WO2022079228A1

WO2022079228A1 - Smoking article comprising a particulate tobacco substituent

Info

Publication number: WO2022079228A1
Application number: PCT/EP2021/078592
Authority: WO
Inventors: Miguel SORIANO; Theodorus VERLAAN
Original assignee: Jt International Sa
Priority date: 2020-10-15
Filing date: 2021-10-15
Publication date: 2022-04-21
Also published as: CN116348003A; JP2023544785A

Abstract

The invention relates to a smoking article (1) comprising an aerosol generator (2) and a flavoring device, which is suitable for releasing a flavoring substance (4) to a stream of aerosol generated by the aerosol generator (2), wherein the flavoring device comprises an inert carrier material (6). The flavoring substance (4) is releasably adhered to the carrier material (6) and comprises tobacco particles (7) having an average particle size (SD₅₀ laser diffraction) < 30 μm. Furthermore, the invention relates to a replaceable cartridge (12) comprising a flavoring device, which is suitable for releasing a flavoring substance (4) to a stream of aerosol generated by an aerosol generator (2), wherein the flavoring device comprises an inert carrier material (6) and the flavoring substance (4) releasably adhered to the carrier material (6). The flavoring substance (4) comprises tobacco particles (7) having an average particle size (SD₅₀ laser diffraction) < 30 μm. Furthermore, the invention is directed to a method for producing a smoking article.

Description

Smoking article comprising a particulate tobacco substituent

Description

The present invention is directed to a smoking article comprising an aerosol generator and a flavoring device, which is suitable for releasing a flavoring substance to a stream of aerosol generated by the aerosol generator, wherein the flavoring device comprises an inert carrier material and to a replaceable cartridge for such a smoking article. Furthermore the invention is directed to a method for producing the same.

Smoking articles comprising an aerosol generator and a flavoring device are known from the state of the art and are used in many different variations.

An electronic smoking article usually comprises a power source such as a battery, a container for an e-liquid, such as a cartridge or tank, and an atomizer, including a heating element that atomizes the e-liquid. The e-liquid usually contains propylene glycol and glycerin as major ingredient. Mostly only less than 5 % (weight/weight (w/w)) of the e-liquid are other additives such as nicotine and flavors. Since the e-liquid is heated to a temperature of roughly up to 100 - 250 °C within to create an aerosolized vapor, some flavors could not be included in an e-liquid because the flavoring molecules tend to decompose because of the heat treatment. Thus, e-liquids comprising tobacco extracts are usually not suitable to provide a vapor having a desired tobacco taste.

To overcome this problem attempts have been made to add flavors to the aerosol / the vapor after its production. For example, US 2019/0045837 A1 discloses a flavor delivery device for adding flavor to an aerosol stream generated by a smoking article. This device comprises an electrical heating element and a flavorant provider which is heatable by the heating element. However, also in this flavor delivery device the flavor is heat treated.

Furthermore, US 104 70488 B2 discloses a flavour delivery material comprising a polymer matrix having domains in which a flavour composition is arranged. This flavour composition comprises a flavorant which is arranged in pores or pockets of the polymer or is dispersed therein. The flavorant of the flavour composition is only released when the polymer matrix is broken.

It would be desirable to provide a smoking article for enabling the consumer to conveniently and effectively incorporate a desired tobacco flavor to the aerosol prior to inhalation. It would be particularly desirable if such a smoking article could be adapted to enable the consumer to select from a variety of different tobacco flavors. Furthermore, it would be desirable if the flavoring device could be refillable or exchangeable to allow reusage of the (other parts) smoking article. Preferably, such a smoking article could be manufactured with common handling machines.

These problems are solved by a smoking article according to claim 1 , a replaceable cartridge for a smoking article according to claim 11 and a method according to claim 13.

A smoking article according to the invention comprises an aerosol generator and a flavoring device. The flavoring device is suitable for releasing a flavoring substance to a stream of aerosol generated by the aerosol generator. The flavoring device comprises an inert carrier material, to which the flavoring substance is releasably adhered. The flavoring substance comprises tobacco particles having an average particle size (sDso laser diffraction) < 30 pm.

