Inner liner sheet material containing no metal layer
The inner liner sheet material with a biodegradable barrier layer addresses recyclability and contamination issues by eliminating the metal layer, enhancing recyclability and reducing production costs.
Patent Information
- Application Number
- JP2025532559
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-12-08
- Filing Date
- 2023-12-05
- Publication Date
- 2025-12-05
AI Technical Summary
Existing inner liner sheets for aerosol-generating articles, which are typically multi-layered and include a metal layer, face challenges in recyclability and contamination of manufacturing machinery due to flavoring methods, leading to increased production costs and inefficiencies.
An inner liner sheet material composed of a base layer and a biodegradable barrier layer without a metal layer, where the barrier layer is less permeable to injected substances, allowing for improved recyclability and reduced contamination.
The solution enhances recyclability and reduces machinery contamination, thereby lowering production costs and improving manufacturing efficiency.
Smart Images
Figure 2025539499000001_ABST
Abstract
Description
[Technical Field]
[0001] The present invention relates to an inner liner sheet material for lining a packaging unit of at least one aerosol-generating article, a method for manufacturing such an inner liner sheet material, the packaging unit, a method for manufacturing the packaging unit, and the use of a biodegradable barrier layer in the inner liner sheet material. [Background technology]
[0002] Aerosol-generating articles refer not only to filter cigarettes and other smoking articles in which a substance is burned to form smoke, but also to articles that generate an aerosol from an aerosol-generating material without requiring combustion of the aerosol-generating material. Such articles are often referred to as "heat-and-burn" aerosol-generating articles because the aerosol-generating material is heated to a relatively low temperature to induce aerosol formation but prevent combustion of the materials contained within the aerosol-generating material.
[0003] Aerosol-generating articles come in a variety of flavored varieties. Flavoring of aerosol-generating articles can be achieved by incorporating flavoring ingredients directly into the aerosol-generating material or by including flavoring ingredients in thread-like or encapsulated form within the aerosol-generating material or its associated corresponding filter section. However, such flavoring methods can contaminate manufacturing machinery with residual flavor contaminants, necessitating thorough cleaning before unflavored aerosol-generating articles can be produced. Furthermore, such flavoring methods can require complex machinery, increasing production costs and efficiency.
[0004] To mitigate such drawbacks, aerosol-generating articles may be flavored by an indirect flavoring method, e.g., a flavor transfer process, in which an object not defined as an aerosol-generating article contains an infused substance, and the object is then placed in the vicinity of at least one aerosol-generating article for a predetermined period of time, during which the flavor components of the infused substance transfer from the object to the aerosol-generating article.
[0005] Conventionally, the object containing the injection substance is an inner liner sheet, which contains a plurality of aerosol-generating articles and is itself typically housed within a paper-based box. Such inner liner sheets typically comprise a multi-layer structure including a paper base, a metal layer, and an adhesive layer therebetween. The multi-layer structure is typically manufactured by a lamination process.
[0006] An inner liner sheet is known from U.S. Patent No. 6,692,835 B1, in which a paper layer is adhesively bonded to an aluminum foil layer, which is provided with a polyvinyl alcohol slip coating, the slip coating being intended to prevent the aluminum foil layer from sticking to the corresponding machinery during the manufacture and processing of the inner liner sheet.
[0007] Due to the nature of the multi-layer structure of the inner liner sheet, which not only exhibits layers of various material types as a result of lamination, but also shows that they are permanently assembled, recyclability of the inner liner sheet is difficult to achieve.
[0008] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide an inner linersheet material that has improved environmental impact. Summary of the Invention
[0009] According to a first aspect of the present invention, there is provided an inner liner sheet material for lining the interior surface of a packaging unit for at least one aerosol-generating article, the inner liner sheet material comprising a base layer and a barrier layer, the base layer comprising an injecting substance, and the inner layer sheet material does not comprise a metal layer.
[0010] The inner linersheet material may be a layered body exhibiting length and width dimensions significantly greater than the corresponding thickness-defining dimensions. The inner linersheet material may be defined as exhibiting two outer surfaces separated by the thickness of the inner linersheet material.
