Aerosol-Generating Substrate Comprising Granulated Flavoured Particles

Abstract

An aerosol-generating article includes a foamed tobacco-containing aerosol-generating substrate and a plurality of non-tobacco granulated flavour particles incorporated into the aerosol-generating substrate which is provided in the form of a semi-solid matrix. The granulated flavour particles can be distributed evenly in the semi-solid matrix or the granulated flavour particles can be provided in an increasing gradient density towards the longitudinal central axis of the aerosol-generating article.

Claims

1. An aerosol-generating article comprising a foamed tobacco-containing aerosol-generating substrate and a plurality of non-tobacco granulated flavour particles incorporated into the aerosol-generating substrate.

2. The aerosol-generating article according to claim 1, wherein up to 10.0% of a total weight of the aerosol-generating substrate is the plurality of granulated flavour particles.

3. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles is provided in the aerosol-generating substrate with a density of less than 2.0 g/cm.sup.3.

4. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles is provided ranging from between 2.0 wt. % and 10.0 wt. % of a total weight of the aerosol-generating substrate.

5. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles comprises a gel of a polysaccharide.

6. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles comprises a gel of a polysaccharide containing no gelling agent.

7. The aerosol-generating article according to claim 1, wherein each of the granulated flavour particles has a mean diameter of between 0.1 mm and 3 mm.

8. The aerosol-generating article according to claim 1, further comprising a tobacco-containing portion comprising the aerosol-generating substrate and a filter portion.

9. The aerosol-generating article according to claim 1, wherein the aerosol-generating substrate incorporating the plurality of non-tobacco granulated flavour particles is provided in an increasing gradient density towards a longitudinal central axis of the aerosol-generating article.

10. A method of preparing an aerosol-generating substrate for smoking, comprising the steps of: a. providing a mixture comprising at least one of propylene glycol, 1, 3-Propanediol, glycerol, water, gum, or binder; b. thereafter, mixing the mixture; c. thereafter, providing tobacco-containing material into the mixture; d. thereafter, mixing the mixture; e. thereafter, providing a plurality of granulated non-tobacco flavour particles into the mixture to form an aerosol-generating substrate; and f. thereafter, mixing the mixture.

11. The method according to claim 10, wherein in each of steps b, d, and f, the mixture is constantly mixed for a certain amount of time and heated at above room temperature.

12. The method according to claim 10, wherein in each of steps b, d, and f, the mixture is constantly mixed for at least 6 minutes and/or is heated at 45° C. and/or is aerated.

13. The method according to claim 10, further comprising a step of providing a first layer of the aerosol-generating substrate encircled by a second layer of the aerosol-generating substrate, wherein the first layer has a higher volume and/or density of granulated flavour particles than the second layer.

14. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles is provided in the aerosol-generating substrate with a density of less than 1.0 g/cm.sup.3.

15. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles is provided in the aerosol-generating substrate with a density of less than 0.5 g/cm.sup.3.

16. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles is provided in the aerosol-generating substrate with a density of between 0.01 g/cm.sup.3 and 0.1 g/cm.sup.3.

17. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles is provided ranging from between 3.5 wt. % and 7.0% of a total weight of the aerosol-generating substrate.

18. The aerosol-generating article according to claim 1, wherein the plurality of granulated flavour particles is provided ranging from between 4.5 wt. % and 6.0% of a total weight of the aerosol-generating substrate.

19. The aerosol-generating article according to claim 1, wherein each of the granulated flavour particles has a mean diameter of between 0.5 mm and 2 mm.

20. The aerosol-generating article according to claim 1, wherein each of the granulated flavour particles has a mean diameter of 1.5 mm.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0033] FIG. 1 shows a side view of an aerosol-generating article of the present invention.

[0034] FIG. 2 shows a cross section view from point W of the FIG. 1.

[0035] FIG. 3 illustrates the comparison of flavour delivery of aerosol-generating substrate with or without granulated flavour particles.

DETAILED DESCRIPTION OF THE INVENTION

[0036] FIG. 1 shows a side view of an aerosol-generating article 100 according to the first embodiment of the present invention. The aerosol-generating article 100 comprises a filter portion 10 and a tobacco-containing portion 20. The elongated cylindrical article 100 comprises a longitudinal central axis X. Aerosol-generating substrate 24 that is provided in a semi-solid matrix comprising granulated flavour particles are provided in the tobacco-containing portion 20.

[0037] FIG. 2 shows a cross section view at point W as shown the FIG. 1 where the cross section was sectioned in the tobacco-containing portion 20. The aerosol-generating article 100 comprises a central axis X. Aerosol-generating substrate 24 that is provided in form of semi-solid matrix comprises a plurality of granulated flavour particles 22. The granulated flavour particles 22 can be randomly distributed within the tobacco-containing portion 20 to have an evenly distributed profile or can be distributed in an increasing gradient density towards the central axis, as shown in the FIG. 2.

