amorphous solid does not
comprise filler.
In examples, the amorphous solid comprises gelling agent and filler, taken
together, in
an amount of from about 10 wt%, 20 MO, 25 WM, 30 wtO, 35 wt%, 40 wt%, 45 wt%,
50 wt%, 55 wt% or from about 6o wt%. In examples, the amount of gelling agent
and
filler, taken together, is no more than 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65
wt%, or no
more than 6o wt% of the amorphous solid. In examples, the amorphous solid
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comprises gelling agent and filler, taken together, in an amount of from about
20 to 6o
wt%, 25 to 55 wt%, 30 to 50 wt%, or 35 to 45 wt% of the amorphous solid.
The filler, if present, may comprise one or more inorganic filler materials,
such as
calcium carbonate, pedite, vermiculite, diatomaceous earth, colloidal silica,
magnesium
oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic
sorbents,
such as molecular sieves. The filler may comprise one or more organic filler
materials
such as wood pulp, cellulose and cellulose derivatives. In particular cases,
the
amorphous solid comprises no calcium carbonate such as chalk.
In some examples which include filler, the filler may be fibrous. For example,
the filler
may be a fibrous organic filler material such as wood pulp, hemp fibre,
cellulose or
cellulose derivatives. Without wishing to be bound by theory, it is believed
that
including fibrous filler in an amorphous solid may increase the tensile
strength of the
material.
In some examples, the amorphous solid does not comprise tobacco fibres. In
particular
examples, the amorphous solid does not comprise fibrous material.
In some embodiments, the amorphous solid may comprise from about 0.1 wt%, 0.5
wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt% or 10 wt% to about 8o wtO, 50 wtO, 45 wt%, 40
wt%,
35 wt%, 30 wt% or 2 5w1% of an aerosol former material (all calculated on a
dry weight
basis). For example, the amorphous solid may comprise 0.5-40 wt%, 3-35 wt% or
10-
wt% of an aerosol former material.
The aerosol former material may act as a plasticiser. If the content of the
plasticiser is
too high, the amorphous solid may absorb water resulting in a material that
does not
create an appropriate consumption experience in use. If the plasticiser
content is too
low, the amorphous solid may be brittle and easily broken.
In some embodiments, the aerosol former included in the amorphous solid
comprises
one or more polyhydric alcohols, such as propylene glycol, triethylene glycol,
1 ,3-
butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-
, di- or
triacetate; and/or aliphatic esters of mono-, di- or polycarboxylic acids,
such as
dimethyl dodecanedioate and dimethyl tetradecanedioate.
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In some cases, the aerosol former material comprises one or more compound
selected
from erythritol, propylene glycol, glycerol, triacetin, sorbitol and xylitol.
In some cases,
the aerosol former material comprises, consists essentially of or consists of
glycerol.
The amorphous solid material may comprise a combustion retarding salt. The
combustion retarding salt used herein is a chemical compound consisting of an
ionic
assembly of cations and anions. The salts used herein are those whose anion
and/or
whose cation may be effective in retarding combustion. In some embodiments,
the salt
is an inorganic salt.
In some embodiments, the salt is a halide salt, i.e. has a halide anion. In
some
embodiments, the salt is a chloride salt or a bromide salt. The presence of
high
concentrations of chloride or bromide has been shown to retard combustion.
In some embodiments, the salt may be an alkali metal salt, i.e. has an alkali
metal
cation. In some embodiments, the salt has an alkali earth metal cation. In
some
embodiments, the salt has a zinc cation or an iron cation, such as ferric or
ferrous
cation. In some embodiments, the salt has an ammonium cation or phosphonium
cation.
In some embodiments, the salt mat be an alkali metal halide, such as sodium
chloride
or potassium chloride. The salt may be an alkali earth metal halide, such as
magnesium
chloride, calcium chloride. The salt may be another metal halide, such as zinc
chloride
or sodium bromide.
In some embodiments, the salt has a carboxylate anion. For example, the salt
may be an
alkali metal carboxylate, such as potassium citrate, potassium succinate,
potassium
malate, potassium acetate, potassium tartrate, potassium oxalate, sodium
citrate,
sodium succinate, sodium acetate, or sodium malate.
In other embodiments, the salt has an anion selected from: borate, carbonate,
phosphate, sulphate, or sulphamate.
Factors that may influence the selection of salt will include, for example,
melting point,
which may be at least 450 C. In some embodiments, the salt is soluble in
water. In
some embodiments, the salt is selected to provide a desired pH to the material
it is
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added to. In some embodiments, the salt will not significantly change the pH
of the
material.
In some embodiments, the combustion retarding salt selected may have one or
more
advantageous properties, such as: inertness, solubility in a precursor liquid,
solubility,
or distribution in the amorphous solid material or precursor material to the
amorphous
solid material, density or other properties known in the art.
In some embodiments, the combustion retarding slat comprises, consists
essentially of,
io or consists of sodium chloride, potassium chloride, sodium bromide,
and/or potassium
bromide.
Depending on the combustion retarding or other physical properties desired,
the
components of the salt may be in free base form, salt form, or as a complex,
or as a
solvate. The combustion retarding salt may be of any density and any
crystalline
structure.
In some embodiments, the combustion retarding salt is incorporated into or
added to
the amorphous solid material dissolved in a solvent or liquid carrier. In some
embodiments, the combustion retarding salt is suspended in a liquid carrier.
The
solvent or liquid carrier may be an aqueous or organic liquid, and may be
polar or non-
polar depending on it suitable application.
The liquid carrier or precursor solvent may be advantageously selected to be
readily
removed during the manufacture of the combustion retarding material to leave
the
combustion retarding slat in or on the amorphous solid material.
In some embodiments, the liquid carrier is a mixture of liquids, including
aqueous
liquid (water) and no-aqueous liquid (e.g. glycerol). Upon removal of the
water
following application of the salt, the glycerol will be retained in the
amorphous solid
material, where it offers flexibility and assists in aerosol formation upon
heating.
The amorphous solid may comprise a colourant. The addition of a colourant may
alter
the visual appearance of the amorphous solid. The presence of colourant in the
amorphous solid may enhance the visual appearance of the amorphous solid and
the
aerosol-generating material. By adding a colourant to the amorphous solid, the
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amorphous solid may be colour-matched to other components of the aerosol-
generating material or to other components of an article comprising the
amorphous
solid.
A variety of colourants may be used depending on the desired colour of the
amorphous
solid. The colour of amorphous solid may be, for example, white, green, red,
purple,
blue, brown or black. Other colours are also envisaged. Natural or synthetic
colourants, such as natural or synthetic dyes, food-grade colourants and
pharmaceutical-grade colourants may be used. In certain embodiments, the
colourant
io is caramel, which may confer the amorphous solid with a brown
appearance. In such
embodiments, the colour of the amorphous solid may be similar to the colour of
other
components (such as tobacco material) in an aerosol-generating material
comprising
the amorphous solid. In some embodiments, the addition of a colourant to the
amorphous solid renders it visually indistinguishable from other components in
the
aerosol-generating material.
The colourant may be incorporated during the formation of the amorphous solid
(e.g.
when forming a slurry comprising the materials that form the amorphous solid)
or it
may be applied to the amorphous solid after its formation (e.g. by spraying it
onto the
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-generating material may comprise an acid. The acid may be an
organic
acid. In some of these embodiments, the acid may be at least one of a
monoprotic acid,
a diprotic acid and a triprotic acid. In some such embodiments, the acid may
contain at
least one carboxyl functional group. In some such embodiments, the acid may be
at
least one of an alpha-hydroxy acid, carboxylic acid, dicarboxylic acid,
tricarboxylic acid
and keto acid. In some such embodiments, the acid may be an alpha-keto acid.
In some such embodiments, the acid may be at least one of succinic acid,
lactic acid,
benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic
acid,
malic acid, formic acid, sorbic acid, benzoic acid, propanoic and pyruvic
acid.
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Suitably the acid is lactic acid. In other embodiments, the acid is benzoic
acid. In other
embodiments the acid may be an inorganic acid. In some of these embodiments
the
acid may be a mineral acid. In some such embodiments, the acid may be at least
one of
sulphuric acid, hydrochloric acid, boric acid and phosphoric acid. In some
embodiments, the acid is levulinic acid.
In some embodiments, an acid is included when the aerosol-generating material
comprises nicotine. In such embodiments, the presence of an acid may stabilise
dissolved species in the slurry from which the aerosol-generating material is
formed.
io The presence of the acid may reduce or substantially prevent evaporation
of nicotine
during drying of the slurry, thereby reducing loss of nicotine during
manufacturing.
