Aerosol-generating substrate comprising particulate flavouring particles

Abstract

An aerosol-generating article is provided.SOLUTION: The present invention relates to an aerosol-generating article 100 comprising a tobacco-containing foamed aerosol-generating substrate 24 and a plurality of non-tobacco particulate flavour particles 22 incorporated within the aerosol-generating substrate provided in the form of a semi-solidified matrix. The particulate flavour particles may be uniformly distributed in the semi-solidified matrix or the particulate flavour particles may be provided in an increasing gradient density towards the central longitudinal axis (X) of the aerosol-generating article.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to an aerosol-generating substrate and a method for producing the same. The present invention also relates to an aerosol-generating article comprising the aerosol-generating substrate, the aerosol-generating substrate being provided in the form of a semi-solid matrix. [Background technology]

[0002] A proliferation of different types of aerosol-generating articles and devices for use therewith as alternatives to cigarette smoking has been available commercially over the past decade. These include conventional e-cigarettes, which generate an inhalable, usually flavored, aerosol or vapor from a liquid that is electrically heated in contact with a battery-powered heating element.

[0003] Another common alternative is a non-combustion heated aerosol-generating article that includes an aerosol-forming substrate that is resistively or inductively heated at a relatively low temperature, e.g., below 350°C, to avoid combustion. A dose of inhalable aerosol can then be emitted from the aerosol-generating article. The emitted aerosol comes from an aerosol-forming agent incorporated into the tobacco material.

[0004] Tobacco materials typically used in such non-combustion heat-not-burn aerosol-generating articles are made, for example, from reconstituted tobacco (Recon or RTB). Recon can be defined as a sheet-form tobacco material obtained by collecting the remaining waste of tobacco leaves, waste, stems, or other related parts after a processing procedure.

[0005] European Patent Application No. 3528652 relates to a new form of aerosol-generating substrate provided in the form of a mousse. Such a form of aerosol-generating article is described as advantageous because it provides more uniform heating of the tobacco-containing agent and / or inhalable auxiliary, a good aerosol quality, and highly efficient extraction. However, it should be noted that due to its non-solid form, flavor is lost very quickly, thus providing the user with an overall poor smoking experience.

[0006] U.S. Patent Application No. 20190261685 relates to an aerosol-generating substrate for use in an aerosol source component. The substrate can include a fibrous filler, an aerosol-forming material, and a plurality of heat-conducting elements. The substrate can be formed as a sheet, and the heat-conducting elements can be part of the sheet. A flavorant can also be provided in the aerosol-generating substrate.

[0007] WO 03009711 describes another method aimed at increasing or changing the strength and intensity of flavors. It proposes placing a capsule containing a flavorant in the filter section. When pressure is applied to the capsule, it bursts and releases the aroma material into the filter to change the taste of the tobacco. Summary of the Invention

[0008] It would therefore be desirable to provide a solution to overcome the above-mentioned problems and to provide an alternative that can provide a more pleasant smoking and / or vaping experience.

[0009] In a further aspect, it is also an object of the present invention to provide a solution for improving the sensory properties of the above-mentioned consumable products.

[0010] The inventors of the present invention have found a solution to the problems discussed above and propose in a first aspect of the present invention to provide an aerosol-generating article comprising a foamed aerosol-generating substrate containing tobacco and a plurality of non-tobacco particulate flavour particles incorporated into the aerosol-generating substrate.

[0011] A second aspect of the present invention provides an aerosol-generating article comprising a tobacco-containing portion and a filter portion, wherein the tobacco-containing portion comprises an aerosol-generating substrate as defined above.

[0012] A third aspect of the present invention provides a method of making an aerosol-generating substrate, the method comprising the steps of: (a) providing a mixture comprising one or more ingredients selected from the list consisting of propylene glycol, 1,3-propanediol, glycerol, water, a gum, and a binder; (b) mixing the mixture; (c) providing a tobacco-containing material within the mixture; (d) mixing the mixture; (e) providing a plurality of granular flavor particles within the aerosol-generating substrate; and (f) mixing the mixture.