[0038] The inventors of the present invention discovered that although aerosol-generating substrate 24 provided in form of a semi-solid matrix such as tobacco mousse is superior to standard reconstituted tobacco (e.g. more uniform heating, a good quality aerosol, and extremely efficient extraction of the tobacco ingredient containing agent and/or the inhalable agent), its non-solid form, induces fast disappearance of the top flavours used in the tobacco recipe within the first few puffs of consumption, hence affecting negatively the overall smoking experience.

[0039] The invention provides a solution to compensate for the fast flavour disappearance experienced with semi-solid matrix aerosol-generating substrates by the introduction in the substrate of flavour particles in granulated form. For the avoidance of doubts and full clarity of the present disclosure, the terms “granulated particles” shall not be construed limitedly to only regular, rounded, granules of flavoured material but shall be understood in the context of the present invention as particles of a substantially 3-dimensional shape, such as irregular granules or flakes. Hence, the granulated flavour particles can be small pieces of flavoured sheet that is flavoured encapsulated. The particles can be provided by cutting or shredding sheet of flavoured material into fine pieces or particles, where the dimension of the particles can be adjusted accordingly. The granulated flavour particles 22 can then be added to the semi-solid matrix (e.g. mousse) substrate recipe to avoid quick flavour release so that consistent gradual release of flavour during vaping process can be ensured. To this end, it is disclosed that the granulated flavour particles 22 can be added in the end of the mixing process to minimize flavour loss.

[0040] The granulated flavour particles 22 can be obtained through any conventional methods within the common general knowledge of a skilled person. As an example, a flavour can be coated with a polysaccharide, with or without adding any gelling agent, such as a metal chloride, to the material. Alternatively, a combination of polysaccharide and one or more flavouring materials can be used to provide the granulated flavour particles 22. The polysaccharide serves as a substrate is found to be an excellent medium to carry the flavouring ingredients. The granulated flavour particles 22 can be provided having a mean diameter of between about 0.1 mm and about 3 mm, preferably between about 0.5 mm and about 2 mm, or more preferably around 1 mm.

[0041] It is however noted that in the process of preparing the granulated flavour particles, extremely high temperatures e.g. higher that 85° C. should be avoided in order to preserve the flavour. Flavours tend to be lost or turn weaker on such high temperatures. For this reason, the granulated flavour particles are only introduced into the mixture in the last (or second last) step in order to maximally preserve its flavour.

[0042] The granulated flavour particles 22 proposed in the present invention can be provided in any kind of flavour that is permitted in the tobacco industry. Typical flavours are for instance fruity, berry, menthol, wood, chocolate, tobacco etc.

[0043] In some examples, it was found out that the polysaccharide used in the invention can be gelled by applying heat. Thus, no gelling agent is required. Accordingly, the granulated flavour particles 22 according to the invention contains no gelling agent such as a metal chloride. Thus, for example, an unfavourable decomposed product of the chloride is not produced in the mainstream smoke during smoking.

[0044] In order to increase the flavour content of the granulated flavour particles, it is necessary that the flavour is effectively blended or coated with the polysaccharide. The present inventors have found that it is effective that a flavour and a polysaccharide are sufficiently kneaded and emulsified in a heated aqueous solution, and the emulsified state that the flavour coated with the gelled polysaccharide is present in the aqueous solution is maintained while the granulated flavour particles are prepared. That is, in granulated flavour particles that can be sufficiently kneaded and emulsified and can keep the emulsified state, high flavour content can be finally obtained.

[0045] On the other hand, it has been found out that, in a system that cannot keep the emulsified state in the aqueous solution during the preparation of the material even when sufficient kneading and emulsifying are performed, high flavour content cannot be attained. The granulated flavour particles 22 of the invention may contain for instance 18 wt. % or more, preferably 60 wt. % or more, more preferably 70 wt. % or more of flavour. In other words, these numbers represent the granulated (or encapsulated) flavour contains this amount of flavour in it by weight.

[0046] As an example, the polysaccharide that can keep an emulsified state as described above is preferably a single component system of carrageenan, agar, gellan gum, tamarind gum, psyllium seed gum or konjak glucomannan, or a composition system of combined two or more components selected from the group consisting of carrageenan, locust bean gum, guar gum, agar, gellan gum, tamarind gum, xanthan gum, tara gum, konjak glucomannan, starch, cassia gum and psyllium seed gum. At the time of the emulsification, it is preferred to use an ordinarily used emulsifier, such as lecithin, together.

[0047] Preferably, the granulated flavour particles 22 are provided in an increasing gradient density towards the longitudinal axis X compared to being evenly distributed within the aerosol-generating substrate 22. Higher density of granulated flavour particles 22 in the central position permits consistent and prolonged flavour delivery, as will be discussed below, see for instance Sample 1 of FIG. 3 where the granulated flavour particles 22 are distributed in an increasing gradient density towards the longitudinal central axis X.

EXAMPLES

[0048] The present invention will now be described in detail with reference to examples thereof. However, these examples serve merely as illustrative purpose and do not limit the scope of the invention.

