TOBACCO CONSTITUENT RELEASING COMPONENTS, METHODS OF MAKING THE COMPONENTS AND ARTICLES COMPRISING THE COMPONENTS

Abstract

Tobacco constituent releasing components comprising an agglomerated structure formed from a precursor composition comprising tobacco particles and one or more aerosol forming agents, processes for preparing tobacco constituent releasing components, and various tobacco industry products including the tobacco constituent releasing components.

Description

The present application is a National Phase entry of PCT Application No. PCT/GB2020/050085, filed Jan. 16, 2020 which claims priority from GB Patent Application No. 1900627.9 filed Jan. 16, 2019, each of which is hereby fully incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to tobacco constituent releasing components comprising tobacco particles in an agglomerated structure. The disclosure also relates to tobacco industry products including the tobacco constituent releasing components and to methods of manufacturing the tobacco constituent releasing components.

BACKGROUND

It is known to provide a source of tobacco constituents from which said tobacco constituents are released upon heating the source without combustion. Drawbacks associated with such sources can include, for example, inadequate control of the release of the tobacco constituents, and only a relatively small proportion of the constituents being released during the normal use of the product.

SUMMARY

According to a first aspect of the disclosure, a tobacco constituent releasing component is provided, comprising an agglomerated structure formed from a precursor composition comprising tobacco particles, the release of the tobacco constituents upon heating the component without combustion being controlled by adjusting one or more of: (i) the surface area to volume ratio of the component; and (ii) the amount of aerosol forming agent(s) included.

In some embodiments, the one or more aerosol forming agent is included in an amount of from about 3% to about 30% by weight of the component, preferably in an amount of from about 15% to about 30% by weight of the component.

According to a second aspect of the disclosure, a tobacco constituent releasing component is provided comprising an agglomerated structure formed from a precursor composition comprising tobacco particles and at least 10% by weight of at least one aerosol forming agent, the tobacco constituent releasing component having one or more undulating or irregular surfaces and/or channels within the component, and wherein the tobacco within the component does not have a basic pH.

In some embodiments, the tobacco constituent releasing component has one or more inner channels extending through the component.

In some embodiments, the tobacco constituent releasing component has a cross-sectional shape of a spoked wheel or a star.

In some embodiments, the agglomerated structure is formed by extrusion.

In some embodiments, the aerosol forming agent is one or more selected from the group consisting of glycerol, propylene glycol and glyceryl triacetate.

In some embodiments, the tobacco constituent releasing component is impregnated with one or more aerosol forming agents, and/or the tobacco particles are impregnated with the one or more aerosol forming agents.

In some embodiments, the tobacco constituent releasing component comprises at least 50% by weight tobacco particles.

In some embodiments, the tobacco constituent releasing component comprises at least 80% by weight a combination of tobacco particles and aerosol forming agent.

In some embodiments, the tobacco particles have an average diameter no greater than 0.5 mm and preferably wherein the tobacco particles have an average particle size within the range of about 0.1 to about 0.4 mm.

In some embodiments, the tobacco constituent releasing component has a generally rod-shaped external form.

In some embodiments, the tobacco constituent releasing component has a diameter of from about 4 mm to about 10 mm, and preferably from about 5 mm to about 8 mm.

In some embodiments, the tobacco constituent releasing component has a length of from about 5 mm to about 80 mm, and preferably from about 10 mm to about 25 mm.

In some embodiments, the tobacco constituent releasing component does not have a basic pH and/or the precursor composition does not have a basic pH.

In some embodiments, the precursor composition does not include a basic pH adjusting agent.

In some embodiments, the tobacco constituent releasing component further comprises one or more binders, preferably wherein the one or more binders are selected from the group consisting of: starches, polysaccharides, pectins, celluloses, cellulose derivatives such as carboxymethylcellulose, and alginates.

In some embodiments, the tobacco constituent releasing component does not comprise a binder to assist agglomeration of the tobacco particles.

In some embodiments, the tobacco constituent releasing component further comprises one or more flavor-modifying additive.

According to a third aspect of the disclosure, a process for preparing a tobacco constituent releasing component is provided, comprising forming an agglomerated structure from a precursor composition comprising tobacco particles, wherein a desired release of the tobacco constituents is provided upon heating the component without combustion by adjusting one or more of: (i) the surface area to volume ratio of the component; and (ii) the amount of aerosol forming agent(s) included.

In some embodiments, the process is for preparing a tobacco constituent releasing component according to the first aspect.

According to a fourth aspect of the disclosure, a process for preparing a tobacco constituent releasing component is provided, comprising forming by extrusion an agglomerated structure from a precursor composition comprising tobacco particles and at least 10% by weight of at least one aerosol forming agent, the extruded tobacco constituent releasing component having one or more undulating or irregular surfaces and/or channels within the component, and wherein the process does not include adjusting the pH of the tobacco within the component to a basic pH.

In some embodiments of the processes, the precursor composition is extruded to form the agglomerated structure.

In some embodiments of the processes, the precursor composition is extruded through a die to provide one or more inner channels extending through the component.

In some embodiments of the processes, the precursor composition is extruded through a die to provide the component with a cross-sectional shape of a spoked wheel or a star.

In some embodiments of the processes, the precursor composition is heated to a temperature of from about 40° C. to about 120° C.

In some embodiments of the processes, the precursor composition is cooled during or after extrusion, preferably wherein the precursor composition is cooled by exposure to a surface having a temperature of from about 5° C. to about 15° C.

In some embodiments of the processes, the pH of the component and/or of the precursor composition is not adjusted to a basic pH.

In some embodiments of the processes, the precursor composition does not include a basic pH adjusting agent.

According to a fifth aspect of the disclosure, there is provided, in the preparation of a tobacco constituent releasing component having an agglomerated structure formed from a precursor composition comprising tobacco particles and one or more aerosol forming agents, the use of a step of selecting one or more of: (i) the surface area to volume ratio of the component; and (ii) the amount of aerosol forming agent(s) included, to provide the tobacco constituent releasing component with a desired release of the tobacco constituents upon heating the component without combustion.

In some embodiments, the use is for preparing a tobacco constituent releasing component according to the first aspect.

In some embodiments of the use, the surface area to volume ratio of the component is increased by forming the agglomerated structure to provide one or more inner channels extending through the component.

In some embodiments of the use, the component has a cross-sectional shape of a spoked wheel or a star.

In some embodiments of the use, the pH of the component and/or of the precursor composition is not adjusted to a basic pH.

In some embodiments of the use, the precursor composition does not include a basic pH adjusting agent.

According to a sixth aspect of the disclosure, a smoking article comprising a filter and a rod of smokeable material is provided, the filter comprising a tobacco constituent releasing component according to the first aspect.

According to a seventh aspect of the disclosure, a filter or filter element for a combustible smoking article is provided, comprising a tobacco constituent releasing component, the tobacco constituent releasing component comprising an agglomerated structure formed by extruding a precursor composition comprising tobacco particles, the tobacco constituent releasing component delivering flavor to mainstream smoke upon use of the smoking article, wherein the pH of the component and/or of the precursor composition is not adjusted to a basic pH.