[0011] The inner liner sheet material may be provided as a continuous product, for example from a bobbin.
[0012] The base layer may be a substrate layer onto which any one or combination of the following layers is disposed:
[0013] A layer refers to a layered object exhibiting length and width dimensions that are significantly greater than the corresponding thickness dimensions. The layers of inner liner sheet material may exhibit distinct boundaries or interfaces between adjacent layers, such that the individual layers are geometrically distinguishable. Absorption of additional components into one or more of the layers of inner liner sheet material does not result in the formation of a layer, but rather the formation of additional additives or components of the associated layer or layers.
[0014] The barrier layer is disposed on the base layer. Specifically, the barrier layer may be disposed on the outer surface of the base layer opposite the surface onto which the injection substance is provided.
[0015] The barrier layer may be disposed directly on the base layer, in which case there may be no other layer between the barrier layer and the base layer.
[0016] The inner liner sheet material may consist of a base layer and a barrier layer. Specifically, the inner liner sheet material includes only a base layer and a barrier layer. This does not exclude the injection material from being absorbed into the base layer or the barrier layer.
[0017] The barrier layer is the layer of the inner liner sheet material that is least permeable to the injectate. The barrier layer can be adapted to prevent or impede migration of compounds to and from the inner sheet material. Specifically, the barrier layer is adapted to limit penetration of the injectate from the base layer to its outermost surface. Specifically, the barrier layer is adapted to be less permeable to the injectate than the base layer. The barrier layer may be adapted to prevent penetration of the injectate. This helps prevent loss of the injectate to the external environment and redirect penetration and diffusion of the injectate toward at least one aerosol-generating article.
[0018] The barrier layer may be biodegradable.
[0019] The barrier layer may be oleophobic.
[0020] The barrier layer may be hydrophobic.
[0021] The barrier layer may be an outer layer of the inner linersheet material. The barrier layer may define one of the outer surfaces of the inner linersheet material. The barrier layer may be one of the outermost surfaces of the inner linersheet material.
[0022] The barrier layer is less permeable to the injected substance than the base layer.
[0023] The barrier layer may exhibit an alcohol permeation level of less than 0.8 grams per square meter per day, preferably less than 0.1 grams per square meter per day, more preferably less than 0.01 grams per square meter per day, and most preferably less than 0.001 grams per square meter per day.
[0024] The alcohol permeation level may be a menthol permeation level. More specifically, the barrier layer may exhibit a menthol permeation level of less than 0.8 grams per square meter per day, preferably less than 0.1 grams per square meter per day, more preferably less than 0.01 grams per square meter per day, and most preferably less than 0.001 grams per square meter per day.
[0025] Specifically, the barrier layer may contain polyvinyl alcohol. The barrier layer may further contain glyoxal, preferably 0.1 to 1 weight percent glyoxal. Such components may enhance the barrier effect against alcohol or menthol penetration. Polyvinyl alcohol and glyoxal may also prevent swelling of the inner liner sheet material, which may occur as a result of the injected substance. Reduced swelling of the inner liner sheet material may also improve the inner liner sheet material's mechanical resistance to friction during processing.
[0026] The base layer may comprise paper.
[0027] The base layer may consist primarily of paper.
[0028] The base layer may consist solely of paper.
[0029] The base layer may include a paper fiber layer and a paper coating. The base layer may include paper, or may consist primarily of paper, and may include a paper fiber layer and a paper coating. The paper coating may modify some properties of the underlying paper fiber layer, affecting the physical or chemical properties of the resulting base layer. For example, the paper coating may improve the chemical absorption properties, or coefficient of friction, and overall surface quality, such as smoothness, of the base layer. The paper fiber layer may exhibit a paper coating on one or both of its outer surfaces. The paper coating may include a polymer.
[0030] The paper fiber layer may be a calendered kraft paper.
[0031] The paper coating may be clay-based.
