Carrier for a functional component for use in mixing an aerosol precursor liquid, and associated apparatus and method

Abstract

A carrier, apparatus and method for making an aerosol precursor liquid suitable for aerosolized delivery by a device such as an electronic cigarette. A carrier is fluid permeable and comprises a tobacco-derived medium for carrying a functional component, the medium being configured to release the functional component into a fluid to provide an aerosol precursor liquid infused with the functional component. A method for mixing an aerosol precursor liquid for aerosolized delivery of a functional component by an aerosol delivery device comprises bringing the tobacco-derived medium carrying the functional component into contact with fluid and allowing the fluid to saturate the medium to thereby cause the medium to release the functional component into said fluid to form an aerosol precursor liquid infused with the functional component. A receptacle comprising a chamber for the carrier is provided for mixing the aerosol precursor liquid. Example functional components include nicotine and nicotine salts.

Claims

1. A carrier for a functional component for use in mixing an aerosol precursor liquid for aerosolized delivery by an aerosol generating device, wherein said carrier is fluid permeable and comprises: a tobacco-derived medium for carrying said functional component, the medium being constrained within the carrier and configured to release said functional component when contacted with a fluid to provide an aerosol precursor liquid infused with said functional component, the aerosol precursor liquid being suitable for supply to a fluid reservoir of an aerosol generating device for aerosolized delivery by said aerosol generating device.

2. The carrier as claimed in claim 1, wherein the medium comprises tobacco.

3. The carrier as claimed in claim 2, wherein the tobacco is in the form of tobacco leaf, tobacco stem, tobacco powder, or tobacco dust.

4. The carrier as claimed in claim 3, wherein the tobacco is in the form of a reconstituted sheet.

5. The carrier as claimed in claim 1, wherein the functional component comprises nicotine or a nicotine salt.

6. The carrier as claimed in claim 5, wherein the nicotine salt is selected from a group consisting of: nicotine hydrochloride, nicotine dihydrochloride, nicotine monotartrate, nicotine bitartrate, nicotine bitartrate dihydrate, nicotine sulphate, nicotine zinc chloride monohydrate and nicotine salicylate, and mixtures thereof.

7. The carrier as claimed in claim 1, wherein the medium is configured to release said functional component into said fluid responsive to the presence of said fluid.

8. The carrier as claimed in claim 1, wherein the medium is configured to release said functional component into said fluid to form a solution.

9. The carrier as claimed in claim 1, wherein the carrier is in the form of a tablet, gel, capsule, cartridge, pod or pouch.

10. The carrier as claimed in claim 1, wherein the medium is fluid permeable.

11. The carrier as claimed in claim 1, wherein the functional component is substantially evenly distributed within the medium.

12. The carrier as claimed in claim 1, wherein the functional component comprises a pH-adjusting agent.

13. The carrier as claimed in claim 12, wherein the pH-adjusting agent is selected from a group consisting of: carbonates including monocarbonate, bicarbonate and sesquicarbonate, acetates, glycinates, gluconates, borates, glycerophosphates or citrates of alkaline metals or ammonium, phosphate systems including monohydrogenphosphate, dihydrogenphosphate and trihydrogenphosphate, metal hydroxides such as sodium hydroxide and potassium hydroxide, and mixtures thereof.

14. The carrier as claimed in claim 1, wherein the medium is enclosed in a fluid soluble film or membrane.

15. The carrier as claimed in claim 14, wherein the fluid soluble film is selected from a group consisting of: Polyester woven mesh, PVA mesh, Nylon, filter paper, silk, Hemp, PVC, PP, Cotton.

16. The carrier as claimed in claim 1, wherein the medium comprises a filler.

17. The carrier as claimed in claim 16, wherein the filler is selected from a group consisting of: tobacco dust, cellulose, any plant matter (i.e tobacco stems), Sugar, Foam, porous matrix (desiccant/beads), polysaccharides, polyols, sugars, natural fibres, microcrystalline cellulose, cellulose and cellulose derivatives.

18. The carrier as claimed in claim 1, wherein the functional component comprises a flavouring.

19. The carrier as claimed in claim 18, wherein the flavouring is selected from a group consisting of: Mild Menthol, Mixed Berry, Cool Menthol, Peach, Cream Cake, Melon Medley, Apple, Shisha Grape, Virginia Tobacco, American Blend Red.

