Packaging for aerosol delivery products and aerosol delivery products made therefrom

Abstract

A wrapper well suited for use in aerosol delivery products, such as heat-not-burn sticks, is disclosed. The wrapper includes a base web made from cellulose fibers combined with filler particles. The base web can be coated on at least one side with a permeability reducing composition and / or treated with a fire-retardant salt. The base web is constructed to have a basis weight, specific volume, and permeability to produce an aerosol delivery stick having low burn characteristics.

Description

[0001] Related applications

[0002] This application is based on and claims priority to U.S. Provisional Patent Application Serial No. 63 / 152,140, ​​filed February 22, 2021, which is incorporated herein by reference. background

[0003] Smoking products such as cigarettes are typically made by wrapping a stick of tobacco in wrapping paper. At one end, the smoking product usually includes a filter through which the product is drawn. The filter is attached to the smoking product using tipping paper adhered to the white wrapping paper. The wrapping paper and tipping paper used to manufacture smoking products are typically made from wood or other cellulose fibers and may contain one or more fillers, such as calcium carbonate.

[0004] When a smoking product is inhaled, it produces mainstream smoke, which is inhaled through the filter. Mainstream smoke can contain many different components that give the smoking product its specific flavor, which includes not only sensations identified through taste but also sensations identified through smell. In addition to producing mainstream smoke, traditional smoking products also produce sidestream smoke. The smoke exhaled by a smoker and the sidestream smoke are commonly referred to as secondhand smoke.

[0005] In the past, those skilled in the art have created heated tobacco products that generate aerosols and provide users with an experience similar to traditional cigarettes without producing secondhand smoke. These types of smokeless products are often referred to as heated but not burned sticks. Heated but not burned sticks are placed in an aerosol generator and heated at a low temperature to produce an inhalable aerosol without burning the tobacco. For example, a heated but not burned stick may contain tobacco that is heated to produce an aerosol without burning the tobacco. Similar to conventional smoking products, heated but not burned sticks contain a column of aerosol-generating material surrounded by packaging. The aerosol-generating material can be made in various forms, such as from different sheets similar to cigarettes, from aggregated sheets of material, from cut wire bundles from extruded columns of material, or from cut wire bundles from a single sheet. The heated but not burned stick can be placed in a heating device that heats the stick to a temperature, for example, from about 200°C to about 350°C. The heating device, for example, may use electrical components, may burn fuel, or may create a heat-generating chemical reaction.

[0006] Unlike traditional smoking products, heated but not-burning sticks should be non-flammable. In particular, when exposed to an open flame or heating element (such as an electric lighter), the heated but not-burning stick should not be able to maintain its lit end. Ideally, for example, a heated but not-burning stick should not be able to be lit and inhaled like a traditional cigarette. Furthermore, when placed in a heated but not-burning device, the heated but not-burning stick preferably does not produce any significant amount of combustion products. Moreover, various regulations now require that heated but not-burning sticks cannot be used as traditional cigarettes.

[0007] To address these issues, packaging for heated but non-combustible rods has been manufactured in the past by laminating aluminum onto a paper substrate. However, aluminum adds significant costs to the product and is non-biodegradable.

[0008] In view of the above, there is a need for an improved packaging for heated but non-combustible rods. In particular, there is a need for an improved packaging that makes the heated but non-combustible rods non-flammable. Summary of the Invention

[0009] Generally, this disclosure relates to a packaging for constructing aerosol delivery products, such as heated but not combustible sticks. In one aspect, the packaging produces a non-combustible product when it surrounds a tobacco stick, is placed in a conventional smoking machine, and is ignited. The packaging of this disclosure can be made primarily of biodegradable materials and is therefore environmentally friendly. Additionally, the packaging can be constructed without adversely interfering with the aerosol-generating properties of the aerosol-generating materials contained within the aerosol delivery product.

[0010] According to this disclosure, in order to produce packaging capable of producing non-flammable products, various parameters of the packaging are controlled within certain tolerance ranges. It has been found that by adjusting and controlling various parameters, combinations of multiple properties can provide the desired non-flammable characteristics for the packaging. For example, in one embodiment, the packaging contains a combination of cellulose fibers and flame-retardant fillers. It has been found that the amount of filler present in the web, the basis weight of the web, the specific volume of the web, and the inherent permeability of the web can produce packaging particularly suitable for the production of heated but not burned rods and other aerosol products. Optionally, the web may also contain a coating and / or a phosphorus-based flame retardant. Alternatively, packaging with specific properties is produced, including a combination of a coating and a phosphorus-based flame retardant. The phosphorus-based flame retardant may be impregnated in the paper or incorporated into the coating.

[0011] In one aspect, this disclosure relates to a packaging for aerosol delivery products (such as heated but not burning rods). The packaging includes a base web containing cellulose fibers mixed with a flame-retardant filler. The base web has a first side and an opposing second side. The flame-retardant filler may be present in the base web (uncoated web) in an amount from about 15% by weight to about 55% by weight, such as from about 18% by weight to about 52% by weight. In one aspect, the flame-retardant filler is present in the base web in an amount of less than 50% by weight. The base web has a specific volume of less than about 2.0 cc / g, such as less than about 1.7 cc / g, such as less than about 1.5 cc / g, such as less than about 1.2 cc / g, such as less than about 1.1 cc / g, such as less than about 1 cc / g, and generally greater than about 0.6 cc / g, such as greater than about 0.7 cc / g. In one aspect, the volume is from about 0.85 cc / g to about 1.05 cc / g. The base web (uncoated) has a basis weight of about 30 gsm to about 85 gsm, such as about 40 gsm to about 80 gsm, such as about 45 gsm to about 75 gsm.

[0012] The base fabric may have an inherent permeability of less than about 100 mL / min, such as less than about 85 mL / min, less than about 70 mL / min, less than about 55 mL / min, less than about 40 mL / min, less than about 30 mL / min, less than about 20 mL / min, or less than about 15 mL / min. The permeability may be greater than about 5 mL / min, such as greater than about 10 mL / min or greater than about 25 mL / min.

[0013] The base web may have an inherent porosity of less than about 10 CORESTA units (CU), such as less than about 8 CU or less than about 5 CU. As used herein, “inherent” porosity or permeability refers to the porosity or permeability of the base web prior to the application of any coating or surface treatment (such as perforation).

