Method for processing tobacco fines into a discontinuous tobacco material

Abstract

A method for processing tobacco granules into a non-continuous tobacco material is provided, the method including the steps of providing a pre-sized stem tobacco material having a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm. The method also includes the steps of combining the pre-sized stem tobacco material with tobacco granules to produce a tobacco initial material, and treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to an elevated temperature, and subjecting the initial material to an elevated pressure to bond the tobacco granules to the stem tobacco material. Also provided are the non-continuous tobacco material produced by the method, components for a delivery system including the non-continuous tobacco material produced by the method, and products and smoking articles including the components.

Description

Technical Field

[0001] The present invention relates to a method for processing tobacco fines into a discontinuous tobacco material, and components, products, and smoking articles containing the discontinuous tobacco material. Background

[0002] It is known that reprocessing of tobacco fines carried out at various times during tobacco processing (for example, during transportation, tobacco preparation, cigarette manufacture) can lead to meaningful use. For example, tobacco fines can be used as one of the starting materials for tobacco reconstruction (for example, for manufacturing reconstituted tobacco). Such processes usually enable the production of a continuum of tobacco material (film, sheet, thread, etc.).

[0003] Patent specification DE10065132A1 discloses a method for producing agglomerates from tobacco dust. Summary

[0004] According to a first aspect of the present disclosure, a method for processing tobacco fines into a discontinuous tobacco material, the method comprising: preparing a pre-sized rib tobacco material having a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm; combining the pre-sized rib tobacco material with tobacco fines to produce a tobacco starting material; and processing the starting material by bringing the starting material to a predetermined increased moisture content, subjecting the starting material to a temperature increase, and subjecting the starting material to a pressure increase to bond the tobacco fines to the rib tobacco material.

[0005] The pre-sized petiole material can have a Dp90 particle size of less than 2.9 mm, preferably less than 2.8 mm, less than 2.7 mm, less than 2.6 mm, less than 2.5 mm, less than 2.4 mm, less than 2.3 mm, less than 2.2 mm, less than 2.1 mm or less than 2 mm. The pre-sized petiole material can have a Dp50 particle size of less than 1.9 mm, optionally less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm or less than 1 mm. The pre-sized petiole material can have a Dp10 particle size of at least 100 microns, optionally at least 150, 200, 250, 300 or 350, 400 or 500 microns.

[0006] The step of preparing the pre-sized petiole tobacco material can include preparing a starter petiole material and reducing the particle size of the starter petiole material using a hammer mill.

[0007] The increase in temperature can be obtained by applying external heat and / or is a result of generating mechanical pressure.

[0008] The initial material can further include winowing.

[0009] The tobacco fines can have a particle size of less than 1 mm, optionally less than 0.5 mm.

[0010] The tobacco fines can be mechanically bonded to the pre-sized petiole tobacco material without using any binder added from the outside. In some embodiments, the tobacco fines are bonded by a natural binder or by a binder inherently present in the tobacco fines and / or the petiole tobacco material.

[0011] The material to be processed can be processed by continuously transporting the material.

[0012] The step of processing the initial material may include transferring the initial material through a conveyor that enhances mechanical pressure. The conveyor may include an extruder. The conveyor can be operated at a throughput of more than 100 kg / hr, preferably at least 110 kg / hr, preferably at least 115 or 120 kg / hr.

[0013] In some embodiments, the material to be processed is processed in batches.

[0014] The method may include pre-adjusting the petiole material and / or winowing to one or more of the following parameters: temperature: in the range of 80 - 147 °C, humidity: in the range of 6 - 14 mass% OV, and pressure (gas overpressure): 0 - 8 bar.

[0015] The method may include pre-adjusting the petiole material and / or winowing to one or more of the following parameters: temperature: in the range of 100 - 120 °C, humidity: in the range of 8 - 12 mass% OV, and pressure (gas overpressure): 0 - 3 bar, preferably 0 - 1 bar.

[0016] The step of processing the initial material includes bringing the initial material to a moisture content in the range of 10 - 50 mass% OV (oven volatile matter).

[0017] In some embodiments, the step of processing the initial material includes bringing the initial material to a moisture content of at least 10% (oven volatile matter). In some embodiments, the step of processing the initial material includes bringing the initial material to a moisture content of 50% OV (oven volatile matter) or less. In some embodiments, bringing the initial material to a predetermined moisture content is performed before feeding the processed tobacco material through a shirring gap.

[0018] The step of processing the initial material may include heating the initial material to a temperature in the range of 60 - 180 °C, preferably in the range of 100 - 140 °C, preferably in the range of 110 - 130 °C.

[0019] In some embodiments, the step of treating the initial material includes heating the initial material to a temperature of at least 60°C, preferably at least 100°C or at least 110°C. In some embodiments, the step of treating the initial material includes heating the initial material to a temperature of 180°C or less, preferably 140°C or less, preferably 130°C or less. In some embodiments, heating the initial material to a predetermined temperature is performed before feeding the treated tobacco material through the shirring gap.

[0020] The step of treating the initial material may include pressurizing the initial material to a pressure in the range of 10 to 200 bar, preferably in the range of 40 to 150 bar, preferably in the range of 60 to 120 bar.

[0021] In some embodiments, the step of treating the initial material includes pressurizing the initial material to a pressure of at least 10 bar, preferably at least 40 bar, preferably at least 60 bar. In some embodiments, the step of treating the initial material includes pressurizing the initial material to a pressure of 200 bar or less, preferably 150 bar or less, preferably 120 bar or less. In some embodiments, pressurizing the initial material to a predetermined pressure is performed before feeding the treated tobacco material through the shirring gap.

[0022] The discontinuous tobacco material may be a fibrous and / or granular material.

[0023] The initial tobacco material may include at least 30 (mass)% tobacco fines, preferably at least 35 (mass)% or at least 40 (mass)% tobacco fines.

[0024] The initial tobacco material may include 50 (mass)% or less tobacco fines, preferably 45 (mass)% or less or 45 (mass)% or less tobacco fines.

[0025] In embodiments where the tobacco fine material contains foreign tobacco and / or other plant substances, the initial tobacco material may contain 70% by mass or less of tobacco fines, preferably 65% by mass or less or 60% by mass or less of tobacco fines.

[0026] The initial tobacco material may contain at least 5% by mass of tobacco winoeing, preferably at least 7% by mass, 8% by mass, 9% by mass, or 10% by mass of tobacco winoeing.

[0027] The initial tobacco material may contain 20% by mass or less of winoeing, preferably 18% by mass or less, 15% by mass or less, 12% by mass or less, or 10% by mass or less of winoeing.

[0028] The initial tobacco material may contain at least 30% by mass of pre-sized petiole tobacco material, preferably at least 40% by mass, 45% by mass, or 50% by mass of pre-sized petiole tobacco material.

[0029] The initial tobacco material may contain 70% by mass or less of pre-sized petiole tobacco material and, preferably, 60% by mass or less, 55% by mass or less, or 50% by mass or less of pre-sized petiole tobacco material.

[0030] The tobacco fines may contain tobacco factory dust, may consist of tobacco factory dust, or may consist essentially of tobacco factory dust.

[0031] The tobacco fines may contain foreign tobacco and / or other plant substances. For example, the tobacco fines may contain, in addition to the tobacco material, 30 to 50%, preferably about 40%, of foreign tobacco, and 20 to 40%, preferably 25 to 31%, of other plant substances. In some embodiments, the tobacco fines may contain foreign tobacco such as Rajangan and / or Krosok tobacco and kretek materials that may include clove dust. For example, the tobacco fines may consist of, may consist essentially of, or may contain tobacco mill dust generated in the manufacture of kretek smoking articles.

[0032] The tobacco fines may have a Dp50 particle size of less than 1 mm, preferably less than 0.5 mm.

[0033] The method may include exposing the treated tobacco material to a pressure drop and as a result flash evaporating it.

[0034] The method may include feeding the treated tobacco material through a shirring gap such that the treated tobacco material fibrillates by expansion.

[0035] The shirring gap may have a width in the range of 10 to 2000 microns, preferably in the range of 50 to 300 microns.

[0036] The shirring gap may be disposed between shirring surfaces, and the rotating shirring member includes one of the shirring surfaces.

[0037] The shirring member may include a plurality of grooves, optionally at least 80 grooves, optionally at least 90, 100, 120, 140, 160 or 180 grooves. Each groove may have a maximum width of up to 2 mm, optionally up to 1.5 mm or 1 mm.

[0038] Each groove may have a maximum width of at least 0.3 mm, optionally at least 0.5 mm, 0.7 mm or 1 mm.

[0039] The method may include rotating the shirring member at an angular velocity of at least 10 rpm, preferably at least 100 rpm, 300 rpm, 350 rpm or 350 rpm. In some embodiments, the method includes rotating the shirring member at an angular velocity of 700 rpm or less.

[0040] The discontinuous tobacco material may have an average fiber diameter of less than 0.9 mm, preferably less than 0.8 mm. The discontinuous tobacco material may have a density index in the range of 350 - 600 kg / m 3

[0041] According to a second aspect of the present disclosure, there is provided a discontinuous tobacco material produced by the method of the first aspect described above.

[0042] According to a third aspect of the present disclosure, there is provided a component for a delivery system including a discontinuous tobacco material produced by the method of the first aspect described above.

[0043] The component may further include a second tobacco material, preferably, the second tobacco material may be cut-rag tobacco.

[0044] By including the discontinuous tobacco material, during use of the component, the delivery of tar can be configured to increase compared to when the component does not include the discontinuous tobacco material.

[0045] By including the discontinuous tobacco material, during use of the component, the delivery of tar can be configured to increase by at least 1.5 (mass)%, 2 (mass)% or 2.5 (mass)% for every 5 (mass)% of the discontinuous tobacco material included.

[0046] By including the discontinuous tobacco material, during use of the component, the delivery of nicotine can be increased compared to when the component does not include the discontinuous tobacco material.

[0047] ​ The discontinuous tobacco material can be configured to increase nicotine delivery by at least 1.5 (mass)%, 2 (mass)%, or 2.5 (mass)% for each 5 (mass)% of the discontinuous tobacco material included, during use of the component.

[0048] By including the discontinuous tobacco material, during use of the component, the delivery of carbon monoxide can be reduced as compared to the case where the component does not include the discontinuous tobacco material.

[0049] By including the discontinuous tobacco material, during use of the component, the ratio of delivering carbon monoxide to tar can be reduced as compared to the case where the component does not include the discontinuous tobacco material.

[0050] The discontinuous tobacco material can be configured to reduce the ratio of delivering carbon monoxide to tar by at least 1.5 (mass)%, 2 (mass)%, or 2.5 (mass)% for each 5 (mass)% of the discontinuous tobacco material included, during use of the component.

[0051] The component may include a tobacco rod for a combustible aerosol supply system.

[0052] By including the discontinuous tobacco material, during use of the component, the pressure drop across the entire component can be suppressed as compared to the case where the component does not include the discontinuous tobacco material.

