FLAVOR DELIVERY ARTICLE FOR A SMOKING SUBSTITUTE APPARATUS

Abstract

A smoking substitute apparatus comprising a flavorant delivery article having a granulated composition comprising a flavorant, a binder and a carrier.

Claims

1. A smoking substitute apparatus comprising a flavorant delivery article having a granulated composition comprising a flavorant, a binder and a carrier.

2. A smoking substitute apparatus comprising a flavorant delivery article having granules that comprise a flavorant, a binder and a carrier, wherein each of the granules has a substantially uniform composition throughout.

3. A smoking substitute apparatus according to any one of the preceding claims wherein the flavorant delivery article is positioned in an airflow channel upstream from a mouth end such that, when in use, flavorant is transferred to a flow through the airflow channel.

4. A smoking substitute apparatus according to any one of the preceding claims wherein the flavorant delivery article is provided as the granulated composition or granules in an aerosol-permeable container.

5. A smoking substitute apparatus according to claim 4 wherein the aerosol-permeable container is a non-woven fabric pouch.

6. A smoking substitute apparatus according to claims 3 and 4 wherein the aerosol-permeable container is formed as two aerosol-permeable filters positioned in the airflow channel either side of the granulated composition or granules.

7. A smoking substitute apparatus according to any one of the preceding claims having a reservoir that contains a flavorless e-liquid.

8. A smoking substitute apparatus according to any one of the preceding claims wherein the mean average particle size of the granulated composition or granule size of the granules is up to 5 mm.

9. A smoking substitute apparatus according to any one of the preceding claims wherein the granulated composition or each of the granules comprises a disintegrant.

10. A smoking substitute apparatus according to any one of the preceding claims wherein the granulated composition or granules comprise up to 20 wt % of the flavorant.

11. A smoking substitute apparatus according to any one of the preceding claims wherein the smoking substitute apparatus is an aerosol delivery apparatus.

12. A method of manufacturing a flavorant delivery article for a smoking substitute apparatus, comprising a step of granulating a carrier, a flavorant and a binder to form granules, wherein each of the granules has a substantially uniform composition throughout.

13. A method according to claim 12, further comprising a step of sealing the granules in an aerosol-permeable container.

14. A method of delivering flavor to a user of a smoking substitute apparatus, the method comprising: the user inhaling an aerosol generated by a smoking substitute apparatus according to any one of claims 1 to 11; wherein the flavor delivery article is positioned so that, when in use, it is perceptible to the user during inhalation.

15. Use of a flavorant delivery article in smoking substitute apparatus, wherein the flavorant delivery article is as defined in claim 1 or claim 2.

Description

SUMMARY OF THE FIGURES

[0092] So that the disclosure may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the disclosure will now be discussed in further detail with reference to the accompanying figures, in which:

[0093] FIGS. 1A to 1C show a general smoking substitute system configured to provide an e-liquid to a user.

[0094] FIG. 2 is a schematic of a single pouch filled with granules or a granulated composition before the excess non-woven fabric has been trimmed.

[0095] FIG. 3 is a front cutaway view of a smoking substitute apparatus having the pouch of FIG. 2 that has been trimmed to size and positioned in the airflow channel upstream of the mouth end.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0096] Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0097] FIGS. 1A and 1B illustrate a smoking substitute system in the form of an e-cigarette system 101. The system 101 comprises an e-cigarette device defining a main body 102 of the system 101, and a smoking substitute apparatus in the form of an e-cigarette consumable (or “pod”) 103. The smoking substitute apparatus is a smoking substitute apparatus. In the illustrated embodiment the consumable 103 (smoking substitute apparatus) is removable from the main body (e-cigarette device), so as to be a replaceable component of the system 101. In other words, the e-cigarette system 101 is a closed system.