In some embodiments, the filter or filter element for a combustible smoking article comprises a tobacco constituent releasing component according to the first aspect.

According to an eighth aspect of the disclosure, an apparatus for heating smokeable material without combustion to volatilize at least one component of the smokeable material is provided, the smokeable material comprising one or more tobacco constituent releasing components according to the first aspect.

In some embodiments, the apparatus further comprises liquid which is to be heated to form a vapor, optionally wherein the liquid does not comprise nicotine.

In some embodiments of the apparatus, the smokeable material is heated by the vapor.

In some embodiments of the apparatus, a means for heating the liquid to form a vapor is included, but a separate means for heating the smokeable material is not included.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the disclosure will now be described, by way of example only, with reference to accompanying drawings, in which:

FIG. 1 is a flow chart showing key steps of a process according to certain embodiments of the present disclosure;

FIGS. 2a, 2b and 2c show examples of nozzle designs for forming extruded agglomerates having inner channels, while FIGS. 2d and 2e show how such a die may be used to shape the extruded agglomerate;

FIG. 3 shows a series of extruded agglomerates, showing different cross-sectional geometries forming inner channels;

FIG. 4a shows an example of a die used to produce granules by extrusion, while FIG. 4b shows how such a die may be used to form the extruded agglomerates;

FIG. 5 is a schematic representation of some extruded granules;

FIG. 6 is a schematic cross-sectional view of a tobacco heating product for heating smokeable material to volatilize at least one component of the smokeable material including a tobacco constituent releasing component;

FIG. 7 is a schematic view of a Hybrid device for heating smokeable material to volatilize at least one component of the smokeable material including a tobacco constituent releasing component;

FIG. 8 is a schematic cross-sectional view of an example of a cartridge containing multiple tobacco constituent releasing components;

FIG. 9 is a schematic side view of a combustible smoking article including a filter comprising multiple tobacco constituent releasing components;

FIG. 10 is a schematic side view of a combustible smoking article including a filter comprising a single tobacco constituent releasing component; and

FIG. 11 is a schematic side view of a combustible smoking article including a multi-segment filter wherein one filter segment is a tobacco constituent releasing component.

DETAILED DESCRIPTION

The disclosure relates to tobacco constituent releasing components that are formed from tobacco particles. These components are able to release tobacco constituents including flavors and nicotine. They may also act as a carrier for other materials that are to be released. The tobacco constituent releasing components are suitable for incorporation into various tobacco industry products.

At least some of the released constituents are directly derived from the tobacco particles used to form the components. In some embodiments, further materials may be added to the components for release. These further materials may, for example, also comprise tobacco constituents added to supplement those directly derived from the tobacco particles. Alternatively or in addition, the further materials added to the components for release may not be derived from tobacco. For example, the components may also, in some embodiments, carry and release other flavors, including those not derived from tobacco.

Incorporated into a tobacco industry product, the tobacco constituent releasing component is able to modify the aerosol produced by said product during use. The flow of air or aerosol over and/or through the component, optionally with heating, causes the release of materials from the component. The released materials may, in some embodiments, include tobacco constituents such as flavors and aromas, as well as other tobacco derived materials such as nicotine, and, where included in the tobacco constituent releasing component, materials that are not derived from tobacco or are not derived from the tobacco particles included in the components.

The released materials become entrained in the air or aerosol, modifying it. In some embodiments, the flavor, aroma or taste of the aerosol produced by the tobacco industry product is modified by the tobacco constituent releasing component. In some embodiments, the aerosol is enriched with natural tobacco flavors and aromas. Additionally or alternatively, the aerosol is modified with non-tobacco flavors as a result of flavors or flavor sources being incorporated into the tobacco constituent releasing components. In further embodiments, the aerosol may be modified by the addition of nicotine. In yet further embodiments, the mouthfeel of the aerosol may be modified by materials, such as aerosol forming agents, released by the tobacco component releasing components.

The tobacco constituent releasing components are agglomerated structures formed from a precursor composition comprising tobacco particles. This means that the components are a mass or cluster formed by fusing or adhering multiple particles to one another. The constituent particles include tobacco particles. In some embodiments, particles of other materials may also be included.

An important aspect of the disclosure is that the release of materials from the tobacco constituent releasing components may be controlled and adapted to the specific requirements of the tobacco industry product into which it is to be incorporated. In particular, it is desirable to control the rate and extent of release. The release of materials is key for providing the desired flavor profile during use of the tobacco industry product, as well as the desired sensorial experience. In particular, it may be desirable to control how quickly the release occurs following commencement of the use of the product, the longevity of release and the consistency of release. It is also important to ensure that a significant proportion of the materials to be released contained in the tobacco constituent releasing component is actually released during the normal use of the tobacco industry product.

A tobacco constituent releasing component is provided, comprising an agglomerated structure formed from a precursor composition comprising tobacco particles, the release of the tobacco constituents upon heating the component without combustion being controlled by adjusting one or more of: (i) the surface area to volume ratio of the component; and (ii) the amount of aerosol forming agent(s) included.

In order to improve release of the tobacco constituents and other materials from the component during use in a tobacco industry product (where the component is heated but not combusted), it is desirable for the component to have a high surface area to volume ratio. An increased surface area of the tobacco constituent releasing component will increase the release of the tobacco constituents and other materials. The increased surface area to volume ratio means that more of the tobacco constituents and other materials will be situated closer to the surface of the component, so that they are heated and released more readily, and a greater proportion is released. As used herein, an increased surface area or an increased surface area to volume ratio refers to in a comparison with the surface area of a solid structure which is roughly spheroid or has a cylindrical rod shape or the same volume.

As described in greater detail below, the shape of the tobacco constituent releasing components may be selected to increase the surface area to volume ratio, for example by increasing the surface area by creating undulating or irregular surfaces or by creating channels within the components. It is desirable to reduce the distance from the surface of the component of the tobacco constituents and other materials to be released, so that as much of these materials may be released during use of the tobacco industry product, rather than remaining trapped within the agglomerated structure. Increased proximity of the tobacco constituents and other materials to the surface of the tobacco constituent releasing component will also mean that the materials can be released in a controlled manner as they will be more readily heated and volatilize when the component is heated.

The surface area of the tobacco constituent releasing component, and thus the release of the tobacco constituents and other materials, may also be increased by the presence of pores within the agglomerated structure. Such pores will reduce the density of the agglomerated structure, enhancing thermal transfer throughout the tobacco constituent releasing component. In some embodiments, pores may be formed by including porous materials in the precursor composition. Selecting larger diameter tobacco particles and/or tobacco particles with a narrow particle size distribution can also enhance the formation of small gaps or pores within the agglomerated structure. Alternatively or in addition, pores may be formed in the agglomerated structure after the agglomerated structure has been made from the precursor composition, for example by puncturing the structure or by selectively removing part or parts of the agglomerated structure.

Thus, a combination of the shape of the tobacco constituent releasing component and the porosity/density may be selected to control the surface area to volume ratio and/or to control: (i) the heat transfer rate; (ii) the aerosol production rate; (iii) the amount of aerosol produced; and (iv) the extent of the release of the tobacco constituents and other materials.