[0013] The inventors have found that the aerosol-generating article according to the present invention, by virtue of the granular (e.g., non-tobacco) flavoring particles, is capable of providing consistent flavor delivery throughout a smoking experience typical of non-combustion heating consumable article use, i.e., an average of 12 to 20 puffs. Because the aerosol-generating article is provided in a semi-solid substrate, i.e., a foam, the granular flavoring particles include a hardened "shell-like" surface, which ensures extended flavor release and therefore consistent flavor delivery throughout the entire smoking experience, as opposed to prior art articles that typically lose flavor after the first few puffs.

[0014] Particulate flavor particles as described herein refer to tobacco-containing and / or non-tobacco particulate flavor particles. In other words, flavoring particles can include particles with or without tobacco / nicotine flavoring.

[0015] According to some embodiments, up to about 10.0% by weight of the total weight of the aerosol-generating article is granular flavor particles. The granular flavoring particles may be uniformly or irregularly dispersed within the substrate. In such cases, typically about 5.0% by weight (based on the total weight of the aerosol-generating substrate) of granular flavoring particles is sufficient to provide consistent flavor release throughout.

[0016] To this end, in embodiments in which the particulate flavoring particles are distributed in a gradient, the highest concentration (or density) of the particulate flavoring particles is located closer to the central longitudinal axis than in the peripheral regions of the tobacco-containing portion. Such a location of the particulate flavoring particles allows for a consistent and prolonged release of flavor over time until the end of the vaping period. For example, a concentration of 0.01 g / cm in the peripheral region of the aerosol-generating article may be 0.01 g / cm. 3 to, for example, about 2.0 g / cm 3 toward the longitudinal central axis of the aerosol-generating article. 3 The aerosol-generating substrate may be provided with an increasing gradient density of particulate flavoring particles, with the density increasing stepwise from less than 100 to 1000. Such an arrangement of particulate flavoring particles is particularly advantageous for aerosol-generating devices having an oven-like heating chamber in which the tobacco-containing portion of the aerosol-generating article is heated externally at its exterior surface rather than internally.

[0017] It is also noted that a uniform distribution of granular particles does not necessarily guarantee consistent flavor delivery, i.e., from the first puff to the last puff, and therefore a uniform distribution of granular flavor particles will yield less favorable results than the aforementioned distribution of increasing gradient densities of granular flavor particles.

[0018] In embodiments, the aerosol-generating substrate may be provided in at least two steps, where in a first step, a first layer of aerosol-generating substrate containing a higher density (or concentration) of particulate flavoring particles may be provided, followed by a second layer of aerosol-generating substrate containing a lower concentration of particulate flavoring particles. This allows for a gradient of increasing concentration of particulate particles towards the longitudinal axis (central axis) of the aerosol-generating article, thus allowing for consistent and extended release of flavor over time until the end of the vaping period.

[0019] According to some preferred embodiments, the granular flavor particles have a density of 2.0 g / cm 3 less than 1.0 g / cm 3 less than 0.5 g / cm 3 Less than, or more preferably 0.01 g / cm 3 ~0.1g / cm 3 The aerosol-generating article is provided with a density between .

[0020] In some embodiments, the granular flavour particles are provided in an amount ranging from 2.0% to 10.0% by weight of the total weight of the aerosol-forming base, preferably from 2.5% to 8.0% by weight of the total weight of the aerosol-forming base, preferably from 3.5% to 7.0% by weight of the total weight of the aerosol-forming base, and most preferably from 4.5% to 6.0% by weight of the total weight of the aerosol-forming base.

[0021] In some embodiments, the granular flavor particles have an average diameter of between about 0.1 mm and about 3 mm, preferably between about 0.5 mm and about 2 mm, or more preferably about 1.5 mm.

[0022] In some embodiments, the granular flavor particles comprise a polysaccharide gel, for example, the granular particles comprise a flavor coated with a polysaccharide without adding any gelling agent, such as a metal chloride, to the material.