[0098] As is apparent from FIGS. 1A and 1B, the consumable 103 is configured to engage the main body 102. FIG. 1A shows the main body 102 and the consumable 103 in an engaged state, whilst FIG. 1B shows the main body 102 and the consumable 103 in a disengaged state. When engaged, a portion of the consumable 103 is received in a cavity of the main body 102 and is retained in the engaged position by way of a snap-engagement mechanism. In other embodiments, the main body 102 and consumable 103 may be engaged by screwing one into (or onto) the other, through a bayonet fitting, or by way of an interference fit.

[0099] The system 101 is configured to vaporize an aerosol-former, which in the illustrated embodiment, is in the form of a nicotine-based e-liquid 104. The e-liquid 104 comprises nicotine and a base liquid including propylene glycol and/or vegetable glycerin. In the present embodiment, the e-liquid 104 is flavorless (and does not include any added flavorant). That is, if the e-liquid 104 were to be inhaled (i.e., in aerosol form) by a user, it would not have a particularly perceptible flavor or taste.

[0100] As is more apparent from FIG. 1C, this e-liquid 104 is stored within a reservoir in the form of a tank 105 that forms part of the consumable 103. In the illustrated embodiment, the consumable 103 is a “single-use” consumable 103. That is, upon exhausting the e-liquid 104 in the tank 105, the intention is that the user disposes of the entire consumable 103. In other embodiments, the e-liquid (i.e., aerosol former) may be the only part of the system that is truly “single-use”. That is, the tank may be refillable with e-liquid or the e-liquid may be stored in a non-consumable component of the system. For example, the e-liquid may be stored in a tank located in the main body or stored in another component that is itself not single-use (e.g., a refillable cartomizer).

[0101] The tank 105 surrounds, and thus defines a portion of, a passage 106 that extends between an inlet 107 and an outlet 108 at opposing ends of the consumable 103. In this respect, the passage comprises an upstream end at the end of the consumable 103 that engages with the main body 102, and a downstream end at an opposing end of the consumable 103 that comprises a mouthpiece 109 of the system 101. When the consumable 103 is engaged with the main body 102, a user can inhale (i.e., take a puff) via the mouthpiece 109 so as to draw air through the passage 106, and so as to form an airflow (indicated by arrows) in a direction from the inlet 107 to the outlet 108 of the passage 106. Although not illustrated, the passage 106 may be partially defined by a tube (e.g., a metal tube) extending through the consumable 103. The passage 106 is in fluid communication with a gap defined between the consumable 103 and the main body 102 (when engaged) such that air outside of the system 101 is drawn into the passage 106 (during an inhale).

[0102] The smoking substitute system 101 is configured to vaporize the e-liquid 104 for inhalation by a user. To provide this, the consumable 103 comprises a heater having of a porous wick 110 and a resistive heating element in the form of a heating filament 111 that is helically wound around a portion of the porous wick 110. The porous wick 110 extends across the passage 106 (i.e., transverse to a longitudinal axis of the passage 106) and opposing ends of the wick 110 extend into the tank 105 (so as to be submerged in the e-liquid 104). In this way, e-liquid 104 contained in the tank 105 is conveyed from the opposing ends of the porous wick 110 to a central portion of the porous wick 110 so as to be exposed to the airflow in the passage 106 (i.e., caused by a user inhaling).

[0103] The helical filament 111 is wound about this exposed central portion of the porous wick 110 and is electrically connected to an electrical interface in the form of electrical contacts 112 mounted at the end of the consumable that is proximate the main body 102 (when engaged). When the consumable 103 is engaged with the main body 102, the electrical contacts 112 contact corresponding electrical contacts (not shown) of the main body 102. The main body electrical contacts are electrically connected to a power source (not shown) of the main body 102, such that (in the engaged position) the filament 111 is electrically connected to the power source. In this way, power can be supplied by the main body 102 to the filament 111 in order to heat the filament 111. This heat is transferred from the filament 111 to the porous wick 110 which causes e-liquid 104 conveyed by the porous wick 110 to increase in temperature to a point at which it vaporizes. The vaporized e-liquid becomes entrained in the airflow and, between the vaporization point at the filament 111 and the outlet 108 of the passage 106, condenses to form an aerosol. This aerosol is then inhaled, via the mouthpiece 109, by a user of the system 101.