In certain embodiments, the aerosol-generating material comprises a gelling
agent
comprising a cellulosic gelling agent and/or a non-cellulosic gelling agent,
an active
substance and an acid.
In some embodiments, the aerosol-generating material comprises one or more
cannabinoid compounds selected from the group consisting of: cannabidiol
(CBD),
tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic
acid
(CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC),
cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV),
cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV),
cannabigerol monomethyl ether (CBGM) and cannabielsoin (CBE), cannabicitran
(CBT).
The aerosol-generating material may comprise one or more cannabinoid compounds
selected from the group consisting of cannabidiol (CBD) and THC
(tetrahydrocannabinol).
The aerosol-generating material may comprise cannabidiol (CBD).
The aerosol-generating material may comprise nicotine and cannabidiol (CBD).
The aerosol-generating material may comprise nicotine, cannabidiol (CBD), and
THC
(tetrahydrocannabinol).
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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
benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid,
myristic acid, and
propylene carbonate. In some embodiments, the aerosol former comprises one or
more
polyhydric alcohols, such as propylene glycol, triethylene glycol, 1 ,3-
butanediol and
glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or
triacetate; and/or
aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl
dodecanedioate
and dimethyl tetradecanedioate.
The one or more other functional materials may comprise one or more of pH
regulators, colouring agents, preservatives, binders, fillers, stabilizers,
and/or
antioxidants.
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.
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 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 lo% by weight of the composition. In some
embodiments,
the filler component is absent.
The tobacco material may contain an aerosol-former material. In some
embodiments,
the aerosol-former material of the tobacco material may be glycerol, propylene
glycol,
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or a mixture of glycerol and propylene glycol. Glycerol may be present in an
amount of
from to to 20 % by weight of the tobacco material, for example 13 to 16 % by
weight of
the composition, or about 14% or 15% by weight of the composition. Propylene
glycol, if
present, may be present in an amount of from 0.1 to 0.3% by weight of the
composition.
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
_to the tobacco material can be as defined herein.
In one example, the aerosol-former material may comprise an amorphous solid
material comprising 40% menthol, 16% glycerol, 20% binder (alginate/pectin
mix), and
20% fibres (wood pulp).
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. A
consumable may also comprise an aerosol generator, such as a heater, that
emits heat
to cause the aerosol-generating material to generate aerosol in use. The
heater may, for
example, comprise combustible material, a material heatable by electrical
conduction,
or a susceptor. The consumable may be any shape or size that is appropriate to
the
smoking device. In an embodiment of the invention, the consumable is a rod
shape.
A susceptor is a material that is heatable by penetration with a varying
magnetic field,
such as an alternating magnetic field. The susceptor may be an electrically-
conductive
material, so that penetration thereof with a varying magnetic field causes
induction
heating of the heating material. The heating material may be magnetic
material, so that
penetration thereof with a varying magnetic field causes magnetic hysteresis
heating of
the heating material. The susceptor may be both electrically-conductive and
magnetic,
so that the susceptor is heatable by both heating mechanisms. The device that
is
configured to generate the varying magnetic field is referred to as a magnetic
field
generator, herein.
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An aerosol-modifying agent is a substance, typically located downstream of the
aerosol
generation area, 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 ¨
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 110 mm to about 121 MM).
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
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 30 mm 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 10 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.
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The filamentary tow or filter 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(i-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,
io such as fibres having a cross section which is 'Y' shaped, 'X' shaped or
'0' shaped. The
fibres of the tow may have 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. The cross section
of the
fibres may have an isoperimetric ratio L2/A of 25 or less, 20 or less, or15 or
less, where
L is the length of the perimeter of the cross section and A is the area of the
cross
section. Such fibres have a relatively low surface area for a given value of
denier per
filament, which improves delivery of aerosol to the consumer. Filter material
described
herein also includes cellulose-based materials such as paper. Such materials
may have
a relatively low density, such as between about 0.1 and about 0.45 grams per
cubic
centimetre, to allow air and/or aerosol to pass through the material. Although
described as filter materials, such materials may have a primary purpose, such
as
increasing the resistance to draw of a component, that is not related to
filtration as
such.
Figure 1 shows a side-on cross-sectional view of an article 1 for use in a non-
combustible aerosol provision system.
In the present embodiment, the article 1 comprises a mouthpiece 2, and a
component 3
connected to the mouthpiece 2. The component 3 is an aerosol-generating
section
which comprises an aerosol-generating substrate formed from a source of
aerosol-
generating material. The source of aerosol-generating material may be in the
form of a
cylindrical rod of aerosol-generating material 4, as shown. In other examples,
the
aerosol-generating section may comprise a cavity for receiving a source of
aerosol-
generating material.
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The aerosol-generating material may comprise a plurality of elongate strips 5
of
aerosol-generating material. For example, in some embodiments, the aerosol-
generating material 4 may comprise a plurality of elongate strips 5 of an
aerosolisable
material and/or a plurality of elongate strips 5 of an amorphous solid
material. In some
embodiments, the aerosol-generating material 4 consists of a plurality of
elongate
strips 5 of aerosolisable material. In some embodiments, the aerosol-
generating
material 4 may be crimped. Optionally, the aerosol-generating material 4 may
be
crimped to a depth in the range of about 20 Um to about 1 mm. A sheet of
aerosol-
generating material 4 may have a thickness of about 200 UM to about 250 um.
In the present embodiment, the cylindrical rod of aerosol-generating material
4 is
circumscribed by a wrapper 6. The wrapper 6 may be a moisture impermeable
wrapper.
In embodiments where the aerosol-generating material 4 comprises a plurality
of
elongate strips 5, the plurality of elongate strips 5 of aerosol-generating
material 4 may
be aligned within the aerosol-generating section such that their longitudinal
dimension
is in parallel alignment with the longitudinal axis X of the component 3.
Alternatively,
the strips 5 may generally be arranged such that their longitudinal dimension
is aligned
transverse to the longitudinal axis of the component 3.
Where the shredded sheet comprises a plurality of strips of material 5, the
dimensions
of each strip 5 may vary between different strips. For example, a shredded
sheet or
aerosol-generating material may comprise a first population of strips 5 and a
second
population of strips 5, wherein the dimensions of the strips of the first
population are
different to the dimensions of the strips of the second population. In other
words, the
plurality of strips 5 may comprise a first population of strips having a first
aspect ratio
and a second population of strips 5 having a second aspect ratio that is
different to the
first aspect ratio. A first dimension, or cut width, of the strips 5 of
aerosolisable
material 4 is between about 0.8 mm and 5 mm, in some embodiments between about
0.9 mm and 2 mm, in some embodiments between about 0.9 mm and 1.5 mm.
The component 3 is configured for use in a non-combustible aerosol provision
device
comprising an aerosol generator for insertion into the aerosol generating
section of the
component 3. The aerosol generator may be a heating element which is a
resistive
heating element or an inductive heating element. The component 3 is configured
to
receive the aerosol generator in the rod of aerosol-generating material 4.
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In some embodiments, the mouthpiece 2 may comprises a cooling section 8, which
is
positioned immediately downstream of and adjacent to the component 3 of
aerosol-
generating material 4. In the present embodiment, the cooling section 8 is in
an
abutting relationship with the source of aerosol-generating material 4. The
mouthpiece
2 comprises a body of material 7 downstream of the cooling section 8, and a
hollow
tubular element 9 downstream of the body of material 7, at the mouth end of
the article
1.
io The cooling section 8 may comprises at least one hollow channel. The
cooling section 8
may be formed from, for example, but not limited to, a plurality of layers of
paper
which are parallel wound, with butted seams, or spirally wound layers of
paper,
cardboard tubes, tubes formed using a papier-mâché type process, moulded or
extruded plastic tubes or similar. The cooling section 8 is manufactured to
have a
rigidity that is sufficient to withstand the axial compressive forces and
bending
moments that might arise during manufacture and whilst the article 1 is in
use.
The body of material 7 and hollow tubular element 9 each define a
substantially
cylindrical overall outer shape and share a common longitudinal axis. The body
of
material 7 is wrapped in a first plug wrap 12. In the present example, the
body of
material 7 is formed from a filamentary tow. The tow may comprises plasticised
cellulose acetate tow.
In other examples, different materials can be used to form the body of
material 7. For
instance, rather than tow, the body 7 can be formed from paper, for instance
in a
similar way to paper filters known for use in cigarettes. For instance, the
paper, or
other cellulose-based material, can be provided as one or more portions of
sheet
material which is folded and/or crimped to form body 7. Alternatively, the
body 7 can
be formed from tows other than cellulose acetate, for instance polylactic acid
(PLA),
other materials described herein for filamentary tow or similar materials. The
hollow
tubular element 9 may be formed as described above in relation to the body of
material
7.