The tobacco constituent releasing components according to the disclosure include at least one aerosol forming agent. It is known to use aerosol forming agents to improve the mouthfeel of aerosols. The amount of aerosol forming agent that is included in tobacco components or materials, such as those included in tobacco heating products, tends to be limited as the aerosol forming agents are generally in liquid form and are present on the surface of the tobacco material they are added to. As a result, in practice the inclusion of more than about 10% by weight of the aerosol forming agent renders the material difficult to handle and process.

However, as discussed in greater detail below, embodiments of the present disclosure allow greater amounts of aerosol forming agent to be included. This provides greater flexibility in selecting the amount of aerosol forming agent and this may be used to control or adjust the release of tobacco constituents and other materials from the tobacco constituent releasing components. Release of the aerosol forming agent in the form of an aerosol as a result of the heating (but not combustion) of the tobacco constituent releasing component not only improves the properties of the aerosol generated by the tobacco industry product the component is incorporated into, but also enhances the release of tobacco constituents and other materials from the component. This is particularly the case where the tobacco and/or the agglomerated structure is impregnated with the aerosol forming agent.

The amount of aerosol forming agent will also influence the rate at which the aerosol is generated.

The aerosol forming agent may be, for instance, a polyol aerosol generator or a non-polyol aerosol generator, preferably a non-polyol aerosol generator. It may be a solid or liquid at room temperature, but preferably is a liquid at room temperature. Suitable polyols include sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol. Suitable non-polyols include monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, and esters such as diacetin, triacetin, triethyl citrate or isopropyl myristate. A combination of aerosol forming agents may be used, in equal or differing proportions. Glycerol, propylene glycol and glyceryl triacetate (also known as triacetin) are particularly preferred.

In this disclosure, the release of the tobacco constituents or other materials is not controlled by adjusting the pH of the tobacco and/or the precursor composition or of the tobacco constituent releasing component. Such pH adjustment can change the nature of the constituents and may be undesirable or unacceptable from a regulatory standpoint for some products in some jurisdictions.

Tobacco Particles

The tobacco particles present in the precursor composition have a size small enough to ensure that multiple such particles can be agglomerated to form tobacco constituent releasing components having desired dimensions based upon their intended use. Smaller tobacco particles have a greater surface area to volume ratio and they may therefore exhibit enhanced release of tobacco constituents compared to particles of larger sizes.

In addition, the size of the tobacco particles (and of other particles in the precursor composition) will have an effect on the porosity and density of the agglomerated structures and tobacco constituent releasing components. Thus, the size of the tobacco particles may be selected to produce a more porous agglomerated structure, which will have an impact on the release of the tobacco constituents. Thus, the size of the tobacco particles is another factor that may be adjusted in order to influence the release of tobacco constituents.

The extrusion processes used to form the agglomerated structures can be sensitive to the size of the particles within the composition being extruded. Therefore, it may be desirable for the particles in the precursor composition, including the tobacco particles, to have an average particle size of no greater than about 0.5 mm, or to have an average particle size of no greater than about 0.3 mm, when measured by sieving. In some embodiments, it may be desirable for the tobacco particles in the precursor composition to have an average particle size of no greater than about 0.5 mm, or to have an average particle size of no greater than about 0.3 mm, when measured by sieving. In some embodiments, the average particle size is within the range of about 0.1 to about 0.4 mm, or in the range of about 0.2 to about 0.3 mm. In some embodiments, at least about 90% of the particles of the precursor composition will have a particle size within the range of 0.1 to 0.5 mm. In some embodiments, at least about 90% of the tobacco particles of the precursor composition will have a particle size within the range of 0.1 to 0.5 mm. In some embodiments, none of the particles in the precursor composition have a particle size greater than 1 mm.

Tobacco particles for inclusion in the tobacco constituent releasing components may be formed by grinding, shredding, cutting or crushing tobacco material. Suitable machinery to create such tobacco particles includes, for example, shredders, cutters, or mills, such as hammer mills, roller mills or other types of commercially available milling machinery.

Without wishing to be bound by any one particular theory, it is speculated that the chopping of the tobacco to form the tobacco particles enhances the release of tobacco constituents including volatile flavors and aromatic constituents, as well as nicotine. The increased surface area of the tobacco particles is also thought to aid volatilization. The smaller tobacco particles also improve the homogeneity of agglomerated structures formed therefrom together with other components.

The tobacco material used to form the tobacco particles may be any type of tobacco and any part of the tobacco plant, including tobacco lamina, stem, stalk, ribs, scraps and shorts or mixtures of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed here. The tobacco may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-processed or unprocessed, and may be, for instance, solid stems (SS); shredded dried stems (SDS); steam treated stems (STS); or any combination thereof. The tobacco material may be fermented, cured, uncured, toasted, or otherwise pre-treated.

Additional Components of Precursor Composition

In some embodiments, the precursor composition comprises a diluent. The diluent may be in solid or liquid form. In some embodiments, the diluent is inert or substantially inert.

In some embodiments, the agglomerated structure formed from the precursor composition may have an increased surface area by including in the precursor composition particles of an inert filler material. Suitable inert fillers may be porous or non-porous.

In some embodiments, the precursor composition does not include a binder or binding additive. In other embodiments, the precursor composition comprises a binder or binding additive. The binding additive may be selected to assist in the formation of an agglomerated structure by helping to adhere the tobacco particles to each other and to other components in the composition. Suitable binding additives include, for example, starches, polysaccharides, pectins, celluloses, cellulose derivatives such as carboxymethylcellulose, and alginates.

In some embodiments, the tobacco constituent releasing components may include a flavor-modifier, to modify the flavor provided by the tobacco particles or to add flavor. In some embodiments, the flavor-modifier—modifier may be included in the precursor composition. Alternatively or in addition, the flavor-modifier may be added to or applied to the agglomerated structure. Flavor-modifiers include, for example, casing materials, as well as “flavor” and “flavorant” materials which, where local regulations permit, may be used to create a desired taste or aroma in a product for adult consumers.

They may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), flavor enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, oil, liquid, gel, wax or powder.

In some embodiments, the pH of the tobacco of the tobacco constituent releasing components is not adjusted. In particular, in some embodiments, the component does not have a basic pH and/or the precursor composition does not have a basic pH. Additionally or alternatively, the precursor composition preferably does not include a basic pH adjusting agent.

In some embodiments, water may be added to the precursor composition as a processing aid. For example, the presence of water may help to dissolve components of the precursor composition, and/or it may assist with binding or improve agglomeration.

Forming the Agglomerated Structures

FIG. 1 is a flow chart showing the key steps in the processes of the present disclosure. The tobacco starting material, which may be pre-treated or pre-processed, is provided in the form of particles having the desired particle size. The tobacco precursor composition is formed, comprising the tobacco particles, at least one aerosol forming agent and, in some embodiments, may include further additional components. These additional components may be in liquid form or in solid form. Additional solid components are preferably in particulate or powder form. In other embodiments, the additional components may be introduced into the agglomerated structure separate from the tobacco precursor composition.

In some embodiments, water may be added to the precursor composition as a processing aid. For example, the presence of water may help to dissolve components of the precursor composition, and/or it may assist with binding or improve agglomeration.