[0053] The component may include a tobacco material including a discontinuous tobacco material and a second tobacco material, where at least 4.5 (mass)%, 5.5 (mass)% or 6.5 (mass)% of the tobacco material is the discontinuous tobacco material produced by the method of the first aspect above, and optionally, at least 7 (mass)%, 8 (mass)%, 9 (mass)%, 10 (mass)%, 11 (mass)%, 12 (mass)%, 13 (mass)%, 14 (mass)%, 15 (mass)%, 16 (mass)%, 17 (mass)%, 18 (mass)%, 19 (mass)% or 20 (mass)% of the tobacco material is the discontinuous tobacco material produced by the method of the first aspect above.

[0054] The component may be for an aerosol supply system. The component may be a tobacco rod for a cigarette, cigar or cigarillo.

[0055] The component may be for a non-combustible aerosol supply system and optionally includes a tobacco material, where at least 5 (mass)% of the tobacco material is the discontinuous tobacco material produced by the method of the first aspect above.

[0056] The component may be a tobacco rod.

[0057] According to a fourth aspect of the present disclosure, there is provided a product including the component according to the third aspect above.

[0058] According to a fifth aspect of the present disclosure, there is provided a smoking article including the component according to the third aspect above.

[0059] Here, with reference to the drawings, embodiments will be described by way of non-limiting examples only.

Brief Description of the Drawings

[0060]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

[0061] Referring to FIG. 1, a method for processing tobacco fines into a discontinuous tobacco material is shown.

[0062] The discontinuous tobacco material produced by the method can then be incorporated into a product. The product may be a component for a delivery system described herein, for example, an aerosol supply system. In some embodiments, the aerosol supply system is a combustible aerosol supply system or a non-combustible aerosol supply system. The component may be, for example, a tobacco rod. In a particular embodiment, the component is a tobacco rod for a cigarette or a tobacco heating system. The product may be an article used in a combustible aerosol supply system, such as a cigarette, cigarillo, cigar, or tobacco for a pipe or hand-rolled or self-made cigarette. Alternatively, the product may be used in or with a non-combustible aerosol supply system that releases compounds from an aerosol-forming material without burning the aerosol-forming material to generate an aerosol using a combination of aerosol-forming materials such as e-cigarettes, heated tobacco, and hybrid systems. Alternatively, the product may be for use in or with an aerosol-free delivery system that delivers at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or by another method without forming an aerosol, including but not limited to articles such as lozenges, gums, patches, articles containing inhalable powders, and oral products containing snus or sniff tobacco.

[0063] A method for processing tobacco fines into a discontinuous tobacco material includes the steps of (S1) preparing a pre-sized stalk tobacco material having a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm; (S2) forming a tobacco initial material by combining the pre-sized stalk tobacco material with a stalk tobacco material; and (S3) treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to a temperature increase, and subjecting the initial material to a pressure increase to bond the tobacco fines to the stalk tobacco material.

[0064] The pre-sized stalk material refers to a stalk tobacco material that has been subjected to a step of pre-sizing before combining the stalk material with the tobacco fines to form the initial material.

[0065] In some embodiments, the step of preparing the pre-sized stalk tobacco material includes preparing a material having a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of 0.7 mm to 1.5 mm.

[0066] In some embodiments, the pre-sized stalk tobacco material has a particle size of less than 3 mm or less than 2 mm. In one embodiment, the step of pre-sizing includes passing the stalk material through a 3 mm or 2 mm sieve and discarding or treating all materials that do not pass through the sieve to reduce their size.

[0067] Pre-sizing the petiole material to a Dp90 value of less than 3 mm and a Dp50 value of less than 2 mm has been found to improve quality, particularly the consistency of the produced discontinuous material and the rigidity of the material against mechanical stress. This means that, without sacrificing the quality of the component or product, including its functional properties, components or products described herein, such as components for an aerosol supply system, can contain a large amount of discontinuous material. Thus, a large amount of winowing and tobacco fines can be recycled. It has also been found that such pre-sized petiole material means that the pressure defibering device can be operated at a higher throughput so that a greater amount of discontinuous material can be produced per hour. The production of the discontinuous material is also more repeatable and consistent. In some embodiments, the pressure defibering device operates at a throughput of at least 100 kg / hr, preferably at least 110, 115 or 120 kg / hr.

[0068] In addition, pre-sizing the petiole material allows the use of larger petiole materials, for example, longer or mixed shafts, which can be processed to have a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm, for example a Dp90 particle size of less than 2.5 mm and a Dp50 particle size of 0.7 mm to 1.5 mm. Thus, the process does not rely on the availability of short shafts.

[0069] Also, pre-sizing the petiole material results in less "flaking" in the produced discontinuous material, as described in more detail below.

[0070] Pre-sizing the petiole material has also been found to reduce the separation between the shaft and the tobacco fines during mixing, for example, during processing in a mixing silo. The petiole material and the tobacco fines, especially tobacco dust, have different particle sizes and shapes, and generally result in the petiole material floating upward while the dust collects at the bottom. This demixing can cause variations in the amount of shaft and tobacco fines delivered to the defibrating device because the ratio of fines delivered to the defibrating device decreases as the ratio of the shaft increases. It has been found that pre-sizing reduces this separation between the shaft and the tobacco mill dust in the mixing silo and thus results in a more consistent and more stable density of the discontinuous material being produced.

[0071] In some embodiments, the pre-sized petiole material has a Dp90 value of less than 2.9 mm, for example 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1 or less than 2 mm. In some embodiments, the Dp90 value may be less than 1.9, 1.8, 1.7, 1.6 or 1.5 mm.

[0072] The Dp90 value refers to the particle size value at which 90% by mass of the petiole material is smaller. For example, when the Dp90 value is 3 mm, 90% (by mass) of the pre-sized petiole material has a particle size of less than 3 mm.

[0073] In some embodiments, the pre-sized petiole material has a Dp50 value of less than 1.9 mm, for example 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1 or less than 1 mm. In some embodiments, the pre-sized petiole material has a Dp50 value of less than 0.9 or 0.8 mm. Alternatively or in addition, the Dp50 value may be greater than 0.5 mm, 0.6 mm or 0.7 mm. In some embodiments, the Dp50 value is between 0.7 mm and 1.5 mm.

[0074] The Dp50 value refers to the value of the particle size where 50 mass% of the petiole material is smaller. As an example, when the Dp50 value is 2 mm, 50 (mass)% of the pre-sized petiole material has a particle size of less than 2 mm.

[0075] Smaller Dp50 and Dp90 values indicate a smaller particle size, and thus less separation of the pre-sized petiole material from other components of the tobacco starting material, and also fewer flakes in the resulting discontinuous tobacco material.

[0076] In some embodiments, the step (S1) of pre-sizing the petiole material results in a pre-sized petiole material having a Dp10 value of at least 100 micrometers, preferably at least 150, 200, 250, 300 or 350 micrometers. In some embodiments, the Dp10 value can even be at least 400 or 500 micrometers.

[0077] The Dp10 value refers to the value of the particle size where 10 mass% of the petiole material is smaller. As an example, when the Dp10 value is 100 micrometers, 10 (mass)% of the pre-sized petiole material has a particle size of less than 100 micrometers. A larger Dp10 value indicates a decrease in the amount of fine dust, i.e., a decrease in the density of the resulting discontinuous tobacco material, meaning that the amount extracted as winowing is reduced.

[0078] In some embodiments, the step (S1) of preparing the pre-sized petiole material includes preparing the petiole material and feeding the petiole material to a micronization device configured to reduce the size of the petiole material. The micronization device may be a milling / cutting / shredding device. In one embodiment, the micronization device is a hammer mill. The hammer mill has advantageously been found to reduce the amount of dust generated. In another embodiment, the micronization device is a centrifugal cutter. In another embodiment, the micronization device is a shredder. The shredder may be, for example, a notched short axis and shaft fiber.

[0079] In another embodiment, the petiole material is pre-sized without any milling / cutting / shredding of the petiole material. Instead, axes having a particle size outside a specific range are removed to classify the petiole material. This pre-sizing may involve, for example, sieving the petiole material through a mesh having a mesh size of 3 mm and discarding the petiole material that does not pass through the sieve. For example, if the Dp50 value and / or the Dp90 value is still greater than or less than the target value (e.g., 3 mm), the material may be passed through additional sieves as necessary to remove overly large / small material until the target Dp50 value and / or Dp90 value is achieved, or a material of a specific size may be added to achieve the target Dp50 value and / or Dp90 value.

[0080] In some embodiments, the petiole material is pre-sized to have a particle size less than 2 mm (e.g., mesh size No. 10). In some embodiments, the petiole material is pre-sized to have a particle size less than 1.9 mm, 1.8 mm, 1.7 mm, 1.6 mm, or 1.5 mm. The pre-sizing may be optical (e.g., using a microscope), using a sieve, or using a classifier or sifter. In one embodiment, the petiole material is pre-sized to have a particle size less than 1.68 mm (e.g., mesh size No. 12).

[0081] In some embodiments, the step of forming the tobacco starting material (S2) further includes combining the pre-sized petiole material with tobacco fines having winowing. Thus, in this embodiment, the tobacco starting material includes tobacco factory dust, tobacco winowing, and pre-sized petiole tobacco material.

[0082] "Tobacco fines" refers to small pieces of tobacco that are considered to be a problem, particularly conventionally (e.g., from the perspective of taste), and that can be simply released by inhalation or used to produce reconstituted tobacco (tobacco film). In particular, tobacco fines are smaller than the width of a tobacco cut (e.g., less than 1 mm), and more specifically, tobacco fines are smaller than the width of a tobacco cut (e.g., less than 0.5 mm). That is, tobacco fines have a particle size of less than 0.5 mm.

[0083] In some embodiments, the tobacco fines comprise, consist of, or consist essentially of tobacco factory dust.

[0084] "Tobacco factory dust" refers to fine dust generated as a by-product of the processing of tobacco and the manufacture of tobacco products such as cigarettes. Tobacco factory dust / tobacco dust has a particle size of less than 0.5 mm. In some embodiments, the tobacco factory dust has a Dp50 of 125 micrometers. This means that 50% by mass of the tobacco dust has a particle size of less than 125 micrometers.

[0085] "Tobacco fines" refers to a material consisting of or consisting essentially of tobacco, and also includes tobacco materials containing foreign tobacco and / or a mixture of tobacco and other plant materials.

[0086] "Plant material" refers to any material derived from a plant.

[0087] "Tobacco" and "tobacco material" refer to any material derived from plants of the genus Nicotiana.

[0088] "Other plant substances" or "non-tobacco plant substances" refer to any material derived from any plant that is not a plant of the genus Nicotiana. Thus, non-tobacco plant substances include, but are not limited to, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, nettles, hibiscus, gynostemma, licorice, matcha, mate, orange peel, papaya, rose, sage, green tea or black tea, thyme, cinnamon, clove, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, ginger, magnolia, silantro, bergamot, orange blossom, guaiacum, crossandra, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, caraway, verbena, tarragon, geranium, mulberry, Japanese radish, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint can be selected from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v., and Mentha suaveolens.