[0023] In some embodiments, it is effective to thoroughly knead the flavor and polysaccharide and emulsify them in a heated aqueous solution, and maintain the emulsified state in which the flavor coated with the gelling polysaccharide is present in the aqueous solution while the flavor-containing material is being prepared.

[0024] Furthermore, in some embodiments, the granular flavor particles comprise a polysaccharide gel and do not contain a gelling agent, so that undesirable degradation products of chloride do not form in mainstream smoke during smoking.

[0025] According to some embodiments, the aerosol-generating substrate / article further comprises one or more ingredients selected from the group consisting of propylene glycol, 1,3 propanediol, glycerol, water, gums, flavorants, additives, nicotine, and binders.

[0026] According to some embodiments, aerosol-generating substrates / articles containing granular (non-tobacco) flavor particles are provided with a density that increases along the longitudinal central axis of the aerosol-generating article. This results in better flavor retention characteristics for the aerosol-generating article. A more consistent and prolonged flavor delivery has been observed over the entire vaping process (e.g., about 15 puffs).

[0027] As disclosed herein, the semi-solid matrix of the aerosol-generating substrate may be in the form of a foam, mousse, gel, or viscous liquid.

[0028] Additionally, according to some embodiments, the aerosol-generating article comprises an aerosol-generating substrate and a tobacco-containing portion comprising a filter portion.

[0029] Furthermore, according to some embodiments, the present invention further comprises providing a gum to the mixture prior to step (e), i.e., providing a plurality of granular flavor particles within the aerosol-generating substrate. The gum provides good binding properties.

[0030] Furthermore, according to some embodiments, in each step the mixture is continuously mixed and heated slightly above room temperature for a certain amount of time.

[0031] Further, according to some embodiments, the mixture is continuously mixed and / or heated to about 45° C. and / or aerated for at least 6 minutes.

[0032] According to some preferred embodiments, the method further comprises providing a first layer of aerosol-generating substrate surrounded by a second layer of aerosol-generating substrate, the first layer having a higher volume and / or density of granular flavor particles than the second layer, such that an increasing gradient density of granular flavor particles can be provided in the aerosol-generating article. [Brief explanation of the drawings]

[0033] [Figure 1] 1 shows a side view of an aerosol-generating article of the present invention. [Figure 2] 2 shows a cross-sectional view taken from point W in FIG. 1. [Figure 3] 1 shows a comparison of flavor delivery of aerosol-generating substrates with and without granular flavor particles. DETAILED DESCRIPTION OF THE INVENTION

[0034] 1 shows a side view of an aerosol-generating article 100 according to a first embodiment of the present invention. The aerosol-generating article 100 comprises a filter portion 10 and a tobacco-containing portion 20. The elongated cylindrical article 100 comprises a central longitudinal axis X. An aerosol-generating substrate 24, provided as a semi-solid matrix containing granular flavour particles, is provided in the tobacco-containing portion 20.

[0035] Figure 2 shows a cross-section at point W shown in Figure 1, with the cross-section taken within the tobacco-containing portion 20. The aerosol-generating article 100 includes a central axis X. An aerosol-generating substrate 24, provided in the form of a semi-solid matrix, includes a plurality of granular flavour particles 22. The granular flavour particles 22 may be randomly dispersed within the tobacco-containing portion 20 to have a uniformly distributed profile, or may be distributed with a density that increases in a gradient towards the central axis, as shown in Figure 2.

[0036] The present inventors have discovered that while an aerosol-generating substrate 24 provided in the form of a semi-solid matrix, such as a tobacco mousse, offers advantages over standard reconstituted tobacco (e.g., more uniform heating of tobacco ingredients and / or inhalable adjuvants, a better aerosol quality, and highly efficient extraction), its non-solid form causes a rapid loss of the best flavors used in the tobacco recipe within the first few puffs, thus negatively impacting the overall smoking experience.