Finally, the precursor composition is formed into an agglomerated structure, i.e., a monolithic structure formed from multiple tobacco particles and the other components of the precursor composition. In some embodiments, the agglomerated structure may be formed from the precursor composition by a process including one or more steps selected from the group consisting of granulation and/or extrusion, and optionally also spheronisation.

Granulation of the precursor composition involves the binding or fusing together of the particles of the precursor composition to form larger, multi-particle entities which are referred to herein as agglomerated structures. The multi-particle entities formed by granulation are called granules and they may have various geometric shapes, including, for example, the general form of spheres, cylinders, and the like.

In one embodiment, the granulation step used is wet granulation. In wet granulation, granules are formed by the addition of a granulation liquid onto a powder bed. Agitation in the system, along with the wetting of the components within the precursor composition, results in the aggregation of the particles to produce wet granules. The granulation liquid may be at least partially removed by drying to provide dry granules. The granulation liquid may be water-based or solvent-based. Suitable granulation liquids include, for example, water, glycerol, ethanol and isopropanol, either alone or in combination. In some embodiments, the granulation liquid comprises an aerosol forming agent, such as glycerol or one of the other agents mentioned herein, and/or a binder or binding agent. In some embodiments, no water is added to the precursor composition to aid granulation.

In another embodiment, the granulation step used is dry granulation. In dry granulation, granules are formed without using a granulation liquid. This type of process has the advantage that it does not expose the precursor composition to moisture and so there is no requirement to expose the granules to heat in order to dry them. Forming granules by dry granulation involves compacting and densifying the precursor composition, usually under high pressure.

Extrusion of the precursor composition involves the feeding of the precursor composition through an orifice to produce an extruded agglomerate. The process, which applies pressure to the precursor composition combined with shear forces, results in agglomerated structures.

Extrusion may be performed using one of the main classes of extruders: screw, sieve and basket, roll, and ram extruders. Forming the tobacco constituent releasing components by extrusion has the advantage that this processing combines mixing, conditioning, homogenizing and molding of the precursor composition.

In some embodiments, during extrusion the free-flowing precursor composition is exposed to elevated pressure and temperature and is forced though an orifice, such as a shaping die, to form an extruded agglomerate. In some embodiments, the extruded agglomerate has an elongated form and/or it may be cut into segments of a desired length as it exits the orifice. A rod-like extruded agglomerate may subsequently be cut into segments of desired length.

In some embodiments, the precursor composition comprising tobacco particles is exposed to temperatures from about 40° C. to about 150° C., or from about 80° C. to about 130° C. within the extruder. The composition may be exposed to pressures ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die being used.

In some embodiments, due to the relatively high density of the extruded agglomerate and the relatively open surface of the tobacco particles within it, the tobacco constituent releasing components formed from the extruded agglomerate exhibit good heat transfer and mass transfer, which has a positive impact on the release of tobacco constituents, such as flavors and nicotine.

In some embodiments, the extrusion may be a generally dry process, with the precursor composition being a substantially dry material that includes tobacco particles, as well as optionally other particulate materials including, for example, base, diluent, solid flavor modifiers, etc.

In some embodiments, liquids may be added to the precursor composition during the extrusion process. For example, water may be added to the precursor composition, for example as a processing aid to assist dissolution or solubilisation of components of the composition, or to aid binding or agglomeration. Alternatively or additionally, a wetting agent may be added to the precursor composition.

In some embodiments, the liquid may be an aerosol forming agent such as glycerol or others discussed herein. When liquid is added to the precursor composition in this manner, the liquid is applied not only on the surface, but, as a result of the extruder pressure combined with the intensive mixing by high shear forces, the extruded agglomerate becomes impregnated with the liquid. Where the liquid is an aerosol forming agent, this can result in a high availability of the aerosol forming agent in the agglomerated product to enhance evaporation of flavor components from the tobacco particles and other components of the agglomerated structure, enhancing release of tobacco constituents from the resultant extruded tobacco constituent releasing components.

In some embodiments, in view of the impregnation of the extruded agglomerate with the aerosol forming agent, greater volumes of this agent can be incorporated into the tobacco constituent releasing component than if the aerosol forming agent were simply being applied to the surface of the precursor composition or of the extruded agglomerate. In some embodiments, the amount of aerosol forming agent incorporated into the tobacco constituent releasing component may be at least about 3% by weight, at least about 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19% by weight, or at least about 20% by weight. In some embodiments, the amount of aerosol forming agent incorporated into the tobacco constituent releasing component may be up to about 15%, up to about 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29% by weight or up to about 30% by weight.

In some embodiments, the one or more aerosol forming agent is included in an amount of from about 3% to about 30% by weight of the component, preferably in an amount of from about 15% to about 30% by weight of the component.

The extruded agglomerate will be shaped by the orifice or die through which it is forced. In some embodiments, the extruded agglomerate is cut into pieces of desired length. The pieces formed in this way may be used as tobacco constituent releasing components or they may undergo further processing.

In some embodiments, the orifice or die is shaped to provide a solid strand of extruded agglomerate. For example, the extruded agglomerate may have the form of a solid cylindrical rod. Alternatively, the extruded agglomerate may have different cross-sectional shapes, including oval, polygonal (such as triangular, square, etc.), and stars.

In some embodiments, the extruded composition is formed into a desired shape selected to enhance or promote the release of flavor, for example by providing a form having a large surface area per unit volume. This large surface area may be provided on the outer surface of the extruded agglomerate, for example by selecting cross-sectional shapes with large perimeter. Alternatively or in addition, the large surface area may be provided through the creation of channels within the extruded agglomerate.

In some embodiments, the orifice or die is shaped to provide an extruded agglomerate with inner channels. These inner channels provide further surface area and can enhance tobacco constituent release.

Examples of some nozzle or die designs are shown in FIGS. 2a, 2b and 2c. These nozzles or dies have orifices 21 through which the extruded composition is forced to produce an extruded agglomerate with a cartwheel-like spoked structure. These nozzles or dies are used in an extruder, as shown in FIGS. 2d and 2e, in which the direction of the flow of the material being extruded is indicated by the arrow A.

FIG. 3 is an image of a series of extruded agglomerates, showing different cross-sectional geometries including inner channels. Some of these extruded agglomerates have been made using the nozzle designs of FIGS. 2a, 2b and 2c.

Tobacco constituent releasing components formed from such shaped extruded agglomerate sections have an inner channel structure which has advantageous adjustable strand ventilation properties and a significantly enlarged inner surface leading to improved heat and mass transfer. As a result, such components exhibit better, more uniform release of flavor by evaporation. Furthermore, the structure with inner channels exhibits significantly improved strength in both the radial and axial directions, which is beneficial for the further processing of the extruded agglomerate, for example when it is cut into segments.

In some embodiments, the diameter of the tobacco constituent releasing component is from about 4 mm to about 10 mm, or the diameter may be from about 5 mm to about 8 mm.

In some embodiments, the tobacco constituent releasing component is a cylindrical tobacco segment. In some embodiments the cylinder has a diameter of from about 5 mm to about 8 mm and a length of from about 5 mm to about 80 mm, from about 15 mm to about 50 mm, or from about 20 mm to about 30 mm.