[0089] The non-tobacco plant substance may be clove. For example, the clove materials include, but are not limited to, the following types of clove materials: Jawa, Bali, Manado, and / or Manado secondary grade.

[0090] Therefore, in some embodiments, the tobacco fines contain tobacco and non-tobacco plant substances. For example, the tobacco fines may contain tobacco and clove materials.

[0091] The clove material can consist of, or can essentially consist of, clove processing dust that can be generated as a by-product during the processing of clove buds.

[0092] The processing of clove buds may include the following steps: 1. Separation of clove plant substances; 2. Sieving; 3. Adjustment using, for example, an adjustment screw and / or a temperature of about 70°C, and adjustment of the moisture content to 30 - 45% (for example, 38%); 4. Bulking, for example, in a bulking silo for at least 3 hours; 5. Cutting; 6. Drying, for example using warm air, until a moisture content of less than 12%.

[0093] In a preferred embodiment, the clove material that may be present in the tobacco fines comprises clove processing dust generated during the cutting step of the clove bud treatment. Preferably, the tobacco fines do not contain substances generated during the separation of clove plant material, for example due to the possibility of the presence of foreign matter and / or unwanted silica content.

[0094] The use of clove material in tobacco fines can provide a unique flavor and sensory experience to the end user. Clove is known to have sensory effects, including in particular the characteristics of aroma, spice, tingle, crackling, and throat soothe. Therefore, the sensory stimulation characteristics of the discontinuous tobacco material produced by the disclosed method can be changed and improved.

[0095] Mixing cloves into tobacco material has a historical precedent in some regions and can be called "kretek blend" or "kretek material".

[0096] Thus, in some embodiments, the tobacco fines comprise kretek material. For example, the tobacco fines may comprise, consist of, or consist essentially of tobacco factory dust generated during the manufacture of a smoking article comprising kretek material.

[0097] The kretek material may comprise 20 - 80% by mass, for example about 69 - 75% by mass, of tobacco.

[0098] The kretek material may comprise foreign tobacco material.

[0099] Examples of "imported tobacco" include, but are not limited to, the following tobacco materials: Rajangan tobacco (which may be dark Rajangan tobacco or light Rajangan tobacco), Krosok, Madura, Maesan, Weleri, Pakpie Ploso, Temanggung, KASTURI, Boyolali, and / or Ploso.

[0100] The kretek material may contain 30 - 50% (by mass), for example, about 40% (by mass) of imported tobacco.

[0101] The kretek material may contain 20 - 40% (by mass), for example, 25 - 31% (by mass) of clove material.

[0102] Therefore, the tobacco fines may contain the kretek blend material. As an example, a mild kretek blend may have the following composition: Rajangan tobacco (38% by mass), stalk tobacco material (14% by mass), Krosok tobacco (4% by mass), FCV / Oriental tobacco (19% by mass), and clove material (25% by mass).

[0103] As a further example, another kretek blend may have the following composition: Rajangan tobacco (30% by mass), stalk tobacco material (11% by mass), Krosok tobacco (5% by mass), FCV / Oriental tobacco (23% by mass), and clove material (31% by mass).

[0104] Generally, the kretek blend may contain 30 - 38% (by mass) of Rajangan tobacco, 11 - 14% (by mass) of stalk tobacco material, 4 - 5% (by mass) of Krosok tobacco, 19 - 23% (by mass) of FCV / Oriental tobacco, and 25 - 31% (by mass) of clove material.

[0105] In some embodiments, the tobacco fines include the cretek material and additional clove material as defined herein. For example, the tobacco fines may include tobacco material, cretek material, and clove processing dust. The cretek material and clove processing dust may be included in the tobacco fines in a ratio of 40:5 to 50:1, such as a ratio of 47:3 (ratio of cretek material to clove processing dust by mass weight).

[0106] In some embodiments, the tobacco fines include the tobacco dust, cretek material, and additional clove material as defined herein. For example, the tobacco fines may include tobacco factory dust generated during the manufacture of a smoking article containing tobacco material, cretek factory dust generated during the manufacture of a smoking article containing cretek material, and clove processing dust generated as a byproduct during the processing of clove buds.

[0107] Tobacco winoeing is the coarsely shredded shaft particles, main veins or stems, but can include some leaf blades and reconstituted sheets, which are usually considered undesirable in an aerosol supply system due to their size and shape and are thought to impair the quality of an aerosol supply system, such as a cigarette, and have already been classified and removed from the shredded tobacco. For this reason, conventionally, winoeing is usually recycled or discarded as waste.

[0108] Tobacco winoeing can refer to winoeing from cigarette manufacturing (CPP-winoeing = winoeing from cigarette manufacturing / packaging) or winoeing from tobacco processing (TP-winoeing). The term "winoeing" hereinafter includes both winoeing obtained from cigarette manufacturing and that for tobacco processing, unless otherwise specified.

[0109] In step (S3), to maintain the adhesion of the tobacco fines to the petiole tobacco material and winoeing, the initial tobacco material is also subjected to enhanced mechanical pressure, particularly elevated temperature and humidity.

[0110] The initial tobacco material is brought to a predetermined increased moisture content. Also, the material to be treated is subjected to a temperature increase, which can be achieved in particular by applying heat from the outside and / or by mechanically generating pressure.

[0111] In some embodiments, the initial tobacco material is heated to a temperature of 60°C to 180°C, preferably 100°C to 140°C, more preferably 110°C to 130°C.

[0112] In some embodiments, the initial tobacco material is brought to a pressure of 10 to 200 bar, in particular 40 to 150 bar, preferably 60 to 120 bar. Unless otherwise specified herein, pressure refers to the above atmospheric pressure.

[0113] In some embodiments, the residence time of the initial tobacco material may be less than 3 minutes, in particular less than 2 minutes, preferably less than 1 minute.

[0114] As a result of step (S3), the tobacco fines are bound to the stalk material and the winnowing, subsequently producing a discontinuous tobacco material that can be used in the manufacture of an aerosol supply system. This eliminates the need for separate and expensive processes. The tobacco fines are simply bound / adhered to the remaining material.

[0115] As a result of this process, there is a significant shift towards larger particles in the size distribution.

[0116] Accordingly, the tobacco starting material is subjected to elevated temperature and a defined level of humidity under mechanical pressure (e.g., in an extruder or a conveyor screw conditioner). By means of the mechanical pressure, the tobacco fines are pressed onto and intimately bonded to a pre-sized stalk tobacco material and a wrapper. As a result, the bonding of the tobacco fines to the stalk material and the wrapper is very strong, and the tobacco material processed as proposed by the present invention is resistant to the normal pressures occurring during cigarette manufacture, i.e., the tobacco fines no longer fall off when being transported by air under normal manufacturing conditions. Accordingly, the mechanical stability is higher than in the case of conventional tobacco film materials.

[0117] A higher proportion of tobacco fines in the tobacco starting material is advantageous because it means that tobacco fines, which are usually unwanted by-products of manufacture, can be recycled instead of being discarded as would otherwise be the case. In some embodiments, the tobacco starting material comprises at least 30 (mass)% tobacco fines, preferably at least 35 (mass)% tobacco fines.

[0118] In some embodiments, the tobacco starting material comprises 50 (mass)% or less tobacco fines, preferably 45 (mass)% or less tobacco fines or 40 (mass)% or less tobacco fines. It has been found that the use of 50% tobacco fines, preferably 45% or less tobacco fines or 40% or less tobacco fines is advantageous because high amounts have an adverse effect on the quality of the resulting discrete tobacco products, make the resulting discrete tobacco products denser and increase the production of discrete tobacco extracted as wrapper.

[0119] In some embodiments, the tobacco starting material comprises tobacco fines in the range of about 30 to 50 (mass)%. A tobacco starting material having in the range of 30 to 50% uses, on the one hand, a beneficial amount of tobacco fines that would otherwise be discarded, and on the other hand, does not use an excessive amount of tobacco fines that would otherwise negatively affect the quality of the discontinuous tobacco material produced and cause it to become dense, achieving a good balance between the two. Preferably, the tobacco starting material comprises tobacco fines in the range of about 35 (mass)% to 45 (mass)%, preferably about 40 (mass)% of tobacco fines. The tobacco fines may comprise, consist of, or consist essentially of tobacco dust.

[0120] In some embodiments, the tobacco starting material comprises tobacco dust in the range of about 30 to 50 (mass)%, preferably in the range of 35 (mass)% to 45 (mass)%, preferably about 40 (mass)% of tobacco dust.

[0121] In embodiments where the tobacco fines material comprises foreign tobacco and / or other vegetable substances, the tobacco starting material can comprise up to 70 (mass)% of tobacco fines, preferably up to 65 (mass)% or 60 (mass)% of tobacco fines.

[0122] In some embodiments, the tobacco starting material comprises at least 5 (mass)% of tobacco winoeing, preferably at least 7, 8, 9, or 10 (mass)% of tobacco winoeing. In some embodiments, the tobacco starting material comprises 20 (mass)% or less of tobacco winoeing, preferably 15 (mass)% or less of winoeing.

[0123] In some embodiments, the tobacco starting material comprises tobacco winoeing in the range of 5 to 20 (mass)%, preferably in the range of 5 to 15 (mass)%, preferably about 10 (mass)% of winoeing. In some embodiments, the winoeing is not pre-sized.

[0124] In some embodiments, the initial tobacco material comprises at least 30 (mass)% of pre-sized petiole tobacco material, preferably at least 40 (mass)%, 45 (mass)% or 50 (mass)% of pre-sized petiole tobacco material.

[0125] In some embodiments, the initial tobacco material comprises 70 (mass)% or less of pre-sized petiole tobacco material, preferably 65 (mass)% or less, 60 (mass)% or less, 55 (mass)% or less or 50 (mass)% or less of pre-sized petiole tobacco material.

[0126] In some embodiments, the initial tobacco material comprises pre-sized petiole tobacco material in the range of 30 - 70 (mass)%, preferably pre-sized petiole tobacco material in the range of 40 - 60 (mass)%, preferably about 50 (mass)% of pre-sized petiole tobacco material.

[0127] In some embodiments, the initial tobacco material comprises 30 - 50 (mass)% of tobacco fines, 5 - 20 (mass)% of tobacco winoeing, and 30 - 70 (mass)% of petiole tobacco material. However, it should be recognized that other amounts of tobacco fines, winoeing and petiole tobacco material are possible. Preferably, the initial material comprises 20 - 40 (mass)% of tobacco fines, 10 - 15 (mass)% of tobacco winoeing, and 40 - 60 (mass)% of petiole tobacco material. More preferably, the initial material comprises 25 - 35 (mass)% of tobacco fines, 10 - 15 (mass)% of tobacco winoeing, and 45 - 55 (mass)% of petiole tobacco material.

[0128] In some embodiments, the tobacco fines may comprise, consist of, or consist essentially of tobacco dust material, such as tobacco factory dust. The tobacco fines may comprise foreign tobacco and / or a mixture of tobacco and other vegetable substances.

[0129] In embodiments where the tobacco particulate material includes foreign tobacco and / or other plant substances, the initial tobacco material may include 30 to 70 (mass)% tobacco fines, up to 20 (mass)% tobacco winoeing, and 30 to 70 (mass)% tobacco stem material. However, it should be recognized that other amounts of tobacco fines, winoeing, and tobacco stem material are possible. Preferably, the initial material includes 20 to 65 (mass)% tobacco fines, 0 to 15 (mass)% tobacco winoeing, and 40 to 60 (mass)% tobacco stem material. More preferably, the initial material includes 25 to 60 (mass)% tobacco fines, 0 to 10 (mass)% tobacco winoeing, and 35 to 55 (mass)% tobacco stem material.

[0130] As a result of step (S3), there is no need to add additional or foreign binders to bind the tobacco fines to the tobacco shaft and winoeing, and neither binders unrelated to tobacco nor inherent binders, i.e., binders that are naturally present in tobacco, are required. Instead, the tobacco fines can be bound to the tobacco shaft and winoeing mechanically and / or by a certain amount of binder (inherent binder) that is naturally present in the tobacco. Such inherent binders (e.g., starch, resin, and sugar) are activated, thus causing the tobacco fines to bind firmly to the tobacco shaft and winoeing. This is in contrast to methods that rely on the addition of binders, including methods that produce films or masses that rely on the addition of binders.

[0131] The processing preferably results in a product that is a non - continuous tobacco material, particularly a fibrous and / or granular material or filler. In other words, the method is ready to be consumed, for example, to manufacture a tobacco rod for a cigarette or a tobacco heating device, and produces a product that can be used directly in an aerosol supply system. This is very different from the manufacture of tobacco films (continuous tobacco materials) which are more complex to manufacture and still require cutting and drying after manufacture. The product obtained as a result of the present disclosure has a size and moisture content suitable for direct use as a filler for an aerosol supply system, including cigarettes and tobacco heating devices.

[0132] In some embodiments, the initial material is processed in batches and in particular is pressed in a batch, for example in a piston - cylinder unit.

[0133] The discontinuous tobacco material produced by the method of FIG. 1 has been found to have increased tar and nicotine delivery, reduced carbon monoxide delivery, a reduced carbon monoxide to tar ratio, a reduced pressure drop across components including the discontinuous tobacco material, and reduced firmness and packing values for components including the discontinuous tobacco material.

[0134] Referring now to FIG. 2, another embodiment of a method for processing tobacco fines into a discontinuous tobacco material is shown.

[0135] The method of the embodiment of FIG. 2 is similar to the method of FIG. 1 and includes the step (S1) of preparing a pre - sized rib tobacco material having a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm, the step (S2) of combining the pre - sized rib tobacco material with tobacco fines to form an initial tobacco material, and the step (S3) of processing the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to a temperature increase, and subjecting the initial material to a pressure increase to bond the tobacco fines to the rib tobacco material. A detailed description of these steps (S1 - S3) will not be repeated below.

[0136] The method of FIG. 2 further includes the step (SoA) of adjusting the rib material, the step (SoB) of adjusting the winowing, the step (S4) of feeding the initial material through a shirring gap to form a discontinuous tobacco material, and the step (S5) of cooling the discontinuous tobacco material.

[0137] It should be recognized that in some embodiments (not shown), one or more of steps (SoA), (SoB), (S1), (S2), (S3), (S4), or (S5) may be combined. As an example, the tobacco starting material can be adjusted while moving through the screw feeder of the supply device, for example while in the supply device being brought to initial conditions (such as temperature, humidity, and pressure), or can be adjusted in the defibering device.

[0138] Also, it should be recognized that in some embodiments (not shown), one or more of steps (SoA), (SoB), (S1), (S2), (S3), (S4), or (S5) may be in a different order, or may be omitted entirely. For example, the tobacco shaft, winowing, and / or tobacco fines may be combined after adjustment. The stalk material may be adjusted before or after being subjected to the sizing step (S1). However, in this example, the stalk material is adjusted before being subjected to the sizing step (S1).

[0139] In steps (SoA) and (SoB), the stalk material and the winowing are each brought to one or more of the following initial conditions (the pressure value is always higher than atmospheric pressure): Temperature: 80 to 147 °C, preferably 100 to 120 °C Humidity: in the range of 6 to 14%, preferably in the range of 8 to 12% Pressure (gas overpressure): 0 to 8 bar, preferably 0 to 3 bar, preferably 0 to 1 bar.

[0140] That is, the stalk material is brought to one, two or more, or all of the above conditions in step (SoA), and separately, the winowing is brought to one, two or more, or all of the above conditions in step (SoB). Step (SoA) may be before or after step (SoB), or may be simultaneous with step (SoB). In some embodiments, steps (SoA) and (SoB) are combined.

[0141] This pre-adjustment can be carried out under atmospheric conditions. Alternatively, in some embodiments, the pre-adjustment process is operated at a pressure higher than atmospheric pressure, as described in patent specification DE10304629A1. During pre-adjustment and / or simultaneously during the process (above atmospheric pressure), the casing and the flavorant may be added by methods known to those skilled in the art.

[0142] Preferably, in step (SoA), the stalk material is brought to all the above initial conditions. Preferably, in step (SoB), the winowing is brought to all the above initial conditions.

[0143] To combine the tobacco fines with the stalk tobacco material, step (S3) of treating the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to a temperature increase, and subjecting the initial material to a pressure increase is preferably operated based on one or more of the following parameters: Temperature: 80 - 180 °C, preferably 125 - 156 °C Humidity: in the range of 15 - 50%, preferably in the range of 18 - 45% Mechanical pressure: 80 - 250 bar, preferably 72 - 132 bar.

[0144] Preferably, step (S3) is operated based on all of the above parameters for temperature, humidity, and mechanical pressure. In other words, the material is brought to the above values of temperature, humidity, and pressure.

[0145] In step (S3), as described above, the tobacco initial material is subjected to a pressure increase. In step (S4) of feeding the initial material through a shirring gap to form a discontinuous tobacco material, this increased pressure drops again. This usually occurs when the tobacco initial material exits a processing device (e.g., an extruder, a screw conveyor, a piston - cylinder unit) that subjects the material to increased temperature, pressure, and humidity. The pressure drop upon discharge from this shirring gap results in flash evaporation, thereby expanding the material. This advantageously enhances the filling ability of the material.

[0146] In step (S3), the tobacco starting material is heated and placed under pressure to improve the flavor through a chemically operated process (e.g., Maillard reaction or caramelization), and energy for promoting shirring and expansion through the shirring gap is also conserved. The pressure generation and heating may be operated with a standard plug screw feeder, and in particular, its housing may also be heated.

[0147] In some embodiments, the step of processing the starting material (S3) and / or the step of feeding the starting material through the shirring gap to form a discontinuous tobacco material (S4) are carried out using an apparatus having the configuration shown in FIG. 3.

[0148] In step (S4), feeding the starting material through the shirring gap to form a discontinuous tobacco material promotes fibrillation of the material. In some embodiments, when exiting the shirring gap and entering the atmosphere, entrained water and further optionally other entrained components rapidly evaporate, which, in addition to the shirring effect, causes fibrillation and expansion of the material in the shirring gap. The humidity of the material decreases by flash evaporation in the range of 5 to 25%, preferably 10 to 20%, depending on the pressure and temperature of the process, and the components contained in the tobacco also decrease to a certain extent. It has been found advantageous when the shirring gap surfaces move relative to each other to prevent and eliminate blockage. This ensures that the entire cross-section of the gap is used, that certain physical conditions prevail in the gap, and ultimately a uniform product is obtained. To achieve this purpose, it has also been proven advantageous when the gap surfaces are structured or shaped, for example, having grooves as described in detail below.

[0149] In step (S5), the tobacco material is cooled, for example, from above 100°C to room temperature, which can be performed on a conveyor belt based on air inhalation and can be operated from below. During the cooling process, the tobacco material loses more moisture due to evaporation by cooling, thereby making it possible to reach the moisture level of the final product without a dryer. The cooled tobacco material can have a moisture content in the range of, for example, 10% to 20%, preferably in the range of 13% to 16%.

[0150] In some embodiments, the tobacco material is supplied through the expansion and drying process, and then the discontinuous tobacco material has a reduced moisture content, for example, in the range of 10% to 20%, preferably in the range of 13% to 16%.

[0151] The discontinuous tobacco material produced by the method of FIG. 2 has been found to have increased tar and nicotine delivery, reduced carbon monoxide delivery, a reduced ratio of carbon monoxide to tar, a reduced pressure drop across components containing the discontinuous tobacco material, and reduced firmness and packing density values of components containing the discontinuous tobacco material.

[0152] These properties of the discontinuous tobacco material produced by the method of FIG. 2 were observed by the manufacture and comparison of 40 samples of the first and second types of cigarettes.

[0153] The first type of cigarette is a king-size cigarette including a filter with a length of 21.8 mm and a tobacco rod with a length of 60.8 mm, and the tobacco rod was manufactured from 100% discontinuous tobacco material produced by the method of FIG. 2. It should be noted that usually, as discussed above, cigarettes are considered to contain only a very small part, for example, 5% or 10% of discontinuous tobacco material.

[0154] The second type of cigarette is a king-size cigarette that includes a filter 21.8 mm in length and a tobacco rod 60.8 mm in length, and the tobacco rod was manufactured from 100% flake cut tobacco wrapped in an outer wrapper.

[0155] Both the first and second types of cigarettes have a tobacco rod with an outer circumference of 24.7 mm.

[0156] In addition, the inclusion of the discontinuous tobacco material resulted in a pressure drop across the entire component during smoking of the tobacco rod compared to when the tobacco rod did not contain the discontinuous tobacco material.

[0157] Also, the properties of the discontinuous tobacco material generated by the method of FIG. 2 were observed by the manufacture and comparison of 40 samples of the first and second types of cigarettes containing 25% cut-rolled expanded stalk (CRES).

[0158] The first type of cigarette is a king-size cigarette that includes a filter 21.8 mm in length and a tobacco rod 60.8 mm in length, and the tobacco rod was manufactured by blending 25% cut-rolled expanded stalk (CRES) with 75% of the discontinuous tobacco material generated by the method of FIG. 2.

[0159] The second type of cigarette is a king-size cigarette that includes a filter 21.8 mm in length and a tobacco rod 60.8 mm in length, and the tobacco rod was manufactured by blending 25% cut-rolled expanded stalk (CRES) with 75% flake cut tobacco, and wrapping it with an outer wrapper.

[0160] Both the first and second types of cigarettes have an outer circumference of 24.7 mm.

[0161] Next, 40 cigarettes of the first type and 40 cigarettes of the second type were tested using an RM20H smoking device compliant with ISO4387 to measure tar, nicotine and carbon monoxide delivered per cigarette; the ratio of carbon monoxide to tar; tar delivered per puff of each cigarette; and nicotine delivered per puff of each cigarette.

[0162]

Table 1

[0163] Table 2 above shows the average measured values of 40 cigarettes of the first type and 40 cigarettes of the second type. As before, the results show that the discontinuous tobacco material produced by the method of Figure 2 has increased tar and nicotine delivery, decreased carbon monoxide delivery, a reduced ratio of carbon monoxide to tar, and a reduced pressure drop across the components including the discontinuous tobacco material. This is shown despite the fact that both the cut-rag tobacco and the discontinuous tobacco material are made from the same type of tobacco. In other words, both the cut-rag tobacco and the discontinuous tobacco material are derived from the same type of tobacco plant, but the discontinuous tobacco material includes a mixture of pre-sized stalks, winowing and tobacco fines, which are processed according to the method of Figure 2.

[0164] Referring now to Figure 3, a processing apparatus 1 is shown. In this embodiment, the processing apparatus 1 is a pressure defibering device 1.

[0165] The pressure defibering device 1 comprises a chamber housing 2 with a conveyor screw 3 disposed therein that is rotated by means of a drive mechanism 4, such as a motor 4.

[0166] The pressure defibering device 1 further comprises an inlet 5A for tobacco material, an inlet 6A for water and an inlet 6B for casing and / or flavorant. The pressure defibering device 1 may further include an inlet 7 for steam.

[0167] The initial tobacco material is supplied to the tobacco material inlet 5A, placed in the chamber housing 2, where the initial tobacco material passes along the chamber housing 2 by the rotation of the conveyor screw 3 so that the initial tobacco material passes from the tobacco material inlet 5A to the outlet 5B. There is a head 8 at the outlet 5B of the chamber housing 2, which includes a generally conical recess 8A.

[0168] The shirring member 10 is received in the recess 8A. The shirring gap 9 is formed between the shirring member 10 and the inner wall of the recess 8A. The initial tobacco material is transferred through the gap 9 by the screw 3. The outlet 5B of the chamber 2 is in the form of an orifice connecting the interior of the chamber 2 and the recess 8A. The orifice can be disposed at the gap apex of the generally conical recess 8A. The defibered tobacco material discharged is represented by reference numeral 12.

[0169] In some embodiments, the shirring member 10 is in the form of a cone. The shirring gap 9 may be annular.

[0170] The shirring member 10 is connected to an actuator mechanism 11 configured to rotate the shirring member 10. The shirring member 10 can rotate about its central axis, and the rotation is indicated by the curved arrow in FIG. 3. In some embodiments, the actuator mechanism 11 includes a motor.

[0171] In some embodiments, the actuator mechanism 11 is configured to move the shirring member 10 axially to adjust the size of the gap 9.

[0172] The axial movement of the shirring member 10 is indicated by the double-headed arrow in FIG. 3, showing that the shirring member 10 moves towards the head 8 and away from the head 8. Thus, the shirring member 10 can be firmly retained in its axial position but can also move axially. As a result, the width of the gap 9 can be adjusted or adapted, and in some embodiments, a counterpressure can occur in the direction in which the gap 9 closes. The actuator mechanism 11 can be configured to move the shirring member 10 using a hydraulic or pneumatic actuator axially or by using a linear gear configuration such as a rack and pinion gear assembly driven by a motor.

[0173] The first part of the process of defibering tobacco stalks is carried out under a pressure higher than atmospheric pressure in step (S3). This overpressure occurs as soon as the initial tobacco material is supplied to the inlet 5A and the initial tobacco material is transferred along the chamber 2 via the screw 3.

[0174] The shirring gap 9 is arranged at the outlet end 5B of the chamber 2. The gap 9 substantially closes the chamber 2 in the same way as an extruder.

[0175] The gap 9 may have a substantially annular cross-section. The width of the gap 9 in the axial direction of the conveyor screw is determined by the axial position of the shirring member 10. Thus, in embodiments where the axial position of the shirring member 10 is adjustable, the width of the gap 9 is also adjustable.

[0176] In step (S3), the initial tobacco material is subjected to an increase in pressure (up to a maximum of 200 bar) and an increase in temperature (especially above 100 °C). In addition to the mechanical pressure generated by the transfer of the initial tobacco material towards gap 9, a shearing force acts in conjunction with the wall on the pitch of the conveyor screw, so that an additional force also acts on the initial tobacco material, causing granulation and fibrillation of the initial tobacco material. The shirring effect can be assisted by introducing an air flow through the housing wall or by introducing additional flow resistance. In addition, steam may be introduced at several points in order to adjust the humidity, temperature and pressure in the conveyor screw or in chamber 2. As a result of the introduction of steam, and also due to the natural water content of the stalks from the conditioning process, additional fibrillation of the initial tobacco material occurs because the water evaporates rapidly as it exits gap 9. Under pressure, the moisture in the initial tobacco material evaporates rapidly because the pressure drops to the downstream side of the air pressure in gap 9, thus causing flash evaporation.

[0177] In some embodiments, the initial tobacco material is placed under a pressure mechanically pressed, especially with respect to the shirring gap 9 in chamber 2. This may be the case where the material is positioned under pressure by means of a conveyor screw that presses the material towards the outlet end of chamber 2 of the heated screw conveyor in which the shirring gap 9 is located. Also, the initial material may be coarsely pre-granulated or coarsely pre-fibrillated in chamber 2 while being fed towards the shirring gap.

[0178] In some embodiments, the shirring gap 9 is closed under pretension and is intermittently opened by the pressure of the tobacco material so that the material passes through gap 9. Alternatively, advantageously, the material may be fed continuously through the continuously open shirring gap 9.

[0179] In some embodiments, the shirring gap 9 has a width in the range of 50 to 300 micrometers.

[0180] In some embodiments, the pressure chamber 2 has a transfer system in the form of a plug screw feeder for transferring the tobacco material from the inlet 5A to the outlet 5B. In some embodiments, the pressure is generated by mechanical means, such as by a plug screw feeder, although other systems within the principles of the present disclosure, such as using a piston system, may also be used, or the pressure may be generated by the use of gas pressure, such as the supply of pressurized gas, which is not mechanical or not only mechanical.

[0181] When using a plug screw feeder, in some embodiments, there are features that reduce the chamber volume in the region towards the outlet, such as having a smaller screw pitch.

[0182] In some embodiments, a mechanical pre-chopping feature or a pre-disaggregation feature is disposed in the pressure chamber 2. In one embodiment, a screw chamber pressure adjustment device is disposed upstream of the device proposed by the present invention, either in the same pressure chamber housing or in another pressure chamber housing connected upstream. This type of pressure adjustment device is described, for example, in Patent DE10304629A1 and can be combined with the pressure disaggregation device 1 of the present disclosure. The pressure adjustment device 1 can incorporate all the structural features illustrated in FIG. 1, which are described in the relevant description of DE10304629A1, and for further details, reference can be made to these structural features.

[0183] In some embodiments, the pressure chamber 2 includes inlets for regulators or casing agents and flavorants.

[0184] The conditioning and pressure defibration process depends on the pressure conditions under which the conditioning is carried out. In some embodiments, the tobacco starting material is conditioned under atmospheric conditions and supplied, for example via a hopper, by means of a conveyor chute or conveyor belt into a supply device, such as inlet 5A. One or more components of the tobacco starting material may be conditioned separately. As an example, the stalk material and the winnowing can be separated separately and then combined with each other and with the tobacco fines. In some embodiments, the stalk material is conditioned before pre-sizing.

[0185] In some embodiments, the supply device includes a silo (not shown) and a screw feeder (not shown). The tobacco starting material is stored in the silo and supplied by the screw feeder, where the screw feeder supplies the tobacco starting material to the inlet 5A of the pressure defibration device 1.

[0186] The supply device can be configured to supply a predetermined flow rate of the tobacco starting material to the processing device 1. In some embodiments, the supply device is configured to supply the tobacco starting material to the processing device 1 at a flow rate in the range of 50 to 250 kg / h, preferably in the range of 95 to 175 kg / h.

[0187] The conditioning process can be carried out at an intermediate point on the axis of the chamber 2 by introducing water and casing at each of the inlets 6A and 6B. In some alternative embodiments (not shown), the water and casing (and / or flavorant) are introduced at the same inlet, or only one of the water and casing is introduced into the chamber 2.

[0188] In step (S4), the tobacco starting material passes through the gap 9 and undergoes shirring between the head 8 and the wall of the shirring member 10, and when the material exits the gap 9, the flash evaporation described above occurs. Thus, the gap 9 acts as a shirring gap 9. Both the shirring and the flash evaporation contribute to a well-defibrated discontinuous tobacco product, which can be used in an aerosol supply system.

[0189] In some embodiments, the shirring member 10 rotates about its axis of rotation and helps prevent occlusion from occurring at the gap 9. This rotation of the shirring member 10 may be continuous or intermittent, or may change the direction of rotation. This is the case where the rotation may be a full rotation or only a quarter or a third rotation or a small / large unit rotation. In an alternative embodiment (not shown), the shirring member 10 is fixed and the head 8 rotates, for example, being coupled to a drive mechanism. However, in a further embodiment, it should be recognized that the head 8 and the shirring member 10 do not rotate relative to each other.

[0190] In some embodiments, the head 8 and the shirring member 10 each include shirring surfaces 13 and 14, where a gap 9 is formed between the shirring surfaces 13 and 14. In some embodiments, the shirring surfaces 13 and 14 are substantially opposed.

[0191] In some embodiments, one or both of the shirring surfaces 13 and 14 have one or more surface formations, such as grooves or other rough surfaces (such as ridges or depressions). In some embodiments, the surface formation, such as a groove, may have a radial depth of at least 0.2 mm or at least 1 mm. The surface formation may promote the shirring of the tobacco starting material and also promote more uniform pressure conditions leading to a more uniform final product. In some embodiments, the grooves extend parallel to the central axis of the shirring member 10.

[0192] In some embodiments, the shirring member 10 includes more than 80 grooves, preferably at least 90, 100, 120, 140, 160 or 180 grooves.

[0193] In some embodiments, each groove has a maximum width in the range of 0.5 to 1.5 mm. The width of each groove may be constant or variable. It has been found that the smaller the width of the groove, the smaller and lighter the fibers in the defibrated discontinuous tobacco material. The width of the groove is in the circumferential direction of the shirring member 10.

[0194] In some embodiments, the shirring surfaces 13 and 14 are movable in directions away from each other and towards each other. In some embodiments, the shirring member 10 is biased with respect to the head 8 such that the shirring surfaces 13 and 14 are adjacent and thus the gap 9 is closed. Alternatively, the shirring surfaces 13 and 14 are movable in directions away from each other and towards each other at a fixed distance or a fixed and adjustable distance, in which case the shirring surfaces 13 and 14 are located at a fixed distance of 10 to 2000 microns, preferably 50 to 300 microns. These values relate to the smooth shirring surfaces 13 and 14. Alternatively, if the shirring surfaces 13 and 14 include grooves, for example, the distance refers to the distance between the portions of the surfaces 13 and 14 between each groove.

[0195] In some embodiments, the grooves of the shirring member 10 extend longitudinally or transversely in the direction in which the shirring surfaces 13 and 14 move.

[0196] In some embodiments, the shirring surface 14 of the head 8 is fixed, but the shirring surface 13 of the shirring member 10 moves axially. In some embodiments, the shirring surface 14 of the head 8 moves axially, but the shirring surface 13 of the shirring member 10 remains fixed.

[0197] In some embodiments, the shirring surface 14 of the head 8 is fixed, but the shirring surface 13 of the shirring member 10 rotates. In some embodiments, the shirring surface 14 of the head 8 rotates, but the shirring surface 13 of the shirring member 10 remains fixed.

[0198] The rotation and axial movement of the shirring surfaces 13 and 14 can be caused by the same actuator mechanism 1. Alternatively, a first actuator mechanism can rotate one of the shirring surfaces 13 and 14, while a second actuator mechanism can axially move said one or the other of the shirring surfaces 13 and 14.

[0199] In some embodiments, the shirring surfaces 13 and 14 move towards each other continuously or intermittently, or in one or more directions, or back and forth.

[0200] In some embodiments, the gap 9 may be an annular gap, preferably a conical gap.

[0201] In step (S5), the material is cooled. The material may be cooled while being conveyed, for example, on a conveyor belt.

[0202] The resulting defibrated product exhibits properties similar to those of the petioles processed by a shredder in terms of appearance and use. However, the pressure defibrillation process and the devices of FIGS. 1 - 3 do not have the drawback of generating a large amount of dust, which is because this is the case when processing petioles with a shredder and does not require much moisture adjustment, and subsequent drying can be dramatically reduced or eliminated.

[0203] In some embodiments, the generated discontinuous material has an average fiber diameter of less than 0.95 mm, preferably less than about 0.9 mm or 0.85 mm. In some embodiments, the average fiber diameter is about 0.8 mm or less. The average fiber diameter may be less than 0.8 mm. In some embodiments, the average fiber diameter ranges from 0.6 - 0.8 mm. A smaller average fiber diameter results in a lighter discontinuous material, which has a lower density. The generated discontinuous material with a lower density has been found to reduce the discontinuous material extracted as winowing and also reduce the total tobacco material extracted as winowing by a rod maker.

[0204] The generated discontinuous material may be a regenerated material without a binder.

[0205] Pre-sizing the petiole material to a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm also reduces the "flakes" in the generated discontinuous material. Flakes are generated when large, uncrushed pieces of petiole cross over the grooves of the shurring member and exit the chamber of the defibering device. These flakes often have a particle size larger than the width of one or two grooves of the shurring member and can have a diameter equivalent to that of a regular or king size cigarette. Flakes are relatively light and are therefore generally not extracted as winowing, which may have an adverse effect on the taste of the final product and can cause an increased pressure drop in an aerosol supply system, such as in a cigarette. When the generated discontinuous material is formed into a rod, the flakes can cause inconsistencies in rod formation and thus potentially affect the final stability of the rod, which further means that more discontinuous material falls from the ends of the rod. By pre-sizing the petiole material, the flakes are reduced and thus such problems are alleviated.

[0206] Referring now to FIG. 4, another embodiment of the processing apparatus is shown. The processing apparatus includes a pressure defibering device 1 of the type described above with reference to FIG. 3. The processing apparatus further includes a pressure regulating device 20 connected upstream of the pressure defibering device 1.

[0207] The pressure defibering device 1 and the pressure regulating device 20 form part of a combined system for pressure regulation and defibering.

[0208] The pressure adjustment device 20 may be of the type particularly illustrated in FIG. 1 of the present document DE10304629A1 and described in the relevant part of its description, which is hereby incorporated by reference. This has an inlet 25 for the tobacco material and a differential pressure cell rotary through passage 26 through which the initial tobacco material is introduced into the pressure chamber 21, where it is conveyed using the conveyor screw 22. The conveyor screw 22 is driven by a drive mechanism, for example a motor 24.

[0209] At the end of the chamber 21 there is an outlet 27 for the tobacco material, which supplies the inlet 5A of the pressure defibering device 1. In some embodiments, unlike the device described in the patent document DE10304629A1, there is no differential pressure through passage at the outlet of the pressure adjustment device. Instead, the initial tobacco material is conveyed to the inlet 5A of the pressure defibering device 1 by the pressure in the chamber 22.

[0210] In other embodiments, the outlet from the pressure adjustment device 22 is operated using a rotary through passage to reduce the pressure. In such embodiments, the tobacco material may be transferred to the pressure defibering process at a pressure in the pressure adjustment chamber that is lower than, for example, atmospheric pressure. In some embodiments, the initial tobacco material is first treated by the pressure adjustment device 20 and then conveyed to another pressure defibering device 1. The initial tobacco material can be conveyed between the pressure adjustment device 20 and the pressure defibering device 1 manually or automatically, for example using a conveyor belt or an air conveyor.

[0211] However, as illustrated in FIG. 4, it is preferable to avoid pressure drop during the transfer from the pressure adjustment device 20 to the pressure defibering device 1, and to enable the application of a pressure higher than the atmospheric pressure throughout the processing region from the start of adjustment to the defibering process. The tobacco initial material is supplied through the pressure difference resistant cellular wheel through-hole 26. The pressure resistance of the through-hole 26 at one end during operation and the gap 9 always filled with the defibered tobacco material enables the maintenance of a pressure higher than the atmospheric pressure throughout the combined device. To achieve this purpose, the sealing of the cellular wheel through-hole 26 can be optimized by heating its housing.

[0212] When the tobacco initial material is introduced into the chamber 22, the material becomes a pressure higher than the atmospheric pressure, which can be maintained by introducing steam to compensate for the natural leakage rate (gap and leakage volume) of the cellular wheel through-hole 26. The tobacco initial material is heated by steam, and the moisture content increases. In principle, it is considered possible to operate the drying process in the chamber using supersaturated steam, but when used for defibering, it is usually advantageous when the introduced tobacco initial material has a large moisture content.

[0213] The tobacco initial material is transferred through the adjustment chamber 21 by the conveyor screw 22. Different situations (screw pitch, rotation speed, and chamber inclination) can be used for this purpose, thereby setting the residence time of the tobacco initial material. In some embodiments, the residence time is 2 to 10 minutes.

[0214] Water, casing, and / or flavoring materials may also be added during the pressure adjustment process. After the process, the tobacco initial material is transferred to the pressure defibering device 1 through the outlet 27. The process of introducing the tobacco initial material can also be facilitated when the housing is also of a hopper-type design. In some embodiments, the typical residence time of the tobacco initial material in the pressure defibering device 1 is less than 2 minutes, particularly less than 1 minute. Then, the tobacco material exits the pressure defibering device 1 in the desired state described above.

[0215] It is also conceivable to use an adjustment screw that operates at a pressure lower than atmospheric pressure instead of the pressure adjustment screw.

[0216] In some embodiments, the pressure defibering device 1 includes a short-axis or twin-shaft conveyor having a shirring gap outlet for defibering tobacco material. The shirring gap includes an orifice through which the material is shirred as it passes through.

[0217] FIG. 5 illustrates another embodiment of a combined system for pressure adjustment and defibering. The pressure adjustment device 20 and the pressure defibering device 1 are the same as those described above with reference to FIGS. 3 and 4, and thus the detailed description below will not be repeated. The difference is that the conveyor screw of the adjustment device 20 and the defibering screw of the pressure defibering device 1 are provided on the same shaft and driven by a single motor. When the same rotational speed is used for both screws, different residence times can be obtained in the two process steps by using different methods, for example, by different cross-sections / volumes or options for discharge within the area of the adjustment process.

[0218] In the embodiments of FIGS. 4 and 5, steam and an adjusting agent, such as water and casing, are introduced through appropriate inlets of the pressure adjustment device 20. The corresponding inlets for water, adjusting agent, and steam are omitted from the pressure defibering device 1. Flavoring agents and / or casing can be introduced in both pressure ranges, i.e., in one or both pressure chambers, or at atmospheric pressure, i.e., outside the chamber.

[0219] In some embodiments, the generated discontinuous tobacco material has a density index in the range of 350 - 600 kg / m 3 The "density index" of the discontinuous tobacco material can be calculated as follows:

[0220] Grind the discontinuous tobacco material in a mill for 3 seconds to shorten the fiber length. Examples of mills that can be used to grind the discontinuous tobacco material include coffee grinders, such as the Bialetti (trademark) manual coffee grinder (European product number 8002617994316). However, other types of mills are also suitable for grinding the discontinuous tobacco material to shorten the fiber length.

[0221] Next, classify the discontinuous tobacco material and collect the material with a particle size in the range of 0.5 mm to 1.00 mm. As an example, the discontinuous tobacco material can be passed through a first sieve to collect the discontinuous tobacco material with a particle size of 1 mm or less, and the material with a particle size greater than 1 mm can be excluded. Then, the collected discontinuous tobacco material can be passed through a second sieve to exclude the material with a particle size less than 0.5 mm. Alternatively, a sieve machine or other suitable device may be used.

[0222] Next, store 50 g of the collected discontinuous tobacco material with a particle size of 0.5 - 1 mm in a climate-controlled environment at 22 °C and a relative humidity of 60% for 24 hours.

[0223] Next, measure the density index using a Borgwaldt DD 60A hydrometer, which is performed in the same way as the method for calculating the filling degree value, but the height before measurement is reset using a transparent disk made of acrylic glass with a diameter of 59.5 mm and a height of 15 mm. That is, the reset of the height is performed including the transparent disk. More specifically, fill the graduated cylinder of the hydrometer with a part (30 g) of the discontinuous tobacco material, and place the transparent disk on the discontinuous tobacco material. Tap the graduated cylinder gently to make the surface between the discontinuous tobacco material and the transparent disk flat and uniform. Next, obtain the measured value in the same way as the method for measuring the filling degree value.

[0224] The density index (DI) (kg / m 3 ) is calculated by the following formula: DI=(m / (9*π*h)*1000 DI = density index (kg / m3), M = mass of the material (g), h = height (cm).

[0225] The density index (DIb) of the dry reference material can be calculated according to the following formula: DIb = DI / ((100 - OV) / 100) DIb = density index of the dry reference material (kg / m 3 ), OV = oven volatile matter (%) [directly determined after measurement with a hydrometer].

[0226] In some embodiments, the density index ranges from 350 to 600 kg / m 3 .

[0227] In some embodiments, the density index of the dry reference material ranges from 300 to 550 kg / m 3 .

[0228] It has been found that when the density index of the generated discontinuous tobacco material is low, the discontinuous material extracted as winowing decreases, and similarly, the total amount of tobacco material extracted as winowing by the rod maker also decreases.

[0229] The present disclosure also relates to the manufacture of components for delivery systems such as aerosol delivery systems.

[0230] The delivery systems described herein can be implemented as combustible aerosol delivery systems, non-combustible aerosol delivery systems, or delivery systems that do not use aerosols.

[0231] The method includes forming a tobacco mixture by combining a discontinuous material with tobacco material (e.g., shredded tobacco), and then forming components from the tobacco mixture. In some embodiments, for combustible products, the tobacco mixture includes at least 4.5% (by mass) of the discontinuous material, preferably at least 5.5% (by mass), 6% (by mass), 6.5% (by mass), 7% (by mass), 8% (by mass), 9% (by mass), 10% (by mass), 11% (by mass), 12% (by mass), 13% (by mass), 14% (by mass), 15% (by mass), 16% (by mass), 17% (by mass), 18% (by mass), 19% (by mass) or 20% (by mass) of the discontinuous material. In some embodiments, for combustible products such as combustible aerosol supply systems, the tobacco mixture includes 25% (by mass) or less of the discontinuous material.

[0232] In some embodiments, for non-combustible products, such as non-combustible aerosol supply systems, the tobacco mixture preferably includes at least 5% (by mass) and up to 100% (by mass) of the discontinuous material.

[0233] In some embodiments, there is provided a component of a non-combustible aerosol supply system, the component including an expanded tobacco material. The methods described herein produce an expanded tobacco material, which can be produced, for example, in an aerosol generation section of an article for use in a non-combustible aerosol supply system or a non-combustible delivery system as described herein. Also provided is a non-combustible delivery system or a non-combustible aerosol delivery system including an expanded tobacco material, for example a tobacco material produced by the methods described herein. The non-combustible aerosol supply system can be, for example, a heated tobacco product or a hybrid system for generating an aerosol using a combination of aerosol generating materials where one of the materials is an expanded tobacco material. The expanded tobacco material can deliver at least one substance, which may or may not contain nicotine, to the user orally, nasally, transdermally or by another method that does not form an aerosol, for example, but not limited to, lozenges, gums, patches, articles including inhalable powders, and oral products such as snus or moist snuff, in a delivery system that does not use an aerosol. The expanded tobacco material can be produced by exposing the tobacco material to a pressure drop to flash evaporate it. Alternatively or in addition, the expanded tobacco material can be produced by feeding the tobacco material through a shirring gap such that the tobacco material fibrillates by expansion.

[0234] In some embodiments, the component is for a combustible aerosol supply system or a non-combustible aerosol supply system. In some embodiments, the component is a tobacco rod.

[0235] The present disclosure further relates to an aerosol supply system and parts of an aerosol supply system including a non-continuous material manufactured in accordance with the present disclosure.

[0236] As used herein, the term "delivery system" encompasses a system for delivering at least one substance to a user and includes the following: Combustible aerosol supply systems such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or self-acting cigarettes (regardless of whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials); Non-combustible aerosol supply systems that release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as electronic cigarettes, heat-not-burn tobacco products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials; Delivery systems that do not use aerosols to deliver at least one substance, which may or may not contain nicotine, to the user orally, nasally, transdermally, or by another method that does not form an aerosol, such as, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral products such as snus or wet snuff tobacco is intended to include.

[0237] As used herein, the term "aerosol supply system" is intended to encompass combustible and non-combustible aerosol supply systems that deliver at least one substance to the user, including: Combustible aerosol supply systems such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or self-acting cigarettes (regardless of whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials); Non-combustible aerosol supply systems that release compounds from aerosol-generating materials without burning the aerosol-generating materials, such as electronic cigarettes, heat-not-burn tobacco products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials are included.

[0238] According to the present disclosure, a "combustible" aerosol supply system is a system in which the aerosol-generating constituent material (or its components) of the aerosol supply system is burned or ignited during use to facilitate the delivery of at least one substance to the user.

[0239] In some embodiments, the delivery system is a combustible aerosol supply system such as a system selected from the group consisting of cigarettes, cigars, and cigars.

[0240] In some embodiments, the present disclosure relates to components for use in a combustible aerosol supply system, such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier release components (capsules, threads, or beads), or papers (such as plug wrap, tip paper, or cigarette paper).

[0241] According to the present disclosure, a "non-combustible" aerosol supply system is a system in which the aerosol-generating constituent material (or its components) of the aerosol supply system is not burned or ignited to facilitate the delivery of at least one substance to the user.

[0242] In some embodiments, the delivery system is a non-combustible aerosol supply system such as a power supply type non-combustible aerosol supply system.

[0243] In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also known as a vaping device or an electronic nicotine delivery system (ENDS), but it should be noted that the presence of nicotine in the aerosol-generating material is not a prerequisite.

[0244] In some embodiments, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0245] In some embodiments, the non-combustible aerosol supply system is a hybrid system that uses a combination of aerosol-generating materials to generate an aerosol, and is a hybrid system that may heat one or more of the aerosol-generating materials. Each aerosol-generating material may be, for example, in the form of a solid, liquid or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or non-tobacco products.

[0246] Typically, the non-combustible aerosol supply system may include a non-combustible aerosol supply device and a consumable used with the non-combustible aerosol supply device.

[0247] In some embodiments, the present disclosure relates to a consumable containing an aerosol-generating material and configured to be used with a non-combustible aerosol supply device. These consumables are sometimes referred to as articles throughout the present disclosure.

[0248] In some embodiments, the non-combustible aerosol supply system, such as its non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, a power supply or a heat source. In some embodiments, the heat source includes a carbon-based substrate that can be excited to disperse power in the form of heat to the aerosol-generating material in the vicinity of the heat source or to the electrothermal material.

[0249] In some embodiments, the non-combustible aerosol supply system may include a region for receiving a consumable, an aerosol generator, an aerosol generation region, a housing, a mouthpiece, a filter and / or an aerosol modifier.

[0250] In some embodiments, the consumables used with the non-combustible aerosol supply device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material moving component, an aerosol generator, an aerosol generating area, a housing, a winding paper, a filter, a mouthpiece, and / or an aerosol modifier.

[0251] In some embodiments, the substance to be delivered may be an aerosol generating material or a material not intended to be aerosolized. If desired, any material may include one or more active ingredients, one or more fragrances, one or more aerosol forming materials, and / or one or more other functional materials.

[0252] In some embodiments, the substance to be delivered includes an active substance.

[0253] As used herein, the active substance may be a bioactive material that is a material intended to achieve or enhance a physiological response. The active substance can be selected, for example, from nutraceuticals, nootropics, and psychotropic drugs. The active substance may be natural or obtained synthetically. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6 or B12 or C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, hemp, or another plant substance.

[0254] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0255] In some embodiments, the substance to be delivered includes an active substance.

[0256] The active substance used in this specification may be a bioactive material that is a material intended to achieve or enhance a physiological response. The active substance can be selected, for example, from nutraceuticals, nootropics, and psychotropics. The active substance may be natural or obtained by synthesis. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6, B12, or C), melatonin, cannabinoids, or their constituents, derivatives, or combinations. The active substance may include one or more constituents, derivatives, or extracts of tobacco, hemp, or another plant substance.

[0257] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0258] As described herein, the active substance may include one or more constituents, derivatives, or extracts of hemp, such as one or more cannabinoids or terpenes.

[0259] As described herein, the active substance may include one or more plant substances or their constituents, derivatives or extracts, or may be derived therefrom. As used herein, the term "plant substance" includes, but is not limited to, any material derived from plants, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, pods, husks, etc. Alternatively, the material may include active compounds naturally present in the plant substance, active compounds obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, sheets, etc. Examples of plant substances include tobacco, eucalyptus, star anise, hemp, cocoa, flax, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, hemp, ginger, ginkgo, nettle, hibiscus, ginkgo biloba, licorice, matcha, mate, orange peel, papaya, rose, sage, green tea or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, perilla, turmeric, frankincense, silantro, bergamot, orange blossom, kinkan, crossgry, valerian, pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, caraway, vervain, tarragon, geranium, mulberry, Japanese radish, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. Mint can be selected from the following mint varieties: Mentha arvensis, Mentha cultivars, Mentha nilaca, Mentha piperita, Mentha piperita citrata cultivars, Mentha piperita cultivars, Mentha spicata crispa, Mentha cardiophylla, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cultivars and Mentha suaveolens.

[0260] In some embodiments, the active substance comprises, or is derived from, one or more plant substances or their constituents, derivatives or extracts, and the plant substance is tobacco.

[0261] In some embodiments, the active substance comprises, or is derived from, one or more plant substances or their constituents, derivatives or extracts, and the plant substance is clove. Cloves contain eugenol, which is known to contribute to the taste characteristic of cloves and is thought to have analgesic effects in traditional Chinese medicine.

[0262] In some embodiments, the active substance comprises, or is derived from, one or more plant substances or their constituents, derivatives or extracts, and the plant substance is selected from eucalyptus, star anise, cocoa and hemp.

[0263] In some embodiments, the active substance comprises, or is derived from, one or more plant substances or their constituents, derivatives or extracts, and the plant substance is selected from rooibos and fennel.

[0264] In some embodiments, the substance to be delivered comprises a fragrance.

[0265] As used herein, the terms “flavor” and “flavoring” refer to materials that can be used to create a desired taste, aroma, or other sensory feeling in products for adult consumers, if permitted by local regulations.These may include natural flavoring materials, vegetable substances, extracts of vegetable substances, materials obtained by synthesis, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, magnolia leaves, chamomile, perilla, clove, maple, matcha, menthol, peppermint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, damson, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, frankincense, bergamot, geranium, cart, naswar, kinma, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang, sage, fennel, wasabi, pepper, ginger, coriander, coffee, marijuana, mint oil derived from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, turmeric, silantro, ginger lily, crossandra, valerian, pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphor), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or alternative sugars (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and may also include other additives such as charcoal, chlorophyll, minerals, vegetable substances, or breath fresheners.These may be imitation products, synthetic or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid like oil, a solid like powder, or a gas.

[0266] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes flavor components of cucumber, blueberry, citrus fruits, and / or redberry. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from hemp.

[0267] In some embodiments, the flavor may include a sensation inducer intended to achieve somatosensory sensations that are chemically induced and perceived, usually by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of olfactory or taste nerves, and these may include agents that cause heating, cooling, percussion pain, and tingling effects. Suitable heat agents may include, but are not limited to, vanillyl ethyl ether, and suitable coolants may include, but are not limited to, eucalyptol WS-3.

[0268] The aerosol generating material is a material capable of generating an aerosol when excited, for example, by heating, irradiation, or any other method. The aerosol generating material may be in the form of a solid, liquid, or gel that may or may not contain, for example, an active substance and / or a flavorant. In some embodiments, the aerosol generating material may include an "amorphous solid", which can alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can hold some fluid, such as a liquid, inside. In some embodiments, the aerosol generating material may include, for example, from about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of an amorphous solid.

[0269] The aerosol generating material may comprise one or more active substances and / or fragrances, one or more aerosol forming materials, and optionally one or more other functional materials.

[0270] The aerosol forming material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material may comprise one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0271] The one or more other functional materials may comprise one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0272] The material may be present on or in a support to form a substrate. The support may be, for example, paper, card, cardboard, thick paper, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may comprise them. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded in the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0273] A consumable is an article that contains or consists of an aerosol-forming material and is intended to be partially or wholly consumed by a user during use. The consumable may include one or more other components, such as an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol-forming area, a housing, a roll of paper, a mouthpiece, a filter and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater, that releases heat during use to generate an aerosol from the aerosol-forming material. The heater may include, for example, a combustible substance, a material heatable by electrical conduction, or a susceptor.

[0274] A susceptor is a material heatable by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and thus its penetration by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, and thus its penetration by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and thus the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0275] An aerosol modifier is a substance typically located downstream of the aerosol-forming area and configured to modify the generated aerosol, for example by changing the taste, aroma, acidity or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier release component capable of selectively releasing the aerosol modifier.

[0276] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavorant, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a thread, or granules. The aerosol modifier may not use a filter medium.

[0277] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy, thereby releasing one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator can be configured to expose the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0278] To address various problems and advance the art, the entire disclosure herein, by way of example, shows various embodiments that can practice the claimed invention and provide for the manufacture of superior tobacco materials. The advantages and features of the disclosure are only those of representative samples of the embodiments and are not comprehensive and / or exclusive. They are presented only for the purpose of assisting in the understanding of the claimed features and teachings. The advantages, embodiments, examples, functions, features, structures, and / or other aspects of the disclosure should not be regarded as limitations to the disclosure as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments can be utilized and modifications can be made without departing from the scope and / or spirit of the disclosure. The various embodiments can suitably include, consist of, or consist essentially of various combinations of the disclosed elements, components, features, parts, steps, means, etc. Additionally, the disclosure includes other inventions not claimed herein but that may be claimed in the future.

Claims

1. A method for manufacturing a discontinuous tobacco material by processing tobacco fines, comprising: preparing a pre-sized stalk tobacco material having a Dp90 particle size of less than 3 mm and a Dp50 particle size of less than 2 mm; combining the pre-sized stalk tobacco material with tobacco fines to produce an initial tobacco material; processing the initial material by bringing the initial material to a predetermined increased moisture content, subjecting the initial material to a temperature increase, and subjecting the initial material to a pressure increase to bond the tobacco fines to the stalk tobacco material.

2. The method according to claim 1, wherein the pre-sized stalk material has a Dp90 particle size of less than 2.9 mm, optionally less than 2.8, 2.7, 2.6, 2.5, 2.4, 2.3, 2.2, 2.1 or 2 mm.

3. The method according to claim 1 or 2, wherein the pre-sized stalk material has a Dp50 particle size of less than 1.9 mm, optionally less than 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1 or 1 mm.

4. The method according to any one of claims 1 to 3, wherein the pre-sized stalk material has a Dp10 particle size of at least 100 microns, optionally at least 150, 200, 250, 300 or 350, 400 or 500 microns.

5. The method according to any one of claims 1 to 4, wherein the step of preparing the pre-sized stalk tobacco material comprises preparing a starter stalk material and reducing the particle size of the starter stalk material using a hammer mill.

6. The method according to any one of claims 1 to 5, wherein the temperature increase is obtained by applying external heat and / or is a result of generating mechanical pressure.

7. The method according to any one of claims 1 to 6, wherein the tobacco fines have a particle size of less than 1 mm, optionally less than 0.5 mm.

8. The method according to any one of claims 1 to 7, wherein the tobacco fines are mechanically bonded to the pre-sized stalk tobacco material without using any externally added binder.

9. The method according to any one of claims 1 to 8, wherein the material to be processed is processed by continuously transporting the material.

10. The method according to any one of claims 1 to 9, wherein the step of processing the initial material includes passing the initial material through a conveyor that enhances mechanical pressure for transfer.

11. The method according to claim 10, wherein the conveyor includes an extruder.

12. The method according to claim 10 or 11, wherein the conveyor is operated at a throughput of more than 100 kg / hr.

13. The method according to any one of claims 1 to 12, wherein the initial material further includes winowing.

14. Pre-adjusting the petiole material and / or winowing to one or more of the following parameters: Temperature: in the range of 80 to 147 °C, humidity: in the range of 6 to 14 mass% ov, and pressure (gas overpressure): 0 to 8 bar, the method according to claim 13.

15. Pre-adjusting the petiole material and / or winowing to one or more of the following parameters: Temperature: in the range of 100 to 120 °C, humidity: in the range of 8 to 12 mass% ov, and pressure (gas overpressure): 0 to 3 bar, the method according to claim 14.

16. The method according to any one of claims 1 to 15, wherein the step of processing the initial material includes bringing the initial material to a moisture content in the range of 10 to 50 mass% ov (oven volatile matter).

17. The method according to any one of claims 1 to 16, wherein the step of processing the initial material includes heating the initial material to a temperature in the range of 60 to 180 °C.

18. The method according to any one of claims 1 to 17, wherein the step of processing the initial material includes pressurizing the initial material to a pressure in the range of 10 to 200 bar.

19. The method according to any one of claims 1 to 18, wherein the discontinuous tobacco material is a fibrous and / or granular material.

20. The method according to any one of claims 1 to 19, wherein the tobacco initial material includes at least 30 (mass)% of tobacco fines.

21. The method according to any one of claims 1 to 20, wherein the tobacco initial material includes 50 (mass)% or less of tobacco fines.

22. The method according to any one of claims 1 to 21, wherein the tobacco initial material includes at least 5 (mass)% of tobacco winowing.

23. The method according to any one of claims 1 to 22, wherein the tobacco initial material includes 20 (mass)% or less of tobacco winowing.

24. The method according to any one of claims 1 to 23, wherein the initial tobacco material comprises at least 30% (by mass) of pre-sized stalk tobacco material.

25. The method according to any one of claims 1 to 24, wherein the initial tobacco material comprises 70% (by mass) or less of pre-sized stalk tobacco material.

26. The method according to any one of claims 1 to 25, wherein the tobacco fines comprise, consist of, or consist essentially of tobacco factory dust.

27. The method according to any one of claims 1 to 26, wherein the tobacco fines have a Dp50 particle size of less than 1 mm.

28. The method according to any one of claims 1 to 27, comprising exposing the treated tobacco material to a pressure drop and as a result flash evaporating it.

29. The method according to any one of claims 1 to 28, comprising feeding the treated tobacco material through a shirring gap such that the treated tobacco material fibrillates by expansion.

30. The method according to claim 29, wherein the shirring gap has a width in the range of 10 to 2000 microns.

31. The method according to claim 29 or 30, wherein the shirring gap is disposed between shirring surfaces, and the rotating shirring member comprises one of the shirring surfaces.

32. The method according to claim 31, wherein the shirring member comprises a plurality of grooves, optionally at least 80 grooves.

33. The method according to claim 31 or 32, comprising rotating the shirring member at an angular velocity of at least 10 rpm.

34. The method according to any one of claims 1 to 33, wherein the discontinuous tobacco material has an average fiber diameter of less than 0.9 mm.

35. The discontinuous tobacco material has a density index in the range of 350 to 600 kg / m ３ The method according to any one of claims 1 to 34.

36. A method of manufacturing a component for a delivery system, comprising manufacturing a discontinuous tobacco material by the method according to any one of claims 1 to 35.

37. The method according to claim 36, wherein the component further comprises a second tobacco material.

38. The method according to claim 37, wherein the discontinuous tobacco material is configured such that, during use of the component, tar delivery is increased compared to when the component did not contain the discontinuous tobacco material.

39. The method according to claim 38, wherein by including the discontinuous tobacco material, during use of the component, for every 5% (by mass) of the discontinuous tobacco material included, the delivery of tar is increased by at least 1.5% (by mass), 2% (by mass) or 2.5% (by mass).

40. The method according to claim 37, wherein by including the discontinuous tobacco material, during use of the component, the delivery of nicotine is increased as compared to the case where the component does not include the discontinuous tobacco material.

41. The method according to claim 40, wherein by including the discontinuous tobacco material, during use of the component, for every 5% (by mass) of the discontinuous tobacco material included, the delivery of nicotine is increased by at least 1.5% (by mass), 2% (by mass) or 2.5% (by mass).

42. The method according to any one of claims 37 to 41, wherein by including the discontinuous tobacco material, during use of the component, the delivery of carbon monoxide is decreased as compared to the case where the component does not include the discontinuous tobacco material.

43. The method according to any one of claims 37 to 42, wherein by including the discontinuous tobacco material, during use of the component, the ratio of delivering carbon monoxide to tar is decreased as compared to the case where the component does not include the discontinuous tobacco material.

44. The method according to claim 43, wherein by including the discontinuous tobacco material, during use of the component, for every 5% (by mass) of the discontinuous tobacco material included, the ratio of delivering carbon monoxide to tar is decreased by at least 1.5% (by mass), 2% (by mass) or 2.5% (by mass).

45. The method according to any one of claims 37 to 44, wherein the component includes a tobacco rod for a combustible aerosol supply system.

46. The method according to any one of claims 37 to 45, wherein by including the discontinuous tobacco material, during use of the component, the pressure drop across the entire component is suppressed as compared to the case where the component does not include the discontinuous tobacco material.

47. The component includes a tobacco material including the discontinuous tobacco material and the second tobacco material, and at least 4.5% (by mass), 5.5% (by mass) or 6.5% (by mass) of the tobacco material is a discontinuous tobacco material produced by the method according to any one of claims 1 to 35, and optionally, at least 7% (by mass), 8% (by mass), 9% (by mass), 10% (by mass), 11% (by mass), 12% (by mass), 13% (by mass), 14% (by mass), 15% (by mass), 16% (by mass), 17% (by mass), 18% (by mass), 19% (by mass) or 20% (by mass) of the tobacco material is a discontinuous tobacco material produced by the method according to any one of claims 1 to 35. A method according to any one of claims 37 to 46.

48. The method according to any one of claims 36 to 47, wherein the component is for an aerosol supply system.

49. The method according to claim 48, wherein the component is a tobacco rod for a cigarette, a cigar or a cigarillo.

50. The method according to claim 48, wherein the component is for a non-combustible aerosol supply system, optionally includes a tobacco material, and at least 5% (by mass) of the tobacco material is a discontinuous tobacco material produced by the method according to any one of claims 1 to 35.

51. The method according to any one of claims 36 to 50, wherein the component is a tobacco rod.

52. A method for manufacturing a product including a component, including manufacturing the component by the method according to any one of claims 36 to 51.

53. A method for manufacturing a smoking article including a component, including manufacturing the component by the method according to any one of claims 36 to 51.

54. A method for manufacturing a smoking article including a discontinuous tobacco material, including manufacturing the discontinuous tobacco material by the method according to any one of claims 1 to 35.

Images