Dried tobacco article manufacturing

Abstract

To provide dried tobacco article manufacturing.SOLUTION: An aerosol generating article for use in a heat-not-burn device comprises: a container comprising a substantially hermetically sealed enclosure; and a smokable material included in the substantially hermetically sealed enclosure, and comprising dried tobacco lamina material and at least one other aerosol generating agent, where the smokable material has a moisture content below 12 wt.% based on the total weight of the smokable material.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an aerosol product article for use in an aerosol generating device, a system including the aerosol product article and an aerosol generating device, and a method for producing the aerosol product article. [Background technology]

[0002] Aerosol generating devices, or e-cigarettes, are now mainstream products that mimic traditional cigarettes. There are many types of aerosol generating devices, one of which has a method of operation that heats tobacco products to generate aerosols without burning tobacco. These so-called heat-not-burn (HNB) devices are becoming more and more popular.

[0003] Non-combustion heating devices generally operate with a tobacco article that is inserted into the device and heated by a heating element contained in the non-combustion heating device. A variety of tobacco articles are commercially available. Although tobacco articles that resemble classic cigarettes are the most common, tobacco articles in the form of cartridges, such as capsules, that contain tobacco material are a valid alternative. Because the tobacco material remains in the capsule while the article is consumed, there is less residue after the article is consumed and less cleaning of the aerosol generating device is required. Furthermore, the design of the capsule allows for the use of different materials, such as thermally conductive materials, that allow for more rapid heating of the tobacco material.

[0004] To meet consumer needs, it is desirable to provide tobacco products with different tastes and smoking characteristics. This is generally achieved by adding aerosol-forming agents, such as humectants, to tobacco to enhance the flavor, amount of nicotine, and amount of aerosol generated from the tobacco. However, humectants are hygroscopic and attract moisture from the atmosphere, so that the moisture content of the tobacco product increases over time. The more moisture a tobacco product contains, the more heat is required to generate aerosol from the tobacco product. As a result, the energy source must provide more energy and the battery will drain faster. Furthermore, the varying amount of moisture in the composition makes it difficult to precisely control the delivery of volatile substances (nicotine and flavors). Summary of the Invention [Problem to be solved by the invention]

[0005] It is therefore desirable to provide a capsule-type tobacco product with the above advantages, which does not require extensive heating of the tobacco product to generate an aerosol and allows for more precise control of the taste experience. [Means for solving the problem]

[0006] One or more of these objects are achieved by the subject matter of the independent claims. Preferred embodiments are the subject matter of the dependent claims.

[0007] The present invention provides a device that solves some or all of the above problems.

[0008] A first embodiment of the present invention relates to an aerosol product for use in a non-combustion heating device, the aerosol product comprising: a container including a substantially sealed housing; and smokable material contained within the substantially sealed housing, the smokable material comprising a dry tobacco layered material and at least one other aerosol forming agent, the smokable material having a moisture content of less than 12% by weight of a total weight of the smokable material.

[0009] According to the second embodiment, in the first embodiment, the smokable material preferably has a moisture content of less than 11% by weight, more preferably less than 10% by weight, most preferably less than 9% by weight and / or preferably greater than 5% by weight, more preferably greater than 6% by weight, most preferably greater than 7% by weight.

[0010] The above configuration allows the moisture content in the aerosol product to be maintained relatively low. Aerosol generating agents, such as humectants and solvents used to provide nicotine and flavor, tend to draw moisture from the atmosphere, causing the moisture content of the smokable material to increase. By substantially sealing the housing containing the smokable material, exposure to the atmosphere is reduced and the moisture content remains constant. Because water requires a lot of heat to evaporate, and some of this heat is also transferred to the mouthpiece, less water means less heating of the mouthpiece, which is desirable for the user. Furthermore, the time required to generate an aerosol decreases as the moisture content of the smokable material decreases.

[0011] According to a third embodiment, in any one of the preceding embodiments, the dried tobacco material comprises reconstituted tobacco (RTB) material.

[0012] RTB materials are generally provided in relatively homogenous sheets that facilitate the cutting and portioning of the tobacco material for use as smokable material, and in particular facilitate the use of the tobacco layer in containers having relatively small volumes.

[0013] According to a fourth embodiment, in any one of the preceding embodiments, the at least one other aerosol generating agent is a humectant, a solvent and / or a flavoring agent.

[0014] According to a fifth embodiment, in any one of the preceding embodiments, the at least one aerosol generating agent is selected from glycols such as propylene glycol or triethylene glycol; glycerol; glycerol derivatives; acids such as lactic acid; triethyl citrate; triacetin; polyols such as sorbitol; non-polyols such as monohydric alcohols; high boiling point hydrocarbons; esters such as diacetin, triacetin, triethylene, triethyl citrate, glycol diacetate; myristic acids such as ethyl myristate and isopropyl myristate; aliphatic carboxylic acid esters such as methyl stearate, dimethyl tetradecanedioate and dimethyl dodecanedioate, or combinations thereof.

[0015] By providing at least one other aerosol generating agent, such as a humectant, a solvent and / or a flavoring agent, the delivery of the aerosol can be improved. The aerosol provided to the user can be adjusted according to the user's preferences. For example, the at least one other aerosol generating agent can increase the concentration of the aerosol provided to the user and / or provide a particular flavor and / or a particular amount of nicotine.

[0016] According to a sixth embodiment, in any one of the preceding embodiments, the container is a pod including a flange and a sealing membrane attached to the flange.

[0017] Forming the container as a pod including a flange and a sealing membrane attached to the flange results in a relatively simple construction of a substantially sealed enclosure. Furthermore, the flange provides a contact area that allows for a stronger connection between the container and the sealing membrane so that the enclosure is more durable. In particular, an adhesive can be applied to the flange to chemically connect the flange to the sealing membrane, or the sealing membrane can be mechanically deformed to surround the flange connection, thereby increasing the strength of the connection.

[0018] According to the seventh embodiment, in the preceding embodiments, the sealing membrane is attached to the flange using any one or more of an adhesive, preferably an epoxy adhesive, heat sealing, ultrasonic welding and / or laser welding.