[0104] The power source of the main body 102 may be in the form of a battery (e.g., a rechargeable battery). The main body 102 may comprise a connector in the form of, e.g., a USB port for recharging this battery. The main body 102 may also comprise a controller that controls the supply of power from the power source to the main body electrical contacts (and thus to the filament 111). That, is the controller may be configured to control a voltage applied across the main body electrical contacts, and thus the voltage applied across the filament 111. In this way, the filament 111 may only be heated under certain conditions (e.g., during a puff and/or only when the system is in an active state). In this respect, the main body 102 may include a puff sensor (not shown) that is configured to detect a puff (i.e., inhalation). The puff sensor may be operatively connected to the controller so as to be able to provide a signal, to the controller, which is indicative of a puff state (i.e., puffing or not puffing). The puff sensor may, for example, be in the form of a pressure sensor or an acoustic sensor.

[0105] Although not shown, the main body 102 and consumable 103 may comprise a further interface which may, for example, be in the form of an RFID reader, a barcode or QR code reader. This interface may be able to identify a characteristic (e.g., a type) of a consumable 103 engaged with the main body 102. In this respect, the consumable 103 may include any one or more of an RFID chip, a barcode or QR code, or memory within which is an identifier and which can be interrogated via the interface.

Exemplary Granulation Method

[0106] In an example method of the present disclosure, a carrier HPMC is added to a mixing vessel and sealed before supercool menthol flavorant and the liquid binder are added. The carrier is stirred ready for the addition of the liquid components of the granulation process.

[0107] The supercool menthol flavorant component is then added directly on to the carrier HPMC. The addition of the supercool menthol flavor is done dropwise to the stirring mixture to ensure even distribution and loading of the flavor onto the carrier mix.

[0108] The pullulan liquid binder is in the form of a 20% stock solution. The stock solution is produced by dissolving the appropriate amount of pullulan liquid binder in the appropriate amount of water. Once fully dissolved, the pullulan liquid binder is then added dropwise to the stirring carrier HPMC and supercool menthol flavorant to form granules. The pullulan liquid binder protects the flavor from being evaporated from the resulting granules. The granulation process is judged visually, either by eye or automated video monitoring equipment, to ensure the correct amount of pullulan liquid binder is utilized and that there is no over granulation or grouping of granules.

[0109] Upon addition of each component to the granule mixture, the granules are emptied onto a small tray and separated. The individual granules are then allowed to dry for 24 hrs inside of a fume hood. Shorter drying times may be advantageous in keeping the flavor on the granules and prevent over evaporation.

Exemplary Pouching of the Granules

[0110] FIG. 2 illustrates a non-woven fabric pouch 201 according to the present disclosure. When dry, the granules or granulation mixture may be sealed inside a non-woven fabric pouch. The pouch is sized at 15 mm by 15 mm for filling. A 10 mm allowance 203 was placed on each side to allow for effective sealing of the pouch. The pouch is filled with approximately 500 mg of granulated composition or granules 205. The pouch is sealed and the 10 mm allowance is trimmed down to size to provide a pouch having a 5 mm.sup.2 surface that is sized to fill the cavity in an airflow channel at the top of the smoking substitute apparatus. With reference to FIG. 3, sealing the granules inside a nonwoven fabric pouch 305 in this way safely conceals the granulated composition or granules in the tip of the smoking substitute apparatus 301 and causes the airflow through the channel to pass over and/or through the granules thereby extracting and transferring the flavorant to the user when they inhale through the mouth end 303.

[0111] The sealing of the pouch may be achieved by ultrasonic sealing, hydroentanglement or needle punching, thereby avoiding the need to incorporate a plastic sealant material such as polypropylene into the pouch.

[0112] The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the disclosure in diverse forms thereof.

[0113] While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the disclosure.

[0114] For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

[0115] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0116] Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0117] It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

[0118] The words “preferred” and “preferably” are used herein refer to embodiments of the disclosure that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims.