Methods, compositions and devices for functionalizing aerosols of non-combustible smoking articles

Abstract

The present invention discloses an apparatus and method for delivering an aerosol-forming component and a separate functional component to produce a functionalized aerosol vapor that mimics the sensory characteristics and properties of mainstream smoke experienced by smoking a conventional tobacco-based smoking article. The apparatus comprises: an aerosol-forming liquid adapted to deliver the aerosol-forming liquid to a heating device; a downstream chamber or zone containing the functionalized component, the functionalized component comprising one or more sensory components such as taste, fragrance and / or nicotine delivery components. The method comprises generating an aerosol from the aerosol-forming liquid and functionalizing the aerosol by applying the aerosol to a substrate for transmitting, delivering or applying one or more sensory properties.

Description

[0001] The present application is a divisional application of an application with a filing date of January 24, 2014, an application number of 201480005863.6, and an invention name of “Methods, components and devices for functionalizing aerosols for non-combustible smoking articles”. Technical Field

[0002] The present invention relates to methods, compositions and apparatus for producing functionalized aerosols that mimic the sensory characteristics and performance of mainstream smoke produced by conventional tobacco-based smoking articles. Background Art

[0003] Electronic cigarettes are popular substitutes for traditional smoking articles that burn tobacco products to produce mainstream smoke for inhalation. Unlike traditional tobacco-based smoking articles, electronic cigarettes produce steam for inhalation based on aerosols that generally imitate the mainstream smoke of traditional tobacco-based smoking articles. However, it is generally believed that the aerosol-based steam produced by electronic cigarettes cannot achieve the same "quality" experience as traditional smoking articles. The applicant found that the lack of this experience "quality" is at least partially caused by using a composite aerosol to form a liquid solution to produce aerosol-based steam. More particularly, the composite aerosol forms a liquid solution including an aerosol-forming liquid and one or more tastes, fragrances or nicotine delivery components. In addition, it is believed that the use of this composite aerosol to form a liquid solution can lead to the formation of chemical or pharmacologically incompatible components. Moreover, it is believed that the interaction between the various components of the composite aerosol forming liquid solution may cause chemical, pharmacological and / or thermal instability, which in turn may lead to particle precipitation, pollution of the aerosol heating element or chemical degradation of the solution, and other constraints on the transmission of aerosol vapor. Each of these drawbacks compromises the sensory performance and quality of aerosol-based vapors produced by electronic cigarettes. It is therefore desirable to provide an improved method, composition and apparatus for producing a functionalized aerosol having enhanced sensory characteristics and performance that more closely mimics the smoking experience provided by mainstream smoke of traditional tobacco-based smoking articles. Summary of the invention

[0004] It is an object of the present invention to provide a method, composition and apparatus for producing a functionalized aerosol vapor that mimics the sensory characteristics and properties of mainstream smoke experienced by a user inhaling a conventional tobacco-based smoking article.

[0005] Another object of the present invention is to provide a method for forming a functionalized aerosol vapor comprising a two-step process. The first step of the process comprises generating an aerosol from an aerosol-forming liquid. The second step of the process comprises functionalizing the aerosol by applying the aerosol to a substrate, thereby transmitting, delivering or applying one or more organoleptic properties such as taste, fragrance and / or nicotine to the aerosol.

[0006] It is a further object of the present invention to provide a method wherein the first step of generating an aerosol comprises providing an optimal aerosol particle size distribution for a desired aroma, taste and / or nicotine delivery profile which is subsequently imparted to the aerosol in a second step of the process.

[0007] Yet another object of the present invention is to provide a method wherein the first step of the process comprises generating an aerosol having properties for optimizing the taste, aroma and / or nicotine delivery performance of the aerosol during the second step of the method of the present invention. For example, the aerosol-forming liquid may comprise an excipient such as water that forms an aerosol having properties for activating an exothermic or endothermic reaction during the second step of the process.

[0008] It is a further object of the present invention to provide a method wherein aerosol vapor pressure is used as a mechanism to deliver, transfer or apply taste, flavor and / or nicotine properties during the second step of the process.