[0019] According to an eighth embodiment, in any one of the preceding embodiments, the container comprises a metal, preferably aluminum or stainless steel, a ceramic and / or a polymeric material, preferably polyester, or a polymer laminate (e.g. polyolefin based such as PP, PE, PET) comprising a diffusion barrier such as PVDC, LDPE, LLDPE, HDPE, or a metallized polymer film such as metallized PE or PET, or a polymer (such as polyester) with a thin film coating.

[0020] According to a ninth embodiment, in any one of the preceding embodiments, the container comprises a material having a moisture vapor transmission rate (MVTR) of at most 2, preferably at most 1.5, more preferably at most 1.

[0021] According to a tenth embodiment, in any one of the preceding embodiments, the container includes a thermally conductive material and is configured to transfer heat to the smokable material by the thermally conductive material.

[0022] According to an eleventh embodiment, in the preceding embodiments, the thermally conductive material comprises a metal, preferably aluminum and / or stainless steel.

[0023] This allows aerosol to be generated without the need for a heating element within the smoking article, which allows for a simple design of the container. Furthermore, if the container comprises a thermally conductive material, heat provided from an external source is more efficiently conducted to the tobacco product, thereby reducing the energy consumption of the device.

[0024] According to a twelfth embodiment, in any one of the preceding embodiments, the container is configured to be in heat communication with a resistive and / or radiative heating element configured to heat the smokable material within the container.

[0025] According to a thirteenth embodiment, in any one of the first to ninth embodiments, the aerosol product is configured to be heated using induction heating, and the susceptor is preferably embedded in the tobacco material and / or container.

[0026] The above configuration of the aerosol production article allows for aerosol generation even when an external heater is not available. For example, the aerosol production article may be inserted into a device that includes only an induction coil configured to inductively heat a smokable article such that an aerosol is formed. This allows for the omission of a complex heating element, thereby eliminating the need for additional components in the aerosol production article and reducing the requirements for heating the article in the aerosol generation device. Thus, the aerosol production article may be used in a variety of aerosol generation devices.

[0027] According to a fourteenth embodiment, in any of the preceding embodiments, the aerosol product item is configured to be inserted into a heating chamber configured to be heated by a heating assembly using resistive heating, radiative heating and / or inductive heating, the heating assembly being preferably comprised by a non-combustion heated device.

[0028] A fifteenth embodiment of the present invention relates to a method of producing an aerosol product article, preferably according to any one of the preceding embodiments, comprising the steps of drying the tobacco layered material, mixing the dried tobacco layered material with at least one other aerosol forming agent to obtain a smokable material having a moisture content of less than 12% by weight, preferably less than 11% by weight, more preferably less than 9% by weight and / or preferably more than 5% by weight, more preferably more than 6% by weight, and most preferably more than 7% by weight of the total weight of the smokable material, and substantially hermetically enclosing the smokable material within a housing contained by the aerosol product article.

[0029] The above method makes it possible to obtain smoking articles described in the previous embodiments, in particular aerosol product articles having a relatively low moisture content, which can be heated without the need to apply significant heat to the aerosol product articles.

[0030] According to the sixteenth embodiment, in the preceding embodiment, the drying, mixing and encapsulating steps are carried out one by one, and the time interval between carrying out each of the drying, mixing and encapsulating steps is at most 60 minutes.

[0031] According to a seventeenth embodiment, in the preceding embodiments, the time interval is at most 1 minute, preferably at most 10 seconds.

[0032] Performing the steps one at a time substantially instantly and / or within a relatively short time interval prevents smokable materials having a relatively low moisture content from drawing moisture from the atmosphere, thereby ensuring that the moisture content is maintained at a relatively low level.

[0033] According to the 18th embodiment, in any one of the 15th to 17th embodiments, the drying step includes one or more of the steps of drying tobacco leaves, cutting the dried tobacco leaves into small pieces to obtain a tobacco layered material, and drying the tobacco layered material to obtain a dried tobacco layered material.

[0034] The moisture content of the tobacco layered material can be further reduced by drying an already dried tobacco material.

[0035] According to the 19th embodiment, in any one of the 15th to 18th embodiments, the drying step is carried out for at most 10 seconds, preferably at most 5 seconds, and most preferably at most 2 seconds.

[0036] The above arrangement dries the tobacco material for only a relatively short period of time, thus preventing damage to the delicate natural material.

[0037] According to the twentieth embodiment, in any one of the fifteenth to nineteenth embodiments, the drying step involves a drum drying process, a freeze drying process and / or a spray drying process.

[0038] The drying method described above allows the tobacco layered material to be dried as needed without damaging the tobacco material.

[0039] According to a 21st embodiment, in any one of the 15th to 20th embodiments, the step of substantially hermetically enclosing the aerosol product includes one or more of the steps of providing a container including a sealable housing, filling the container with smokable material, and closing and substantially hermetically sealing the container filled with smokable material.

[0040] According to the 22nd embodiment, in any one of the 15th to 21st embodiments, at least one, preferably all, of the drying, mixing and encapsulating steps are carried out in a controlled atmosphere, preferably a humidity-controlled atmosphere, and / or the atmosphere to which the tobacco material is exposed between steps is controlled, preferably humidity-controlled, and the humidity-controlled atmosphere preferably has a relative humidity (RH) of less than 50% RH, more preferably less than 30% RH, and most preferably less than 20% RH.

[0041] Controlling the atmosphere during the manufacturing process makes it possible to prevent the smokable material from drawing moisture from the atmosphere, particularly when the atmosphere is controlled so that the relative humidity of the atmosphere is low.

[0042] According to a twenty-third embodiment, in any one of the fifteenth to twenty-second embodiments, the mixing step is carried out in a substantially sealed agitator tank.

[0043] By carrying out the mixing step in a substantially enclosed mixer tank, the smokable material is unable to draw additional moisture from the atmosphere, which is particularly relevant during the mixing step since the smokable material is particularly susceptible to the effects of atmospheric humidity.