[0032] The base layer includes an injection material. If the base layer exhibits a paper coating, the injection material may be provided on a surface of the base layer that is not covered with the paper coating. The injection material may be provided on a surface of the base layer opposite the surface that exhibits the paper coating.
[0033] The infusion substance may be a liquid. In such a case, the infusion substance may also comprise a carrier component. Such a carrier component may be a solvent that allows dissolving at least one flavor component to form a liquid solution of the infusion substance. The carrier component may be realized by the compound ethanol.
[0034] The injectate may be at least partially absorbed into the base layer.
[0035] The injectable substance may be provided in the form of an injection layer. The injectable substance may be a solid or gel-like substance provided on the base layer in the form of such an injection layer.
[0036] The injectate may be a flavor carrier adapted to transfer flavor to the adjacent aerosol-generating article. The injectate is adapted to at least partially migrate or diffuse into the aerosol-generating article. The injectate may be a compound or a mixture of at least two compounds. The two compounds may further comprise at least one flavor component.
[0037] The infusion may include at least one flavor component. The at least one flavor component may be an essential oil. The essential oil may contain volatile compounds extracted from plants. The at least one flavor component may be derived from a plant, such as thyme, eucalyptus, cinnamon, or rose. The at least one flavor component may be derived from a fruit, such as strawberry, mango, banana, or watermelon. The at least one flavor component may be derived from a mint, such as peppermint or spearmint.
[0038] The at least one flavor component may include menthol, more particularly synthetic menthol.
[0039] The flavoring ingredients may be of natural or artificial origin.
[0040] If the base layer includes a paper coating on one of its outer surfaces, the barrier layer may be adjacent to the paper coating. The barrier layer may be directly adjacent to the paper coating, with no other layers in between.
[0041] These properties of the barrier layer obviate the need for a metal layer to provide a barrier to the injected material, and therefore the inner liner sheet material may not include a metal layer.
[0042] The inner liner sheet material does not include a metal layer, and the absence of such a layer improves the recyclability of the inner liner sheet material.
[0043] According to a second aspect of the present invention, there is provided a packaging unit comprising at least one aerosol-generating article, a container, and an inner linersheet material according to the first aspect of the present invention, wherein the inner linersheet material at least partially surrounds the at least one aerosol-generating article, the inner linersheet material is at least partially surrounded by the container, and the barrier layer is further away from the at least one aerosol-generating article than from the base layer.
[0044] The injectate may be adapted to migrate at least partially from a base layer within the packaging unit to the aerosol-generating article.
[0045] Specifically, the barrier layer is adjacent to at least one interior surface of the container.
[0046] The base layer may be in direct contact with the aerosol-generating article.
[0047] The container may comprise paper.
[0048] The barrier layer may be adjacent to at least one interior surface of the container.
[0049] According to a third aspect of the present invention, there is provided a method for manufacturing an inner liner sheet material for lining an interior surface of a packaging unit for at least one aerosol-generating article, the method comprising the steps of providing a barrier layer on a base layer and providing an injectable substance on the base layer, the barrier layer being applied directly onto the base layer.
[0050] The injectate may be at least partially absorbed into the base layer, while the barrier layer may be the least permeable layer of the inner linersheet material to the injectate.
[0051] The injectate may be sprayed onto the base layer.
[0052] The method may further include unwinding the base layer with the barrier layer from a coil. After providing the barrier layer to the base layer, both layers may be coiled for transport and further processing purposes. The base layer and barrier layer may then be unwound from said coil, for example, to provide an infusion material to the base layer.
[0053] The method may further include winding the base layer provided with the barrier layer and the infusion substance into a coil, and the resulting inner linersheet material may be wound into a coil for transport and further processing purposes.
[0054] Specifically, the base layer of the method may be paper and the infused substance may be menthol.
[0055] A barrier layer may be coated onto the base layer.
[0056] The barrier layer may be printed onto the base layer.
[0057] The barrier layer may be sprayed onto the base layer.
[0058] The barrier layer may be applied onto the base layer by coating, printing or spraying processes known in the art.
[0059] The base layer may be adjacent to at least one aerosol-generating article.