[0014] The packaging may optionally further include a coating disposed on a first side of the base web. The coating comprises a permeability-reducing composition. The permeability-reducing composition may, for example, comprise microcrystalline cellulose gel, alginate, starch, cellulose derivatives, or mixtures thereof.

[0015] In another aspect, the packaging may optionally contain a phosphorus-based flame retardant impregnated into the uncoated or coated packaging. Phosphorus-based flame retardants may include, for example, monosodium phosphate, disodium phosphate, monoammonium phosphate, etc. In yet another embodiment, the phosphorus-based flame retardant may be incorporated into a coating applied to the packaging. For example, the phosphorus-based flame retardant may be combined with a permeability-reducing composition.

[0016] Flame-retardant fillers present in the base fabric may include clay particles, silicate particles, metal hydroxide particles, etc. For example, flame-retardant fillers may include kaolin particles, aluminum hydroxide particles, calcium silicate particles, or mixtures thereof. The flame-retardant filler particles may have an average particle size of about 0.1 micrometers to about 30 micrometers, such as about 2 micrometers to about 15 micrometers. As used herein, the particle size of the filler can be determined by light scattering or laser diffraction. Such particle size analyzers are commercially available from Horiba Scientific, such as the LA-960 particle size analyzer.

[0017] The coating of the permeability-reducing composition can be a continuous coating or a discontinuous coating. As used herein, a continuous coating is an uninterrupted coating over a treated area of ​​a substrate. On the other hand, a discontinuous coating is an intermittent coating over a treated area, forming untreated areas within the treated area. Packages comprising multiple spaced-apart annular bands formed from the coating composition are, for example, discontinuous coatings as used herein.

[0018] When the coating is a continuous coating, it typically covers more than about 20%, such as more than about 40%, more than about 65%, more than about 80%, more than about 85%, more than about 90%, or more than about 95% of the surface area of ​​the first side of the base web. In the case of this coating, the coating may have a basis weight of about 0.5 gsm to about 10 gsm.

[0019] The coated base material can have a permeability of less than about 25 mL / min, such as less than about 18 mL / min, less than about 15 mL / min, less than about 12 mL / min, less than about 10 mL / min, less than about 8 mL / min, less than about 6 mL / min, or less than about 4 mL / min. The permeability can also be greater than 0 mL / min, such as greater than about 0.1 mL / min or greater than about 1 mL / min.

[0020] The coated base web can typically have a porosity of less than about 3 CU, such as less than about 2 CU.

[0021] When present, phosphorus-based flame retardants can be impregnated onto substantially the entire surface area of ​​the packaging or selected areas of the packaging. For example, phosphorus-based flame retardants can be impregnated into strips or portions of the packaging (e.g., applied in a pattern).

[0022] When phosphorus-based flame retardants are impregnated into packaging materials, the phosphorus-based flame retardant can typically impregnate more than about 20%, such as more than about 40%, more than about 65%, more than about 80%, more than about 85%, more than about 90%, or more than about 95% of the surface area of ​​the base fabric. The phosphorus-based flame retardant impregnated into the packaging material can be added by weight from about 0.5 gsm to about 10 gsm.

[0023] In another embodiment, a phosphorus-based flame retardant may be incorporated into a permeability-reducing composition and applied as a coating to packaging. The permeability-reducing composition may include a flash point lowering substance, such as a natural or synthetic polymer, blended with the phosphorus-based flame retardant. Once applied to packaging, the dried coating may contain a phosphorus-based flame retardant typically in amounts greater than about 0.5% by weight, such as greater than about 1% by weight, such as greater than about 1% by weight, such as greater than about 2% by weight, such as greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 20% by weight, such as greater than about 30% by weight, and typically less than about 50% by weight, such as less than about 40% by weight, such as less than about 30% by weight. Alternatively, the flash point lowering substance may be present in the dried coating in amounts from about 10% by weight to about 99% by weight, including all increments of 1% by weight therebetween.

[0024] When the packaging of this disclosure contains a phosphorus-based flame retardant, the packaging may contain fillers such as calcium carbonate or magnesium oxide, and may not contain flame-retardant fillers.

[0025] The uncoated base web may have a diffusion rate of less than about 0.8 cm / s, such as less than about 0.7 cm / s or less than about 0.6 cm / s. On the other hand, the coated web may have a diffusion rate of less than about 0.2 cm / s, such as less than about 0.15 cm / s or less than about 0.1 cm / s.

[0026] The packaging according to this disclosure may be a single-layer packaging or may include multiple layers. For example, the packaging may include two layers. When multiple layers are included, the base web of this disclosure includes one of the layers. In one aspect, for example, the base web may be an inner layer of a two-layer packaging or an outer layer of a two-layer packaging.

[0027] This disclosure also relates to aerosol delivery products, such as heated but not combustible rods. A heated but not combustible rod comprises a column of aerosol-generating material. The packaging as described above surrounds the column of aerosol-generating material. The aerosol-generating material can be made from any suitable plant material. For example, in one embodiment, the aerosol-generating material is tobacco, such as shredded tobacco, cast tobacco, or reconstituted tobacco produced through a papermaking process. The aerosol-generating material can be in any suitable form, such as aligned or misaligned cut bundles, curled sheets, granules, beads, fragments, or cylinders. The aerosol-generating material can be combined with a humectant to generate an aerosol upon heating. The packaging of this disclosure can be incorporated into the heated but not combustible rod such that the heated but not combustible rod is non-flammable when tested according to a flammability test. The heated but not combustible rod passes the above test while having a diameter of about 5 mm to about 6 mm or about 6.5 mm to about 9.5 mm.

[0028] Other features and aspects of this disclosure are discussed in more detail below. Attached Figure Description

[0029] The full and implementable disclosure of this invention is set forth in more detail in the remainder of the specification (including with reference to the accompanying drawings), in which: Figure 1 This is a plan view of one embodiment of a heating but not burning device equipped with a heating but not burning rod according to the present disclosure; Figure 2 This is a plan view of an alternative embodiment of a heating but not burning device equipped with a heating but not burning rod containing aerosol generating material, wherein cooling and filtration functions are part of the heating device; and Figure 3 This is another implementation of a heated but non-burning rod heated by a coal tip without an electrical system.