[0044] A twenty-fourth embodiment of the present invention relates to a method of producing an aerosol product preferably as described in any one of the first to fourteenth embodiments, comprising the steps of mixing reconstituted tobacco material (RTB) with at least one other aerosol forming agent to obtain a slurry, drying the slurry to obtain smokable material having a moisture content of less than 12% by weight, preferably less than 11% by weight, more preferably less than 9% by weight of the total weight of the smokable material and / or preferably greater than 5% by weight, more preferably greater than 6% by weight, most preferably greater than 7% by weight of the total weight of the smokable material, and substantially hermetically enclosing the smokable material within a housing contained by the aerosol product article.

[0045] The use of reconstituted tobacco materials facilitates the manufacture of smokable materials; that is, reconstituted tobacco materials are generally provided in sheets that are easier to handle and work with. Furthermore, reconstituted tobacco materials are often provided in a variety of configurations; for example, one type may contain higher concentrations of volatile substances (such as nicotine and flavor compounds) than another type. Thus, it is easier to provide smokable materials with specific desired characteristics.

[0046] A 25th embodiment of the present invention relates to an aerosol product according to any one of the 1st to 14th embodiments, obtainable by a method according to any one of the 15th to 22nd embodiments.

[0047] A 26th embodiment of the present invention relates to an aerosol generation system comprising an aerosol product article as described in any one of the first to fourteenth embodiments and / or manufactured according to any one of the fifteenth to twenty-third embodiments, and an aerosol generation device configured to receive the aerosol product article, the aerosol generation device comprising a power source and a heating assembly powered by the power source, the heating assembly including a resistive heating system, a radiative heating system and / or an inductive heating system.

[0048] According to a 27th embodiment, in the preceding embodiment, the aerosol generation device includes a piercing member, which is configured to pierce the housing of the aerosol product article and create an opening in the housing when the aerosol generation system is assembled by inserting the aerosol product article into the aerosol generation device.

[0049] According to the twenty-eighth embodiment, in the preceding embodiment, the aerosol generating device includes a mouthpiece including a piercing member.

[0050] According to the 29th embodiment, in any one of the 26th to 28th embodiments, the aerosol generating device comprises: a first piercing member configured to pierce a housing of the aerosol product article and create a first opening in the housing when the aerosol generation system is assembled by inserting the aerosol product article into the aerosol generation device; a second piercing member configured to pierce the housing of the aerosol product article and create a second opening in the housing when the aerosol generation system is assembled by inserting the aerosol product article into the aerosol generation device; Includes.

[0051] According to the 30th embodiment, in the preceding embodiment, the first opening is an air inlet configured to supply air into the housing, and the second opening is an aerosol outlet configured to release an aerosol from the housing.

[0052] By providing a piercing member in the aerosol generating device, preferably in the mouthpiece, the user can open an opening in the housing when he / she wants to use the device. In fact, when the aerosol is generated in the substantially sealed housing in the aerosol product, the aerosol can only exit through this opening. Moreover, the substantially sealed housing remains closed until the user wants to consume the product. Thus, the low moisture content can be maintained until the capsule is opened / pierced, i.e., until the user wants to consume the product.

[0053] Preferred embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0054] [Figure 1] FIG. 2 is a schematic diagram of an aerosol product in an exemplary embodiment. [Diagram 2] FIG. 2 is an exploded view of an aerosol generation system in an exemplary embodiment in a disassembled state. [Diagram 3] FIG. 1 is a schematic diagram illustrating an assembled aerosol generating system in an exemplary embodiment. [Figure 4] FIG. 2 is a schematic diagram illustrating a drying process in an exemplary embodiment. [Diagram 5] FIG. 2 is a schematic diagram illustrating a mixing process in an exemplary embodiment. [Figure 6] FIG. 1 is a schematic diagram illustrating an encapsulation step in an exemplary embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0055] In the following, preferred embodiments of the present invention will be described with reference to the drawings.

[0056] 1 is a schematic diagram of an aerosol product article 100 according to an exemplary embodiment. The aerosol product article 100 includes a container 110 including a substantially sealed housing 111 and smokable material 112 contained within the substantially sealed housing 111. The smokable material 112 includes a dry tobacco layered material and at least one aerosol forming agent other than the dry tobacco layered material, and the moisture content of the smokable material 112 is less than 12% by weight, preferably less than 11% by weight, more preferably less than 10% by weight, most preferably less than 9% by weight, and / or greater than 5% by weight, preferably greater than 6% by weight, and most preferably greater than 7% by weight of the total weight of the smokable material 112. In some examples, the moisture content is in the range of 5% to less than 12% by weight, or preferably 5% to 11% by weight, or preferably 5% to 10% by weight, or preferably 5% to 9% by weight of the total weight of the smokable material 112. In some further examples, the moisture content is in the range of 6% to less than 12%, or preferably 6% to 11%, or preferably 6% to 10%, or preferably 6% to 9% by weight of the total weight of the smokable material 112. In some further examples, the moisture content is in the range of 7% to less than 12%, or preferably 7% to 11%, or preferably 7% to 10%, or preferably 7% to 9% by weight of the total weight of the smokable material 112.

[0057] The smokable material 112 is configured to provide an inhalable aerosol when heated to a certain temperature. In an exemplary embodiment, the aerosol is formed at between 100°C and 350°C, preferably between 150°C and 300°C, more preferably between 190°C and 270°C, and most preferably between 200°C and 250°C. In an exemplary embodiment, heat may be provided to the aerosol product article 100 by an external heat source, such as a heating assembly 212 of an aerosol generating device into which the aerosol product article 100 may be inserted. In this embodiment, heat is transferred by thermal conduction from the external heat source through the container 110 of the aerosol product article 100 to the smokable material 112. In another exemplary embodiment, the aerosol product article 100 may include a susceptor, configured to heat the smokable material 112 when an electromagnetic field is applied to the aerosol product article 100. The susceptor may be embedded in the smokable material 112 and / or the container 110. The coil for providing the electromagnetic field can be part of the aerosol product article 100 or part of an external device, such as an aerosol generation device 210 that includes a power source 212.