[0037] The present invention provides a solution to compensate for the rapid flavor loss experienced by semi-solid substrate aerosol-generating substrates by introducing flavor particles into the substrate in granular form. For the sake of clarity and clarification of this disclosure, the term "granulated particles" should not be construed as being limited to regular, rounded granules of flavoring material, but should be understood in the context of the present invention as particles of substantially three-dimensional shape, such as irregular granules or flakes. Thus, granulated flavor particles may be small pieces of flavored and encapsulated flavored sheets. The particles can be provided by cutting or shredding a sheet of flavoring material into fine pieces or particles, where the particle size can be adjusted accordingly. Granulated flavor particles 22 can then be added to semi-solid substrate (e.g., mousse) base formulations to avoid rapid flavor release and ensure a consistent, gradual release of flavor during the vaping process. To this end, it is disclosed that granulated flavor particles 22 can be added at the end of the mixing process to minimize flavor loss.

[0038] The granular flavor particles 22 can be obtained through any conventional method within the general knowledge of those skilled in the art. For example, the flavor may be coated with a polysaccharide, with or without the addition of a gelling agent such as a metal chloride to the material. Alternatively, a combination of a polysaccharide and one or more flavoring materials can be used to provide the granular flavor particles 22. Polysaccharides serve as a substrate and have been found to be an excellent medium for carrying flavoring ingredients. The granular flavor particles 22 can be provided having an average diameter of between about 0.1 mm and about 3 mm, preferably between about 0.5 mm and about 2 mm, or more preferably about 1 mm.

[0039] However, it is noted that in the process of preparing granular flavor particles, extremely high temperatures, for example, temperatures higher than 85°C, should be avoided in order to preserve the flavor. The flavor tends to be lost or weakened at such high temperatures. For this reason, the granular flavor particles are only introduced into the mixture in the last (or penultimate) step in order to maximize the retention of their flavor.

[0040] The granular flavor particles 22 proposed in this invention can be provided in any type of flavor approved by the tobacco industry, such as fruity, berry, menthol, wood, chocolate, tobacco, etc.

[0041] In some embodiments, it has been found that the polysaccharides used in the present invention can be gelled by the application of heat. As such, no gelling agent is required. Accordingly, the granular flavor particles 22 according to the present invention do not contain gelling agents such as metal chlorides. Thus, for example, undesirable decomposition products of chlorides are not produced in mainstream smoke during smoking.

[0042] In order to increase the flavor content of granular flavor particles, it is necessary for the flavor to be substantially blended with or coated with a polysaccharide. The present inventors have found that it is effective to thoroughly mix and emulsify the flavor and polysaccharide in a heated aqueous solution, and to maintain this emulsified state in which the flavor coated with the gelling polysaccharide is present in the aqueous solution during the preparation of the granular flavor particles. That is, a high flavor content can ultimately be obtained in granular flavor particles that can be thoroughly mixed and emulsified and can maintain the emulsified state.

[0043] On the other hand, it has been found that systems that cannot maintain an emulsified state in an aqueous solution during material preparation, even when sufficient kneading and emulsification are performed, cannot achieve a high flavor content. The granular flavor particles 22 of the present invention can contain, for example, 18% by weight or more of flavor, preferably 60% by weight or more, and more preferably 70% by weight or more of flavor. In other words, these values ​​represent the amount of flavor that the granular (or encapsulated) flavor contains therein by weight.

[0044] For example, the polysaccharide capable of maintaining an emulsified state as described above is preferably a single-component system of carrageenan, agar, gellan gum, tamarind gum, psyllium seed gum, or konjac glucomannan, or a composition system of a combination of two or more components selected from the group consisting of carrageenan, locust bean gum, guar gum, agar, gellan gum, tamarind gum, xanthan gum, tara gum, konjac glucomannan, starch, cassia gum, and psyllium seed gum. During emulsification, it is preferred to use a commonly used emulsifier such as lecithin together.

[0045] Preferably, the granular flavor particles 22 are provided at an increasing gradient density towards the longitudinal axis X, as opposed to being uniformly distributed within the aerosol-generating substrate 22. A higher density of granular flavor particles 22 in a central location allows for a more consistent and prolonged flavor delivery, as discussed below, see for example sample 1 in Figure 3, in which the granular flavor particles 22 are distributed at an increasing gradient density towards the central longitudinal axis X.