20. A method for mixing an aerosol precursor liquid for aerosolized delivery of a functional component by an aerosol delivery device, which method comprises the steps of: bringing a fluid permeable carrier, which has a tobacco-derived medium which carries said functional component constrained within the fluid permeable carrier, into contact with fluid; and allowing the fluid to saturate the medium to thereby cause the medium to release the functional component into said fluid to form a liquid infused with the functional component for use in the aerosol delivery device.

21. The method of claim 20, further comprising the step of agitating the medium in the fluid.

22. The method of claim 21, wherein the step of agitating the medium comprises shaking a receptacle comprising the medium and the fluid.

23. The method of claim 20, wherein the step of bringing the medium into contact with the fluid comprises introducing said medium into a receptacle holding said fluid.

24. The method of claim 20, wherein the step of bringing the medium into contact with the fluid comprises introducing said fluid into a receptacle holding said medium.

25. The method as claimed in claim 21, further comprising the step of: introducing an agitation member into a receptacle before performing the step of agitating the medium in the fluid.

26. The method as claimed in claim 21, further comprising the step of refilling a reservoir of an aerosol generating device with the liquid infused with the functional component.

27. A receptacle for mixing a liquid for use in an aerosol delivery device, which receptacle comprises a chamber containing a carrier as claimed in claim 1.

28. An aerosol delivery device comprising the receptacle as claimed in claim 27.

29. The aerosol delivery device as claimed in claim 28, wherein the receptacle is configured to be removably coupled to said aerosol delivery device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A complete understanding of preferred embodiments of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent, detailed description, provided by way of example only and in which:

(2) FIG. 1 is an exploded perspective view illustration showing a prior art fluid dispenser of the type typically used for refilling the reservoir of an aerosol-generating device;

(3) FIG. 2 is a an exploded perspective view illustration showing a fluid dispenser of the type described in connection with FIG. 1 being used to dispense liquid into the reservoir of an aerosol-generating device;

(4) FIG. 3 is shows a perspective view of a carrier in accordance with the teachings of the present invention;

(5) FIG. 4 is an illustrative view of a manufacturing process for producing pouches for use in accordance with the present invention, and;

(6) FIGS. 5a, 5b, and 5c show the steps undertaken to form a solution including a functional component in accordance with the present invention.

DETAILED DESCRIPTION OF THE DRAWINGS

(7) Before the invention is described in further detail, it is to be understood that the invention is not limited to the particular embodiments described, as such may, of course, vary. It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and not intended to be limiting, since the scope of the present invention will be limited by the appended claims.

(8) Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs or as determined by the context in which such terms are used. Although any methods and materials similar or equivalent to those described herein can also be used in the practise or testing of the present invention, a limited number of exemplary methods and materials are described herein.

(9) It must be noted that as used herein and in the appended claims, the singular forms of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

(10) All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and materials in connection with which the publications are cited. The publications discussed herein are provided solely for their disclosure prior to the filing date of the present patent application. Nothing herein is to be construed as an admission that the present invention is not entitled to antedate such publication by virtue of prior invention. Further, if dates of publication are provided, they may be different from actual publication dates and may need to be confirmed independently.

(11) The disclosure herein is directed to a carrier for functional components for making an aerosol precursor for an aerosol-generating device, together with the apparatus and methods for producing such aerosol precursor, and has applicability to the filling and refilling of refillable fluid reservoirs of such aerosol-generating devices with an aerosol precursor together with the making of such aerosol precursor.

(12) FIG. 1 is shows an eyedropper type liquid dispenser 5 of the type presently used for refilling aerosol-delivery devices. The liquid dispenser 5 includes a container 10, a dispensing portion 20 that comprises a liquid-dispensing tip 22, and a cap portion 30 that may be integrally formed with the neck portion 18 of the dispenser 10, the dispensing portion 20, or may be removable. As illustrated in FIG. 1, the cap portion 30 is removable and has a hinged portion 32 for permitting the lid portion 36 to be opened about the hinge portion 32 to expose the liquid-dispensing tip 22. Also illustrated is projection 34 which is provided to facilitate easy opening of the lid portion 36 by the user and when in the closed position prevents leakage from the liquid-dispensing tip 22.

(13) Referring now to FIG. 2, a liquid dispenser 10 of the type described in relation to FIG. 1 is shown, together with a cross-sectional view of a portion of the body 110 of an aerosol-delivery device 100 in which a reservoir 120 for liquid is located. The aerosol-delivery device 100 illustrated in FIG. 2 is of a type where access to the reservoir 120 is integrally formed with the aerosolization chamber. Thus, the reservoir 120 is typically located in the proximal end 115 of the mouthpiece (not shown) and comprises a coiled heating element 130.