[0058] At least one other aerosol generating agent is added to the smokable material 112 to enhance the taste and / or generation of the aerosol. In an exemplary embodiment, the at least one other aerosol generating agent may be one or more of a solvent, a humectant, and / or a flavoring agent. Exemplary aerosol generating agents are glycols, such as propylene glycol or triethylene glycol; glycerol; glycerol derivatives; acids, such as lactic acid; triethyl citrate; triacetin; polyols, such as sorbitol; non-polyols, such as monohydric alcohols; high boiling point hydrocarbons; esters, such as diacetin, triacetin, triethylene, triethyl citrate, glycol diacetate; myristic acids, such as ethyl myristate and isopropyl myristate; aliphatic carboxylic acid esters, such as methyl stearate, dimethyl tetradecanedioate, and dimethyl dodecanedioate, or combinations thereof. The at least one other aerosol generating agent may also include flavorings to obtain apple, cherry, chocolate, honey, grape, menthol, mint, peach, rum, strawberry, "sweet" (including bubble gum, candy, mango, blueberry, strawberry, orange, gum mint, banana, and toffee) and / or vanilla flavors, for example, by adding one or more of ethyl vanillin (vanilla), menthol, isoamyl acetate (banana oil), or other commonly known flavorings. Additionally, caffeine or nicotine may also be added to enhance the user's taste sensation.

[0059] A high moisture content means that the smokable material 112 must evaporate more liquid before it reaches the temperature required to obtain an aerosol from the smokable material 112. However, excessive heat can be a disadvantage because it requires more power and can also cause the device providing the heat to heat up, which a user may not want. Furthermore, some devices 210 may only be able to provide a certain amount of heat when the moisture content is high, such that it may take an uncomfortably long time for an aerosol to be provided by the smokable material 112.

[0060] Thus, in exemplary embodiments, the at least one other aerosol forming agent represents between 5% and 50% by weight of the dried tobacco layered material, preferably between 8% and 30% by weight of the dried tobacco layered material, and most preferably between 10% and 25% by weight of the dried tobacco layered material. These ranges have been proven to produce an aerosol with good user characteristics, i.e., provide the user with good taste, good mouthfeel, and smokable material 112 that heats up quickly without the need for excessive heat.

[0061] In conventional aerosol product articles 100, smokable materials 112 having a low moisture content and some aerosol generating agents, such as glycerol, tend to draw moisture from the atmosphere, causing the moisture content of the smokable material 112 to increase over time. In view of the above, however, it is beneficial to maintain a constant low moisture content of the smokable material 112. This may be achieved by storing the smokable material 112 in a substantially sealed enclosure 111 such that exposure of the smokable material 112 to the atmosphere is minimized. That is, the substantially sealed enclosure 111 should at least be sealed such that moisture cannot enter the enclosure 111. This prevents, or at least makes it more difficult, the smokable material 112 from drawing moisture from the surrounding atmosphere, keeping the moisture content constant.

[0062] To prevent the smokable material 112 from drawing moisture through the container 110, the container 110 beneficially comprises a material that has a relatively low moisture vapor transmission rate (MVTR) / water vapor transmission rate (WVTR) or oxygen transmission rate (OTR). 2 MVTR / WVTR or OTR is a measure of the amount of moisture / water that passes through a surface in 24 hours, while OTR indicates the amount of oxygen / gas that passes through a surface. Thus, the lower the MVTR / WVTR or OTR of a container material, the greater the container's ability to maintain a constant moisture content, as less liquid and / or oxygen can diffuse through the material.

[0063] To facilitate heating of the smokable material 112 to reach the temperatures necessary to form an inhalable aerosol, container materials that exhibit good thermal conductivity properties are preferred.

[0064] In exemplary embodiments, the container 110 may include or be made of a material such as a metal, ceramic, polymeric material, or combination thereof, and a thermally conductive material configured to transfer heat to the smokable material 112. For example, the thermally conductive material may include a metal such as aluminum and / or stainless steel, or a polymer / ceramic material with good thermal conductivity.

[0065] 10cm 3 / m 2 / Less than 24h, preferably 8cm 3 / m 2 / Less than 24h, preferably 6cm 3 / m 2 / Less than 24h, most preferably 5cm 3 / m 2 Polymers with MVTR / WVTR / OTR less than 1×10^-3 cm^2 / 24h are considered to have good MVTR / WVTR / OTR properties, while metals such as aluminum or stainless steel have MVTR / WVTR / OTR less than 1×10^-3 cm^2 / 24h. 3 / m 2 / 24h (aluminum foil) or 1×10^-5cm 3 / m 2 It may further have an MVTR / WVTR / OTR of less than 1 / 24h (stainless steel). Although the above would seem to indicate that metal is the preferred material for the container 110, containers comprising polymers are less expensive and easier to manufacture when compared to metallic containers. Thus, in some embodiments, containers comprising polymeric materials are preferred.

[0066] While an inexpensive base material is preferred, if thermal conductivity and MVTR / WVTR / OTR are also important, the thermal conductivity and MVTR / WVTR / OTR of the base material can be increased by orders of magnitude by applying a coating, such as a thin film coating, to the vessel 110. In an exemplary embodiment, the vessel 110 can include a base material including ceramic, polymeric material, or metal, with a coating that enhances the thermal conduction properties of the vessel 110, for example by providing a particularly good thermal conductor, such as gold or platinum, in the coating. In another exemplary embodiment, the vessel 110 can include a coating that enhances the MVTR or OTR properties of the vessel 110 (i.e., lowers the MVTR / OTR). In this case, the coating acts as a diffusion barrier for the vessel 110 to prevent or at least make it more difficult for oxygen and / or steam to pass through / diffuse through the vessel 110.