By means of various nozzle designs and/or different process parameters within the extruder, including the temperature, pressure and shear forces, extruded agglomerates with different physical properties may be prepared, including different heat transfer properties, draft resistance, and capable of producing different aerosols and/or of modifying aerosols being drawn through the extruded agglomerate.

The make up of the precursor composition can also play a very significant role in determining the physical and mechanical properties of the extruded material and, as a consequence, of the tobacco constituent releasing components.

In some embodiments, the extruded agglomerate is shaped upon discharge from the extruder. In some embodiments, the extruded agglomerate is cut to an initial length, for example, 1 meter, and allowed to cool before then being cut into sections of the desired length to provide tobacco constituent releasing components of the desired dimensions.

In some embodiments, the extruded agglomerate may be cooled just before or just as it leaves the extruder. In some embodiments, the cooling is intensive and involves exposing the extruded agglomerate, which will be at an elevated temperature, for example from about 30° C. to about 100° C., or from about 40° C. to about 70° C., to a cooling means that will reduce the temperature to within a range of from about 0° C. to about 25° C., or from 5° C. to about 15° C. This rapid cooling of the extruded agglomerate may enhance the internal and external stability of the extruded agglomerate. In some embodiments, it is the die that is cooled to achieve this effect.

In some embodiments, it may be desirable to control the temperature of the precursor composition during extrusion, including before feeding the composition through the die. This is especially the case where the precursor composition includes temperature sensitive components, such as aerosol forming agents such as glycerol. Thus, in some embodiments, extrusion of the precursor composition includes reducing the temperature of the precursor composition before it reaches the die. Such cooling of the precursor composition may result in the formation of an extruded agglomerate with beneficial properties, or may improve the strand-shaping process, for example where channels are to be formed within the extruded agglomerate strand.

In some embodiments, the precursor composition may be granulated prior to extrusion. Where the precursor composition includes multiple different types of particles, this granulation step can enhance homogenization within the extruded agglomerate. The granulated precursor composition may be fed into an extruder to form the tobacco constituent releasing components.

Granulation of the precursor composition involves the binding or fusing together of the particles of the precursor composition to form larger, multi-particle entities which are agglomerated structures. The multi-particle entities formed by granulation are called granules and they may have various geometric shapes, including, for example, the general form of spheres, cylinders, and the like.

In one embodiment, the granulation step used is wet granulation. In wet granulation, granules are formed by the addition of a granulation liquid onto a powder bed. Agitation in the system, along with the wetting of the components within the precursor composition, results in the aggregation of the particles to produce wet granules. The granulation liquid may be at least partially removed by drying to provide dry granules. The granulation liquid may be water-based or solvent-based. Suitable granulation liquids include, for example, water, ethanol and isopropanol, either alone or in combination. In some embodiments, the granulation liquid comprises an aerosol forming agent, such as glycerol.

In another embodiment, the granulation step used is dry granulation. In dry granulation, granules are formed without using a granulation liquid. This type of process has the advantage that it does not expose the precursor composition to moisture and so there is no requirement to expose the granules to heat in order to dry them. Forming granules by dry granulation involves compacting and densifying the precursor composition, usually under high pressure.

In some embodiments, spheronisation is used to further process extruded segments. These segments are typically cylindrically-shaped and are cut or broken into uniform lengths following extrusion. They are then gradually transformed into spherical shapes by spheronisation. This shaping occurs as a result of plastic deformation and spheronisation can lead to spherical agglomerated structures, often with a nearly uniform diameter.

Incorporation into a Product

A tobacco industry product refers to any item made in, or sold by the tobacco industry, typically including a) cigarettes, cigarillos, cigars, tobacco for pipes or for roll-your-own cigarettes, (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes); b) non-smoking products incorporating tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes such as snuff, snus, hard tobacco, and heat-not-burn (HnB) products; and c) other nicotine-delivery systems such as inhalers, aerosol generation devices including e-cigarettes, lozenges and gum. This list is not intended to be exclusive, but merely illustrates a range of products which are made and sold in the tobacco industry.

One or more of the tobacco constituent releasing components disclosed herein may be incorporated into an aerosol provision device. As used herein, an aerosol provision device includes vapor devices such as e-cigarettes, devices for heating smokeable material such as tobacco heating devices and Hybrid devices.

As used herein, the apparatus for heating smokeable material to volatilize at least one component of the smokeable material includes so-called “heat not burn” products or tobacco heating devices or products, which release compounds by heating, but not burning, smokeable material.

Hybrid devices are devices in which a liquid, such as a nicotine-containing liquid or a nicotine-free liquid, is heated to form an aerosol and this aerosol is then drawn through a smokeable material, such as a tobacco segment, picking up tobacco flavors or wherein a separate aerosol is formed by heating a smokeable material. In some embodiments, the device includes a means for heating the smokeable material directly, in addition to, or as an alternative to, the heating of the smokeable material by the aerosol formed by heating the liquid to form an aerosol.

The tobacco constituent releasing component may be positioned within an apparatus or device so that the tobacco constituents that are released become entrained in an aerosol generated by the apparatus or device upon use, modifying the properties of the aerosol, for example by imparting tobacco constituents, including tobacco flavor, to that aerosol. Additionally or alternatively, the tobacco constituent releasing component may itself generate an aerosol during use, said aerosol including the released tobacco constituents.

In some embodiments, an apparatus or device may be provided with a filter having tobacco constituent releasing component located within said filter. This may be in addition to or instead of the apparatus or device including other tobacco constituent releasing components.

In some embodiments the filter or filter element may comprise a filter material which has a filtering effect. Suitable filter material may include, for example, tow comprising or consisting of cellulose acetate, polylactic acid, and/or other suitable polymers, or the filter or filter element may comprise a hard material such as plastic with holes.

In some embodiments where multiple tobacco constituent releasing components are incorporated into a filter, this may be in a “Dalmatian” style filter section, where the tobacco constituent releasing components are dispersed throughout a fibrous filter plug material. Alternatively, the tobacco constituent releasing components may be located in a cavity within the filter. The cavity may, for example, be a cavity section positioned between two (or more) adjacent filter plugs or the cavity may be a pocket defined within a filter plug. In such embodiments, the tobacco constituent releasing components may be small in size, for example in the form of granules.

In other embodiments, a larger, single tobacco constituent releasing component is incorporated into a filter. For example, a single tobacco constituent releasing component may be embedded in a fibrous filter plug material.

Alternatively, the tobacco constituent releasing component may be incorporated into a multi-segment filter, the tobacco constituent releasing component itself making up one of the filter segments. In such embodiments, the tobacco constituent releasing component may have any shape or size, but it may be advantageous for the component to a have a cylindrical shape and the dimensions similar to or compatible with those of the filter segments. In some embodiments, the tobacco constituent releasing component may be surrounded by filter material such as a layer of fibrous filter tow, to form a filter segment. In other embodiments, the tobacco constituent releasing component may have the dimensions of a filter plug and it may be incorporated into a filter with one or more adjacent filter plugs. Alternatively, a tobacco constituent releasing component may be included in a cavity section positioned between two (or more) adjacent filter plugs.

