JP7638307B2 - Filter Rod Consumables - Google Patents

Description

The present invention relates to a filter rod consumable for use in an aerosol delivery system. The present invention also relates to a system including the filter rod consumable, as well as kits and methods of using the consumable and uses thereof.

background

Smoking articles, such as cigarettes, cigars, etc., burn tobacco during use to produce tobacco smoke. Attempts to provide alternatives to these smoking articles have been made by creating products that release compounds without combustion. Examples of such products are so-called "heat-not-burn" products or tobacco heating devices or products that release compounds by heating, rather than burning, smoking material.

overview

According to a first aspect of the invention described herein, there is provided a filter rod consumable for use in an aerosol delivery system, the flavoring insert comprising a filter and one or more capsules containing an aerosolizable material including nicotine and a basic solution contained in the filter, the basic solution being capable of being released from the capsules upon actuation by a user to contact the aerosolizable material.

In some embodiments, the aerosol delivery system is a non-flammable aerosol delivery system.

In some embodiments, the non-combustible aerosol delivery system is a hybrid system that includes an aerosol-generating material that is heated to volatilize constituents, and a liquid that is heated to form a vapor.

In some embodiments, the basic solution has a pH of about 8 to about 10. In some embodiments, the basic solution has a pH of about 8 to about 9.

In some embodiments, the basic solution includes one or more bases or a basic buffer system.

In some embodiments, the one or more bases are selected from the group consisting of hydroxides, carbonates, and bicarbonates.

In some embodiments, the basic solution includes a fragrance.

In some embodiments, the aerosolizable material includes tobacco granules.

In some embodiments, the aerosolizable material comprises one or more selected from the group consisting of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco flakes, and reconstituted tobacco.

In some embodiments, the aerosolizable material includes one or more aerosol-forming materials.

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

In some embodiments, the filter comprises one or more filter materials selected from the group consisting of cellulose acetate (CA), polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers.

In some embodiments, the filter comprises a filamentary tow material. In some embodiments, the aerosolizable material is dispersed within the filter tow.

In some embodiments, one or more capsules containing the basic solution are surrounded by a filter material.

In some embodiments, the filter includes a gap between two spaced apart sections of filter material, and the aerosolizable material is disposed in the filter gap.

In some embodiments, one or more capsules containing a basic solution are disposed in the filter cavity.

According to a second aspect of the invention described herein, there is provided an aerosol delivery system comprising a filter rod consumable according to the first aspect.

In some embodiments, the system is an aerosol-generating material heating system that includes an aerosol-generating material that is heated to form an aerosol.

In some embodiments, the system is a hybrid system that includes an aerosol generating material that is heated to volatilize constituents, and a liquid that is heated to form a vapor.

In some embodiments, the aerosol-generating material is heated by steam.

In some embodiments, the liquid is a nicotine-free liquid.

In some embodiments, the device includes a means for heating the liquid to form a vapor, but does not include a separate means for heating the aerosol-forming material.

In some embodiments, the aerosol generated by the system is drawn through a filter rod consumable.

In some embodiments, the filter rod consumable forms the mouthpiece of the system.

According to a third aspect of the invention described herein, there is provided a kit comprising a filter rod consumable according to the first aspect and a device for use in generating an inhalable aerosol.

According to a fourth aspect of the invention described herein, there is provided a method for modifying an aerosol generated by an aerosol delivery system by drawing the aerosol through a filter rod consumable according to the first aspect.

According to a fifth aspect of the invention described herein, there is provided a method of generating an inhalable aerosol, the method comprising the steps of actuating one or more capsules containing a basic solution in a filter rod consumable according to the first aspect, and volatilizing components of an aerosolizable material to form an inhalable aerosol.

According to a sixth aspect of the invention described herein, there is provided a use of a filter rod consumable according to the first aspect for modifying an aerosol generated by an aerosol delivery system.

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

FIG. 1 is a schematic diagram of a filter rod consumable according to an embodiment of the present invention. FIG. 13 is a schematic diagram of a filter rod consumable according to an alternative embodiment of the present invention. FIG. 1 is a schematic diagram of a hybrid system for heating an aerosol-forming material to volatilize at least one component of the aerosol-forming material, the hybrid system including an insert according to an embodiment of the present invention.

Detailed Description

The present invention relates to a filter rod consumable for use in an aerosol delivery system.