[0067] For example, the polymer may be one or more of polyester, or a polymer laminate (e.g., polyolefin-based, such as PP, PE, PET) that includes a moisture barrier, such as PVDC, LDPE, LLDPE, HDPE, or a metallized polymer film, such as metallized PE or PET, or a polymer (such as polyester) with a thin barrier coating.

[0068] As seen in FIG. 1 , the container 110 may include at least one flange 113 at an opening of the container 110. The flange 113 may be part of the container 110 or may be attached to the container 110. The sealing membrane 114 may be connected to the at least one flange 113 such that the membrane 114 substantially seals the container 110. Substantially sealed (or sealed), as used herein, refers to being closed such that the atmosphere within the container 110 is only slightly exposed to the atmosphere outside the container 110, preferably not at all exposed to the atmosphere outside the container 110. The sealing membrane 114 may be directly connected to the flange 113 or may be attached to an intermediate layer between the flange 113 and the sealing membrane 114, such as an adhesive, such as a glue, e.g., an epoxy adhesive, configured to connect the sealing membrane 114 with the flange. The sealing membrane 114 may be attached to the flange 113 mechanically, for example by pressing and / or deforming the sealing membrane 114 onto the flange 113 by applying pressure and / or by welding, such as ultrasonic welding or laser welding, or chemically, for example by adhesive or a chemical reaction between the sealing membrane 114 and the flange 113, or a combination thereof. The sealing membrane 114 may also be attached to the flange 113 by heat, for example heat sealing. The sealing membrane 114 preferably has a relatively low MVTR / WVTR / OTR and preferably a relatively high thermal conductivity. Providing the container 110 with the flange 113 and the sealing membrane 114 facilitates the sealing membrane 114 to be connected to the container 110, and therefore facilitates the encapsulation of the container 110.

[0069] In the exemplary embodiment, the container 110 is formed as a pod having a frusto-conical shape. In this embodiment, the flange 113 is configured to surround a circular region of the frusto-conical shape with a larger diameter that forms the opening of the container 110. Inside the frusto-conical container 110, a housing 111 is formed into which the smokable material 112 is inserted. A circular thin sealing membrane 114 is connected to the container 110 by the flange 113 to substantially hermetically enclose / seal the container. When so formed, the smokable material 112 is substantially hermetically enclosed within the pod. If a material with good MVTR / WVTR / OTR properties is used for the container 110, the moisture content of the smokable material 112 inside the pod will be maintained. Because the sealing membrane 114 is thin, it is possible to pierce the sealing membrane 114 to form an opening in the container 110 and access the smokable material 112.

[0070] 2 shows an exploded view of an aerosol generation system 200 in a disassembled state including an aerosol generation device 210, an aerosol product article 100, and a mouthpiece 215 having a piercing member 214, according to an exemplary embodiment. The aerosol generation device 210 may include a heating assembly 212 and a power source 211 configured to power the heating assembly 212. The power source 211 may be a battery that provides power to the heating assembly 212.

[0071] The heating assembly 212 may include a resistive or inductive heating system configured to provide heat to the aerosol product article 100. In another embodiment, the heating assembly 212 may include a coil configured to heat the smokable material 112 by applying an electromagnetic field to a susceptor in / within the aerosol product article 100.

[0072] The mouthpiece 215 may be removably attached to the aerosol generation device 210, or the mouthpiece 215 may be permanently attached to the device 210. According to an exemplary embodiment, if the mouthpiece is removable, the mouthpiece 215 may include a threaded portion configured to be screwed into the device 210. In another embodiment, the mouthpiece 215 may also be fastened to the device 210 by a protrusion or recess and / or a spring, which cooperates with a recess or protrusion, respectively, on the device 210. According to another exemplary embodiment, if the mouthpiece is permanently attached, the mouthpiece 215 may include a hinge that allows the mouthpiece to rotate about an axis perpendicular to the longitudinal axis of the device. This rotation allows the mouthpiece to be in an open or closed position. In such an embodiment, the mouthpiece may further include a protrusion or recess that cooperates with a recess or protrusion, respectively, on the device 210, so that the mouthpiece can be maintained on the device 210 when the aerosol generation system 200 is assembled and during use of the aerosol generation device 210.

[0073] The piercing member 214 may be part of the mouthpiece 215 or may be separate from the mouthpiece 215. The piercing member 214 is preferably configured to pierce the sealing membrane 114 of the container 110 and enter the substantially sealed housing 111 when the aerosol generation system 200 is assembled. When the piercing member 214 pierces the container 110, at least a portion of the piercing member 214 is received by the housing 111.

[0074] In another embodiment, the aerosol generation device 210 may include a first piercing member and a second piercing member preferably configured to pierce the sealing membrane 114 of the container 110 into the substantially sealed housing 111 when the aerosol generation system 200 is assembled. In this configuration, the first piercing member creates a first opening and the second piercing member creates a second opening. The first opening is an air inlet configured to supply air into the housing and the second opening is an aerosol outlet configured to release the aerosol from the housing.

[0075] When the aerosol generating system 200 is in a disassembled state, the container is not pierced and the substantially sealed housing 111 remains substantially sealed, and therefore the moisture content of the smokable material 112 within the substantially sealed housing remains substantially constant.

[0076] 3 shows an assembled aerosol generating system 200 according to another embodiment, in which the aerosol product article 100 (not shown in FIG. 3) is placed inside the aerosol generating device 210 and the housing 111 containing the smokable material is opened.

[0077] That is, in the embodiment shown in Figure 3, the aerosol generation system 200 is assembled by inserting the aerosol product article 100 into the aerosol generation device 210 and attaching the removable mouthpiece 215 including the piercing member 214 to the aerosol generation device 210 such that the substantially sealed housing 111 is opened by the piercing member 214. That is, when assembled, the piercing member 214 pierces an opening in the preferably sealing membrane 114 of the container 110.

[0078] In other embodiments, the aerosol generation system 200 may be assembled by inserting the aerosol product article 100 into the aerosol generation device 210 that includes a piercing member 214. In such embodiments, the substantially sealed housing 111 is not pierced by attaching the mouthpiece 215 to the aerosol generation device 210, but rather by a piercing mechanism included in the aerosol generation device 210.