[0030] The reference numerals are used repeatedly in this specification and drawings to indicate the same or similar features or elements of the invention. Detailed Implementation

[0031] Those skilled in the art will understand that this discussion is merely a description of exemplary embodiments and is not intended to limit the broader aspects of this disclosure.

[0032] Generally, this disclosure relates to a paper product that can be incorporated into all different types of aerosol delivery products. Such products may include heated but not combustible sticks, smoking products, cigarettes, hand-rolled products, etc. In one application, the packaging can produce a product with low flammability. For example, this paper product is ideally suited for use as packaging in the production of non-flammable heated but not combustible sticks.

[0033] The ability to convert packaging materials produced from cellulose fibers into aerosol delivery products with low flammability is problematic. Historically, paper packaging materials have been combined with metal films (such as aluminum foil) to produce packaging materials with reduced flammability. However, this disclosure relates to a packaging material that does not include a metal foil layer but still enables the production of aerosol delivery products with low flammability. Various parameters of the packaging material are combined, adjusted, and controlled to produce packaging materials with desired properties. According to this disclosure, for example, the packaging material is composed of a cellulose base web containing a specific level of flame-retardant filler. Additionally, the base web is formed to have a relatively high basis weight and low volumetric properties. Furthermore, the base web includes a relatively low inherent permeability and is optionally coated with a permeability-reducing composition.

[0034] Of particular advantage is that packaging with low flammability can be constructed as described above without interfering with the generation of aerosols in the heated but not combustible rod. In fact, the packaging disclosed herein offers a variety of advantages and benefits compared to previously manufactured low-flammability packaging. For example, this packaging can improve at least one property of the heated but not combustible rod compared to many prior designs.

[0035] In addition, the paper disclosed herein can be made primarily of biodegradable materials, making the packaging environmentally friendly while providing the necessary non-flammable properties for heated but non-combustible applications.

[0036] refer to Figure 1 This illustration shows one embodiment of an aerosol generating apparatus that can be used according to the present disclosure. The aerosol generating apparatus 10 includes a channel or opening 12 for receiving a heated but not combustible rod 14. The aerosol generating apparatus 10 includes a heating device 16 that heats but does not combust the aerosol generating material contained within the heated but not combustible rod 14. The heating device may include any suitable heating device capable of exposing the heated but not combustible rod 14 to temperatures sufficient to generate aerosols. In one aspect, the heating device 16 is a coal tip. For example, in one embodiment, the heating device 16 may include an electrically heated element powered by a battery and may be located around or inside the aerosol generating material and may be made of one or more heating elements. Alternatively, the heating device may produce heat by burning a fuel such as butane. In yet another embodiment, the heating device 16 may include a substance that reacts together in a chemical reaction to produce heat.

[0037] like Figure 1 As shown, the heated but not-burning stick 14 may have an appearance similar to a conventional cigarette. If desired, the heated but not-burning stick 14 may include a mouthpiece or filter 20. The filter 20 may be made of cellulose acetate tow. In addition to the filter 20, the heated but not-burning stick 14 may also include a cooling section 24. The cooling section 24 is designed to reduce the temperature of the aerosol generated by the heated but not-burning stick 14. The aerosol cooling section 24 may be made of various materials, such as cellulose acetate tubing, a coiled polylactic acid (PLA) membrane, or a perforated paper tube.

[0038] The heated but not combustible rod 14 also includes an aerosol-generating material column 22. For example, the aerosol-generating material can be a combination of a humectant and any suitable plant material such as tobacco. The tobacco material can be a single variety of tobacco or a blend of multiple tobacco types. The aerosol-generating material can be made from natural tobacco leaves, cast tobacco, expanded tobacco, homogenized tobacco, pulp tobacco, reconstituted tobacco, and combinations thereof. The tobacco material can also be combined with various other non-tobacco materials (such as filler particles).

[0039] In addition to tobacco materials, aerosol-generating materials may also include a variety of other materials, such as various other plant materials. In yet another embodiment, aerosol-generating materials may include other non-tobacco plant materials, such as various herbs and flowers (e.g., plant mixtures).

[0040] Aerosol-generating materials can be in any suitable form, such as aligned or misaligned cut wire bundles, coils, particles, beads, debris, or cylinders.

[0041] According to this disclosure, the heated but non-combustible rod 14 may further include a package 26 that at least covers the aerosol generating material 22. The package 26 is manufactured according to this disclosure and has low flammability. The package 26 may be a single layer of paper or may include two or more layers of paper. Optionally, the heated but non-combustible rod 14 may include cork paper that covers the filter 20 and optionally covers the aerosol cooling section 24.

[0042] refer to Figure 2 The illustration shows another embodiment of the aerosol generating device 110. In this embodiment, a filter 120 and an aerosol cooling section 124 are built into the aerosol generating device 110. The aerosol generating device 110 includes an opening 112 or nozzle through which a user can receive aerosol. The aerosol generating device 110 includes a heating device 116 that heats but does not burn a heated but not burned rod 114 incorporated into the device. In this embodiment, the heated but not burned rod 114 does not include an aerosol cooling section or a filter. Instead, the heated but not burned rod 114 includes a column 122 of aerosol generating material surrounded by a packaging 126 according to the present disclosure.

[0043] refer to Figure 3 The illustration shows another embodiment of the heating but not burning device 210. In this embodiment, the heating but not burning rod 14 and... Figure 1 The embodiments shown are substantially the same. Therefore, similar reference numerals have been used to indicate similar elements. The heated but not combustible rod 14 includes a filter 20, an aerosol cooling section 24, and an aerosol generating material 22. A package 26 manufactured according to this disclosure surrounds the aerosol generating material 22. In this embodiment, the heated but not combustible device 210 includes a heating element, such as a coal system, for providing heat to the heated but not combustible rod 14.

[0044] Aerosol-generating materials may contain humectants for a variety of applications. Humectants that may be used include polyols, non-polyols, or mixtures thereof. Polyol humectants include sorbitol, glycerin, propylene glycol, triethylene glycol, or mixtures thereof. Non-polyol humectants include lactic acid, glyceryl diacetate, glyceryl triacetate, triethyl citrate, isopropyl myristate, or mixtures thereof. One or more humectants may be present in the aerosol-generating material in an amount from about 3% by weight to about 50% by weight, including all increments of 1% by weight therein. For example, when producing heated but non-burning rods, the aerosol-generating material may contain a humectant in amounts greater than about 5% by weight, such as greater than about 8% by weight, such as greater than about 10% by weight, such as greater than about 12% by weight, such as greater than about 15% by weight, such as greater than about 17% by weight, and generally less than about 50% by weight, such as less than about 30% by weight, such as less than about 25% by weight, such as less than about 20% by weight.

[0045] According to this disclosure, the aerosol generating material is enclosed in packaging. Once the aerosol generating material is packaged, the aerosol generating rod typically has a circumference of about 4 mm to about 95 mm, such as about 8 mm to about 30 mm. The length of the rod typically has a circumference of about 1 cm to about 25 cm, such as about 12 cm to about 20 cm. The diameter of the heated but non-burning rod can be about 4 mm to about 30 mm, such as about 5 mm to about 9 mm. In one aspect, for example, the diameter can be about 5 mm to about 6 mm. In an alternative embodiment, the diameter can be about 6.5 mm to about 7.5 mm.

[0046] The packaging material of this disclosure, as shown in the figure, is formed from a combination of different parameters and properties. The packaging material is formed from a cellulose base web containing filler, which may be a flame-retardant filler and has selected basis weight, specific volume, permeability, and filler level. Additionally, the packaging material may optionally include a coating of a permeability-reducing composition to produce packaging material with reduced permeability. The packaging material may also optionally contain a phosphorus-based flame retardant. The phosphorus-based flame retardant may be contained within the packaging material or may be contained in the coating of the permeability-reducing composition. Due to the manner in which the base web is formed, it is believed that the coating and the base web have a synergistic relationship in producing packaging material with the desired low flammability characteristics.

[0047] The cellulose fibers used to form the base web can be formed from cork fibers, hardwood fibers, bast fibers, mixtures thereof, etc. Bast fibers that can be used include, for example, flax fibers or combinations thereof. Generally, any suitable cellulose fiber can be used to form the base web. The degree of refinement of the cellulose fibers can vary depending on the specific application. In one aspect, the fibers are highly refined to produce a web with low permeability.

[0048] In one embodiment, to form the base web, cellulose fibers are combined with flame-retardant fillers to form an aqueous suspension. The aqueous suspension is then fed through a headbox and deposited onto a moving forming fabric to form a web preform, which is then dried.

[0049] The flame-retardant filler incorporated into the base web according to this disclosure can be any suitable filler composed of particles with low flammability. For example, flame-retardant fillers can reduce flammability by absorbing heat, reflecting heat, releasing moisture, etc. Examples of filler particles that can be used according to this disclosure include clay particles, metal hydroxide particles, metal oxide particles, carbonate particles, mixtures thereof, etc. In one aspect, for example, the filler particles may include clay particles. Clay particles particularly suitable for use in this disclosure include kaolin particles. Alternatively, the filler particles may include silicate particles (e.g., silicate particles that are not considered clay particles). For example, silicate particles may include calcium silicate particles. Metal hydroxide particles are also very suitable for use in this disclosure. For example, in one aspect, the filler particles include aluminum hydroxide particles. In other embodiments, kaolin particles may be combined with aluminum hydroxide particles and / or silicate particles. In one aspect, the filler particles may further include calcium carbonate particles, magnesium oxide particles, calcium chloride particles, etc. Other flame-retardant filler particles include alumina trihydrate particles, magnesium hydroxide particles, magnesia-hydrated magnesium carbonate particles, basic magnesium carbonate particles, magnesite particles, sodium aluminum oxide particles, boehmite particles, magnesium phosphate octahydrate particles, calcium sulfate dihydrate particles, and mixtures thereof. Filler particles typically have an average particle size greater than about 0.1 micrometers, such as greater than about 2 micrometers, such as greater than about 3 micrometers, and typically less than about 30 micrometers, such as less than about 20 micrometers, such as less than about 10 micrometers.

[0050] The amount of filler particles incorporated into the base web (based on the uncoated web) is typically greater than about 15% by weight, such as greater than about 18% by weight. The filler particles are typically present in amounts less than about 55% by weight, such as less than about 52% by weight, such as less than about 50% by weight. In one aspect, the filler particles may be present in the base web in amounts from about 15% to about 25% by weight (including all increments of 1% by weight therebetween). Alternatively, the filler particles may be present in the base web in amounts from about 25% to about 50% by weight (including all increments of 1% by weight therebetween). The type and amount of filler particles incorporated into the base web may depend on various other properties and physical characteristics of the base web, the type of coating applied to the base web, the diameter of the heated but not combustible rod, and the type of filler incorporated into the heated but not combustible rod.

[0051] The basis weight of the base web can be from about 30 gsm to about 100 gsm, including all increments of 1 gsm therebetween. For example, the basis weight can be from about 30 gsm to about 85 gsm, such as from about 40 gsm to about 80 gsm, or from about 45 gsm to about 75 gsm. In one aspect, the basis weight can be from about 33 gsm to about 45 gsm. Alternatively, the basis weight can be from about 45 gsm to about 60 gsm. In yet another embodiment, the basis weight can be from about 60 gsm to about 85 gsm, such as from about 65 gsm to about 75 gsm. The basis weight can be determined according to test method ISO 536:2012. Before measurement, the web should be conditioned at 23°C and 50% relative humidity.

[0052] In addition to having a basis weight within the aforementioned range, the basis web of this disclosure also has a relatively low specific volume. For example, the specific volume can be less than about 2.0 cc / g, such as less than about 1.7 cc / g, such as less than about 1.5 cc / g, such as less than about 1.2 cc / g, such as less than about 1.1 cc / g, such as less than about 1 cc / g, such as less than about 0.95 cc / g. Specific volume is typically greater than about 0.6 cc / g, such as greater than about 0.7 cc / g, such as greater than about 0.75 cc / g. The volume is determined by the thickness and basis weight. The thickness is determined according to test method ISO 534:2011. Before measurement, the web should be conditioned at 23°C and 50% relative humidity.

[0053] Various methods and techniques can be used to produce base webs with the basis weight and specific volume as described above. In one aspect, the base web can be formed in a wet web forming process. To reduce the specific volume of the web, significant suction can be applied to the web during the forming process, during the web discharge process, to compress the web. Additionally, during the web drying process, the web can be pushed towards a drying drum to reduce the specific volume of the web. In addition to being formed to have low specific volume properties, the base webs of this disclosure can also be calendered to reduce the specific volume. For example, calendering can occur at pressures from about 500 psi to about 2000 psi, or from about 800 psi to about 1200 psi.

[0054] The base web may have an inherent permeability of less than about 100 mL / min, such as less than about 85 mL / min, less than about 70 mL / min, less than about 55 mL / min, less than about 40 mL / min, less than about 30 mL / min, less than about 20 mL / min, or less than about 15 mL / min. As used herein, the “inherent” permeability of the base web refers to the permeability of the base web in its uncoated state (e.g., before the application of the permeability-reducing composition). Permeability may be greater than about 5 mL / min, such as greater than about 10 mL / min or greater than about 25 mL / min. Permeability can be determined according to test method ISO 5636-3-2013 and is also referred to as the Bendtsen permeability. Permeability can be measured using an L & W air permeability meter manufactured by Lorentzen & Wettre Products.

[0055] The inherent porosity of the base web is typically less than about 15 CU. As used herein, “inherent” porosity of the base web refers to the porosity of the base web in its uncoated state. Various techniques can be used to control the porosity and permeability of the base web. For example, the porosity and permeability of the base web can be reduced by increasing the amount of refined cellulose fibers and / or decreasing the particle size of one or more fillers. In one aspect, a relatively low porosity in the base web can further improve the non-flammable properties of the packaging. For example, the porosity can be less than about 9 CU, such as less than about 8 CU, such as less than about 7 CU, such as less than about 6 CU, such as less than about 5 CU, such as less than about 4 CU. Porosity is typically about 0 CU or greater, such as greater than about 2 CU.

[0056] The base web of this disclosure can also be treated or contain various additives to improve performance or properties. Alternatively, packaging can be constructed without any other additives or components. For example, packaging may be free of flammability control agents, such as alkali metal salts of carboxylic acids, alkaline earth metal salts of carboxylic acids, or mixtures thereof.

[0057] According to this disclosure, the base web described above can optionally be further treated with a permeability-reducing composition. For example, a coating can be applied to one or both sides of the base web containing the permeability-reducing composition.

[0058] Typically, any suitable permeability-reducing composition can be applied to the base fabric. In one embodiment, for example, the permeability-reducing composition comprises a natural or synthetic polymer. For example, flash point lowering substances that may be used according to this disclosure include alginate, guar gum, pectin, polyvinyl alcohol, polyvinyl acetate, cellulose derivatives (such as ethyl cellulose, methyl cellulose, and carboxymethyl cellulose), starch, starch derivatives, and mixtures thereof. Flash point lowering substances may also include other cellulose-based materials, such as cellulose particles, cellulose fibers, or microcrystalline cellulose comprising colloidal microcrystalline cellulose (gel).

[0059] In one particular embodiment, the ignition-lowering substance may comprise alginate alone or a combination of alginate and starch. Typically, alginate is a derivative of acidic polysaccharides or gums, occurring in brown algae as an insoluble mixture of calcium, sodium, potassium, and magnesium salts. Generally, these derivatives are calcium, sodium, potassium, and / or magnesium salts of high molecular weight polysaccharides composed of D-mannuronic acid and L-guluronic acid in varying proportions. Exemplary salts or derivatives of alginate include ammonium alginate, potassium alginate, sodium alginate, propylene glycol alginate, and / or mixtures thereof.

[0060] In one embodiment, alginate with a relatively low molecular weight can be used. For example, when alginate is contained in a 3% by weight aqueous solution at 25°C, it can have a viscosity of less than about 500 cP. More specifically, alginate can have a viscosity of less than 250 cP, particularly less than 100 cP, under the above conditions, and in one embodiment, a viscosity of about 20 cP to 60 cP. As used herein, the viscosity is determined by a Brookfield LVF viscometer with a suitable mandrel according to the viscosity. At the aforementioned lower viscosity levels, the alginate composition can be formed with a higher solid content, but the solution viscosity remains sufficiently low to allow the composition to be applied to a base fabric using conventional techniques. For example, the solid content of the alginate solution prepared according to this disclosure can be greater than about 6% by weight, particularly greater than about 10% by weight, and more particularly from about 10% by weight to about 20% by weight.

[0061] At the aforementioned solid content levels, the alginate composition can have a solution viscosity greater than about 250 cp, particularly greater than about 500 cp, and even more particularly greater than about 800 cp, and in one embodiment, the viscosity at 25°C is greater than about 1,000 cp. Generally, the solution viscosity of the alginate composition can be adjusted according to the manner in which the composition is applied to a base fabric. For example, the solution viscosity of the composition can be adjusted depending on whether the composition is sprayed onto paper or printed onto paper.

[0062] In other embodiments, it should also be understood that, depending on the application, relatively high molecular weight alginates may be used. For example, alginates contained in a 3% by weight aqueous solution at 25°C may have a viscosity greater than about 500 cp.

[0063] In an alternative embodiment, the ignition point lowering substance may include starch, as well as starch derivatives. Starch, also known as starch, is a polymeric carbohydrate.

[0064] In yet another embodiment, the ignition point lowering substance may be a cellulose derivative, such as carboxymethyl cellulose.

[0065] Other cellulosic materials that can be used include cellulosic slurries or gels, such as microcrystalline cellulose. Cellulosic materials applied to the base web may include fibrous cellulose, one or more fillers, and / or cellulose particles. As used herein, cellulose fibers and cellulose particles are different from derived cellulose such as carboxymethyl cellulose. For example, cellulose fibers and cellulose particles are not completely soluble in water.

[0066] In one embodiment, the cellulose material (such as microcrystalline cellulose) may be combined with one of the other ignition-lowering substances mentioned above (such as alginate, starch, carboxymethyl cellulose, or mixtures thereof).

[0067] In addition to alginate, starch, guar gum, pectin, polyvinyl alcohol, polyvinyl acetate, cellulose derivatives, microcrystalline cellulose, cellulose fibers or granules, starch derivatives, or mixtures thereof, the permeability-reducing composition applied to the base fabric may contain a variety of other ingredients. For example, in one embodiment, a filler may be included in the composition as described above. For example, the filler may be calcium carbonate, calcium chloride, calcium lactate, calcium silicate, calcium gluconate, etc. Besides calcium compounds, various other particulate matter that can be used includes magnesium compounds such as magnesium oxide, clay particles, etc.