Tobacco particles having such a small average particle size are providing a high surface area, which could be contacted by the passing aerosol. This allows transfer of the flavoring molecules from the particles into the aerosol stream. The particle size of < 30 pm has been found to allow transfer of a plurality of flavoring molecules, which contribute to a full tobacco flavor. The particle size allows migration of bigger and smaller molecules from an internal volume of the particles to their surface from which these molecules could pass over to the aerosol stream. The term “inert”, especially in combination with the word “carrier”, means in the context of the present invention, that a first substance does not chemically interact with the second substance (e.g. the carrier). An inert carrier is preferably inert with respect to the aerosol. Thus, the carrier itself remains chemically unchanged when contacted by the aerosol. However, “inert” does not mean that no interaction between the aerosol and the carrier is possible. Especially physical interactions like energy transfer (e.g. heat) is possible. Also other physical properties of the inert material (e.g. the carrier) could change due to such an interaction. For example its density or (specific) surface area could change because of the thermal expansion. Since it is an important feature of preferred embodiments of the invention that a flavoring substance and/or a flavoring molecule is adhered to a surface of an inert carrier and released from its surface upon an activation signal (e.g. contact with an aerosol), also this change of a surface property of the inert carrier material is possible and is not excluded by the term “inert”.

In the context of the present invention also the term “tobacco product” refers to a flavoring substance comprising leaf tobacco particles having an average particle size (sDso laser diffraction) < 30 pm.

Also nicotine could pass over from the tobacco particles to the aerosol in a similar way. Since nicotine has a flavor and is usually a constituent of tobacco, the term “flavoring molecules” also includes nicotine.

This characteristic of the particles could also be explained by quick heating of the small particles after being contacted by the hot aerosol stream, due to which the migration of the flavoring molecules within the tobacco particles starts. Furthermore, the flavoring molecules could reach the particle surface from which they could pass over to the aerosol stream quickly, independently from its position within the particle.

Preferably the average size of the tobacco particles (sDso laser diffraction) is > 1 pm, preferably > 2.5 pm, more preferably > 5 pm, most preferably > 8 pm. It has been found, that grinding of the tobacco particles to a smaller particle size could affect the flavor. It is believed that some of the flavoring molecules of the leaf tobacco decompose due to the high shear energy. Furthermore, some flavoring molecules could exit very small tobacco particles during the grinding process or during a later handling process. This would result in a depletion of these flavoring molecules in the tobacco particles and a flavor composition different with respect to the full tobacco flavor.

To avoid decomposing of flavoring molecules during the grinding process, it has been found advantageous, to reduce the viscosity of the grinding composition. This could be achieved by adding a solvent to this composition. Such a solvent (or “dispersion medium”) is preferably selected from a group comprising water, monovalent alcohols, polyvalent alcohols, sugar alcohols, sugars and polyvalent alcohol esters. By using such a dispersion medium, the average particle size of the tobacco can be adjusted to the desired value, without significant changes of the flavor.

More preferably the one or more dispersion medium is selected from a group comprising water, monovalent alcohol, monovalent aliphatic alcohol, methanol, ethanol, 1-propanol, 2- propanol, 1-butanol, 2-butanol, 2-methyl-1 -propanol, 2,2-dimethylethanol, cyclohexanol, monovalent alcohol having an aromatic substituent, benzyl alcohol, monovalent alcohol containing one or more halogen element monovalent alcohol having one or more ether bond, polyvalent alcohol, glycerol, propylene glycol, sugar alcohol, sorbitol, maltitol, xylitol, erythritol, lactitol, sorbitan, xylose, arabinose, mannose, trehalose, sugar, lactose, sucrose, coupling sugar, glucose, enzyme-saccharified starch syrup, acid-saccharified starch syrup, maltose starch syrup, maltose, isomerized sugar, fructose, reduced maltose, reduced starch syrup, honey, polyvalent alcohol ester, fatty acid polyvalent alcohol ester and fatty acid triglyceride.

Preferably the ratio of the tobacco particles in a dispersion is > 0,5 % (w/w), preferably > 1 % (w/w), > 2 % (w/w) or > 5 % (w/w), more preferably > 10 % (w/w), most preferably > 20 % (w/w) and < 95 % (w/w), preferably < 90 % (w/w), < 80 % (w/w) or < 70 % (w/w), more preferably < 60 % (w/w), most preferably < 50 % (w/w). It has been found that these ratios allow grinding of the tobacco to the desired average particle size in most of the solvents without significant loss of flavor.

Beside the tobacco particles with an average particle size of 30 micrometer or less, the tobacco product preferably comprises a liquid medium like alcohol or water, in which the tobacco particles are dispersed. ln a preferred embodiment, the tobacco particles are dispersed in a liquid medium having a temperature of < 30°C, preferably < 20°C, more preferably < 15°C, most preferably < 10°C, to prevent decomposition and/or dissipation of the tobacco flavoring. Preferably the liquid medium of the dispersion has a temperature of > -20°C, preferably > -10°C, more preferably

> -5°C, most preferably > 0°C, to facilitate its handling. It has been shown that a cold dispersion having temperatures in the above-mentioned range also prevents nicotine decomposition.