(14) The reservoir 120 contains wicking material 125 for transferring liquid held in the chamber into engagement with the coiled heating element 130. The outer walls of the reservoir 120 are typically formed from a plastic material such as high-density polypropylene.

(15) Before attempting to refill the aerosol-delivery device 100 the user must first remove the mouthpiece to provide access to inlet aperture 105 of reservoir 120. The user typically holds the aerosol-delivery device 100 in an orientation in which its proximal end (i.e. the mouthpiece end) is uppermost. The aerosol-delivery device 100 does not necessarily need to be vertical as a slight inclination is possible to facilitate refilling, and indeed a slight inclination can aid refilling as it permits air to more readily enter and replace the volume vacated by the liquid dispensed. However, it has been found that angles greater than around 20 degrees from the vertical can result in spillage.

(16) Refill dispenser is shown held at an angle of approximately 45 degrees from the vertical with the liquid-dispensing tip 22 disposed in the vicinity of the inlet aperture 105 of the aerosol-delivery device so that any droplets expelled therefrom would fall generally in the region of the inlet aperture 105. Users typically find refilling of the reservoir 120 of an aerosol generating device 100 to be easier if the dispenser is held at an angle as their view of the liquid-dispensing tip 22 is not restricted by the body of the dispenser 10.

(17) In use, the user will hold the refill dispenser 10 in an inverted orientation and a droplet of liquid typically forms at the end of the liquid-dispensing tip 22. Any volume in the body of the dispenser 10 that is not filled with liquid is typically air, which naturally rises to the bottom 11 of the dispenser 10 when it is disposed in a substantially inverted orientation. To dispense liquid from the tip 22 the user squeezes the body of the dispenser 10 by applying pressure in the direction of arrows 150a and 150b causing liquid to be expelled from the tip 22. Furthermore, the walls of the dispenser 10 in the region adjacent to the arrows 150a and 150b may be inwardly deformed resulting in a reduction of the internal volume of the dispenser 10. Since the dispenser 10 is typically moulded from a resilient plastic material, as the user releases the inwardly directed pressure applied to the walls of the dispenser 10 they return to their normal position. Consequently, as a volume of liquid has been dispensed from the dispenser 10 into the reservoir 120 the vacant volume will be replaced with air drawn through the tip 22.

(18) Liquid aerosol precursor formulations are typically supplied in premixed form in a dispenser such as an eye dropper bottle into an integral reservoir or into a refillable and/or disposable cartridge that may be a removable cartridge. Accordingly, since the precursor is supplied in a premixed form users typically purchase a variety of formulations of favourite flavourings and/or nicotine strengths.

(19) A first embodiment of the present invention will now be described in relation to FIG. 3 which shows a perspective view of an extraction bag or pouch 200. A main body of the pouch 200 has a generally polygonal shape. As shown in FIG. 3 the main body is generally rectangular shape. The main body has a first surface 204 and a second surface 206 and seams 208 formed around the external edges to define a pocket 210 therebetween. A quantity of a medium 212 for carrying one of more functional components is located in the pocket 210.

(20) In the preferred embodiment of the invention that is illustrated in FIG. 3, the main body is formed from a fluid permeable material having a pore size suitable for constraining the bulk material of the medium to be constrained within the pocket 210.

(21) When manufacturing the pouch 200 a sheet of continuous cylindrical material or sleeve is fed in the direction indicated by arrow A in FIG. 4. The sleeve is held vertically and configured so that as the sleeve is fed over rollers 500. The surfaces of the sleeve separate to form the pocket 210 and is sealed along edge 208a. The sealing may preferably be achieved by the application of pressure and/or heat.

(22) A measured quantity of the medium 212 is then deposited through the open end 208b into the pocket 210 formed between the sealed opposing surfaces 204 and 206. The ratio of the quantity of medium 212 and the dimensions of the pouch 200 are critical as medium that is too tightly packed within the pouch 200 may compromise the subsequent recovery of the nicotine. The surfaces 204 and 206 are sealed along edge 208b to constrain the medium 212 within the pocket 210. Finally, once the surfaces are sealed along edge 208b the main body is cut away from sheet or sleeve along edge 208b and just above the seal. As can be seen from FIG. 4, the seal formed along the upper edge 208b of pouch 200a forms the lower seal 208a of the subsequent pouch 200b above. Consequently, the seal 208 between each pouch should be of sufficient thickness to permit the pouches 200a and 200b to be separated by cutting along the centre of the seal, along the line indicated by dotted line 211 whilst leaving the upper edge 208b of pouch 200a and lower edge 208a of pouch 200b sealed. Thus, horizontal sealing and cutting may be simultaneously performed.