[0079] In embodiments in which the system includes a first piercing member and a second piercing member, the first and second openings are created when the device 210 is assembled. By creating the first and second openings by assembling the device, airflow through the container 110 containing the smokable material 112 is provided only at times when aerosol is to be formed, such that the moisture content within the container remains substantially constant until the system 200 is to be used.

[0080] In another embodiment, the substantially sealed housing 111 may be opened without the use of the piercing member 214. For example, the container 110 may include a predetermined break point that is opened using electrical and / or mechanical force.

[0081] In any of the above embodiments, a user may assemble the aerosol generating device 210 and activate the aerosol generating device 210, preferably by pressing a button. The aerosol generating device may also be activated by a sensor. The sensor may detect that the device has been assembled or may detect a user touch operation after the device has been assembled, and the aerosol generating device may be activated accordingly. This energizes the heating assembly 212 to heat the smokable material 112 and generate aerosol. When the container 110 is opened, the aerosol created inside the aerosol product article 100 exits the housing 111 and is provided to the user via the mouthpiece 215. In another embodiment, the heating assembly 212 does not require activation by the user to be energized, and the heating assembly 212 is energized as soon as the aerosol generating device 210 is assembled. Once the aerosol product article 100 is consumed, the user may open the aerosol generating device 210 and remove the consumed aerosol product article 100.

[0082] In the following, a method for producing the aerosol product article 100 will be described with reference to FIGS. 4 to 6, in which the individual steps of the method are shown according to an exemplary embodiment.

[0083] The method includes a step S110 of drying the tobacco layered material, a step S120 of mixing the dried tobacco layered material with at least one other aerosol generating agent to obtain smokable material 112, and a step S130 of substantially hermetically enclosing the smokable material 112 within a housing 111 contained by the aerosol product article 100.

[0084] In the drying step, the tobacco material is dried to obtain a dried tobacco layered material. Figure 4 illustrates the drying step as a drum drying process, according to an exemplary embodiment.

[0085] The tobacco layered material is obtained by curing tobacco leaves and then cutting the dried tobacco leaves into small pieces. In this embodiment, it is preferred to use a tobacco layered material having an initial moisture content of 10% to 25%, preferably 12% to 22%, more preferably 14% to 20%, and most preferably 16% to 18%. The tobacco layered material is added into the drum 410 of a drum dryer. The drum 410 of the drum dryer is heated (this is indicated by the four parallel arrows in FIG. 4 ) and the tobacco layered material is exposed to a drying air stream 420. In some embodiments, the drying air stream 420 is additionally or alternatively heated. The tobacco layered material is dried by the drying air 420 and / or heat from the drum 410. To maximize the surface exposure of the tobacco layered material to the drying air stream 420 and heat, and thereby maximize drying efficiency, the tobacco layers are moved within the drum 410 by the rotational movement of the drum 410. Moisture evaporated from the tobacco layer is removed from the drum 410 by heat exchanger 430. To increase the rate of evaporation of moisture, the pressure inside the drum 410 may be reduced.

[0086] In other embodiments, the drying step may be one or more of freeze-drying, spray-drying, and / or vacuum-stirred drying. Vacuum drum or vacuum-stirred dryers and spray dryers are commonly available technologies. Where it is necessary to minimize potential damage to the tobacco layered material, the sophisticated and expensive freeze-drying process may be preferred.

[0087] Regardless of the drying technique, the tobacco layered material is heated for at most 5 seconds, preferably at most about 4 seconds, more preferably at most about 3 seconds, and most preferably at most about 2 seconds to minimize damage to the delicate tobacco layered material. The resulting dried tobacco layered material has a moisture content of less than 12%, preferably less than 11%, more preferably less than 10%, and most preferably less than 9% by weight of the dried tobacco layered material.

[0088] Because the moisture content of the dried tobacco material is relatively low, the atmosphere should be controlled during drying step S110 to prevent the dried tobacco layered material from drawing moisture from the surrounding atmosphere. A humidity-controlled atmosphere is preferred, for example an atmosphere with a RH of at most 50% RH, preferably at most 40% RH, more preferably at most 30% RH, and most preferably at most 20% RH. Additionally, the temperature may be controlled to prevent rehydration of the dried tobacco layered material by moisture from the surrounding atmosphere; i.e., the higher the temperature of the atmosphere, the less likely rehydration will occur.

[0089] After the drying step S110, the dried tobacco layered material is mixed with at least one other aerosol-forming agent in a mixing step S120 to obtain the smokable material 112. An exemplary embodiment of the mixing step S120 is shown in Figure 5. The at least one other aerosol-forming agent added can be any one or more of a humectant, a solvent, nicotine, and a flavoring ingredient. Examples of other aerosol-forming agents have already been described above with respect to the aerosol product article 100 of Figure 1.

[0090] 5, the dried tobacco layered material is added to a closed agitator tank 530 that includes a blender 520 and a jet for providing at least one other aerosol generating agent 510. The at least one other aerosol generating agent is added to the dried tobacco layered material by the jet 510 and the mixture is mixed by the blender 520 to obtain the smokable material 112. Because the addition of the at least one other aerosol generating agent increases the moisture content of the mixture, the addition of the at least one other aerosol generating agent must be controlled so that the resulting smokable material 112 has a moisture content of less than 12% by weight of the total weight of the smokable material 112, preferably less than 11% by weight, more preferably less than 10% by weight, and most preferably less than 9% by weight and / or more than 5% by weight, preferably more than 6% by weight, and most preferably more than 7% by weight. In some examples, the moisture content is in the range of 5% to less than 12%, or preferably 5% to 11%, or preferably 5% to 10%, or preferably 5% to 9% by weight of the total weight of the smokable material 112. In some further examples, the moisture content is in the range of 6% to less than 12%, or preferably 6% to 11%, or preferably 6% to 10%, or preferably 6% to 9% by weight of the total weight of the smokable material 112. In some further examples, the moisture content is in the range of 7% to less than 12%, or preferably 7% to 11%, or preferably 7% to 10%, or preferably 7% to 9% by weight of the total weight of the smokable material 112.