[0009] Another object of the present invention is to provide a kind of component and independent functional component that form aerosol, to produce functionalized aerosol steam, it imitates the organoleptic characteristics and the performance of the mainstream smoke experienced by traditional tobacco-based smoking articles.For example, the component that forms aerosol can comprise ethanol, glycerol, propylene glycol, polyethylene glycol, water or its mixture.The functional component can comprise one or more organoleptic components such as taste, fragrance and / or nicotine delivery composition.For example, the functional component can comprise solution or dispersion with taste and / or nicotine delivery composition.Alternately, the functional component can comprise the taste and / or fragrance delivery composition of encapsulation.In addition, the functional component can comprise the gel with taste, fragrance and / or nicotine delivery composition.

[0010] According to another aspect of the invention, the taste, flavor and / or nicotine component may include a vapor pressure modifier such as ethanol.

[0011] Another object of the present invention is to provide a device for generating a functionalized aerosol vapor that simulates the sensory characteristics and performance of mainstream smoke experienced by traditional tobacco-based smoking articles. In one embodiment, the device includes a first chamber or first district containing aerosol-forming liquid, which is suitable for passing aerosol-forming liquid to a heating device. The device also includes a downstream chamber or downstream district containing a functional component, and the functional component includes one or more sensory components such as taste, fragrance and / or nicotine delivery components.

[0012] According to another object of the present invention, the device may include a functional ingredient insert near the mouthpiece. For example, the device may include a disposable flavor insert near the mouthpiece designed to deliver the same number of puffs as a conventional cigarette. It will be appreciated that such an insert may also be suitable for delivering any other organoleptic properties such as taste or nicotine delivery.

[0013] Another object of the present invention is to simplify the filling of flavoring containers during the manufacture of electronic cigarettes, thus increasing manufacturing capacity, since it is easier to have filling stations dedicated to flavored and non-flavored formulations.

[0014] Another object of the present invention is to provide an electronic smoking article having separate containers for an aerosol-forming liquid solution and a flavor, fragrance and / or nicotine solution to extend the shelf life of the respective solutions and the operating life of an electronic cigarette atomizer heating element. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a block diagram of a flavor insert used in an e-cigarette.

[0016] Figure 2 is a block diagram showing a non-flavored aerosol that is formed and then flavored.

[0017] Figure 3 is an exploded isometric view of an electronic cigarette including a flavor insert.

[0018] Figure 4 is a flow chart of one embodiment of an insert for an electronic cigarette according to the present invention.

[0019] Figure 5-18 is a flow chart of various embodiments of an insert for an electronic cigarette according to the present invention. DETAILED DESCRIPTION

[0020] According to one aspect of the present invention, a two-step process is used to form an aerosol having organoleptic properties suitable for delivery using an electronic cigarette. In the first step of the process, an aerosol is formed by a non-flavored formulation located in the first chamber or first zone of the electronic cigarette. Any aerosol forming mechanism (e.g., thermal, mechanical, piezoelectric) can be used in the present invention. Then, a matrix carrying flavor, fragrance and / or nicotine suitable for delivering the desired organoleptic properties to the aerosol is applied to the aerosol. In this step, the flavor, fragrance and / or nicotine delivery components in the high vapor pressure solvent are released into the aerosol before leaving the electronic cigarette mouthpiece. The following simplified diagram shows this two-step process, in which a flavor insert is used to deliver the flavor to the electronic cigarette aerosol.