[0068] In one embodiment, the permeability-reducing composition may further comprise a phosphorus-based flame retardant. Generally, any suitable phosphorus-based flame retardant can be incorporated into the coating formed by the permeability-reducing composition, such as an organophosphorus compound. When incorporated into the coating, the phosphorus-based flame retardant may be water-soluble or water-insoluble. In one aspect, the phosphorus-based flame retardant may be a phosphate, such as an alkali metal salt, alkaline earth metal salt, ammonium salt, other metal salt, or mixture thereof. The phosphorus-based flame retardant may be a monophosphate, diphosphate, or polyphosphate. In yet another aspect, the phosphorus-based flame retardant may be a hydrogen phosphate. For example, the phosphorus-based flame retardant may include sodium phosphate, potassium phosphate, or ammonium phosphate. In one aspect, the phosphorus-based flame retardant may be a phosphate salt of a monocarboxylic acid, dicarboxylic acid, and / or tricarboxylic acid and at least one polyphosphate, pyrophosphate, and / or phosphoric acid. In yet another aspect, the phosphorus-based flame retardant may be a hydroxide that forms a phosphate. In yet another embodiment, the phosphorus-based flame retardant may be cellulose modified with phosphorylated linseed oil or phosphorylated corn oil.

[0069] Specific examples of phosphorus-based flame retardants include monosodium phosphate, disodium phosphate, monoammonium phosphate, monopotassium phosphate, dipotassium phosphate, and mixtures thereof. Other examples include sodium polyphosphate, potassium polyphosphate, and / or ammonium polyphosphate.

[0070] One or more phosphorus-based flame retardants can be incorporated into a permeability-reducing composition such that a dry coating made from the composition contains more than about 0.5% by weight, such as more than about 1% by weight, such as more than about 2% by weight, such as more than about 3% by weight, such as more than about 5% by weight, such as more than about 10% by weight, such as more than about 15% by weight, such as more than about 20% by weight, such as more than about 25% by weight, such as more than about 30% by weight, such as more than about 35% by weight, such as more than about 40% by weight, such as more than about 45% by weight, or more than one or more phosphorus-based compounds. One or more phosphorus-based flame retardants may be present in the dry coating in amounts typically less than about 55%, such as less than about 50% by weight, such as less than about 40% by weight, such as less than about 30% by weight, such as less than about 20% by weight, such as less than about 10% by weight, such as less than about 8% by weight, such as less than about 5% by weight, such as less than about 3% by weight.

[0071] Once dried, the coating formed from the permeability-reducing composition may contain one or more flash point lowering substances, typically from about 3% to 100% by weight (including all increments of 1% by weight). For example, one or more flash point lowering substances may be present in the dried coating in amounts greater than about 10% by weight, such as greater than about 20% by weight, such as greater than about 30% by weight, such as greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 60% by weight, such as greater than about 70% by weight, and typically less than about 90% by weight, such as less than about 80% by weight, such as less than about 70% by weight, such as less than about 60% by weight, such as less than about 50% by weight.

[0072] In one embodiment, the permeability-reducing composition may be water-based. Specifically, the permeability-reducing composition may include an aqueous dispersion, hydrogel, or aqueous solution. Alternatively, the permeability-reducing composition prior to application to paper packaging may include a non-hydrogel, solution, or dispersion. In this embodiment, for example, an alcohol may be present for applying the composition to the packaging.

[0073] Any suitable technique can be used to apply the penetrability-reducing composition to a base web to form a coating. For example, the penetrability-reducing composition can be sprayed, brushed, applied using a moving orifice, or printed onto the base web. In one aspect, gravure printing is used to apply the penetrability-reducing composition to the base web. The coating can be formed by applying the penetrability-reducing composition to the base web in a single step or by using a multi-step operation.

[0074] The amount of coating applied to one side of the base web can vary depending on the specific application. In one embodiment, the permeability-reducing composition forms a continuous coating on the surface of the base web. For example, the coating may cover more than about 20%, more than about 40%, more than about 50%, more than about 65%, more than about 80%, more than about 85%, more than about 90%, more than about 95%, or more than about 98% of the surface area of ​​one side of the web. In one specific embodiment, the permeability-reducing composition may cover 100% of the surface area of ​​one side of the base web.

[0075] Alternatively, the coating can be applied to one side of the base web in discrete regions. In this way, the base web includes treated areas with the permeability-reducing composition and untreated areas. For example, the permeability-reducing composition can be applied to the surface of the base web in any specific pattern. For example, in one embodiment, the permeability-reducing composition can be applied to the base web in the form of an annular strip with a width of about 3 mm to about 20 mm. When applied discontinuously, the permeability-reducing composition can cover more than about 20%, such as more than about 30%, more than about 40%, more than about 50%, more than about 60%, or more than about 70% of the surface area of ​​one side of the base web. When applied discontinuously, the permeability-reducing composition can cover less than about 90%, such as less than about 80%, of the surface area of ​​one side of the base web.

[0076] Typically, the permeability-reducing composition can be applied to the base web in an amount greater than about 0.5 gsm (dry coating weight). This amount is for the area of ​​the base web to be coated. For example, the coating can have a basis weight greater than about 1 gsm, such as greater than about 4 gsm, such as greater than about 6 gsm, such as greater than about 8 gsm, and typically less than about 10 gsm, such as less than about 7 gsm, such as less than about 5 gsm. In one embodiment, the coating has a basis weight of about 1 gsm to about 5 gsm (when applied to the base web).

[0077] Once coated, the base fabric or packaging can have relatively low permeability and porosity within the coated area. For example, permeability within the coated area can be less than about 25 mL / min, such as less than about 20 mL / min, such as less than about 15 mL / min, such as less than about 10 mL / min, such as less than about 5 mL / min, and is generally greater than about 0, such as greater than about 0.1 mL / min, such as greater than about 1 mL / min.

[0078] Within the coating area, the porosity of the base web can be less than about 3 CU, such as less than about 2 CU.