Preferably releasing of the flavoring substance from the carrier material is initiable by an activation signal. This prevents depletion of the flavoring substance during storage to large extends. However, efficient transfer of flavoring molecules to the aerosol stream could be ensured after application of an activation signal to the flavoring substance.

In a preferred embodiment of the invention, the activation signal is selected from a group comprising temperature change, humidity change, moisture change, water contact, contact to liquids, contact to an aerosol, pressure change, electric signal, light and electromagnetic radiation. Especially preferred is activation upon application of high temperatures or contact to an aerosol. Since the aerosol generated in a smoking device usually has a temperature of

> 30°C, preferably > 60°C, > 80°C or > 100°C, more preferably > 150°C, most preferably > 180°C and < 300°C, preferably < 290°C, < 280°C or < 270°C, more preferably < 250°C, most preferably < 200°C, when contacting the flavoring substance, activation in this temperature range is preferred.

However, also other activation signals could be advantageous. In an alternative embodiment, releasing of the flavoring substance from the carrier material is initiable independently from the aerosol. This allows the user to decide whether the flavor should be added to the aerosol or not. Optionally also the intensity of the flavor could be adjusted to individual preferences of the user. Thus, the activation signal could be given by a user, e.g. by an activation means of the smoking device. In a preferred embodiment the activation means is a button which could be touched and/or pressed by the user if additional flavoring of the aerosol is desired. The activation means than applies an activation signal to the flavoring substance, e.g. by energy application (e.g. heat, light, electromagnetic radiation). This signal than initiates transfer of the flavoring substance to the aerosol. Preferably the flavoring device is arranged in the smoking article downstream with respect to the aerosol generator. As described above, this embodiment allows that the aerosol itself could be the activation signal. However, in an alternative embodiment the flavoring substance is provided together with an air stream, to which the aerosol is added at a later stage. Since this embodiment requires a separate activation signal and deposition of flavor molecules in the smoking device upstream the aerosol generator could occur, this embodiment is less preferred. Most preferably the flavoring device is arranged at the downstream end of the smoking device, preferably next to or within the mouthpiece. Since the mouthpiece is usually exchangeable, undesired mixture of different flavors could be easily prevented by exchanging the mouthpiece.

In a preferred embodiment, the flavoring device comprises an aerosol inlet and an aerosol outlet. This embodiment allows continuous passage of the aerosol through the flavoring device. Depending on the flow rate of the aerosol, the amount of flavor intake could be adjusted to individual preferences. However, since smoking is usually a discontinuous procedure, also other embodiments of the flavoring device having only a single opening are suitable. In this embodiment, the aerosol could be brought into contact to the flavoring substance be enriched with the flavoring molecules in a first step and guided to the user in a second step, when the user starts intake of the aerosol. However, since this embodiment requires stabilization of the aerosol for a longer period, this embodiment is less preferred.

In contrast thereto, an embodiment is especially preferred, in which the aerosol inlet and the aerosol outlet are arranged at opposed ends of the flavoring device. This embodiment allows a continuous flow of the aerosol through the flavoring device and a well-defined contact time between the aerosol and the flavoring substance to control the flavor uptake of the aerosol. The number of flavoring molecules taken up by the passing aerosol could be further adjusted by the contact area between the flavoring substance and the aerosol. Preferably, the contact area is widened, e.g. by application of the flavoring substance on the internal surface of a plurality of tubes through which the aerosol is guided in the flavoring device. Alternatively, or in addition thereto, the contact area could be increased by an elongated flow path of the aerosol, which could be realized by a curved flow path.

Preferably, the flavoring device comprises an aerosol passageway along which the flavoring substance bearing carrier material is arranged. This aerosol passageway preferably provides a large surface area, in which the aerosol could contact the flavoring substance and be enriched by the flavoring molecules. Preferably such an aerosol passageway is defined by a tube. A tube having a defined length and diameter (optionally differing along the tube length) has the advantage with respect to undefined geometries (e.g. statistically arranged pores of a porous material) that the contact time of the aerosol with the flavoring substance could be controlled in an easy way. In contrast thereto, a porous material provides different pore sizes and length, which will result in different dwell times and different flavor uptake. Also, condensation of the aerosol along its passage through longer pores might occur.

In a preferred embodiment the flavoring device is arranged in a replaceable cartridge. Such a replaceable cartridge could also include a mouthpiece of the smoking article. Independent whether the replaceable cartridge includes a mouthpiece or not, arranging the flavoring device in a replaceable cartridge offers the possibility to adjust flavor of the aerosol provided by the smoking article to a desired flavor easily. Other parts of the smoking article could be used further. This would reduce costs for the user.