[0060] According to a fourth aspect of the present invention, there is provided a method for producing a packaging unit for at least one aerosol-generating article, the method comprising the step of folding an inner liner sheet material produced according to the third aspect of the present invention.
[0061] According to a fifth aspect of the present invention, there is provided the use of a biodegradable barrier layer in an inner liner sheet material for lining the inner surface of a packaging unit for at least one aerosol-generating article, the inner liner sheet material comprising two layers: a base layer containing an injection substance and a barrier layer, the barrier layer being the layer of the inner liner sheet material that is least permeable to the injection substance.
[0062] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.
[0063] Example 1: An inner liner sheet material for lining the interior surface of a packaging unit of at least one aerosol-generating article, comprising a base layer and a barrier layer, wherein the base layer comprises an injection material, and the inner liner sheet material does not comprise a metal layer. Example 2: An inner liner sheet material as described in Example 1, where the barrier layer is disposed directly on the base layer. Example 3: The inner liner sheet material of Example 1 or 2, wherein the inner liner sheet material consists of a base layer and a barrier layer. Example 4: The inner liner sheet material of any of Examples 1-3, wherein the barrier layer is the least permeable layer of the inner liner sheet material to the injection substance. Example 5: An inner liner sheet material as described in any of Examples 1-4, wherein the barrier layer is biodegradable. Example 6: An inner liner sheet material as described in any of Examples 1-5, wherein the barrier layer is oleophobic. Example 7: An inner liner sheet material as described in any of Examples 1-6, wherein the barrier layer is hydrophobic. Example 8: The inner liner sheet material of any of Examples 1-7, wherein the barrier layer is the outer layer of the inner liner sheet material. Example 9: An inner liner sheet material as described in any of Examples 1-8, wherein the barrier layer is less permeable to the injectate than the base layer. Example 10: An inner liner sheet material described in any of Examples 1 to 9, wherein the barrier layer has an alcohol permeation level of less than 0.8 grams / square meter / day, preferably less than 0.1 grams / square meter / day, more preferably less than 0.01 grams / square meter / day, and most preferably less than 0.001 grams / square meter / day. Example 11: An inner liner sheet material as described in Example 10, wherein the alcohol permeation level is the same as the menthol permeation level. Example 12: The inner liner sheet material of any of Examples 1-11, wherein the barrier layer comprises polyvinyl alcohol. Example 13: The inner liner sheet material of Example 12, wherein the barrier layer further comprises glyoxal. Example 14: The inner liner sheet material of Example 13, wherein the barrier layer comprises 0.1 to 1 wt. % glyoxal. Example 15: An inner liner sheet material according to any of Examples 1-14, wherein the base layer comprises paper. Example 16: An inner liner sheet material according to any of Examples 1 to 14, wherein the base layer consists primarily of paper. Example 17: An inner liner sheet material according to any one of Examples 1 to 14, wherein the base layer consists solely of paper. Example 18: An inner liner sheet material according to any of Examples 1-17, wherein the base layer comprises a paper fiber layer and a paper covering. Example 19: An inner liner sheet material as described in Example 18, wherein the paper fiber layer is a calendered kraft paper. Example 20: An inner liner sheet material as described in Examples 18 or 19, wherein the paper coating is clay-based. Example 21: An inner liner sheet material according to any of Examples 1-20, wherein the injectate is at least partially absorbed within the base layer. Example 22: An inner liner sheet material as described in any of Examples 1, 2, and 4-21, wherein the infusion material is provided in the form of an infusion layer. Example 23: An inner liner sheet material according to any of Examples 1-22, wherein the infusion substance comprises at least one flavoring ingredient. Example 24: An inner liner sheet material as described in Example 23, wherein the at least one flavor ingredient is an essential oil. Example 25: An inner liner sheet material as described in Example 23, wherein at least one flavor ingredient is plant-derived. Example 26: An inner liner sheet material as described in Example 23, wherein at least one flavor component is fruit derived. Example 27: An inner liner sheet material as described in Example 23, wherein at least one flavor component is mint derived. Example 28: An inner liner sheet material as described in Example 23, wherein the at least one flavor component comprises menthol. Example 29: An inner liner sheet material as described in Example 28 wherein the menthol is synthetic. Example 30: A packaging unit having at least one aerosol-generating article, a container, and an inner liner sheet material described in any one of Examples 1 to 29, wherein the inner liner sheet material at least partially surrounds the at least one aerosol-generating article, the inner liner sheet material is at least partially surrounded by the container, and the barrier layer is further away from the at least one aerosol-generating article than from the base layer. Example 31: The packaging unit of Example 30, adapted to allow the injection substance to at least partially migrate from the base layer to the aerosol-generating article within the packaging unit. Example 32: A packaging unit according to example 30 or 31, wherein the barrier layer is adjacent to at least one interior surface of the container. Example 33: A method for manufacturing an inner liner sheet material for lining the interior surface of a packaging unit for at least one aerosol-generating article, the method comprising the steps of providing a barrier layer on a base layer and providing an injection material on the base layer, wherein the barrier layer is provided directly on the base layer. Example 34: The method of Example 33, wherein the injectate is at least partially absorbed into the base layer and the barrier layer is the least permeable layer of the inner liner sheet material to the injectate. Example 35: The method of example 33 or 34, wherein the injection material is sprayed onto the base layer. Example 36: The method of any of Examples 33-35, wherein the method further comprises unwinding the base layer having the barrier layer from a coil. Example 37: The method of any of Examples 33-36, wherein the method further comprises winding the base layer comprising the barrier layer and containing the injection substance into a coil. Example 38: The method of any of Examples 33-37, wherein the base layer is paper and the injectable substance is menthol. Example 39: The method of any of Examples 33-38, wherein the barrier layer is coated onto the base layer. Example 40: The method of any of Examples 33-38, wherein the barrier layer is printed onto the base layer. Example 41: The method of any of Examples 33-38, wherein the barrier layer is sprayed onto the base layer. Example 42: A method for producing a packaging unit for at least one aerosol-generating article, the method comprising the step of folding an inner liner sheet material produced according to any of Examples 33-41. Example 43: Use of a biodegradable barrier layer in an inner liner sheet material for lining the inner surface of a packaging unit for at least one aerosol-generating article, wherein the inner liner sheet material has two layers: a base layer containing an injection substance and a barrier layer, and the barrier layer is the layer of the inner liner sheet material that is least permeable to the injection substance.
[0064] Examples of embodiments of the present invention will now be further described with reference to the following figures: [Brief explanation of the drawings]
[0065] [Figure 1] FIG. 1 shows a cross-sectional view of a prior art inner linersheet material. [Figure 2] FIG. 2 illustrates a cross-sectional view of an inner linersheet material according to one embodiment of the present invention. [Figure 3] FIG. 3 is a cross-sectional view of a method for delivering an implant to a base layer with a barrier layer according to one embodiment of the present invention. [Figure 4] FIG. 4 illustrates a packaging unit with an inner linersheet material according to one embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION
[0066] As shown in FIG. 1, a prior art inner liner sheet material 1 exhibits multiple layers. The base layer 2 includes a paper fiber layer 3 covered with a paper cover layer 4. Such a two-component base layer 2 is common in the manufacture of such paper products. An infusion substance 5 is applied to and absorbed into the paper fiber layer 3 of the base layer 2. To prevent the infusion substance 5 from penetrating and flowing through the paper fiber layer 3 and the paper cover layer 4, a metal layer 6 is provided on the outer surface of the paper cover layer 4. However, the metal layer 6 requires a primer and adhesive layer 7 between it and the base layer 2. This ensures a good bond between the two layers and acts as an initial barrier to prevent the infusion substance 5 from penetrating. Furthermore, to facilitate further processing of such an inner liner sheet material 1, the metal layer 6 must be covered with an outer layer to prevent wear due to friction between the aforementioned metal layer 6 and the corresponding machinery.
[0067] In contrast to prior art inner liner sheet materials 1, the inner liner sheet material 1 according to one embodiment of the present invention shown in Figure 2 shows a single layer, namely, barrier layer 9. A base layer 2 comprises a paper fiber layer 3 covered with a paper cover layer 4. The application of said barrier layer 9, preferably comprising polyvinyl alcohol, to the two-component base layer 2 prevents penetration of the injection substance 5 through said base layer 2 without the need for the application of a metal layer 6.
[0068] In one embodiment of the method according to the invention, the base layer 2 is formed by coating a paper fiber layer 3 with a paper coating layer 4. A barrier layer 9 is then applied onto the base layer 2. The sheet material is wound into a coil 10 and stored. As shown in Figure 3, the coil 10 of the wound base layer 2 with the barrier layer 9 is unwound and guided to a nozzle 11 so that an injection substance 5 is sprayed onto said base layer 2. After said spraying step, the resulting inner liner sheet material 1 is wound onto another coil 12.
[0069] 4 shows a packaging unit 13 comprising an inner liner sheet material 1 surrounded by a container 14. The inner liner sheet material 1 completely encases an aerosol-generating article, not shown, and is immediately adjacent to the interior surface 15 of the container 14.
[0070] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± 10% of A. Within this context, the number A can be considered to include a numerical value that is within the typical standard error for measurement of the property that the number A modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.
Claims
1. An inner liner sheet material for lining an interior surface of a packaging unit for at least one aerosol-generating article, comprising: A base layer; a barrier layer; the base layer comprises an injectable material; the inner liner sheet material does not include a metal layer; An inner liner sheet material wherein the base layer comprises paper.
2. The inner linersheet material of claim 1 , wherein the barrier layer comprises polyvinyl alcohol.
3. 3. The inner linersheet material of claim 1 or claim 2, wherein the barrier layer further comprises glyoxal.
4. The inner linersheet material of any one of claims 1 to 3, wherein the base layer consists primarily or exclusively of paper.
5. The inner linersheet material of any one of claims 1 to 4, wherein the infused substance comprises at least one flavoring ingredient.
6. 6. The inner liner sheet material of claim 5, wherein the at least one flavor component comprises menthol.
7. A package unit, at least one aerosol-generating article; A container and 1. An inner liner sheet material comprising: A base layer; an inner liner sheet material comprising a barrier layer; the base layer comprises an injectable material; the inner liner sheet material does not include a metal layer; the inner liner sheet material at least partially surrounds the at least one aerosol-generating article; the inner liner sheet material being at least partially surrounded by the container; A packaging unit wherein the barrier layer is further away from the at least one aerosol-generating article than from the base layer.
8. The packaging unit of claim 7 , wherein the barrier layer is adjacent to at least one interior surface of the container.
9. 1. A method for manufacturing an inner liner sheet material for lining an interior surface of a packaging unit for at least one aerosol-generating article, said method comprising: providing a barrier layer on the base layer; providing an injectant to the base layer; the barrier layer is provided directly on the base layer; The method wherein the base layer comprises paper.
10. 10. The method of claim 9, wherein the injectate is at least partially absorbed into the base layer and the barrier layer is the least permeable layer of the inner linersheet material to the injectate.
11. The method of claim 9 or 10, wherein the method further comprises unwinding the base layer with the barrier layer from a coil.
12. The method of any one of claims 9 to 11, wherein the method further comprises winding the base layer comprising the barrier layer and containing the injectate into a coil.
13. The method according to any one of claims 9 to 12, wherein the base layer is paper and the injectable substance is menthol.
14. A method for producing a packaging unit for at least one aerosol-generating article, said method comprising the step of folding an inner liner sheet material produced according to any one of claims 9 to 13.
15. Use of a biodegradable barrier layer in an inner liner sheet material for lining the inner surface of a packaging unit for at least one aerosol-generating article, wherein the inner liner sheet material has two layers: a base layer containing an injection substance and the barrier layer, and the barrier layer is the layer of the inner liner sheet material that is least permeable to the injection substance.