[0079] In addition to having relatively low porosity, the coated areas of the base web or packaging also have relatively low diffusivity. Diffusivity can be measured at room temperature (23°C). Typically, the diffusivity of the coated areas of the base web or packaging at 23°C is less than about 0.2 cm / s, such as less than about 0.15 cm / s, such as less than about 0.1 cm / s, such as less than about 0.08 cm / s, such as less than about 0.07 cm / s. The diffusivity of the coated area is zero or typically greater than about 0.02 cm / s and greater than about 0.1 cm / s in one aspect. Diffusivity is measured using a Sodim CO2 diffusivity meter. Uncoated paper may have a diffusivity typically greater than about 0.3 cm / s, such as greater than about 0.4 cm / s, such as greater than about 0.5 cm / s, and typically less than about 0.8 cm / s, such as less than about 0.7 cm / s, such as less than about 0.6 cm / s.

[0080] The paper manufactured according to this disclosure is ideally suited for use as packaging for aerosol delivery products, such as heated but non-burning rods. As described above, the paper can be constructed such that the aerosol delivery product is non-flammable. When incorporated into packaging, the packaging may comprise a single layer of paper or may comprise multiple layers, such as two layers. For example, in one embodiment, the packaging may comprise two layers, and the paper of this disclosure may be an inner layer surrounded by an outer layer. Alternatively, the coated paper may be an outer layer surrounding the inner layer. When used in a two-layer structure, the packaging of this disclosure may have a reduced basis weight. For example, the basis weight of the base web may be from about 20 gsm to about 100 gsm, including all increments of 1% by weight therebetween. For example, the basis weight may be from about 20 gsm to about 80 gsm.

[0081] Paper packaging materials used in combination with the paper of this disclosure to form two-layer packaging can vary depending on the specific circumstances and desired results. For example, the opposing layer can be made of cellulose fibers and may contain fillers, such as white fillers made of calcium carbonate or magnesium oxide. The paper may also contain binders, such as carboxymethyl cellulose, guar gum, or mixtures thereof. Optical brighteners may also be incorporated into the paper.

[0082] Once the packaging material according to this disclosure is incorporated into a heated but not combustible rod, the flammability of the heated but not combustible rod can be tested.

[0083] In yet another embodiment, the phosphorus-based flame retardant can be incorporated into the entire thickness of the packaging by combining it with the cellulose fibers used to form the packaging, rather than into a coating applied to the packaging. For example, in one embodiment, one or more phosphorus-based flame retardants can be impregnated into the packaging. When impregnated into the packaging, the phosphorus-based flame retardant can be water-soluble and applied to the packaging as an aqueous solution during the manufacture of the packaging. For example, the phosphorus-based flame retardant can be sodium phosphate, potassium phosphate, or ammonium phosphate, including monophosphate, diphosphate, and polyphosphate. However, it should be understood that any of the above-described phosphorus-based flame retardants can be incorporated into the packaging along with the cellulose fibers.

[0084] Phosphorus-based flame retardants can be applied to packaging using any suitable method or technique. For example, phosphorus-based flame retardants can be incorporated into an aqueous solution and applied by spraying, immersion, or printing (e.g., using flexographic printing, gravure printing, etc.). In particular, when using printing techniques, phosphorus-based flame retardants can be applied to certain areas (including treated and untreated areas) according to a pattern, or they can be applied uniformly to the entire surface area of ​​the packaging.

[0085] In one embodiment, the phosphorus-based flame retardant is contained in an aqueous solution and applied to the packaging using a sizing press during packaging formation. Using a sizing press to incorporate the phosphorus-based flame retardant into the packaging provides various efficiencies and ensures that the phosphorus-based flame retardant is impregnated throughout the packaging.

[0086] When incorporated into the interior of packaging, the amount of phosphorus-based flame retardant applied to the packaging can vary depending on the specific application and desired results. Typically, the phosphorus-based flame retardant is applied at a concentration greater than approximately 1 mg / m³. 2 It is applied in an amount of approximately 10 gsm. For example, in one embodiment, a relatively small amount is incorporated into the packaging material, which is approximately 1 mg / m³. 2 approximately 20 mg / m 2 In alternative embodiments, one or more flame retardants are incorporated into the packaging in amounts greater than about 0.5 gsm, such as greater than about 1 gsm, such as greater than about 1.5 gsm, and generally less than about 10 gsm, such as less than about 8 gsm, such as less than about 6 gsm.

[0087] According to this disclosure, the above-described techniques can be used to manufacture a variety of different packaging materials. For example, in one embodiment, the packaging material may comprise a combination of flame-retardant filler and phosphorus-based flame retardant, but may be uncoated. In an alternative embodiment, the packaging material may comprise a coating formed from a permeability-reducing composition. The coating may be used in combination with flame-retardant filler and phosphorus-based flame retardant, or may be combined with flame-retardant filler and phosphorus-based flame retardant. In this embodiment, the phosphorus-based flame retardant may be impregnated into the packaging material, may be applied together with the coating, or may be contained in the coating and may also be incorporated into the packaging material.

[0088] In yet another alternative embodiment, the packaging of this disclosure includes a coating formed by combining a permeability-reducing composition with at least one phosphorus-based flame retardant. The phosphorus-based flame retardant may be included in the coating, impregnated into the paper, or both included in the coating and impregnated into the paper. In this embodiment, the packaging may not contain flame-retardant fillers, but may contain other fillers such as calcium carbonate or magnesium oxide. Alternatively, the packaging may contain flame-retardant fillers.

[0089] In one aspect, heated but not-burning rods can be tested according to the smoking regime conditions of ISO 3308:2012. To test flammability, two sets of 20 heated but not-burning rods are placed in a Borgwaldt RM20 kit machine and tested. The machine operates at a suction capacity of 35 mL ± 0.3 mL for 2 seconds. The suction frequency is once every 60 seconds, without obstructing the vents. The heated but not-burning rod is inserted into the rod holder of the machine and ignited on the first puff. If it does not reignite on the second puff, the heated but not-burning rod is considered non-flammable.

[0090] The second test was conducted according to ISO 20778:2018 Smoking Regulation Conditions, with a puff volume of 55 mL ± 0.6 and a puff frequency of once every 30 seconds (HCl test). Furthermore, the HCl test was conducted using a double-packed stick instead of a single-packed stick. The puff duration was 2 seconds, without obstructing the vent. The heated but non-combustible stick manufactured according to this disclosure is considered non-flammable in each of the above tests.

[0091] The present disclosure can be better understood by referring to the following embodiments.