In some embodiments the tobacco constituent releasing component itself may be the filter element in the aerosol provision device, it being capable of filtering condensates and other particulate matter in the aerosol, before the aerosol is inhaled by the user.

According to some embodiments, one or more tobacco constituent releasing components are included in an aerosol provision device or apparatus for heating smokeable material to volatilize at least one component of the smokeable material in which a tobacco segment is heated but not combusted (i.e., a tobacco heating product or so-called Heat-not-Burn product). In some of these products, the tobacco segment is heated to generate an aerosol.

One option is to incorporate the one or more tobacco constituent releasing components in the filter of such products. In some embodiments, multiple tobacco constituent releasing components are incorporated into the filter of a tobacco heating product. In other embodiments, a single tobacco constituent releasing component is incorporated into the filter of a tobacco heating product.

Another option is to incorporate one or more tobacco constituent releasing components in the tobacco segment of such products. In some embodiments, one or more tobacco constituent releasing components may be incorporated into tobacco material to form the tobacco segment. For example, the one or more tobacco constituent releasing components may be dispersed within the tobacco material, such as cut tobacco or reconstituted tobacco, to contribute to the flavor imparted by the tobacco. In other embodiments, the tobacco included in the tobacco segment of the tobacco heating product consists or consists essentially of one or more tobacco constituent releasing components. In one embodiment, the tobacco segment heated by the tobacco heating product consists of or consists essentially of one or more tobacco constituent releasing component. The tobacco constituent releasing component may be heated directly. Where the tobacco segment is multiple tobacco constituent releasing components, these may be held in a container or cartridge. At least portions of the container or cartridge may be permeable to air, to allow air to flow over or through the tobacco constituent releasing components.

FIG. 6 shows a cross-sectional view of an example of a tobacco heating product for heating a smokeable material. The apparatus 11 has a heating chamber 14 which in use contains the smokeable material to be heated and volatilize d. In this embodiment, the smokeable material is in the form of a monolithic tobacco constituent releasing component 13. The smokeable material could however be multiple tobacco constituent releasing components held in the heating chamber or provided in a cartridge like the one illustrated in FIG. 8.

The apparatus 11 of FIG. 6 further has an electronics/power chamber 16 which may, for example, contain electrical control circuitry and/or a power source (not shown). The electrical control circuitry may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the smokeable material via a heating element (not shown). The electrical control circuitry may in use receive a signal from for example a puff-actuated sensor which is sensitive to for example changes in pressure or changes in rate of air flow that occur upon initiation of a draw on the apparatus 11 by a user. The electrical control circuitry can then operate so as to cause heating of the smokeable material “on demand”. Various arrangements for a puff-actuated sensor are available, including for example a thermistor, an electro-mechanical device, a mechanical device, an optical device, an opto-mechanical device and a micro electro mechanical systems (MEMS) based sensor. As an alternative, the apparatus may have a manually operable switch for a user to initiate a puff.

The heating chamber 14 is contained within the housing 12. There may be a support and/or insulating means (not shown) positioned between the heating chamber 14 and the housing 12, for example to assist in heat-insulating the housing 12 from the heating chamber 14, so that the housing 12 does not become hot or at least too hot to touch during use.

The housing 12 includes an inlet 15 through which air is drawn into the apparatus. The housing 12 also includes an outlet 17 at a mouthpiece 18 of the apparatus 11. Air is drawn into the apparatus 11 through the inlet 15, travels through the apparatus picking up tobacco constituents released by the tobacco constituent releasing component 13, and the resulting aerosol generated by the apparatus 11 leaves the apparatus 11 through the outlet 19 and is inhaled by the user.

According to some embodiments, one or more tobacco constituent releasing components are included in a so-called Hybrid product for heating smokeable material to volatilize at least one component of a smokeable material. In some of these products, the tobacco segment is heated to generate an aerosol, in addition to the heating of a liquid, such as a nicotine-containing liquid or a nicotine-free liquid, which is heated by a heat source to form an aerosol or vapor. In some Hybrid products, the aerosol or vapor formed from the liquid is drawn over or through the tobacco segment, picking up tobacco flavors. In other embodiments, the aerosol or vapor formed from the liquid is not drawn over or through the tobacco segment.

In Hybrid products that include a filter, one option is to incorporate the tobacco constituent releasing components in the filter of such products, in a similar manner to that described for tobacco heating products. In some embodiments, multiple tobacco constituent releasing components are incorporated into the filter of a Hybrid product. In other embodiments, a single tobacco constituent releasing component is incorporated into the filter of a Hybrid product.

Where the smoking article is a so-called Hybrid product another option is to incorporate the tobacco constituent releasing components in the tobacco segment of such products. In some embodiments, one or more tobacco constituent releasing components may be incorporated into tobacco material to form the tobacco segment. For example, the one or more tobacco constituent releasing components may be dispersed within the tobacco material, such as cut tobacco or reconstituted tobacco, to contribute to the flavor imparted by the tobacco. In other embodiments, the tobacco included in the tobacco segment of the Hybrid product consists of one or more tobacco constituent releasing components. In one embodiment, the tobacco segment in the Hybrid product consists of or consists essentially of one or more tobacco constituent releasing components.

FIG. 7 shows a cross-sectional view of an example of a Hybrid product for heating a smokeable material and a liquid. The apparatus 21 has a housing 22 containing a chamber 24 which in use contains the smokeable material to be heated and volatilize d. In this embodiment, the smokeable material is in the form of a monolithic tobacco constituent releasing component 23. The smokeable material could however be multiple tobacco constituent releasing components held in the chamber or provided in a cartridge like the one illustrated in FIG. 8. The housing 22 also contains a liquid reservoir 25 containing a liquid 26 to be heated to form a vapor.

The apparatus 21 further has an electronics/power chamber 27 which may, for example, contain electrical control circuitry and/or a power source (not shown). The electrical control circuitry may include a controller, such as a microprocessor arrangement, configured and arranged to control the heating of the smokeable material and of the liquid 26 via one or more heating elements (not shown). The electrical control circuitry may allow the apparatus 21 to be puff-actuated, so as to cause heating of the smokeable material “on demand”. As an alternative, the apparatus 22 may have a manually operable switch for a user to initiate a puff

The housing 22 also includes an inlet 28 through which air is drawn into the apparatus. The housing 22 also includes an outlet 29 at a mouthpiece 30 of the apparatus 21. Air is drawn into the apparatus 21 through the inlet 28, travels through the apparatus picking up the vapor created by heating the liquid 26 in the liquid reservoir 25, and tobacco constituents released by the tobacco constituent releasing component 23, and the resulting aerosol generated by the apparatus 21 leaves the apparatus 21 through the outlet 29 and is inhaled by the user.

The Hybrid device 21 shown schematically in FIG. 7 represents just one possible configuration of such an apparatus. The relative positions of the liquid reservoir 25 and the smokeable material chamber 24 can be changed, as can the path of the air flowing through the apparatus.

In one embodiment, the liquid reservoir is positioned upstream of the smokeable material to be volatilize d. Alternatively, the liquid reservoir may be positioned downstream of the smokeable material to be volatilize d. In a yet further arrangement, the two sources of aerosol in the apparatus may be arranged side-by-side, etc.