In the present example, the hollow tubular element 9, body of material 7 and
cooling
section 8 are combined using a second plug wrap 13 which is wrapped around all
three
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sections. It will be appreciated that any one of the sections may be omitted
from the
mouthpiece 2.
A tipping paper 15 is wrapped around the full length of the mouthpiece 2 and
over part
of the rod of aerosol-generating material 4 and has an adhesive on its inner
surface to
connect the mouthpiece 2 and rod of aerosol-generating material 4. In the
present
example, the rod of aerosol-generating material 4 is wrapped in the wrapper
10, which
forms a first wrapping material, and the tipping paper 15 forms an outer
wrapping
material which extends at least partially over the rod of aerosol-generating
material 4 to
io connect the mouthpiece 2 and rod of aerosol-generating material 4. In
some examples,
the tipping paper 15 can extend only partially over the rod of aerosol-
generating
material 4.
As shown in Fig. 2, the mouthpiece 2 may comprise an aerosol modifying agent
provided within the body of material 7. In the present embodiment, the aerosol
modifying agent is provided in the form of a capsule 17. In other examples,
the aerosol
modifying agent can be provided in other forms, such as material injected into
the body
of material 7 or provided on a thread, for instance the thread carrying a
flavourant or
other aerosol modifying agent, which may also be disposed within the body of
material
7.
The capsule 17 can comprise a breakable capsule, for instance a capsule which
has a
solid, frangible shell surrounding a liquid payload. In the present example, a
single
capsule 17 is used. The capsule 17 is entirely embedded within the body of
material 7.
In other words, the capsule 17 is completely surrounded by the material
forming the
body 7. In other examples, a plurality of breakable capsules may be disposed
within the
body of material 7, for instance 2, 3 or more breakable capsules 17.
The capsule 17 has a core-shell structure. In other words, the capsule 17
comprises a
shell encapsulating a liquid agent, for instance a flavourant or other agent,
which can be
any one of the flavourants or aerosol modifying agents described herein. The
shell of
the capsule 17 can be ruptured by a user to release the flavourant or other
agent into the
body of material 7.
Referring to Fig. 3, the component 3 comprises a first end 21 and an opposing
second
end 22. At least the outer dimensions of the first and second ends 21, 22 are
congruent.
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In the present embodiment, the first end 21 is a free end of the component 3,
which is
furthest from the mouthpiece 2, and the second end 22 is in abutment with the
mouthpiece 2, i.e. closest to the mouthpiece 2. The first end 21 comprises a
first surface
23 and the second end 24 comprises a second surface 24. In the present
embodiment,
the first and second surfaces 23, 24 are congruent.
As shown in Figs. 3 and 4, the component 3 comprises a core section 26. The
core
section 26 extends longitudinally along the length of the longitudinal axis X
of the
component 3. In the present embodiment, the core section 26 extends the length
of the
io component 3. The component 3 further comprises an outer section 27. The
outer
section 27 extends longitudinally along the length of the longitudinal axis A.
In the
present embodiment, the outer section 27 extends the length of the component.
The outer section 27 comprises a first end surface 28 and an opposing second
end
surface 29. In the present embodiment, the first end surface 28 extends in the
same
plane as the first surface 23 of the first end 21 of the component 3, and the
second end
surface 29 extends in the same plane as the second surface 24 of the second
end 22 of
the component 3. In the present embodiment, the first and second end surfaces
28, 29
are congruent
The outer section 27 surrounds the core section 26. Thus, the core section 26
is located
radially inward of the outer section 27. The outer section 27 comprises the
aerosol-
generating material 4, which is configured to generate an aerosol when heated.
The
aerosol-generating material 4 of the outer section 27 of the component 3 may
be a sheet
material or a plurality of elongate strips 5, as previously discussed. The
core section 26
comprises a first material 30. The first material 30 is configured to receive
a heating
element, during use.
In the present embodiment, the core section 26 and the outer section 27 are
formed
coaxially. That is, the longitudinal axis extending through the centre of the
core section
26 is coincident with the longitudinal axis extending through the centre of
the outer
section 27.