Aerosolizable materials containing nicotine can be treated with a base to facilitate the release of nicotine. For example, nicotine is released from nicotine salts in tobacco by reaction with a base. This allows the pH-adjusted nicotine to volatilize at a lower temperature during use.

The inventors have determined that when base-treated tobacco is used in known e-cigarette hybrid devices, nicotine delivery per puff is significantly reduced during use. The reaction between the base and nicotine occurs rapidly, and pH-treated nicotine is liberated more rapidly, and delivery during consumption may be reduced with each puff. The inventors have also observed that pH-treated nicotine may be lost from the device prior to use due to its high volatility.

Furthermore, pH treatment of tobacco leads to the liberation of ammonia. Thus, by controlling the rate of pH treatment, the rate of ammonia release is controlled, which can improve the organoleptic properties of the tobacco (as the ammonia release is slower, the ammonia odor is less intense).

The present invention provides improved uniformity of nicotine delivery per puff by delaying pH treatment of aerosolizable material (e.g., tobacco material) containing nicotine. The present invention uses a basic solution that is adjacent to the aerosolizable material. In use, the basic solution contacts the aerosolizable material and liberates nicotine. In some cases, the rate at which the basic solution contacts the aerosolizable material is controlled in use, thereby controlling the rate of nicotine liberation by pH treatment.

The basic solution is provided in one or more capsules, and prior to release from the capsule, the aerosolizable material containing nicotine is not pH treated to facilitate nicotine release. The basic solution is released only immediately prior to or during use of the aerosol delivery system, and thus pH treatment of the aerosolizable material to enhance nicotine release occurs immediately prior to or during use of the filter rod consumable, resulting in a more controlled release of nicotine during use of the filter rod consumable in the aerosol delivery system.

The filter rod consumable includes a filter and, contained within the filter, one or more capsules that contain an aerosolizable material including nicotine and a basic solution.

One or more capsules containing a basic solution are included to provide the filter rod consumable with a pH adjuster that is kept separate from the aerosolizable material, including nicotine, until the filter rod consumable is used in an aerosol delivery system.

During use, a basic solution is released from one or more capsules and contacts an aerosolizable material that includes nicotine. Upon contact with the basic solution, the pH of the aerosolizable material increases, leading to the formation of the free base form of nicotine.

In some embodiments, the aerosolizable material is tobacco. Adjusting the pH of the tobacco alters the natural equilibrium of those acid-base reactions that bind certain classes of chemicals in the tobacco. For example, in natural tobacco leaves, nicotine tends to bind with organic acids present in the leaves, and is therefore more stable and less likely to volatilize when exposed to moderate heat. When the pH of the leaf is increased, this reduces the natural binding of nicotine with the acids. Such unbound forms of "free" nicotine are more likely to volatilize.

Thus, the purpose of releasing the basic solution from one or more capsules in the filter of the flavoring insert is to provide the nicotine contained in the aerosolizable material in a chemical form that is easily released from the aerosolizable material and/or easily transferred to the aerosol generated by the aerosol delivery system. The nicotine is ideally converted to this easily released form only shortly before or during the time the aerosolizable material is used to generate the aerosol.

In some embodiments, the capsule is activated by a user to release the basic solution prior to or during use of the aerosol delivery system.

In some embodiments, at least one capsule is a breakable capsule, e.g., a capsule having a solid breakable shell surrounding a liquid fill.

In some embodiments, the capsule may be crushable, and release of the basic solution is accomplished by the user crushing the capsule during use. In some such cases, the capsule may be ruptured by a piercing member. In some cases, the piercing member may be moved by the user to contact the capsule, for example, such movement may be activated by a button. In other cases, the piercing member may be provided as part of the device into which the article is inserted, and the piercing member ruptures the capsule when the article is inserted. In still further cases, the basic solution may be encapsulated with an encapsulating material that melts, decomposes, reacts, degrades, swells, dissolves, or deforms to release the basic solution at a temperature above room temperature but at or below the temperature reached in the scented insert during use. For example, the basic solution may be encapsulated with an encapsulating material selected from a polysaccharide or cellulose barrier material, gelatin, gum, gel, wax, or mixtures thereof. In some cases, the encapsulating material is selected from one or more of alginate, dextran, maltodextrin, cyclodextrin, pectin, methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, cellulose ethers, gum arabic, gum ghatti, gum tragacanth, karaya, locust bean, gum acacia, guar, quince seed, xanthan gum, agar gel, agarose gel, carrageenan, furoidan, furcellan, and carnauba wax.