[0021] The formation of non-flavored aerosols in electronic cigarettes can include any known sprayer mechanism. For example, ultrasonic spray (using a piezoelectric element that vibrates and generates high-frequency ultrasonic waves to cause vibration and atomization of the liquid formula), electrospray (using a heating element built on a high-surface component in direct contact with the aerosol-forming material), or spray atomization by passing the aerosol solution through a small venturi injection channel. In general, the properties of the aerosol depend on the rheological and thermodynamic properties of the aerosol-forming liquid and the spray mechanism. Due to the physicochemical stress of the aerosol-forming material during the spraying process (i.e., thermal degradation, shear-induced phase separation, etc.), the properties and delivery consistency of the aerosol may be affected when the liquid is atomized. If the affected aerosol material component is transmitted to the sensory organ, then this will be very relevant to the quality of the aerosol. For example, nicotine may be degraded during thermal spraying; mint and other hydrophobic flavor materials may precipitate due to incompatibility with the hydrophilic aerosol-forming formula. In other cases, the desired sensory material (i.e., mint, tobacco extract, etc.) may not be dissolved in the aerosol-forming liquid at the appropriate viscosity and / or surface tension of the acceptable aerosol, thus limiting the amount delivered to the sensory organ. In addition, since the sensory material (not present in the aerosol formation process) does not affect the viscosity and surface tension, this strategy can be used to improve the consistency of aerosol delivery. These material variables affect the particle size distribution of the aerosol. Having an aerosol formation process before flavoring ensures the consistency of the aerosol, in particular, when it is desired to deliver a consistent amount of nicotine through the aerosol that leaves the mouthpiece of the electronic cigarette.

[0022] Among them, what is attractive to electronic cigarette manufacturers is: a non-flavored aerosol formulation located in the first chamber or the first zone, suitable for forming a particle size distribution and delivering a desired user experience, and which can be further processed for sensory delivery. The basic aerosol formulation suitable for the present invention includes an aerosol-forming material, a vapor pressure regulator, a buffer, a salt, a nucleation site structure, a surfactant, a preservative, and an excipient. In addition, any ingredient that forms a non-flavored aerosol formulation can be used to chemically trigger other ingredients located downstream of the sprayer. For example, water can be used to activate an exothermic or endothermic reaction of a salt located in a downstream insert, thereby causing heat exchange to heat a sublimable material insert or change the particle size distribution of a deliverable aerosol. Non-limiting examples of non-flavored aerosol-forming formulations are included in Table I below.

[0023]

[0024]

[0025] Table I: Aerosol formulation

[0026] Functional formulations for the senses

[0027] The following examples provide matrix formulations suitable for the present invention to change the organoleptic properties of the delivered aerosol, carrying flavors, fragrances and / or nicotine. These formulations can be liquids, dispersions, gels, encapsulated flavors, fibers or any other form and shape that allows close contact with non-flavored aerosol streams. These formulations can have high vapor pressures to allow maximization of their flavor contribution to the aerosol stream. Schematic examples of functionalized formulations that can be included in electronic cigarettes are given below.

[0028] Aroma delivery

[0029] When the formula is liquid, the main formula ingredients in this embodiment include fragrance, vapor pressure regulator, preservative and adjuvant. These formulas can also include other ingredients to further improve the aerosol flow transmitted, such as surfactant, nucleation site, buffer etc. Table II shows non-limiting examples for solution, dispersion, encapsulation and gel formula physical form. These formulas can include final aerosol delivery specification required nicotine.

[0030]

[0031]

[0032] Table II: Functionalized formulations

[0033] Low Solubility / Hydrophobic Sensory Fragrance Delivery

[0034] When the solubility of the sensory material is low, the amount of sensory perception in the aerosol compatible formula is limited. By placing the sensory perception downstream of the aerosol to form a part of the electronic cigarette, a formula with a high concentration of the sensory perception delivered can be formed because they are not limited by the low solubility in the aerosol forming formula. In this embodiment, the formula ingredients may include flavors, vapor pressure regulators, preservatives, and excipients. These formulas may also contain other ingredients to further improve the aerosol flow delivered, such as surfactants, nucleation sites, buffers, etc. The following table gives non-limiting examples of liquids, solutions, and dispersions.

[0035]

[0036]

[0037] Table III: Functionalized formulations

[0038] Low Solubility / Hydrophobic Sensory Fragrance Delivery

[0039] A. Chemical / Thermal Aerosol Delivery Activation

[0040] Because in the practice of the present invention, two or more chambers, compartments or zones with different formulations are used, the present invention also enables the benefits derived from their different natures to obtain further improvements in aerosol delivery. These improvements include the embodiments disclosed in Tables I, II and III above. Two specific cases are described below:

[0041] 1. Chemical equilibrium or chemical reaction activation

[0042] According to this embodiment, the non-flavored formulation may include a chemical component that may react with or affect another chemical component included in the downstream functionalized formulation. -Lowry acid / base theory, it is known that nicotine in a solution is in chemical equilibrium. Therefore, the acid or base component (such as a buffer such as acetic acid, citric acid, etc.) carried by the non-flavored aerosol can be used to control the ionization of nicotine in the aerosol that is finally delivered. Among them, according to this embodiment, the consistency of nicotine delivery can be improved. In addition, if the reactants are kept separate before delivery until mixed in the aerosol vapor, fragile flavoring and taste components can be formed in situ.

[0043] 2. Thermal Activation

[0044] Chemical components included in the non-flavored formulation can react with other chemical components included in the downstream formulation to exothermically or endothermically change the temperature of the aerosol. For example, water in the non-flavored aerosol can react with a salt pod in the downstream portion of the e-cigarette to release heat of hydration, i.e., CuSO 4 This heat can be used to help the sublimation of some sensory perception substances downstream of the electronic cigarette. Another example is to use an endothermic reaction, namely NH 4 Cl et al. This would allow cooling of the aerosol vapor after it is formed, thereby improving the delivery consistency of the aerosol particle size distribution.

[0045] Figure 2 This concept is further illustrated whereby a non-flavored aerosol is formed in an aerosol-forming container wherein an aerosol-forming liquid is in contact with a heating element. As the aerosol moves downstream and interacts with a flavored insert, the aerosol becomes flavored. Figure 2 The sketch of shoWs the main components of the electronic cigarette separately, but it will be appreciated that any combination of the battery, aerosol container and / or flavor insert may be physically integrated With each other, As long as the flavor insert is arranged downstream of the aerosol container as indicated by the arrows.

[0046] This concept decouples aerosol formation from taste, flavor and / or nicotine delivery. The aerosol is thus improved by removing any degradation in quality, nicotine delivery and taste caused by the interaction of the aerosol-forming liquid formulation with the formulation contained in the flavor insert or its thermal degradation / inactivation when in contact with the heating element of the e-cigarette.

[0047] Furthermore, the scent formulation in the insert can be made using a wide range of materials such as common solutions, dispersions, emulsions, gels, creams, powders, pastes, waxes, etc. The scent release can occur thermally, chemically, dissolving, vapor pressure driven, wet, electrically, etc. The insert can be made using one or a combination of different scent matrices such as surface coatings, dissolvable matrices, encapsulated scents, wicking webs, coated webs, etc.

[0048] Although, this concept is based on aerosol fluid dynamics, it can be further enhanced by placing a heating element in the insert to control the release of the flavor.

[0049] The following Figure 3 The embodiment of the device of the present invention shown in FIG. 1 includes an atomizer cartridge loaded with a glycol / water solution in addition to a filter paper insert coated with tobacco extract located before the mouthpiece end. The aerosol delivered in this configuration tastes like a 'tobacco-flavored aerosol'. By way of further example, a vanilla-flavored insert may be used to deliver a vanilla flavor to the aerosol.

[0050] The sketches shown in the following figures illustrate several embodiments of suggested inserts for the practice of the present invention. These embodiments are non-limiting, and it is understood that the present invention may include a combination of one or more of these embodiments.

[0051] A porous matrix of embedded coated fibers or hollow fibers filled with a scented formulation

[0052] Figure 4 An embodiment of a scent formulation in a porous matrix containing embedded fibers of the present invention is shown. The scent can be coated on the fibers contained within the hollow fibers. According to this embodiment, the scent migrates into the aerosol stream to flavor the aerosol stream. It can be activated electrically or by dissolving the scent carrier. Similar release mechanisms can be applied to multiple other embodiments described below.

[0053] Single / multi-layer screen inserts where the screen carries the fragrance like coated fibers, encapsulated fibers, etc.

[0054] Figure 5 An embodiment of the invention comprising a scent embedded in a single or multi-layer screen for delivery to a non-flavored aerosol vapor is shown. According to this embodiment, for example, the release of the encapsulated scent can be activated by water / glycol in the non-flavored aerosol formulation.

[0055] Woven or non-woven mesh or sheet formed of erodible material or any of the above-mentioned fragrance carriers

[0056] Figure 6 An embodiment of the invention is shown that includes a mesh that is fabricated so that flavor is released upon interaction with a non-flavored aerosol.

[0057] Diffusive and / or erodible disk(s)

[0058] Figure 7 Embodiments of the invention are shown that include diffusive or erodible discs that contain a functionalized formulation. For example, the disc can be formulated with a fragrance in a hygroscopic matrix that erodes during inhalation.

[0059] Coil wrapped inserts with coated high areas or mesh structures

[0060] Figure 8 An embodiment of the present invention comprising a coil-wrapped insert having a coating area or mesh structure is shown. The purpose of this design is to maximize the effective interaction between the non-flavored aerosol and the flavored insert. This design is also applicable to several embodiments described herein.

[0061] Porous film or open-cell foam / sponge

[0062] Fig. 9 Embodiments of the invention comprising the use of a porous film or an open cell foam / sponge structure are shown. The porous film may be made of cellulose or any other highly absorbent material suitable for carrying flavour / nicotine. Figure 3 The electronic cigarette shown with the tobacco extract embedded material positioned toward its mouthpiece end is one embodiment of this design.

[0063] Folding fan-shaped seasoning coating insert

[0064] Fig.10 An embodiment of the invention is shown that includes a folded fan shaped flavored coating insert. In addition to maximizing the effective area of ​​action for non-flavored aerosols and flavored inserts, this folded fan shaped design benefits from venturi acceleration to drive the flavor into the aerosol stream.

[0065] 3D Seasoning Coating Inserts

[0066] Fig.11 An embodiment of the flavored coated insert of the present invention including the configuration is shown. In addition to the ease of construction of a solid insert, such an insert can also be made from an erodible flavor / nicotine matrix. One or more flow paths can be used to control the fluid dynamics and maximize the impact energy of the non-flavored aerosol on the flavored insert.

[0067] Discipline

[0068] Fig.12 An embodiment of the invention is shown comprising a bundle of tubes containing flavor / nicotine releasable under pressure differential, temperature and electrical activation. Inhalation can also be a force for releasing flavor.

[0069] Fragrance / nicotine coating channels in honeycomb insert

[0070] Fig.13 The present invention is shown to include a honeycomb structure with flavor / nicotine pods. Control of release can be achieved by different release rates distributed in the honeycomb. This concept of controlling the flavor release rate by changing the activation rate on the flavor insert is applicable to other embodiments of the present invention.

[0071] Release the scent by inhaling - I

[0072] Fig.14 An embodiment of the invention is shown that includes a capsule that contains flavor / nicotine and releases its load under inhalation pressure. This approach can be used as an off / on flavoring option to change the flavor. Although Fig.14 The flavoring of a non-flavored aerosol stream is shown, but it is also applicable to changing the flavoring of a flavored aerosol. Such an insert can be used continuously. These concepts also apply to the following embodiments for releasing a flavor by inhalation or by physical crushing.

[0073] Release of aroma by inhalation or physical crushing - II

[0074] Fig.15 An embodiment of the invention is shown which includes a flavour insert which can be broken under inhalation pressure or by physical crushing to release flavour into the aerosol stream.

[0075] Scent Release Non-Mesh Bags / Mesh Bags

[0076] Fig.16 The embodiment of the present invention including bag is shown, and the bag has a non-woven net of non-woven sensitive material, and the non-woven net usually has a gap that can pass smoke when activated. The net is compressed and constrained, and the compressed state of the fiber is kept when compressed and the gap is filled to prevent its load from leading to its outside. The effective load can be a fragrance, tobacco extract, nicotine delivery enhancement chemical material or other materials desired for regulating non-flavored aerosol. The bag releases its load through perforation. The net can react or dissolve with one or more chemical components in the non-flavored aerosol to be activated. Therefore, the bag formula provides the beneficial effect of extending the shelf life by being protected from interacting with the environment and interacting with each other before use.

[0077] Scent Release Bags

[0078] Fig.17 and18 An embodiment of the present invention including a bag containing a payload is shown. The load can be a flavor, tobacco extract, nicotine, nicotine delivery enhancing chemical material, or other materials desired for adjusting the organoleptic properties of the aerosol. Under mechanical, thermal excitation or similar mixing mechanisms (such as perforation, crushing, opening a valve, etc.), the bag releases its load. Because the bag formula is in a sealed container, the user has an on / off option to use it to adjust the aerosol sensory experience. The invention includes the use of multiple bags or chambers in a rotating configuration aligned with the aerosol flow so that the user can select a specific flavoring to be delivered during the use of an electronic cigarette. In addition, it is also a beneficial effect of the formula to be protected from interacting with the environment and each other before use to extend the shelf life.

Claims

1. An electronic cigarette, comprising: A nebulizer box comprising ethylene glycol and an aqueous solution, wherein the nebulizer box comprises an aerosol forming mechanism configured to generate an aerosol from the ethylene glycol and the aqueous solution, an insert comprising a flavor and an electrical heating element in direct contact with the flavor and configured to facilitate release of the flavor into an aerosol generated from a glycol and water solution, wherein the insert has a coiled structure and a flavor coating region, and wherein the insert is configured such that the flavor remains separated until mixed with the aerosol generated from the glycol and water solution, the flavor being downstream of the aerosol forming mechanism; and A battery portion includes a battery configured to be electrically coupled to both the aerosol-forming mechanism and the electrical heating element.

2. The electronic cigarette according to claim 1, wherein: The flavor is configured to be delivered through a flavor formulation operably associated with the porous matrix of embedded fibers.

3. The electronic cigarette according to claim 2, wherein: The scent formulation is capable of being electrically activated.

4. The electronic cigarette according to claim 1, wherein: The flavoring is configured to be delivered via a flavor formulation operably associated with at least one screen.

5. The electronic cigarette according to claim 4, wherein: The fragrance formulation is configured to be activated by a glycol and water solution.

6. The electronic cigarette according to claim 1, wherein: The insert includes a diffusible disk containing a functionalizing formulation.

7. The electronic cigarette according to claim 6, wherein: The functionalized formulation includes a hygroscopic matrix configured to erode during gettering.

8. The electronic cigarette according to claim 1, wherein: The flavoring is configured to be delivered through a fan-shaped flavoring coating insert.

9. The electronic cigarette according to claim 1, wherein: The insert is a three-dimensional seasoned coated insert.

10. The electronic cigarette according to claim 1, wherein: The insert includes an erodible flavor and / or nicotine matrix.

11. The electronic cigarette according to claim 1, wherein: The insert includes a tube bundle.

12. The electronic cigarette according to claim 11, wherein: The flavoring is configured to be released from the tube bundle by activation of a pressure differential.

13. The electronic cigarette according to claim 1, wherein: The insert includes flavoring agents, vapor pressure regulators, preservatives, and excipients.

14. A method of forming an aerosol vapor, comprising: An aerosol is generated from an aerosol-forming liquid, and the aerosol-forming mechanism comprises a thermal mechanism or a piezoelectric mechanism within an atomizer cartridge in the electronic cigarette; as well as Functionalizing an aerosol by applying the aerosol to a flavoring within an insert having a coiled structure and a flavoring coating area to impart one or more organoleptic properties to the aerosol, wherein the insert includes an electrical heating element that is in direct contact with the flavoring and is configured to assist in imparting the one or more organoleptic properties to the aerosol, and wherein the insert is configured such that the flavoring remains separated until mixed with an aerosol generated from an aerosol-forming liquid, the flavoring being downstream of the aerosol-forming mechanism.

15. The method for forming an aerosol according to claim 14, wherein: Generating the aerosol further includes providing an optimal aerosol particle size distribution for the desired delivered sensory properties.

16. The method for forming an aerosol according to claim 14, wherein: The aerosol-forming liquid comprises an excipient for activating a chemical reaction during the functionalisation step.

17. The method for forming an aerosol according to claim 16, wherein: The auxiliary material includes an aqueous solution.

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