Therefore, the outer section 27 has a cross-section that is annular in shape
in a plane
perpendicular to its longitudinal axis. Thus, the first and second end section
28, 29
have an annular cross-section.
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The aerosol-generating material 4 forming the outer section 27 may comprise
tobacco
material. The sheet or shredded sheet of aerosol generating material 4 forming
the
outer section 27 may comprise a plant-based material, such as a tobacco
material.
The plant-based material may be a particulate or granular material. The
tobacco
material may be a particulate or granular material. In some embodiments, the
tobacco
material is a powder. Alternatively or in addition, the tobacco material may
comprise
may comprise strips, strands or fibres of tobacco. For example, the tobacco
material
_ro may comprise particles, granules, fibres, strips and/or strands
of tobacco. In some
embodiments, the tobacco material consists of particles or granules of tobacco
material.
The tobacco material can comprise reconstituted tobacco material.
The sheet or shredded sheet of aerosol-generating material may comprise
nicotine in an
amount of between about 0.1% to about 0.3% by weight of the sheet or sheet
material.
Paper reconstituted tobacco may also be present in the aerosol-generating
material
described herein. The paper reconstituted tobacco may be any type of paper
reconstituted tobacco that is known in the art.
The aerosol-generating material comprises an aerosol-former material. The
aerosol-
former material comprises one or more constituents capable of forming an
aerosol.
The aerosol-former material comprises one or more of glycerine, glycerol,
propylene
glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-
butylene glycol,
erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl
suberate, triethyl
citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl
acetate, tributyrin,
lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some
examples
the aerosol-former material is glycerol or propylene glycol.
The sheet or shredded sheet comprises a binder. The binder is arranged to bind
the
components of the aerosol-generating material to form the sheet or shredded
sheet.
The binder may at least partially coat the surface of the tobacco material.
Where the
tobacco material is in a particulate form, the binder may at least partially
coat the
surface of the particles of tobacco and bind them together.
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The aerosol-generating material may comprise a filler. In some embodiments,
the
sheet or shredded sheet comprises the filler. The filler is generally a non-
tobacco
component, that is, a component that does not include ingredients originating
from
tobacco. The filler may comprise one or more inorganic filler materials, such
as
calcium carbonate, perlite, vermiculite, diatomaceous eaith, colloidal silica,
magnesium
oxide, magnesium sulphate, magnesium carbonate, and suitable inorganic
sorbents,
such as molecular sieves. The filler may be a non-tobacco fibre such as wood
fibre or
pulp or wheat fibre. The filler can be a material comprising cellulose or a
material
comprises a derivate of cellulose. The filler component may also be a non-
tobacco cast
io material or a non-tobacco extruded material.
In particular embodiments which include filler, the filler is fibrous. For
example, the
filler may be a fibrous organic filler material such as wood, wood pulp, hemp
fibre,
cellulose or cellulose derivatives. Without wishing to be bound by theory, it
is believed
that including fibrous filler may increase the tensile strength of the
material.
The aerosol-generating material herein can comprise an aerosol modifying
agent, such
as any of the flavours described herein. In one embodiment, the aerosol-
generating
material comprises menthol. When the aerosol-generating material is
incorporated
into an article for use in an aerosol-provision system, the article may be
referred to as a
mentholated article.
In some embodiments, the outer section 27 may comprise an aerosol-forming
"amorphous solid", which may alternatively be referred to as a "monolithic
solid" (i.e.
non-fibrous). In some embodiments, the amorphous solid may comprise a dried
gel.
The amorphous solid is a solid material that may retain some fluid, such as
liquid,
within it. The amorphous solid may comprise a flavour. In some embodiments,
the
amorphous solid additionally comprises an active substance. The active
substance may
be tobacco extract. In some embodiments, the amorphous solid may comprises one
or
more active substances and/or flavours, one or more aerosol-former materials,
and
optionally one or more other functional materials. The amorphous solid may be
provided as a plurality of elongate strips.
The aerosol-generating material may comprise a blend of the aerosolisable
material and
the amorphous solid material as described herein. Such aerosol-generating
material
can provide an aerosol, in use, with a desirable flavour profile, since
additional flavour
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may be introduced to the aerosol-generating material by inclusion in the
amorphous
solid material component. Flavour provided in the amorphous solid material may
be
more stably retained within the amorphous solid material compared to flavour
added
directly to the tobacco material, resulting in a more consistent flavour
profile between
articles produced.
