Filter for an aerosol generating article with enhanced flavor delivery system

Abstract

A filter 10 for an aerosol generating article comprises: a substrate end adjacent to an aerosol generating substance; a paper provided as a filtering material 12; one or more flavour capsules 11 located near the substrate end position of the filter to be crushed by a user; and a wrapper 13. The flavour capsule(s) 11 may be located near the substrate end to prevent fallout and bursting into the user’s mouth. The filter 10 may further comprise a mouth end to be handled by lips of a user, wherein the flavour capsule(s) 11 is located closer to the substrate end than the mouth end. The paper 12 may be biodegradable and / or cellulose paper, and / or the paper 12 may be porous so as to provide flavour retention after the capsule(s) 11 is crushed. The filter 10 may be used in a Roll-Your-Own (RYO) product. The filter 10 may preferably have a resistance to draw (RTD) of from about 50mm / Wg to about 75mm / Wg before the capsule(s) 11 is crushed.

Description

FIELD OF INVENTION

[0001] The present disclosure generally relates to the field of aerosol generating articles, and more specifically, to filters for such articles that incorporate flavor capsules for enhanced flavor delivery. BACKGROUND

[0002] Aerosol generating articles, such as cigarettes or e-cigarettes (including Heat Not Bum articles), are commonly used for the delivery of tobacco smoke or aerosol to a user. These articles typically include a filter that is designed to reduce the amount of harmful substances in the smoke that is inhaled by the user and / or to cool the aerosol that is inhaled by the user and / or to define a resistance to draw for the user. The filter is typically made of a material that is capable of trapping particulate matter from the smoke and / or of cooling the aerosol to be delivered by the user and / or of generating a resistance to draw for the user.

[0003] One type of filter that has been used in aerosol generating articles is a cellulose acetate filter. Cellulose acetate filters are typically made from Cellulose acetate, which can provide filtering capabilities, and / or resistance to draw.

[0004] In addition to filtering out harmful substances, some aerosol generating articles also include flavor capsules that are designed to enhance the flavor of the smoke. These flavor capsules can be crushed by the user to release a flavored liquid that mixes with the smoke. The flavored liquid can provide a more enjoyable smoking experience for the user.

[0005] The flavor capsules should not fall out or burst into the user's mouth or liquid should not leak on user fingers. On the other hand, the flavor should be delivered effectively to the user.

[0006] The use of biodegradable materials in the construction of the filter is also an area of interest. Biodegradable materials, such as cellulose paper, can degrade more rapidly than other materials, which can reduce the environmental impact of discarded filters.

[0007] The resistance to draw (RTD) of the filter is another factor that can affect the smoking experience. The RTD is a measure of the effort that is required to draw smoke through the filter. A filter with a high RTD can make it more difficult for the user to draw smoke, while a filter with a low RTD can make it easier.

[0008] In summary, the design and construction of filters for aerosol generating articles involves a number of considerations, including the type of filtering material, the behavior of flavor capsules, the use of biodegradable materials, and the RTD of the filter. SUMMARY OF INVENTION

[0009] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[00010] According to an aspect of the present disclosure, a filter for an aerosol generating article includes a substrate end, arranged to be adjacent to (or on the side of) an aerosol generating substrate of the aerosol generating article. The filter includes a paper, provided as a filtering material and that may be provided as a sheet of paper that may be crimped and gathered to form a rod. The filter also includes one or more flavor capsules to be crushed by a user, and a wrapper. The one or more flavor capsules are located near the substrate end position of the filter. [00011 ] According to other aspects of the present disclosure, the filter may include one or more of the following features. The one or more flavor capsules may be located near the substrate end of the filter to prevent fallout and bursting into the user's mouth. The paper may be biodegradable and / or is cellulose paper. The filter may comprise a mouth end to be handled or grasped by lips of a user, and the one or more flavor capsules may be located closer to the substrate end than to the mouth end. The one or more flavor capsules may be located at a distance from the substrate end lower than 20 mm, or lower than 15 mm, or lower than 12 mm, or lower than 9 mm. The length of the filter may be from 5 to 50 mm (e.g., from 10 to 30mm, e.g., 8 to 24 mm, e.g., 15 to 20mm, e.g., 18 mm). The circumference of the filter may be from 12 to 30 mm (e.g., 15 to 28 mm), more preferably from 17 to 25 mm, (e.g., 18 to 25 mm, e.g., 20 to 24 mm, e.g., 22 to 24 mm, e.g., 23 mm, e.g., 22 mm).