In some embodiments, the vapor produced by heating the liquid in the liquid reservoir flows over or through the smokeable material comprising or consisting of one or more tobacco constituent releasing components. In some embodiments, the elevated temperature of the vapor causes the tobacco constituents to be released. Alternatively or in addition, the smokeable material may be separately heated by a heating means.

In some embodiments, a Hybrid device is provided in which the vapor created by heating a liquid heats the smokeable material in order to volatilize at least one component of the smokeable material. In some embodiments, the liquid is a nicotine-free liquid. In other embodiments, the liquid contains nicotine. Where the smokeable material is heated by the vapor to volatilize at least one component of the smokeable material, in certain embodiments the device does not include a separate means for heating the smokeable material. The smokeable material may comprise or consist of at least one tobacco constituent releasing component.

In other embodiments, the vapor produced by heating the liquid in the liquid reservoir does not flows over or through the smokeable material comprising or consisting of one or more tobacco constituent releasing components. Rather, this vapor and the aerosol generated by heating the smokeable material only mix after they are both formed.

The tobacco heating products and Hybrid products described herein may, in some embodiments, include tobacco segments in the form of containers or cartridges containing one or more tobacco constituent releasing components. These containers or cartridges may be removable. They may replace both the chamber holding the smokeable material and the smokeable material in the apparatus described above with reference to FIGS. 6 and 7, and in the alternative embodiments discussed.

Referring to FIG. 8, a tobacco segment cartridge 31 is shown, comprising a housing 32 defining a cavity within which are held one or more tobacco constituent releasing components according to the disclosure (not shown). The housing 32 may, for example be made from molded plastic or the like. In order to allow air drawn through the device to pass into the cartridge 31 and over or through the one or more tobacco constituent releasing components and then out of the cartridge 31, ventilation holes 33 are provided in the housing 32 of the cartridge 31. In some embodiments, the cartridge 31 may further comprise heating means that is heatable by a suitable means in order to heat the one or more tobacco constituent releasing components held therein.

In some embodiments, one or more tobacco constituent releasing components are incorporated into a filter or a filter element for inclusion in a combustible smoking article.

As used herein, the term “combustible smoking article” includes smokeable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The combustible smoking articles include a rod of smokeable material and a filter comprising at least one filter element.

As used herein, the term “combustible smoking article” does not include Heat-not-Burn (HnB) products, or other nicotine delivery products such as aerosol generation devices including e-cigarettes or Hybrid products.

The tobacco constituent releasing component may be positioned within the filter or within a filter element making up the filter of the combustible smoking article, so that the released tobacco constituents become entrained in an aerosol generated by the smoking article upon use, modifying the properties of the aerosol, for example by imparting tobacco constituents, including tobacco flavor, to that aerosol.

Filters and filter elements for use in combustible smoking articles include filter material to remove certain smoke constituents from the mainstream smoke drawn through the smoking article during use. The filter material is gathered together to form a rod which is cut to form individual filter segments. The filter for a smoking article may be made of one segment of filter rod, or may be made from multiple filter elements, with or without a cavity or spaces between them. A widely used filter material is a continuous tow of filamentary cellulose acetate plasticized with triacetin. Other filter materials can comprise at least one material selected from polyvinyl alcohol (PVOH), polylactic acid (PLA), poly(ε-caprolactone) (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch based materials, paper, aliphatic polyester materials and polysaccharide polymers in the form of sheets or fibers.

The filter can have a cylindrical shape and generally have a length and an overall circumference to suit the type of combustible smoking articles they are to be used in. Smoking articles such as cigarettes and their formats are often named according to the cigarette length: “regular” (typically in the range 68-75 mm, e.g. from about 68 mm to about 72 mm), “short” or “mini” (68 mm or less), “king-size” (typically in the range 75-91 mm, e.g. from about 79 mm to about 88 mm), “long” or “super-king” (typically in the range 91-105 mm, e.g. from about 94 mm to about 101 mm) and “ultra-long” (typically in the range from about 110 mm to about 121 mm).

They are also named according to the cigarette circumference: “regular” (about 23-25 mm), “wide” (greater than 25 mm), “slim” (about 22-23 mm), “demi-slim” (about 19-22 mm), “super-slim” (about 16-19 mm), and “micro-slim” (less than about 16 mm). Accordingly, a cigarette in a king-size, super-slim format will, for example, have a length of about 83 mm and a circumference of about 17 mm. Cigarettes in the regular, king-size format have a circumference of from 23 to 25 mm and an overall length of from 75 to 91 mm.

Each format may be produced with filters of different lengths, smaller filters being generally used in formats of smaller lengths and circumferences. Typically the filter length will be from 15 mm, associated with short, regular formats, to 30 mm, associated with ultra-long super-slim formats. The tipping paper will have a greater length than the filter, for example from 3 to 10 mm longer.

Positioned within the filter of a combustible smoking article, the tobacco constituent releasing components of this disclosure are not exposed to significant temperature increases during use of the smoking article. That said, the temperature within the filter of a conventional cigarette does gradually increase during use. In a conventional combustible smoking article, such as a cigarette, and under normal smoking conditions, such as the ISO smoking regime, the smoking may involve 8-9 puffs and the first 5-6 puffs are accompanied by only slight increases in temperature during the puffs. For example, the first puffs may be accompanied by a temporary increase in temperature of in the region of 1-5° C., with the temperature remaining between 20 and 30° C., and in some cases, between 23 and 26° C. During the final few puffs of a conventional combustible smoking article, such as a cigarette, the temperature starts to increase more during the puffs, with peaks starting to exceed 30° C., and exceeding 60° C. for the penultimate and last puffs.

This temperature change may be used to trigger or assist the release of materials from the tobacco constituent releasing component during use of the smoking article. For example, the rise in temperature may help to volatilize remaining components which have not been released during the first few puffs. Alternatively or in addition, materials may be included in the tobacco constituent releasing component specifically to be released or to enhance release of tobacco constituents at these elevated temperatures.

According to some embodiments, multiple tobacco constituent releasing components are incorporated into the filter element for a combustible smoking article. In other embodiments, a single tobacco constituent releasing component is incorporated into the filter element.

Where multiple tobacco constituent releasing components are incorporated into a filter, this may be in a “Dalmatian” style filter section, where the tobacco constituent releasing components are dispersed throughout a fibrous filter plug material.

Such an arrangement is shown in FIG. 9. Referring to FIG. 9, a smoking article 21 comprises a filter 22 and a cylindrical rod of smokeable material 23, such as tobacco, aligned with the filter 22 such that one end of the smokeable material rod 23 abuts the end of the filter 22. The filter 22 is wrapped in a plug wrap (not shown) and the smokeable material rod 23 is joined to the filter 22 by tipping paper in a conventional manner. The filter 22 is substantially cylindrical and comprises filter material 24 throughout which are dispersed tobacco constituent releasing components 25.

Alternatively, the tobacco constituent releasing components may be located in a cavity within the filter. The cavity may, for example, be a cavity section positioned between two (or more) adjacent filter plugs or the cavity may be a pocket defined within a filter plug. In such embodiments, the tobacco constituent releasing components may be small in size, for example in the form of granules.