In the present embodiment, the core section 26 comprises a hollow tube 31. The
hollow
tube 31 may be generally cylindrical. Thus, in the present embodiment, the
cross-
section of the hollow tube 31 is annular in shape in a plane extending
perpendicularly to
K.) the longitudinal axis of the core section 26. The hollow tube 31
comprises a first end
surface 32 located in the same plane as the first end 21 of the aerosol-
generating
material 4 of the component 3 and a second end surface 33 located in the same
plane as
the second end 22 of the aerosol-generating material 4 of the component 3. In
the
present embodiment, both the first end surface 32 and the second end surface
33 have
an annular cross-section.
In the present embodiment, the hollow tube 31 comprises a perimeter wall 34
surrounding a cavity 35 or hollow. In the present embodiment, the perimeter
wall 34 is
annular in cross-section. The perimeter wall 34 may have a thickness in the
range of
about 50 um to about 1 mm. Additionally or alternatively, the perimeter wall
34 has a
hardness, or firmness, in the range of about 50% to about 98%. That is, the
perimeter
wall may be able to withstand a crushing force of in the range of about 0.1N
before
deformation occurs. The crushing force may be applied in a direction
perpendicular to
the longitudinal axis X.
The cavity 35 extends longitudinally along the length of the tube 31 from the
first end
surface 32 to the second end surface 33. The cavity 35 is configured to
receive a heating
element, during use. Therefore, the cavity 35 may have a diameter in the range
of about
1 mm to about 5 mm, in some embodiments in the range of about 2 mm to about 4
mm
In the present embodiment, the first material is paper. Therefore, the hollow
tube 31 is
formed from paper. Thus, the paper tube 31 may be formed from a plurality of
layers of
paper which are parallel wound, with butted seams or spirally wound layers of
paper,
cardboard tubes, or tubes formed using a papier-mâché type process.
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However, it will be appreciated that in alternative embodiments, the first
material may
be one of, for example, but not limited to, another paper material, bandcast
tobacco,
paper reconstituted tobacco, or an amorphous solid.
The tube 31 is configured to maintain a gap between the outer section 27 of
the
component 3 and a heating element when a heating element is inserted into the
component 3 during use. The tube 31 is configured to prevent contact between
the
outer section 27 of the component 3 and the heating element. Therefore, the
core
section 26 is able to prevent residue forming and/or sticking to the heating
element.
io This in turn improves hygiene and the efficiency of the heating element
for subsequent
uses.
The tube 31 comprises an inner surface 37. The inner surface 37 may comprise
at least
one embossed portion 38, shown in dotted lines in Fig. 3. The at least one
embossed
portion 38 is raised from the inner surface 37 of the tube 31 towards the
centre of the
cavity 35. The at least one embossed portion 38 is configured to minimise
contact
between the tube 31 and a heating element, when a heating element is inserted
into the
cavity 35 of the tube 31. Reducing contact between the tube 31 and a heating
element
can reduce the possibility of the tube 31 becoming damaged during heating of
the
component 3.
In addition, the at least one embossed portion 38 may be configured to
correctly align
the component 3 with the heating element. That is, the at least one embossed
portion
38 may limit the ways in which the heating element can be inserted into the
cavity 35 of
the core section 26 to ensure proper alignment between an article 1 and the
heating
element of a device.
Referring now to Fig. 5, another embodiment of the component 40 is shown. The
component 40 is generally the same as the embodiment of the component 3
described
above so a detailed description will be omitted herein. Furthermore, features
and
components of the component 40 that are the same as features and components of
the
component 3 will retain the same terminology and reference numerals. The main
difference between the second embodiment of the component 40 and the
previously
described component 3 can be found in at least the core section 26.
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In the present embodiment, the core section 26 comprises a loose gather sheet
41. The
loose gathered sheet 41 is gathered to form a central column 42 of material
30. The
central column 42 of material 30 is located inside the outer section 27. The
loose gather
sheet 41 may be gathered such that the density of the column 42 is in the
range of about
50 mg/cm3 to about 800 mg/cm3, in some embodiments about 6o mg to about 600
mg/cm3. In addition or alternatively, the loose gathered sheet 41 may be
gathered such
that the pressure drop across the core section 26 is in the range of about
0.01 mm/Wg
to about 1 mm/Wg
_ro The loose gathered sheet 41 is formed by a first material 30. The first
material 30 may
be at least one of, for example, but not limited to, a paper material,
bandcast tobacco,
paper reconstituted material, or an amorphous solid material. The loose
gathered sheet
41 may be provided in the form of a plurality of elongate strips 5, as
discussed above.