[0092] Example 1 Various tobacco packaging materials are made and incorporated into heated but not burned rods.

[0093] In this embodiment, the aerosol-generating material contained in the heated but not combustible rod is commercially available tobacco material. The tobacco material is reconstituted tobacco. Leaflets are cut, and then the cut filler is wrapped with packaging material. The rod has a diameter of 7 mm and does not include a filter.

[0094] Packaging materials manufactured according to this disclosure comprise wood pulp fibers combined with various types of fillers. A coating comprising a permeability-reducing composition is applied to a first side of each base web. Various permeability-reducing compositions are used. The coated packaging material has a porosity of less than 2 CU and is calendered to have a specific volume of less than 1.1 cc / g.

[0095] The following packaging materials were manufactured:

[0096] Place the heated but not burning stick in the smoke machine and visually observe its burning characteristics. The samples in the table above are ranked based on visual observation. Although all the packaging showed low burning characteristics, samples 1 to 9 showed the best results.

[0097] Example 2 Two additional packages were manufactured according to this disclosure, and various performance properties were tested. More specifically, the following packages were constructed, and the following properties were measured.

[0098]

[0099]

[0100] Example 3 In this embodiment, an additional packaging containing wood pulp fibers was manufactured according to this disclosure. More specifically, the following samples were constructed to demonstrate some benefits and advantages of impregnating the packaging with a phosphorus-based flame retardant and combining the phosphorus-based flame retardant with a coating material (sample numbers 27 and 28). The following samples were constructed:

[0101] As shown above with respect to samples 22 to 24, the non-flammability of the packaging improved with increasing amounts of phosphorus-based flame retardant. As demonstrated by samples 24 and 25, the addition of a coating generally improved the non-flammability. Sample 26 indicates that a combination of phosphorus-based flame retardant impregnated into the packaging with calcium carbonate filler can exhibit good non-flammability. Samples 27 and 28 demonstrate that a combination of phosphorus-based flame retardant and coating material is also effective.

[0102] These and other modifications and variations to the invention can be made by those skilled in the art without departing from the spirit and scope of the invention, which are set forth more specifically in the appended claims. Furthermore, it should be understood that aspects of the various embodiments can be interchanged in whole or in part. Moreover, those skilled in the art will understand that the above description is merely illustrative and is not intended to limit the invention as further described in the appended claims.

Claims

1. A package for a heated but non-burning rod, comprising: A base web comprising a combination of cellulose fibers and flame-retardant filler, the base web having a first side and an opposing second side, the flame-retardant filler being present in the base web in an amount of about 15% to about 55% by weight, the base web having a specific volume of less than about 1.7 cc / g, a basis weight of about 45 gsm to about 85 gsm, a permeability of about 55 mL / min or less, and an intrinsic porosity of less than about 15 CORESTA.

2. The packaging of claim 1, further comprising a coating disposed on the first side of the base web, the coating comprising a permeability-reducing composition.

3. The packaging material according to claim 1, wherein the flame-retardant filler comprises silicate particles or clay particles.

4. The packaging material according to claim 1, wherein the flame-retardant filler comprises kaolin particles.

5. The packaging material according to claim 1, wherein the flame-retardant filler comprises aluminum hydroxide particles.

6. The packaging according to any one of claims 1 to 5, wherein the flame-retardant filler comprises particles having an average particle size of about 0.1 micrometers to about 30 micrometers.

7. The packaging material according to any one of claims 1 to 5, wherein the base web has been calendered.

8. The packaging material according to any one of claims 1 to 5, wherein the base web has a specific volume of less than about 1.3 cc / g.

9. The packaging material according to any one of claims 1 to 5, wherein the base web has a permeability of less than about 30 mL / min.

10. The packaging material according to any one of claims 1 to 5, wherein the base web has a basis weight of about 45 gsm to about 80 gsm.

11. The packaging according to any one of claims 1 to 5, wherein the coating of the permeability reducing composition is continuous, the first side of the base web has a surface area, and wherein the coating covers more than about 20% of the surface area of ​​the first side of the base web.

12. The packaging according to claim 2, wherein the coated base web has a permeability of less than about 20 mL / min.

13. The packaging according to claim 2 or 12, wherein in the area where the coating is applied, the coating has a basis weight of about 0.5 gsm to about 10 gsm.

14. The packaging according to claim 2 or 12, wherein the permeability-reducing composition comprises microcrystalline cellulose, alginate, starch, carboxymethyl cellulose, or a mixture thereof.

15. The packaging material of claim 1, wherein the base web has a basis weight of about 45 gsm to about 75 gsm, and wherein the flame-retardant filler comprises kaolin particles, aluminum hydroxide particles, or a mixture thereof.

16. The packaging material according to any one of claims 1 to 5, wherein the packaging material is a single-layer packaging material.

17. The packaging material according to any one of claims 1 to 5, wherein the packaging material comprises a plurality of layers, and the base web comprises one of the layers.

18. The packaging according to any one of claims 1 to 5, wherein the packaging further comprises a phosphorus-based flame retardant.

19. The packaging of claim 18, wherein the phosphorus-based flame retardant is impregnated into the base web.

20. The packaging according to claim 2, wherein the coating further comprises a phosphorus-based flame retardant.

21. The packaging according to claim 18, wherein the phosphorus-based flame retardant comprises sodium phosphate, potassium phosphate, ammonium phosphate, or a mixture thereof.

22. A package for a heated but non-burning rod, comprising: A base web comprising a combination of cellulose fibers and fillers, the base web having a first side and an opposing second side, the fillers being present in the base web in an amount of about 5% to about 55% by weight, the base web having a specific volume of less than about 1.7 cc / g, a basis weight of about 45 gsm to about 85 gsm, a permeability of about 55 mL / min or less, and an inherent porosity of less than about 15 CORESTA, and wherein the packaging further comprises a coating disposed on the first side of the base web, the coating comprising a combination of a permeability-reducing composition and a phosphorus-based flame retardant, wherein the coating has a basis weight of about 0.5 gsm to about 10 gsm in the coated area.

23. An aerosol delivery product comprising: Aerosol generating material column; and The packaging as described in any of the preceding claims surrounds the column of aerosol-generating material.

24. The aerosol delivery product of claim 23, wherein the aerosol generating material comprises tobacco.

Images