In other embodiments, larger, monolithic tobacco constituent releasing components are incorporated into a filter. For example, a single tobacco constituent releasing component may be embedded in a fibrous filter plug material.

Such an arrangement is shown in FIG. 10, which shows a smoking article 21 comprising a filter 22 and a cylindrical rod of smokeable material 23, wherein the filter 22 comprises a tobacco constituent releasing component 26 which is surrounded by filter material 24.

Alternatively, the tobacco constituent releasing component may be incorporated into a multi-segment filter, the tobacco constituent releasing component itself making up one of the filter segments. In such embodiments, the tobacco constituent releasing component may have any shape or size, but it may be advantageous for the component to a have a cylindrical shape and the dimensions similar to or compatible with those of the filter segments. In some embodiments, the tobacco constituent releasing component may be surrounded by filter material such as a layer of fibrous filter tow, to form a filter segment. In other embodiments, the tobacco constituent releasing component may have the dimensions of a filter plug and it may be incorporated into a filter with one or more adjacent filter plugs. Alternatively, a tobacco constituent releasing component may be included in a cavity section positioned between two (or more) adjacent filter plugs.

Referring to FIG. 11, a smoking article 21 comprises a filter 22 and a cylindrical rod of smokeable material 23, wherein the filter 22 is made up of multiple filter segments. There is a filter segment 27 positioned at the mouth end of the filter and a filter segment 28 positioned at the tobacco rod end of the filter. Positioned between these filter segments, which comprise filter material 24, is a tobacco constituent releasing component 26.

The filters and filter elements of the present disclosure may, in some embodiments, further comprise additives. For example, the additive may be particles of adsorbent material, including, for example, activated carbon, an ion exchange resin, such as CR20, zeolite, silica gel, meerschaum, aluminum oxide (activated or not), carbonaceous resin, magnesium silicate, including Sepiolite (Mg₄Si₆O₁₅(OH)₂.6H₂O) and combinations thereof.

Where the smoking article filter comprises an adsorbent, in some embodiments the tobacco constituent releasing component is positioned downstream of the adsorbent.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior tobacco constituent releasing components and tobacco industry products including the same. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims

1. A tobacco constituent releasing component comprising:

an agglomerated structure formed from a precursor composition comprising tobacco particles and optionally one or more aerosol forming agents;

wherein the tobacco particles comprising one or more tobacco constituents; and

wherein the release of the one or more tobacco constituents upon heating the component without combustion being controlled by adjusting one or more of: (i) a ratio of the surface area to volume of the component, and (ii) an amount of the optional one or more aerosol forming agents included.

2. A tobacco constituent releasing component as claimed in claim 1, wherein the one or more aerosol forming agents is included in an amount of from about 3% to about 30% by weight of the component.

3. A tobacco constituent releasing component as claimed in claim 1, wherein the one or more aerosol forming agents is included in an amount of at least 10% by weight of the component, wherein the tobacco constituent releasing component having one or more undulating or irregular surfaces and/or channels within the component, and wherein the tobacco within the component does not have a basic pH.

4. A tobacco constituent releasing component as claimed in claim 1, further comprising one or more inner channels extending through the component.

5. A tobacco constituent releasing component as claimed in claim 1, wherein the component has a cross-sectional shape of a spoked wheel or a star.

6. A tobacco constituent releasing component as claimed in claim 1, wherein the agglomerated structure is formed by extrusion.

7. A tobacco constituent releasing component as claimed in claim 1, wherein the one or more aerosol forming agents is selected from the group consisting of glycerol, propylene glycol and glyceryl triacetate.

8. A tobacco constituent releasing component as claimed in claim 1, wherein the component is impregnated with the one or more aerosol forming agents, and/or the tobacco particles are impregnated with the one or more aerosol forming agents.

9. A tobacco constituent releasing component as claimed in claim 1, comprising at least 50% by weight tobacco particles.

10. A tobacco constituent releasing component as claimed in claim 1, comprising at least 80% by weight a combination of tobacco particles and one or more aerosol forming agents.

11. A tobacco constituent releasing component as claimed in claim 1, wherein the tobacco particles have an average diameter no greater than 0.5 mm.

12. A tobacco constituent releasing component as claimed in claim 1, wherein the component having a generally rod-shaped external form.

13. A tobacco constituent releasing component as claimed in claim 1, wherein the component having a diameter of from about 4 mm to about 10 mm.

14. A tobacco constituent releasing component as claimed in claim 1, wherein the component having a length of from about 5 mm to about 80 mm.

15. A tobacco constituent releasing component as claimed in claim 1, wherein the component does not have a basic pH and/or the precursor composition does not have a basic pH.

16. A tobacco constituent releasing component as claimed in claim 1, wherein the precursor composition does not include a basic pH adjusting agent.

17. A tobacco constituent releasing component as claimed in claim 1, further comprising one or more binders selected from the group consisting of starches, polysaccharides, pectins, celluloses, cellulose derivatives, carboxymethylcellulose, and alginates.

18. A tobacco constituent releasing component as claimed in claim 1, wherein the component does not comprise a binder to assist agglomeration of the tobacco particles.

19. A tobacco constituent releasing component as claimed in claim 1, the tobacco constituent releasing component further comprising one or more flavor-modifying additives.

20. A process for preparing a tobacco constituent releasing component, comprising:

forming an agglomerated structure from a precursor composition comprising tobacco particles and optionally at least one aerosol forming agent, wherein the tobacco particles comprising one or more tobacco constituents;

wherein a desired release of the one or more tobacco constituents is provided upon heating the component without combustion by adjusting one or more of: (i) a ratio of the surface area to volume of the component, and (ii) an amount of the optional at least one aerosol forming agent included.

21. (canceled)

22. A process as claimed in claim 20, wherein the precursor composition is extruded to form the agglomerated structure, wherein the precursor composition comprises at least 10% by weight of the at least one aerosol forming agent, wherein the extruded tobacco constituent releasing component having one or more undulating or irregular surfaces and/or channels within the component, and wherein the process does not include adjusting the pH of the tobacco within the component to a basic pH.

23. A process as claimed in claim 20, wherein the precursor composition is extruded to form the agglomerated structure.

24. A process as claimed in claim 23, wherein the precursor composition is extruded through a die to provide one or more inner channels extending through the component.

25. A process as claimed in claim 23, wherein the precursor composition is extruded through a die to provide the component with a cross-sectional shape of a spoked wheel or a star.

26. A process as claimed in claim 23, wherein the precursor composition is heated to a temperature of from about 40° C. to about 120° C.

27. A process as claimed in claim 23, wherein the precursor composition is cooled during or after extrusion by exposure to a surface having a temperature of from about 5° C. to about 15° C.

28. A process as claimed in claim 20, wherein the pH of the component and/or of the precursor composition is not adjusted to a basic pH.

29. A process as claimed in claim 20, wherein the precursor composition does not include a basic pH adjusting agent.

30-36. (canceled)

37. A filter or filter element for a combustible smoking article comprising a tobacco constituent releasing component of claim 1, wherein the tobacco constituent releasing component delivering flavor to mainstream smoke upon use of the smoking article, and wherein the pH of the component and/or of the precursor composition is not adjusted to a basic pH.

38-42. (canceled)