In the present embodiment, the loose gathered sheet 41 is formed by a paper
material.
The paper material may be porous. The porosity of the paper material may be in
the
range of about 50 Coresta units to about 10000 Coresta units.
The loose gather sheet 41 is configured to prevent contact between the outer
section 27
of the component 3 and a heating element, when a heating element is inserted
into the
core section 26 of the component. Reducing contact between the outer section
27 and a
heating element can prevent residue forming and/or sticking to the heating
element.
This in turn improves hygiene and the efficiency of the heating element for
subsequent
uses.
In all of the embodiments described above, the first material 30 may comprise
at least
one active substance. Furthermore, in all of the embodiments described above,
the first
material 30 may comprise an aerosol-modifying substance. In addition, in all
of the
embodiments described above, the first material 30 may comprise a flavour.
Thus,
during use, when the component 3 is heated by a heating element, the first
material 30
forming the core section 26 may release at least one active substance and/or
aerosol-
modifying substance and/or flavour.
Furthermore, in some embodiments, the first material 30 may comprise a coating
45.
The coating 45 may be configured to provide an aerosol. In some embodiments,
the
first material 30 may comprise a barrier coating 46 configured to prevent the
first
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material 30 burning or being otherwise damaged during heating. As shown in
Figure 3,
the coating 45 or barrier coating 46 may be provided on the inner surface 37
of the first
material 30, i.e. closest to the central axis X.
A method of forming a component 3 will now be described with reference to Fig.
6. The
method of forming a component for a non-combustible provision article 1
comprises
providing an assembly comprising a sheet of an aerosol-generating substrate 51
and a
first material 30. The sheet of aerosol-generating substrate 51 is formed from
an
aerosol-generating material 4, as described above. The method further
comprises
ro arranging the sheet of aerosol-generating substrate 51 and the first
material 30 into a
component 3 such that the sheet of aerosol-generating substrate forms and
outer
section 27, which surrounds a core section 26 formed by the first material 30.
The method may further comprise forming the first material and the aerosol-
generating
substrate 51 coaxially. The aerosol-generating substrate 51 and first material
30 may be
transported through a manufacturing apparatus 53 separately.
The method may further comprise the step of gathering the aerosol-generating
substrate 51 around the first material 30 to form a coaxial rod. A stream of
aerosol-
generating substrate 51 is fed into a gatherer 54 and gathered around the
stream of the
first material 30. In some embodiments, a plurality of streams of aerosol-
generating
substrate 51 is fed into a gatherer 54 and gathered around the stream of the
first
material 3. The plurality of streams of aerosol-generating material may be fed
into the
gatherer 54 at various positions around the first material 30.
The method step of providing the assembly may comprise providing a pre-formed
tube
31 of the first material 31. The pre-formed tube 31 may be provided to the
gatherer 53.
The apparatus 53 may comprise a tube feeder 55 that is configured to feed a
tube 31
into the centre of the gatherer 53. The tube 31 may be a continuous tube 31.
Alternatively, the method step of providing the assembly may comprise
providing a
sheet of first material 30, and forming a tube 31 from the sheet of first
material 30, as
illustrated in Fig. 7. To form the tube 31 online, the apparatus 53 may
further comprises
a tube forming device 56.
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The method step of providing the assembly may further comprise providing
adhesive
on the sheet of first material 30, and drying the adhesive before gathering
the aerosol-
generating substrate 51 around the first material 30. To adhere the first
material 30 to
form a tube 31, the apparatus 53 may further comprise a gluing station 57. The
gluing
station may be upstream of the tube forming device 56 or integrated therein.
To drying
the adhesive, the apparatus 53 may comprise a drying device 58 downstream of
the of
the tube forming device 56 or integrated therein.
In an alternative method, the method step of providing the assembly may
comprise
providing a sheet of first material 30 and gathering the sheet of first
material together
with the sheet of aerosol-generating material to form a coaxial rod having a
loose
gathered sheet in the core section 26. Therefore, the tube forming device 59
may be
omitted.
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 inventions 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 in future.
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