[0091] The moisture content of the resulting smokable material can be determined, for example, by using a measurement method involving thermogravimetric analysis. In the thermogravimetric method, a sample of the smokable material is taken and placed on a balance to measure the initial weight of the sample. The sample is then dried / heated, for example, using either a drying oven, infrared drying (heating by absorption of infrared rays), halogen drying or microwave drying (heating by absorption of microwaves) until the weight is constant or until a predetermined time is reached. The amount of weight loss during the drying process (or before and after the drying process) is measured and defined as the moisture content of the sample. All substances that volatilize during heating contribute to the reduction in the mass / moisture content of the sample. This may include decomposition products or alcohols, as well as water. Therefore, no distinction is made between water and highly volatile components when using the thermogravimetric method.

[0092] An exemplary thermogravimetric method for determining the moisture content of the resulting smokable material is moisture content measurement using a halogen moisture analyzer. According to this method, in the thermogravimetric method, a sample of the smokable material is taken and placed on a scale to measure the initial weight of the sample. The sample is then dried with a halogen radiator (heated by infrared absorption of the halogen radiator) while remaining on the scale, and the weight loss due to the drying process (i.e., evaporation of moisture in the sample) is continuously measured. The total weight loss after the sample is completely dried (e.g., when a constant mass or a predetermined time is reached) is taken as the moisture content. Because the smokable material 112 includes a tobacco layered material and at least one other aerosol-forming agent, its moisture content is similar not only to the moisture in the tobacco layered material, but also to the moisture in the at least one other aerosol-forming agent and the moisture of any volatile substances that evaporate during the drying process.

[0093] A closed agitator tank 530 is advantageous because it allows for control of the humidity of the atmosphere, preferably the atmosphere inside the tank. In this embodiment, a relative humidity of at most 50% RH, preferably at most 40% RH, more preferably at most 30% RH, and most preferably at most 20% RH, is preferred inside the closed agitator tank 530 to prevent rehydration of the tobacco layered material / smokable material 112.

[0094] The mixing step S120 can be performed as a continuous process as well as a batch process.

[0095] After the mixing step S120, the smokable material 112 is substantially hermetically enclosed in step S 130. Step S130 according to an exemplary embodiment is shown in FIG.

[0096] In a first step of the encapsulation process S130, an empty container 110 is provided having a substantially sealable housing 111. The container 110 comprises a material that has relatively good water vapor barrier properties to protect the tobacco material from rehydration and good thermal conductivity to facilitate heating of the smokable material 112. In this embodiment, the container 110 comprises a metal such as aluminum or stainless steel. Metals have the added advantage of being able to act as susceptors in an inductive heating arrangement. However, other materials such as ceramics or polymers, particularly ceramics or polymers having a coating, may also be used.

[0097] In a second step of the encapsulation process S130, the substantially sealable housing 111 of the container 110 is filled with smokable material 112, preferably by a dispenser 610. Then, in a third step of the encapsulation process S130, the substantially sealable housing 111 of the container 110 is sealed / closed, preferably by a sealing membrane 114. The sealing membrane 114 preferably provides sufficient MVTR / WVTR / OTR properties to prevent rehydration of the smokable material 112, and is preferably configured to be easily pierced by the piercing member 214 of the aerosol generation device 210. The sealing membrane 114 used in this embodiment is a thin aluminum layer that provides good MVTR / WVTR / OTR properties as well as good thermal conductivity, and can be easily pierced / opened by the piercing member 214. Preferably, the container 110 includes a flange 113 that facilitates sealing of the container 110 with the sealing membrane 114. The container 110 may be sealed chemically, by an adhesive such as glue or a chemical reaction, or mechanically, by deformation, welding or application of pressure, or a combination thereof.

[0098] Once the container 110 is substantially sealed, the smokable material 112 is not exposed to the ambient atmosphere until the container 110 is opened by the piercing member 114 during assembly of the device 210. This means that the moisture content of the smokable material 112 remains substantially constant, and thus is less than 12% by weight of the total weight of the smokable material 112, preferably less than 11% by weight, more preferably less than 10% by weight, and most preferably less than 9% by weight.

[0099] As with the previous drying step S110 and mixing step S120, the atmosphere during the encapsulation process S130 is controlled, and in this embodiment is preferably humidity controlled. This humidity controlled atmosphere preferably has a relative humidity of less than 50% RH, more preferably less than 30% RH, and most preferably less than 20% RH.

[0100] In addition to preventing exposure of the smokable material 112 during the drying step S110, the mixing step S120, and the encapsulating step S130, it is preferable to prevent exposure of the smokable material 112 to the atmosphere between each step. One approach to prevent large scale exposure is to reduce the time interval between each process step, preferably performing each step S110, S120, S130 immediately, or at least substantially immediately, one after the other. That is, after step S110 is performed, the dried tobacco layered material is added immediately to the mixer tank, without storage time and / or additional processing, and after step S120 is performed, the smokable material is immediately encapsulated within the container.

[0101] Reducing the time interval between process steps is particularly relevant because many aerosol-forming agents, such as humectants, attract moisture from the atmosphere after at least one other aerosol-forming agent has been mixed with the smokable material 112. For this reason, it is preferred that the time interval between the mixing step S120 and the encapsulating step S130 be less than 60 minutes, preferably less than 10 minutes, more preferably less than 1 minute, and most preferably less than 10 seconds.

[0102] To further reduce exposure of the smokable material 112 to natural ambient air, the atmosphere may be controlled, preferably humidity controlled, during process steps S110, S120, and S130. In an exemplary embodiment, a relative humidity of at most 50% RH, preferably at most 40% RH, more preferably at most 30% RH, and most preferably at most 20% RH is preferred to prevent rehydration of the tobacco layered material / smokable material 112 during at least two of the three processes.

[0103] The above embodiments have been described with reference to a smokable material 112 that includes a tobacco layered material. However, the smokable material 112 may include other tobacco materials, such as reconstituted tobacco. Reconstituted tobacco or reconstituted tobacco sheet is a sheet of homogenized tobacco material. The sheet is generally obtained by mixing tobacco powder or chopped tobacco fibers with a binder to form a slurry. The slurry is then cast onto a moving endless belt and passed through a dryer to remove the water, resulting in a reconstituted tobacco (binder) sheet (also called RTS or RTB). Alternatively, a process similar to papermaking can be used to obtain an RTS / RTB. In such a process, tobacco leaves are cut and mixed with water to extract the water-soluble portion of the tobacco from the tobacco fibers. The remaining tobacco fibers are refined and sent to a papermaking machine to be formed into a sheet. The water-soluble products from the extraction process are then incorporated into the sheet along with a binder and / or a humectant to form a reconstituted tobacco sheet. In this process, the composition of the resulting RTS / RTB can be modified according to consumer preferences. For example, certain volatile substances such as flavorings, aerosol generating substances and / or nicotine may be added to the sheets and / or water soluble products may be added to the sheets in high / low concentrations to obtain RTS / RTB sheets with desired properties.

[0104] All the above embodiments are also applicable to an RTS / RTB instead of (or in addition to) a tobacco layered material. However, when an RTS / RTB is used, the drying step S110 is performed after the mixing step S120. That is, in a first step, a sheet of RTS / RTB is cut into small pieces / portions and then mixed with at least one other aerosol-forming agent as described above with reference to step S120 to obtain the smokable material 112, and in a second step, the mixture / slurry comprising at least one other aerosol-forming agent and the RTS / RTB is dried in a drying step as described above with reference to step S110 to obtain the smokable material 112. For an RTS / RTB, after the drying step, the moisture content of the smokable material 112 is less than 12% by weight of the smokable material 112, preferably less than 11% by weight, more preferably less than 10% by weight, and most preferably less than 9% by weight. The smokable material 112, including the RTS / RTB, is then enclosed within the container as described above with reference to step S130.

[0105] The above-described method for manufacturing the aerosol product 100 makes it possible to produce an aerosol product 100 that has a low moisture content and ensures that this moisture content does not increase unintentionally during the manufacture of the article 100. [Explanation of symbols]

[0106] 100 Aerosol products 110 Container 111 Cabinet 112 Smoking materials 113 Flange 114 Sealing film 120 Mixer tank 200 Aerosol Generation System 210 Aerosol generating device 211 Power supply 212 Heating Assembly 213 Mouthpiece 214 Perforated Members 410 Drums 420 Dry Air Flow 430 Heat exchanger 510 Jet for providing at least one other aerosol generating agent 520 Brenda 530 Closed Mixer Tank 610 Dispenser S110 Drying process S120 Mixing process S130 Encapsulating process

Claims

1. An aerosol-generating article (100) for use in a non-combustion heating device, comprising: a container (110) including a substantially sealed housing (111); a smokable material (112) contained within the substantially sealed housing (111), the smokable material (112) including a dried tobacco layer material and at least one other aerosol-generating agent; and wherein the smokable material (112) has a moisture content of less than 12% by weight of the total weight of the smokable material (112).

2. The aerosol-generating article (100) according to claim 1, wherein the at least one other aerosol-generating agent is a wetting agent and / or a solvent.

3. The aerosol-generating article (100) according to claim 2, wherein the wetting agent is selected from propylene glycol, vegetable glycerin, or a combination thereof.

4. The aerosol-generating article (100) according to claim 1, wherein the container (110) is a pod including a flange (113) and a sealing film (114) attached to the flange (113).

5. The aerosol-generating article (100) according to claim 1, wherein the container (110) includes a thermally conductive material and is configured to transfer heat to the smokable material (112) by the thermally conductive material.

6. The aerosol-generating article (100) according to claim 1, configured to be heated using inductive heating, and a susceptor is embedded in the tobacco material and / or the container (110).

7. A method of manufacturing an aerosol-generating article (100), comprising: a step (S110) of drying a tobacco layer material; a step (S120) of mixing the dried tobacco layer material with at least one other aerosol-generating agent to obtain a smokable material (112) having a moisture content of less than 12% by weight of the total weight of the smokable material; and a step (S130) of substantially sealing and enclosing the smokable material (112) within a housing (111) included by the aerosol-generating article (100).

8. ​ The steps of drying (S110), mixing (S120), and encapsulating (S130) are carried out one by one, and the time interval between each of the steps of drying (S110), mixing (S120), and encapsulating (S130) is at most 60 minutes. The method according to claim 7.

9. The step of drying (S110) is a step of drying tobacco leaves, a step of cutting the dried tobacco leaves into small pieces to obtain a tobacco layered material, and a step of drying the tobacco layered material to obtain a dried tobacco layered material The method according to claim 7, including one or more of.

10. The step of drying (S110) is carried out for at most 10 seconds. The method according to claim 7.

11. At least one of the steps of drying (S110), mixing (S120), and encapsulating (S130) is carried out in a controlled atmosphere, and / or the atmosphere to which the tobacco material is exposed between the steps is controlled. The method according to claim 7.

12. The mixing step is carried out in a substantially sealed agitator tank (120). The method according to claim 7.

13. An aerosol generation system (200), comprising an aerosol generation article (100) according to any one of claims 1 to 6, and an aerosol generation device (210) configured to receive the aerosol generation article (100), the aerosol generation device (210) including a power source (211) and a heating assembly (212) including a resistive heating system or an inductive heating system powered by the power source An aerosol generation system (200) including.

14. The aerosol generation device (210) includes a perforating member (214), and when the aerosol generation system (200) is assembled by inserting the aerosol generation article (100) into the aerosol generation device (210), the perforating member (214) pierces the housing (111) of the aerosol generation article (100) and is configured to create an opening in the housing (111). The aerosol generation system (200) according to claim 13.

15. The aerosol generation device (210) includes a mouthpiece (213) including the perforating member (214). The aerosol generation system according to claim 14.

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