[0046] <Example> The present invention will now be described in detail with reference to several examples thereof, which are provided for illustrative purposes only and are not intended to limit the scope of the invention.

[0047] [Example 1] Kappa-carrageenan (CARRAGEENAN CS-530, San-Ei Gen FFI, Inc.), extracted from red seaweed, was selected as the single polysaccharide, and l-menthol (specialty grade, Wako Pure Chemical Industries, Ltd.) was selected as the flavor. Granular flavor particles for the aerosol-generating base material of Example 2 were prepared by the following procedure.

[0048] Approximately 100 mL of water was added to each 5 g of κ-carrageenan, and then the mixture was heated in a thermostatic chamber at 80°C to fully dissolve the κ-carrageenan in water. A total of 25 g of menthol (TEG-10374410) and 2 mL of a 5% aqueous solution of lecithin (Sunlecithin A-1, Taiyo Kagaku Co., Ltd.) were added, and the mixture was thoroughly emulsified using a homogenizer (High-Performance Mixer DMM, ATEC Japan Co., Ltd.). The emulsified slurry was converted into granular form and dried in a forced air circulating dryer at 40°C for one week. Granular flavor particles with an average diameter of approximately 1.5 mm were obtained. Samples 1 and 2 contain such granular flavor particles.

[0049] [Example 2] Table 2 shows exemplary ratios for tobacco mousse with and without granular flavor particles. To produce exemplary aerosol-generating substrates 24 (Samples 1, 2, and 3), as shown in Figure 3, the ingredients shown in each column of Table 2 were mixed and combined as follows: Note that the flavors in Samples 1 and 2 are provided as granular flavor particles (as described in Example 1), while the menthol flavor in Sample 3 is not provided in granular form, but rather the menthol flavor is provided directly from a liquid mixture and then blended with tobacco mousse to form Sample 3.

[0050] [Table 1] Table 2: Aerosol-generating substrates with granular flavor particles (Samples 1 and 2) or without granular flavor particles (Sample 3)

[0051] Propylene glycol, glycerin, and purified water were whipped and aerated for 5 to 10 minutes at 45°C using a Krups Prep & Cook HP5031 mousse whipping shuffle, preferably at speed "6." When whipping the mousse, the speed can be adjusted so that the volume increases visibly and small bubbles appear, some of which remain in the foam. If the whipping is too fast, mixing becomes dominant and the foam structure tends to collapse and revert to a fluid state. One option is to start whipping slowly and gradually increase the whipping speed as the foam begins to develop a lighter, more mousse-like texture; when you notice that the mousse is losing its mousse-like texture and seemingly becoming less aerated, reduce the speed by about 10%. Rapid cooling with ice or cold water is recommended to maintain the foam structure for the stability portion. Using the Krups equipment described above, best results can be obtained at speeds of 60 to 200 rpm. Given the above description, those skilled in the art will be able to make adaptations within their knowledge.

[0052] In the next step (within 1 minute of the previous step), the gum is added, the mixture is whipped, and aerated using a Krups Prep&Cook HP5031 Mousse Whisk Shuffle at the same speed at 45°C for 5-10 minutes, preferably 6 minutes, after which the tobacco powder is added, whipped, and aerated using the same method at 45°C for 5-10 minutes, preferably 6 minutes.

[0053] The granular flavour particles are then added, followed by the binder (within 1 minute) and the mixture is whipped again and aerated using the same method at 45°C for 5-10 minutes, preferably 6 minutes.

[0054] Finally, the mixture is placed in an oven at 50°C for 18 hours before being packaged and ready to use.

[0055] FIG. 3 shows the perceived intensity (in percentage units) of menthol flavor in the smoke during sensory testing of three different types of aerosol-generating articles as described above.

[0056] Both Sample 1 and Sample 2 contain granular flavor particles 22, while Sample 3 does not contain such granular flavor particles. As shown in Figure 2, the granular flavor particles 22 in Sample 1 are distributed with an increasing gradient density toward the longitudinal central axis, while in Sample 2, randomly distributed granular flavor particles 22 are provided on the aerosol-generating substrate 24. The results showed that Sample 1 and Sample 2 have higher flavor retention properties throughout the vaping process (from puff 0 to puff 14) than Sample 3.

[0057] Surprisingly, when the granular flavor particles are distributed with an increasing gradient density toward the central axis X, a consistent and higher flavor delivery was observed throughout the vaping process. In other words, Sample 1 provided the most consistent flavor delivery throughout the vaping process.

Claims

1. An aerosol generating article (100) comprising a foamed aerosol generating substrate (24) containing tobacco, and a plurality of non-tobacco granular flavor particles (22) incorporated within the aerosol generating substrate (24), wherein the aerosol generating substrate (24) is provided such that the density of the non-tobacco granular flavor particles (22) increases toward the longitudinal central axis (X) of the aerosol generating article (100).

2. The aerosol generating article (100) according to claim 1, wherein up to approximately 10.0% of the total weight of the aerosol generating substrate (24) is the granular flavor particles (22).

3. The granular flavor particles (22) are 2.0 g / cm³ ３ Less than 1.0 g / cm³, preferably 1.0 g / cm³ ３ Less than 0.5 g / cm³, preferably 0.5 g / cm³ ３ Less than, or more preferably 0.01 g / cm³ ３ ~0.1 g / cm ３ The aerosol generating article (100) according to claim 1 or claim 2, provided to the aerosol generating substrate (24) at a density between the above.

4. The aerosol generating article (100) according to any one of claims 1 to 3, wherein the granular flavor particles (22) are provided in an amount between 2.0% by weight and 10.0% by weight of the total weight of the aerosol generating substrate (24), preferably between 2.5% by weight and 8.0% of the total weight of the aerosol generating substrate (24), preferably between 3.5% by weight and 7.0% of the total weight of the aerosol generating substrate (24), and most preferably between 4.5% by weight and 6.0% of the total weight of the aerosol generating substrate (24).

5. The aerosol generating article (100) according to any one of claims 1 to 4, wherein the granular flavor particles (22) include a polysaccharide gel.

6. The aerosol generating article (100) according to any one of claims 1 to 5, wherein the granular flavor particles (22) contain a polysaccharide gel and do not contain a gelling agent.

7. The aerosol generating article (100) according to any one of claims 1 to 6, wherein the granular flavor particles have an average diameter between about 0.1 mm and about 3 mm, preferably between about 0.5 mm and about 2 mm, or more preferably about 1.5 mm.

8. An aerosol generating article (100) according to any one of claims 1 to 7, comprising a tobacco-containing portion (20) including the aerosol generating substrate (24), and a filter portion (10).

9. A method for producing an aerosol generating substrate (24) for an aerosol generating article (100), a. A step of providing a mixture comprising one or more components selected from the list consisting of propylene glycol, 1,3-propanediol, glycerol, water, gum, and a binder. b. A step of mixing the mixture, c. A step of providing tobacco-containing material into the mixture, d. A step of mixing the mixture, e. A step of providing a plurality of non-tobacco granular flavor particles (22) into the aerosol generating substrate (24) such that the density of the non-tobacco granular flavor particles (22) increases toward the longitudinal central axis (X) of the aerosol generating article (100), f. A step of mixing the mixture, A method that includes this.

10. The method according to claim 9, wherein in each step, the mixture is continuously mixed over a certain period of time and heated to a temperature slightly above room temperature.

11. The method according to claim 9 or 10, wherein the mixture is continuously mixed for at least 6 minutes and / or heated to about 45°C and / or aerated.

12. The method according to any one of claims 9 to 11, further comprising the step of providing a first layer of the aerosol generating substrate (24) surrounded by a second layer of the aerosol generating substrate (24), wherein the first layer has granular flavor particles (22) with a higher volume and / or density than the second layer.

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