(23) Turning now to the medium 212 that is constrained within the pouch 212, in the embodiments of the invention illustrated in FIGS. 3-4, the bulk of the medium 212 therein comprises treated organic tobacco material. For the purposes of the present invention it is immaterial whether the organic tobacco material is leaf or stem, or whether it is in shredded, ground, or powdered form provided that the pores of the material from which the surfaces 204 and 206 of the pouch 200 are formed are dimensioned to constrain the organic tobacco material within the pouch 200.

(24) The form of the organic material is immaterial to the teachings of the present invention other than it should be appropriately dimensioned to fit within the pocket of the pouch 200. In a particularly preferred embodiment of the present invention the organic tobacco material is in the form of dust or powder to provide the optimal surface area. The organic tobacco material is typically pre-treated by grinding before being dried.

(25) According to the teachings of the present invention the organic tobacco material is first washed in purified water to remove contaminants. The process of washing the organic material may also cause the material to swell.

(26) A composition of vegetable glycol and pure liquid nicotine is then added to the organic tobacco material. The vegetable glycol causes the nicotine to be more evenly distributed across the organic tobacco material. The intention is to saturate the organic tobacco material with vegetable glycol rather than nicotine but it also enhances the saturation of the nicotine into the material. The composition is preferably in the ratio 1:3 nicotine to vegetable glycol and is added to 3 parts tobacco material.

(27) The damp organic tobacco material is then deposited in the pouch 200. Each pouch 200 will typically comprise 0.7 g of tobacco material, 0.7 g of vegetable glycol, and 0.24 g of nicotine. However it will be apparent to one of ordinary skill in the art that alternative compositions will be appropriate for different types and forms of organic tobacco material and other fillers.

(28) Once the pouch 200 has been sealed as described in the foregoing description, it is placed within a container 300 which is purged of air with a gas such as argon and sealed to prevent evaporation and degradation.

(29) Referring now to FIGS. 5a 5b, immediately prior to requiring the aerosol precursor, the user removes the cap 304 from the neck of the container 300 to expose the aperture 306 and to provide access to the chamber 302 through the aperture 306 to the pouch 200 contained therein. A measured volume of fluid 402 is then dispensed from a dispenser 400 through the aperture 306 of container 300 and into the chamber 302. The measured volume of fluid is such that it does not completely fill chamber 302 but leaves a headspace of air above. The cap 304 is then replaced to seal the chamber with both the measured volume of fluid 402 and the pouch 200.

(30) As shown in FIG. 5c, next the user shakes the container 300 vigorously for period of 10 seconds, before allowing the container 300 to stand for a period of 10 minutes. Upon expiry of the period of 10 minutes the user then shakes the container for a further period of 10 seconds.

(31) The skilled person will appreciate from the foregoing teachings:

(32) The longer the container 300 is shaken the better.

(33) Alternative embodiments include:

(34) a. An additional container in which the medium is constrained, wherein the additional container is removably engaged into the mouth of the above-described container 300.

(35) b. the pouch 200 being aseptically sealed in a bag or package with a frangible seal.

(36) c. a cafetierre type arrangement which, after shaking, constrains the medium in a portion of the container away from the aperture/opening.

(37) d. a capsule having rupturable ends which are penetrated when the capsule is inserted into the device to permit a fluid stream to pass therebetween and which constrain the medium therein.

(38) e. a tablet or gel of organic material which disintegrates when placed in a fluid.

(39) f. a filter fitted into the aperture of the container 200 or capsule.

(40) In the foregoing description various embodiments of the present invention have been presented for the purpose of illustration and description. They are not intended to be limiting or exhaustive or to limit the scope of the invention to the precise form disclosed. Obvious modifications and alternatives are possible in light of the teachings comprised herein. The various embodiments were chosen and described to provide the best illustrations of the principles of the present invention and their practical implementation, and to enable one of ordinary skill in the art to utilise the various embodiments with various modifications as are suited to the use contemplated. All such modifications and variations are within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally and equitably entitled.