[00012] According to other aspects of the present disclosure, the one or more flavor capsules may comprise a shell and may contain a flavor, such as a flavored liquid. The one or more flavor capsules may present an outer dimension comprised between 0.5 mm and 5.0 mm, preferably between 1 mm and 4.5 mm, preferably between 1.5 mm and 4.0 mm, preferably between 2 mm and 3.5 mm, preferably between 2.5 mm and 3.5 mm. The one or more flavor capsules may present a spherical shape.

[00013] According to other aspects of the present disclosure, the filter may have or present a resistance to draw (RTD), before the capsule is crushed, of from about 5 mm / Wg to about 100 mm / Wg, or from about 15 mm / Wg to about 70 mm / Wg, or from about 30 mm / Wg to about 80 mm / Wg, or from about 40 mm / Wg to about 90 mm / Wg, or from about 50 mm / Wg to about 65 mm / Wg, or from about 50 mm / Wg to about 75 mm / Wg. The resistance to draw (RTD) may be measured in accordance with ISO 6565:2015.

[00014] According to another aspect of the present disclosure, a method for making a filter includes advancing one, two or more sheets of filtering material in a longitudinal direction, separating the one, two or more sheets of longitudinally advancing filtering material, and gathering the separated sheets of longitudinally advancing filtering material to form a partially gathered rod of filtering material having a longitudinally extending recess. The method also includes inserting a flavor capsule into the longitudinally extending recess, and gathering the filtering material around the flavor capsule to close the recess and thereby form a rod comprising a longitudinally extending core of filtering material and one or more flavor capsules. The rod may be cut to provide a filter at a given length to be integrated in an aerosol generating article. The one or more flavor capsules are located offset from a middle portion of the longitudinally extending core of the filter.

[00015] According to other aspects of the present disclosure, the method may include one or more of the following features. The two or more sheets of filtering material may be biodegradable paper and / or is cellulose paper.

[00016] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive. BRIEF DESCRIPTION OF FIGURES Non-limiting and non-exhaustive examples are described with reference to the following figures. Fig. 1 is a side view of an aerosol generating substrate featuring the inventive filter, according to aspects of the present disclosure. Fig. 2 presents a longitudinal cross section of the filter incorporated in the aerosol generating article from Fig. 1, in accordance with aspects of the present disclosure. Fig. 3 illustrates a cross section of the filter depicted in Fig. 2, according to aspects of the present disclosure. DETAILED DESCRIPTION

[00017] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.

[00018] The present disclosure relates to a filter for an aerosol generating article, such as a cigarette. In some aspects, the filter may include a paper as a filtering material, one or more flavor capsules to be crushed by a user, and a wrapper. The paper may be provided as a sheet of paper that may be crimped and gathered to form a rod. The one or more flavor capsules may be located near the substrate end position of the filter, which is arranged to be adjacent to an aerosol generating substrate of the aerosol generating article.

[00019] In some cases, the filter may be designed to enhance flavor delivery from the capsule after being crushed. The location of the flavor capsules near the substrate end of the filter may prevent fallout and bursting into the user's mouth. This arrangement may also ensure that the flavor is not retained due to absorption after the capsule is crushed, thereby enhancing the flavor delivery.

[00020] In some aspects, the paper used as a filtering material may be biodegradable and / or cellulose paper. This may provide an environmentally friendly alternative to filters constructed with cellulose acetate. The paper may also be porous so as to provide retention for flavor of the one or more flavor capsules after being crushed.

[00021] In some cases, the filter may be designed for use in a Roll-Your-Own (RYO) product. This may cater to the Botanical market and RYO market that require the lowest retention possible for flavor enhancement.

[00022] In some aspects, the filter may have a resistance to draw (RTD), before the capsule is crushed, within a specific range. This may help improve the airflow through smoking, making it easier to inhale and reducing the likelihood of a tight or plugged draw.

[00023] In some cases, the one or more flavor capsules may contain a flavored liquid. This may enhance the flavor delivery from the capsule after being crushed.

[00024] In some aspects, the paper and the wrapper may have a basis weight within a specific range. This may contribute to the overall quality and performance of the filter.

[00025] In some aspects, the filter may further comprise a hydrophobic material. Without wanting to be bound by theory, it is thought that the hydrophobic material within the filtering material causes water vapour within the element (e.g. filter or cooling element) to condense within the element (e.g. filter or cooling element) which provides the beneficial effect of cooling the vapour as it passes through the element.

[00026] Preferably, the hydrophobic material is distributed throughout the longitudinally extending (e.g., cylindrical, e.g., tubular) core of the element. The applicants have found that this provides an optimal level of vapour cooling and filtration for use in a tobacco heating product or HNB product.

[00027] The hydrophobic coating / material may be any suitable hydrophobic material. For example, the hydrophobic coating / material may a polymer or a blend of polymers. Preferably, the hydrophobic coating / material is a starch, such as a modified starch, for example oxidized starch (E1404). A starch such as a modified starch is preferred as it is inert and provides a non-plastic hydrophobic coating. The hydrophobic coating / material may be present in an amount from 0.01 % to 50 % weight of hydrophobic coating / material with respect to weight of the element (w / w), for example 0.01 % to 20 % w / w, for example 0.1 % to 20% w / w, for example 5% to 20% w / w, for example 10% to 20% w / w, for example 0.1% to 10% w / w, for example 0.1 % to 5 % w / w, for example 0.5% to 2.5% w / w.

[00028] A coated paper according to the present invention may be manufactured by methods known in the art. The hydrophobic coating can be applied to the paper via any of the standard coating methods known in the art.

[00029] The present disclosure also relates to a method for making a filter. The method may involve advancing two or more sheets of filtering material in a longitudinal direction, separating the sheets, gathering the separated sheets to form a partially gathered rod of filtering material having a longitudinally extending recess, and inserting a flavor capsule into the recess. The filtering material may then be gathered around the flavor capsule to close the recess and form a rod comprising a longitudinally extending core of filtering material and one or more flavor capsules. The filtering material surrounding the one or more flavor capsules may be wrapped into a wrapper. A continuous rod may be formed. The continuous rod may be cut to provide a filter to be integrated in an aerosol generating article. The one or more flavor capsules may be located offset from a middle portion of the longitudinally extending core. This method may provide an efficient way of producing filters with enhanced flavor delivery.

[00030] Referring to FIG 1, a side view of an aerosol generating article 100 comprising an aerosol generating rod 20 and a filter 10 according to the present disclosure is depicted. In some aspects, filter 10 may be designed for use in a Roll-Your-Own (RYO) product. This may cater to the Botanical market and RYO markets that require the lowest retention possible for flavor enhancement. The aerosol generating article 100 may be a conventional cigarette, but it may be an e-cigarette, and typically, it can be a Heat Not Burn cigarette. The aerosol generating rod 20 may comprise tobacco, tobacco filler, tobacco shred, reconstituted tobacco, or any another substrate capable of delivering an aerosol, for example when heated. As an example, said another substrate capable of delivering an aerosol, for example when heated, can be provided as a non-tobacco material sprayed, coated, infused or comprised with nicotine.

[00031] In some aspects, filter 10 may include a wrapper 13. Wrapper 13 may be a paper having a basis weight of from 20 to 160 gsm, more preferentially from 24 to 150 gsm, more preferentially from 70 to 150 gsm, more preferentially from 70 to 140 gsm. Wrapper 13 may be a coated paper having a basis weight of from 30 to 350 gsm, more preferentially from 50 to 250 gsm, more preferentially from 80 to 200 gsm, more preferentially from 100 to 180 gsm. This may contribute to the overall quality and performance of filter 10. The basis weight of paper may be measured according to ISO 536:2019.

[00032] In some cases, filter 10 may be designed to provide the lowest retention possible for flavor delivery. This may be achieved by using a paper as a filtering material 12 that is at least partially coated with hydrophobic substance or layer. Alternatively, using a paper as a filtering material 12 that is porous may provide retention for flavor of one or more flavor capsules 11 after being crushed so as to reduce leaks.

[00033] In some aspects, filter 10 may have a feature of a randomized filtering material 12 distribution. This may help improve the airflowthrough smoking, making it easier to inhale and reducing the likelihood of a tight or plugged draw. In some cases, filter 10 may be sustainable and biodegradable, providing an environmentally friendly alternative to filters constructed with cellulose acetate.

[00034] Referring now to FIG 2, a longitudinal cross section of the filter 10 of the aerosol generating article 100 of FIG 1 is depicted. In some aspects, the filter 10 may include one or more flavor capsules 11 located near the substrate end of the filter 10. This configuration may prevent fallout and bursting of the flavor capsules 11 into the user's mouth. In some cases, the flavor capsules 11 may be located closer to the substrate end than to the mouth end of the filter 10. This arrangement may ensure that the flavor is not retained due to absorption after the flavor capsule 11 is crushed, thereby enhancing the flavor delivery.

[00035] In some aspects, the flavor capsules 11 may be located at a distance d shown figure 2 from the substrate end of the filter 10, distance d being lower than 20 mm, or lower than 15 mm, 12 mm, or 9 mm. This may further prevent fallout and bursting of the flavor capsules 11 into the user's mouth. In some cases, the flavor capsules 11 may contain a flavored liquid. This may enhance the flavor delivery from the flavor capsules 11 after being crushed.

[00036] In some aspects, the filter 10 may include a paper as a filtering material 12. The paper 12 may be biodegradable and / or cellulose paper. This may provide an environmentally friendly alternative to filters constructed with cellulose acetate. In some cases, the paper 12 may be porous so as to provide retention for flavor of the one or more flavor capsules 11 after being crushed. In some cases, the paper 12 may comprise or be coated with an hydrophobic substance or layer. This may enhance the flavor delivery from the flavor capsules 11 after being crushed.

[00037] In some aspects, the paper 12 may have a basis weight from 20 gsm to 200 gsm. More preferentially, the paper 12 may have a basis weight from 40 gsm to 180 gsm, more preferentially from 60 gsm to 160 gsm, more preferentially from 80 gsm to 140 gsm, more preferentially from 100 gsm to 120 gsm, more preferentially from 20 gsm to 60 gsm, more preferentially from 30 gsm to 40 gsm. In some aspects, the paper 12 is coated and may have a basis weight from 30 gsm to 350 gsm. More preferentially, the paper 12 may be coated and may have a basis weight from 50 gsm to 300 gsm, more preferentially from 70 gsm to 270 gsm, more preferentially from 90 gsm to 220 gsm, more preferentially from 110 gsm to 180 gsm, more preferentially from 130 gsm to 160 gsm. This may contribute to the overall quality and performance of the filter 10. The basis weight of paper may be measured according to ISO 536:2019.

[00038] In some aspects, the method for making the filter 10 may involve advancing two or more sheets of filtering material 12 in a longitudinal direction, separating the sheets, gathering them to form a partially gathered rod with a longitudinally extending recess, and inserting a flavor capsule 11 into the recess. The filtering material 12 may then be gathered around the flavor capsule 11 to close the recess and form a rod with a longitudinally extending core of filtering material 12 and one or more flavor capsules 11. The longitudinally extending core (filtering material surrounding the one or more flavor capsules) may be wrapped into a wrapper. A continuous rod may be formed. The continuous rod may be cut to provide a filter to be integrated in an aerosol generating article. The flavor capsules 11 may be located offset from a middle portion of the longitudinally extending core. This method may provide an efficient way of producing filters 10 with enhanced flavor delivery.

[00039] Referring now to FIG 3, a cross section of the filter 10 of FIG 2 is depicted. In some aspects, the filter 10 may include a paper as a filtering material 12. The paper 12 may be provided as a sheet of paper that may be crimped and gathered to form a filter 10. In some cases, the paper 12 may be biodegradable and / or cellulose paper. This may provide an environmentally friendly alternative to filters constructed with cellulose acetate.

[00040] In some cases, the filter 10 may be designed to provide the lowest retention possible for enhancing flavor delivery. To this end, and as shown figure 3, the filtering material 12 is randomly crimped and distributed into the rod. This may help improve the airflow through smoking, making it easier to inhale and reducing the likelihood of a tight or plugged filter or article.

[00041] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

Claims

1. A filter for an aerosol generating article, comprising:a substrate end, arranged to be adjacent to an aerosol generating substrate of the aerosol generating article;a paper, provided as a filtering material and that may be provided as a sheet of paper that may be crimped and gathered to form a rod;one or more flavor capsules to be crushed by a user; anda wrapper,wherein the one or more flavor capsules is / are located near the substrate end position of the filter.

2. The filter of claim 1, wherein the one or more flavor capsules is / are located near the substrate end of the filter to prevent fallout and bursting into the user's mouth.

3. The filter of claim 1, wherein the paper is biodegradable and / or is cellulose paper.

4. The filter of claim 1, comprising a mouth end to be handled by lips of a user, and wherein the one or more flavor capsules is / are located closer to the substrate end than to the mouth end.

5. The filter of claim 1, wherein the one or more flavor capsules is / are located at a distance from the substrate end lower than 20 mm, preferably lower than 15 mm, preferably lower than 12 mm, more preferentially lower than 9 mm.

6. The filter of claim 1, wherein the filter is designed for use in a Roll-Your-Own (RYO) product.

7. The filter of claim 1, wherein the paper is porous so as to provide retention for flavor of the one or more flavor capsules after being crushed.

8. The filter of claim 1, having a resistance to draw (RTD), before the capsule is crushed, of from about 5 mm / Wg to about 100 mm / Wg, or from about 15 mm / Wg to about 70 mm / Wg, or from about 30 mm / Wg to about 80 mm / Wg, or from about 40 mm / Wg to about 90 mm / Wg, or from about 50 mm / Wg to about 65 mm / Wg, or from about 50 mm / Wg to about 75 mm / Wg.

9. The filter of claim 1, wherein the one or more flavor capsules is / are contain(s) a flavored liquid.

10. The filter of claim 1, wherein the paper has a basis weight from 20 gsm to 350 gsm, more preferentially the paper may have a basis weight from 40 gsm to 180 gsm, more preferentially from 60 gsm to 160 gsm, more preferentially from 80 gsm to 140 gsm, more preferentially from 100 gsm to 120 gsm, more preferentially from 20 gsm to 60 gsm, more preferentially from 30 gsm to 40 gsm.

11. The filter of claim 1, wherein the wrapper is a paper having a basis weight of from 20 to 160 gsm, more preferentially from 24 to 150 gsm, more preferentially from 70 to 150 gsm, more preferentially from 70 to 140 gsm.

12. A method for making a filter, comprising the steps of:- advancing two or more sheets of filtering material in a longitudinal direction;- separating the two or more sheets of longitudinally advancing filtering material;- gathering the separated sheets of longitudinally advancing filtering material to form a partially gathered rod of filtering material having a longitudinally extending recess;- inserting a flavor capsule into the longitudinally extending recess;- gathering the filtering material around the flavor capsule to close the recess and thereby form a rod comprising a longitudinally extending core of filtering material and one or more flavor capsules,wherein the one or more flavor capsules is / are located offset from a middle portion of the longitudinally extending core.

13. The method of claim 12, wherein the two or more sheets of filtering material are biodegradable paper and / or is cellulose paper.

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