As the basic solution is released from the capsule(s), it comes into contact with the aerosolizable material. This can occur by the aerosolizable material being directly adjacent to the capsule. Alternatively or additionally, the basic solution may be released from the capsule and moved into contact with the aerosolizable material. In some embodiments, this may be done by releasing the basic solution into a wick material that carries the basic solution to the aerosolizable material. In some embodiments, the wick material may help spread the basic solution to or through the aerosolizable material. In some embodiments, a filter material, such as fibrous filter tow, may act as the wick material.

In some embodiments, the basic solution is heated during use to form a vapor and/or aerosol, which flows during use to contact the aerosolizable material. In some cases, the vaporization of the basic solution is puff-activated. This means that pH processing of the aerosolizable material occurs only during the puff, and nicotine release is minimized between puffs (reducing unintentional nicotine loss and providing sustained nicotine delivery during consumption).

In some cases, the basic solution is pumped into contact with the aerosolizable material within the filter rod consumable upon actuation of the pump by the user. The pump may be provided as part of an aerosol delivery system into which the flavored insert is inserted. In some such cases, the pump may be actuated, for example, by a button, so that the user controls the rate of pH treatment of the aerosolizable material, and thus the rate of nicotine release. In some other cases, the pump may be puff actuated, so that pH treatment of the aerosolizable material occurs only during a puff, and nicotine release is minimized between puffs (reducing unintentional nicotine loss and providing sustained nicotine delivery during the consumption period).

In some embodiments in which the filter includes two or more capsules, the capsules may be the same as one another or may differ from one another in terms of size, type, and/or capsule fill.

In some embodiments, the basic solution includes at least one of water, glycerol, and propylene glycol.

In some embodiments, the basic solution has a pH greater than about 8. In some embodiments, the basic solution has a pH less than about 10. In some embodiments, the pH of the basic solution is between about 8 and about 9.

In some embodiments, the basic solution includes one or more bases or a basic buffer system. For example, the one or more bases may be one or more of a hydroxide, a carbonate, and a bicarbonate. In some cases, the basic solution includes sodium hydroxide, potassium hydroxide, calcium hydroxide, sodium bicarbonate, potassium bicarbonate, sodium carbonate, potassium carbonate, calcium carbonate, or a mixture thereof.

The base should be in excess molar ratio to nicotine (in some embodiments, about 1.5 equivalents of base) to drive the acid-base reaction to completion and thus efficiently convert the nicotine salt to free nicotine.

The aerosolizable material containing nicotine is typically a solid. In some cases, the aerosolizable material includes tobacco material. As used herein, the term "tobacco material" refers to any material that includes tobacco or a derivative thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, reconstituted tobacco, chunk tobacco, spheronized tobacco, and/or tobacco extract.

The tobacco used to make the tobacco material may be any suitable tobacco, such as a single grade or blend including Virginia and/or Burley and/or Oriental, cut rag or whole leaf. The tobacco may be tobacco particle "fine powder" or powder, expanded tobacco, stems, expanded stems, and other processed stem materials, such as cut rolled stems. The tobacco material may be ground tobacco or reconstituted tobacco material. The reconstituted tobacco material may include tobacco fiber and may be formed by casting, Fourdrinier-type papermaking techniques with the post-addition of tobacco extract, or extrusion.

For a more rapid acid-base reaction and therefore faster nicotine release, a tobacco substrate with a high surface area is recommended. The tobacco substrate may be in a variety of forms, including, for example, dry ice expanded tobacco (DIET), ground tobacco, extruded tobacco, and granulated tobacco.

The aerosolizable material may additionally contain other ingredients, such as flavorings and/or aerosol-forming materials.

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

In some embodiments, the aerosolizable material may additionally include one or more casings, such as invert sugar, molasses, cane sugar, honey, cocoa, licorice, polyols such as glycerol and propylene glycol, and acids such as malic acid.

In some embodiments, the aerosolizable material may additionally include one or more binders, such as an alginate, cellulose or modified cellulose, starch or modified starch, or natural gum. In some embodiments, the aerosolizable material includes an alginate, such as sodium alginate, calcium alginate, potassium alginate, or ammonium alginate.

In some embodiments, the aerosolizable material may additionally include one or more fillers. In some embodiments, the fillers may include inorganic materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, and magnesium carbonate. In some embodiments, the fillers include chalk. In some embodiments, the fillers may include organic materials such as wood pulp, cellulose, and cellulose derivatives.

The filter rod consumable comprises a filter. The filter may include one or more filter elements or sections aligned along the longitudinal axis of the consumable to form a filter. In some embodiments, the filter elements or sections may be configured to form voids within the filter.

In some embodiments, the filter comprises one or more filter materials. The filter materials may be selected from the group consisting of cellulose acetate (CA), polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers.

In some embodiments, the filter material includes a plasticizer.

The filter material may be a fibrous material. In some embodiments, the fibrous material may be in the form of a tow or web. In other embodiments, the filter material may be a sheet material. In some embodiments, the sheet material is folded or rolled to form a filter or filter element.

In some embodiments, the aerosolizable material and/or one or more capsules are located within or surrounded by the filter material. For example, if the filter material is fibrous tow, the aerosolizable material and/or one or more capsules are dispersed or embedded in the filter material. If the aerosolizable material is a plurality of particles, such as tobacco granules, it may be dispersed with the filter tow. The aerosolizable material may be uniformly or non-uniformly dispersed within the filter material of the filter or filter element.

In some embodiments, one or more capsules containing the aerosolizable material and the basic solution may be located in the same filter element or section.

In some embodiments, the aerosolizable material and/or one or more capsules are located within a void formed in the filter. In some embodiments, the void may contain additional components, such as a fill material, a flavor material, or a wick material.

In some embodiments, the gap is between two spaced apart filter elements. The gap is also surrounded by a wall. The wall may also surround the entire filter and/or the entire consumable.

In one particular exemplary embodiment, the void filter construction has a void section of 28 mm length and a cellulose acetate tow filter section of 6 mm on each end, with an overall length of 40 mm. The void section of the filter may be filled with tobacco material.

In some embodiments, one or more capsules containing the basic solution may be located upstream of the aerosolizable material when the consumable is located for use in the aerosol delivery system. In some embodiments, the capsules are located near the mouth end section to avoid any direct interaction with the heating source.

In some embodiments, the filter rod consumable may include a flavor modifier to modify or add flavor to the flavor delivered by the aerosol delivered by the aerosol delivery system. In some embodiments, the flavor modifier may be included in the aerosolizable material. Alternatively or additionally, the flavor modifier may be added to or included in the basic solution. As used herein, the terms "flavor" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other somatic sensation in products for adult consumers, where local regulations permit. They may be any naturally occurring flavoring material, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, and the like). buie), bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo biloba), hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damienne, marjoram, olive, lemon balm, lemon basil, chives, calvi, barbecue The compositions may include, for example, glyceryl stearate ...

In some embodiments, the flavor comprises menthol, spearmint, and/or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus fruit, and/or red berry flavor ingredients. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor ingredients extracted from tobacco. In some embodiments, the flavor comprises flavor ingredients extracted from cannabis.

In some embodiments, the flavoring may include a sensory elicitor that is intended to achieve somatic sensations that are usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

As used herein, aerosol delivery systems include non-combustion aerosol delivery systems that release compounds from an aerosol-generating material without burning the aerosol-generating material, such as tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-generating materials.

According to this disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials of the aerosol delivery system (or parts thereof) are not combusted or burned to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol delivery system, for example a powered non-combustible aerosol delivery system.

In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol generating material is not required.

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

In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, a tobacco or non-tobacco product.

The filter rod consumable may be incorporated into an aerosol delivery system, e.g., an apparatus for heating an aerosol-generating material to volatilize at least one component of the aerosol-generating material. In some embodiments, the aerosol-generating material used in the aerosol delivery system further includes one or more other aerosol-generating materials, e.g., volatilizable materials.

The present invention also provides an aerosol delivery system comprising a filter rod consumable according to an embodiment of the present invention. In some embodiments, the system comprises a heater. In some embodiments, the heater is battery powered. In some embodiments, the or each heater is an electrical resistance heater.

In some embodiments, the aerosol delivery system is a non-combustion heated assembly that, during use, heats an aerosolizable material to produce an inhalable medium.

In some embodiments, the aerosol delivery system is an e-cigarette hybrid assembly. In some such embodiments, the basic solution may be provided as a component of a first volatilizable material. Heating the material volatilizes the volatilizable material to form an aerosol and/or vapor that includes the basic solution. The aerosol and/or vapor flows through the filter rod consumable and contacts the aerosolizable material to liberate nicotine. In other embodiments, the basic solution is separate from the first volatilizable material.

In some specific embodiments, the aerosol delivery system includes a container that holds a first volatilizable material that includes a liquid component. A heater is provided for volatilizing the first volatilizable material held in the container. Upon use of the aerosol delivery system, the heater volatilizes the first volatilizable material to form a vapor and/or aerosol that passes through the filter rod consumable containing the aerosolizable material and a basic solution released from one or more capsules within the filter rod consumable, entraining one or more components of the aerosolizable material, thereby forming an inhalable medium that passes out of the system and is inhaled by a user.

In some cases, the first volatilizable material comprises a liquid or gel. The first volatilizable material may alternatively be referred to as a vapor/aerosol precursor. Preferably, the first volatilizable material comprises, consists essentially of, or consists of a liquid. Suitable liquids include components customarily used in e-cigarette liquids. The first volatilizable material may include an aerosol-forming material, such as propylene glycol and/or glycerol. Additionally, in some cases, the first volatilizable material includes a flavoring agent. The first volatilizable material typically volatilizes around 150-250°C.

In some cases, the aerosolizable material may be porous to allow the aerosol or vapor to pass through the material. This provides the material with a large contact area for contact with the aerosol and/or vapor. Preferably, the aerosolizable material (prior to use) may have a pH of less than about 7 as measured according to the CORESTA protocol for measuring tobacco pH.

In some cases, the assembly heats the aerosolizable material during use to facilitate release of its components into the inhalation medium. In some cases, one heater may heat both the first volatilizable material and the aerosolizable material. In some cases, a second heater may be provided that heats the aerosolizable material. In some cases, the device does not heat the aerosolizable material, but relies on heat carried by the vapor/aerosol to warm the material (which volatilizes components of the material that are then entrained in the vapor/aerosol stream).

In one embodiment, the assembly includes a cooler or cooling section downstream of the heater and upstream of the aerosolizable material, the cooler or cooling section configured to cool the vaporized material to form an aerosol of droplets that passes through the filter rod consumable and the aerosolizable material during use. The cooler may be configured to essentially act as a heat exchanger to allow recovery of heat from the vapor. The recovered heat may be used, for example, to preheat the aerosolizable material and/or to assist in heating the first volatilizable material. In some embodiments, the cooling section may be part of the filter rod consumable.

In one embodiment, the heater is puff activated, i.e., the device includes a puff detector and heats the first volatilizable material only upon detection of a puff. This means that vapor/aerosol only forms in the device during a puff. This can, in some embodiments, further delay pH processing of the aerosolizable material to reduce unintentional nicotine loss and provide sustained nicotine delivery during the consumption period.

In one embodiment, the container that holds the first volatilizable material is removable. The container may be in the form of a pot or the like (which in some embodiments may be, for example, a ring), and/or cotton wool or the like. The container may be substantially disposable, being replaced in its entirety after use. Alternatively, the arrangement may be such that the user removes the container from the device, replaces the used volatilizable material or refills the container with additional material, and then replaces the container back into the device.

In some cases, the container may not be removable from the device. In such an embodiment, the user may simply replace the used material or refill the container with material as needed after use.

In some cases, the filter rod consumable containing the capsule(s) containing the aerosolizable material and the basic solution is removable from the device. The consumable may be essentially a disposable item that is replaced in its entirety after use.

The filter rod consumables are configured for use in the hybrid devices for generating inhalable media described herein.

The invention also provides a kit comprising a filter rod consumable according to an embodiment of the invention and a device for use in generating an inhalable medium. The device may comprise a heater. Various features described above in relation to the aerosol delivery system are expressly disclosed in combination with the kit aspects of the invention, and features described in relation to the system may be features of the device. Thus, for example, the device may comprise one or more of a puff actuator, a cooling element or cooling zone, an actuation means such as a button, a further heater, etc.

Examples of consumables and devices for generating inhalable media according to some embodiments of the present invention will now be described with reference to the accompanying drawings.

With reference to Figures 1 and 2, an example of a filter rod consumable as described herein is shown. The illustrated consumable 1 is rod-shaped with filter sections or elements 2a, 2b at each end. The filter elements include a filter material, such as fibrous tow. The material of each filter element may be the same or different. In some embodiments, one or more of the filter elements may include additives, such as sorbents, flavorings, etc. The additives of each filter element may be the same or different.

The sections of the filter rod consumable 1 may be held together by a wrapper, such as a wrapping paper, that surrounds the rod.

In the embodiment illustrated in FIG. 1, the filter elements 2a, 2b are adjacent to a void. The void is filled with an aerosolizable material 3, e.g., tobacco granules. The void also contains a capsule 4 containing a basic solution, at least partially surrounded by or embedded in the aerosolizable material. The capsule 4 may be ruptured by a user by applying pressure to the side of the consumable 1. Once the frangible shell of the capsule 4 is broken, the basic solution spreads within the void and comes into contact with the aerosolizable material 3.

In the embodiment illustrated in FIG. 2, the filter elements 2a, 2b are adjacent to a further filter element 2c. The further filter element 2c comprises a filter material in which particles of an aerosolizable material 3, e.g. tobacco granules, are dispersed. The further filter element 2c also contains a capsule 4 containing a basic solution embedded in the filter material. The capsule 4 may be ruptured by a user by applying pressure to the side of the consumable 1. Once the frangible shell of the capsule 4 is broken, the basic solution spreads through the filter material of the filter element 2c and comes into contact with the particles of the aerosolizable material 3.

Referring to FIG. 3, an example of a device 11 for generating an inhalable medium is shown. Broadly speaking, the device 11 volatilizes a liquid contained in a reservoir or container 12 to form a vapor or aerosol, which passes through a filter rod consumable 1 inserted into a void in the housing 13 of the device.

The filter rod consumable 1 shown is illustrated in FIG. 2 and described above. In use, the capsule is ruptured just prior to inserting the consumable 1 into the device 11. This releases the basic solution in the capsule, which contacts the aerosolizable material (in this embodiment, tobacco granules) to adjust the pH of the tobacco and form the free base of nicotine. When the liquid in the device's container 12 is heated by the heater 16, the liquid is vaporized and vapor and/or aerosol is drawn through the filter rod consumable 1 when the user draws on the mouth end 5 of the filter rod consumable 1. The heated vapor warms the aerosolizable material and nicotine and other volatile components are entrained in the aerosol and/or vapor.

In this regard, it may first be noted that a vapor is generally a substance in the gas phase below its critical temperature, meaning that the vapor can be condensed into a liquid, for example by increasing its pressure without decreasing the temperature. An aerosol, on the other hand, is generally a colloid of solid particles or liquid droplets in air or another gas. A "colloid" is a substance in which microscopically dispersed insoluble particles are suspended throughout another substance.

Returning to FIG. 3, the device 11 in this example has a generally hollow cylindrical outer housing 13. Housing 13 has an open end 14. In this example, a tubular filter rod consumable 1 is installed in open end 14. Filter rod consumable 1 is removable from housing 13 by a user.

At or near the other end of the housing 13 is a battery for powering the various components of the device 11, including the heater 16. The battery may be a rechargeable battery or a disposable battery. A controller is also provided in the housing 13 for controlling the operation of the various components of the device 11.

The heater 16 is generally centrally located in the housing 13, i.e., centrally along the length and width of the housing 13 in this illustrated embodiment. In this example, the heater 16 is powered by the battery and is therefore electrically connected to the battery.

The heater may be an electrical resistance heater, including, for example, a nichrome resistance heater, a ceramic heater, or the like. The heater 16 may be, for example, a wire, which may be in the form of a coil, for example, as shown. Alternatively, the heater may be a plate (which may be a multi-layer plate of two or more different materials, one or more of which may be conductive and one or more of which may be non-conductive), a mesh (which may be, for example, woven or non-woven, and may also be multi-layered), a film heater, or the like. Other heating configurations may be used, including non-electrical heating configurations.

In some embodiments, the filter rod consumable 1 is inserted into the device 11 such that there is no air gap between the consumable 1 and the interior of the housing 13, resulting in all aerosol or vapor flowing through the consumable.

The liquid is preferably one that is volatilizable at moderate temperatures, for example in the range of 100-300°C, or more particularly around 150-250°C, as this helps to keep the power consumption of the device 1 low. Suitable materials include those conventionally used in e-cigarette devices, including, for example, propylene glycol and glycerol (also known as glycerin).

The aerosolizable material 3 imparts flavor to the aerosol or vapor generated from the liquid as it passes through the filter rod consumable 1. As the aerosol or vapor passes through and over the aerosolizable material 3, the hot aerosol or vapor entrains nicotine and other tobacco compounds or components from the aerosolizable material 3, thus imparting flavor to the aerosol or vapor as it passes to the mouth end 5 of the consumable 1.

In the embodiment shown in FIG. 3, the only heat source required to heat the aerosolizable material 3 to entrain nicotine and other compounds or components from the aerosolizable material 3 is the hot aerosol or vapor resulting from heating the liquid.

The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and/or exclusive. The advantages, embodiments, examples, features, structures, and/or other aspects described herein should not be considered as limiting the scope of the invention as defined by the claims or the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably include, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. In addition, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims (29)

1. A filter rod consumable for use in an aerosol delivery system , comprising: a filter ; and an aerosolizable material, including nicotine, contained in the filter; and one or more capsules containing a basic solution, wherein the basic solution can be released from the capsules upon actuation by a user to contact the aerosolizable material. 2. The filter rod consumable of claim 1 , wherein the basic solution has a pH of about 8 to about 10. 3. The filter rod consumable of claim 2 , wherein the basic solution has a pH of about 8 to about 9. The filter rod consumable of any one of claims 1 to 3 , wherein the basic solution comprises one or more bases or a basic buffer system. 5. The filter rod consumable of claim 4 , wherein the one or more bases are selected from the group consisting of hydroxides, carbonates, and bicarbonates. The filter rod consumable product according to any one of claims 1 to 5 , wherein the basic solution contains a fragrance. The filter rod consumable of any one of claims 1 to 6 , wherein the aerosolizable material comprises tobacco granules. 8. The filter rod consumable of claim 7 , wherein the aerosolizable material comprises one or more selected from the group consisting of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco flakes, and reconstituted tobacco. The filter rod consumable of any one of claims 1 to 8 , wherein the aerosolizable material comprises one or more aerosol forming materials. 10. The filter rod consumable of claim 9 , wherein the aerosol forming material is selected from the group consisting of glycerol, propylene glycol, and glyceryl triacetate. 11. The filter rod consumable of claim 1, wherein the filter comprises one or more filter materials selected from the group consisting of cellulose acetate (CA), polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly( 1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers. The filter rod consumable of any one of claims 1 to 11 , wherein the filter comprises a filter material that is a filamentary tow material. 13. The filter rod consumable of claim 12 , wherein the aerosolizable material is dispersed within the filamentary tow material . 13. The filter rod consumable of claim 11 or 12 , wherein the one or more capsules containing a basic solution are surrounded by the filter material. 13. The filter rod consumable of claim 1 , wherein the filter comprises a void between two spaced apart sections of filter material, the aerosolizable material being disposed in the void . 16. The filter rod consumable of claim 15 , wherein the one or more capsules containing a basic solution are disposed in the void . An aerosol delivery system comprising a filter rod consumable according to any one of claims 1 to 16 . 20. The aerosol delivery system of claim 17 , which is a non-combustible aerosol delivery system . 20. The system of claim 18 , which is an aerosol-generating material heating system comprising an aerosol-generating material that is heated to form an aerosol. 20. The system of claim 19 , which is a hybrid system comprising an aerosol generating material that is heated to volatilize constituents and a liquid that is heated to form a vapor. 21. The system of claim 20 , wherein the aerosol-forming material is heated by steam. 22. The system of claim 21 , wherein the liquid is a nicotine-free liquid. 23. The system of claim 21 or 22 , including a means for heating a liquid to form a vapor, but not including a separate means for heating the aerosol-forming material. The system of any one of claims 17 to 23 , wherein the aerosol generated by the system is drawn through the filter rod consumable. A system according to any one of claims 17 to 24 , wherein the filter rod consumable forms a mouthpiece of the system. A kit comprising a filter rod consumable according to any one of claims 1 to 16 and a device for use in generating an inhalable aerosol. A method for modifying an aerosol generated by an aerosol delivery system by drawing the aerosol through a filter rod consumable according to any one of claims 1 to 16 . A method for generating an inhalable aerosol, comprising: actuating one or more capsules containing a basic solution in a filter rod consumable product described in any one of claims 1 to 16 ; and volatilizing components of the aerosolizable material to form the inhalable aerosol. 17. Use of a filter rod consumable according to any one of claims 1 to 16 for modifying an aerosol generated by an aerosol delivery system.

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