Example 1

[0049] κ-Carrageenan (CARRAGEENAN CS-530, San-Ei Gen F.F.I., Inc.), which is extracted from red algae seaweed was selected as a single polysaccharide and I-menthol (special grade, Wako Pure Chemical Industries, Ltd.) was selected as a flavour, respectively. The granulated flavour particles for aerosol-generating substrate of Example 2 was prepared by the following procedures.

[0050] To each 5 g of κ-carrageenan about 100 mL of water was added, which was then heated in a thermostat bath of 80° C. to dissolve κ-carrageenan sufficiently in water. A total of 25 g of menthol (TEG-10374410) and 2 mL of a 5% aqueous solution of lecithin (Sunlecithin A-1, Taiyo Kagaku Co., Ltd.) were added thereto, which was sufficiently emulsified by means of a homogenizer (high performance mixer DMM, ATEC Japan Co., Ltd.). This emulsified slurry was turned into a granulated form, which was dried in a forced air circulation dryer of 40° C. for one week. The granulated flavour particles were provided having a mean diameter of about 1.5 mm. Samples 1 and 2 comprise such granulated flavour particles.

Example 2

[0051] Table 2 shows an example ratio of the tobacco mousse with or without granulated flavour particles. For producing exemplary aerosol-generating substrate 24 (Samples 1, 2 and 3) as shown in the FIG. 3, the ingredients given in the respective column of Table 2 were mixed and combined as follows. It is noted herewith that the flavour of Sample 1 and Sample 2 are provided as granulated flavour particles (as explained in the Example 1) whereas the menthol flavour of Sample 3 was not provided as a granulated form but the menthol flavour is provided directly from a liquid mixture and is subsequently blended with the tobacco mousse, forming the Sample 3.

TABLE-US-00001 TABLE 2 Aerosol-generating substrate with (Samples 1, 2) or without (Sample 3) granulated flavour particles. Tobacco Mousse (TM) Samples 1, 2 & 3 Samples 1, 2 & 3 Compounds Ratio Amount (g) Propylene glycol (PG)  24.0 wt.-% 120.0 Glycerine (G)  36.0 wt.-% 180.0 (Granulated) Menthol flavour   5.0 wt.-% 25.0 Purified Water   3.5 wt.-% 17.5 Tobacco Powder  21.0 wt.-% 105 Gum (Roeper 700f)   4.5 wt.-% 22.5 Binder (Ceroga 4550 C)  11.0 wt.-% 55.0 Total 100.0 wt.-% 525.0

[0052] The propylene glycol, the glycerine and the purified water were whipped and aerated for 5-10 min at 45° C. using a Krups Prep & Cook HP5031 mousse whipping shuffle, preferably at speed “6”. When whipping up the mousse, the speed can be adjusted so that the volume visibly increases, and small bubbles appear and partly stay in the foam. If whipping is too fast then mixing will take over and the foamy structure is going to collapse, thus back to fluid. As one option, whipping is started slowly and the whipping speed is slowly increased as the foam begins to develop a lighter, more mousse-like texture; the speed is backed-off by about 10% if it is noticed that the mousse seems to be reducing its mousse-like texture and becoming seemingly less aerated. In order to preserve the foamy structure for creating the stable portion, a sudden cooling with ice or cool water is recommendable. Using the above mentioned Krups device, the best results can be obtained with a speed in between 60 and 200 rpm. Adaptation is within the skilled person's knowledge in accordance with the above description.

[0053] In a next step (within 1 minute of the previous step), the gum was added, and the mixture was whipped and aerated for 5-10 minutes, preferably at 6 min, at 45° C. using a Krups Prep & Cook HP5031 mousse whipping shuffle, with the same speed. Afterwards the tobacco powder was added and whipping, and aeration were carried out for 5-10 min, preferably at 6 min, at 45° C. with the same method.

[0054] Next, the granulated flavour particles were added followed by the binder (within 1 min), and the mixture was again whipped and aerated for 5-10 min, preferably at 6 min, at 45° C. with the same method.

[0055] Finally, the mixture was placed in an oven at 50° C. for approximately 18 hours before is ready to be packed and be used.

[0056] FIG. 3 illustrates the perceived intensity of menthol flavour in smoke (in percentage) during sensory testing of three different types of aerosol-generating articles as explained above.

[0057] Both the Sample 1 and Sample 2 comprise granulated flavour particles 22 whereas the Sample 3 does not comprise such granulated flavour particles. The granulated flavour particles 22 of Sample 1 were distributed in an increasing gradient density towards the longitudinal central axis as shown in the FIG. 2 whereas in the Sample 2, randomly distributed granulated flavour particles 22 were provided to the aerosol-generating substrate 24. The result showed that the Sample 1 and the Sample 2 have higher flavour-retaining property than the Sample 3 throughout the vaping process (from puff 0 to puff 14).

[0058] Surprisingly, when the granulated flavour particles are distributed in an increasing gradient density towards the central axis X, a consistent and higher flavour delivery was observed throughout the vaping process. In other words, Sample 1 rendered the most consistent flavour delivery throughout the entire vaping process.