Since in this embodiment the entire cartridge (optionally also including the mouthpiece) is replaced, the number and area of surfaces of the smoking article on which rests of previously applied flavors could remain, is reduced or even non-existent. Thus, replacing the cartridge provides the flavor of this cartridge without contamination by other flavorants.

It has been found that the carrier material is preferably selected from a group comprising fibres, filtering material, cellulose acetate, fibre tow, or staple fibres, randomly oriented staple fibres, sheets, paper sheet, folded sheet, rolled sheet, crimped sheet, labyrinth, matrix material, sponge type, ceramic material, fleece, multiple tubes, a single tube, granulate, spherical particles, cubes, cuboids and parallelepipeds. These materials are well known in the tobacco industry and could be handled with common handling machines. The surface area of these materials is usually high with respect to its weight. This allows a large contact area with passing aerosol. Since the uptake of flavoring molecules by the aerosol is dependent on the dwell time and the contact area, a large contact area is advantageous to provide the flavored aerosol as soon as possible to the user.

Preferably, the flavoring substance is adhered to a surface of the carrier material. In contrast to other less preferred technics like encapsulation or embedding in a polymer material, this embodiment provides advantages. A major advantage is, that the aerosol immediately contacts the flavoring substance when passing the carrier material. Thus, heat could be transferred from the aerosol to the flavoring substance and/or the carrier at once. Since no energy is required for opening a capsule or softening a polymer, the energy could be transferred to the flavoring substance without significant loss and allows the flavoring molecules transfer into the aerosol stream.

Depending on the carrier material, the adherence mechanism can be different. In a preferred embodiment, a binder is used to establish a bonding between the tobacco particles and the carrier. Preferably the binder is cleavable. Preferably the binder is cleavable by the thermal energy of the aerosol stream.

Preferably the aerosol generator is suitable for generating an aerosol of propylene glycol and/or glycerine. Since the boiling point of these liquids is much higher than that of water, a strong heat source is required for the aerosol generator. The aerosol preferably comprises propylene glycol and/or glycerine. Preferably the aerosol is free from nicotine when generated in the aerosol generator. Especially in combination with propylene glycol and/or glycerine nicotine free compositions are preferred since the auto-ignition temperature of nicotine is only 244 °C. Residues of nicotine could ignite when in contact to the strong heat source of the aerosol generator. However, if nicotine containing aerosol is desired, this embodiment requires a nicotine source downstream the aerosol generator. In a preferred embodiment, the nicotine source is the tobacco product and/or the tobacco particles of the flavoring substance. Reducing or even avoiding nicotine in the liquid medium, could result in a product, which is safer to handle. Not only the risk of auto-ignition could be reduced but also the risk of intoxication of the user due to the manipulation of the e-liquid cartridge.

A further aspect of the invention is a replaceable cartridge for a smoking article, which comprises an aerosol generator, wherein the replaceable cartridge comprises a flavoring device, which is suitable for releasing a flavoring substance to a stream of aerosol generated by the aerosol generator, and differs from known cartridges by a flavoring device which comprises an inert carrier material to which the flavoring substance comprising tobacco particles having an average particle size (sDso laser diffraction) < 30 pm is releasable adhered.

The small tobacco particles having an average particle size of < 30 pm are providing a high surface area, which could be immediately contacted by the aerosol passing this surface. This allows not only quick transfer of the flavoring molecules from the particles into the aerosol stream but also transfer of a naturally occurring mixture of a plurality of flavoring molecules, which together contribute to the full tobacco flavor. Due to the small volume of these tobacco particles the entire particles could be heated by the passing aerosol within a period of less the 0.1 s and. Thus, flavoring molecules of different molecular weight and boiling point could leave the particles and be taken up by the aerosol stream.

The advantages of the preferred embodiments of the smoking article also occur when applied to such a replaceable cartridge for a smoking article. Thus, preferred variations of the smoking article described above are also preferred variations of a replaceable cartridge.

Preferably the carrier is located in a cartridge, more preferably in a flavoring device of the cartridge. Such a cartridge could be sold to an end user. Prior use, the cartridge is placed in a smoking article, preferably downstream of the e-liquid container and/or the aerosol generator. Preferably the cartridge and/or the flavoring device comprises a housing with one or more openings to allow an aerosol entering and leaving the housing. Inside the housing the carrier is located in a position which could be contacted by the aerosol when passing the housing. The flavoring substance / the tobacco product is arranged on a surface of the carrier. When the aerosol passes the surface (e.g. by traveling through/around/along the carrier), it takes up flavoring molecules from the flavoring substance. The flavoring molecules may also include nicotine.

Preferably the aerosol is enriched by flavoring molecules and exits the cartridge and/or the flavoring device through one or more outlet openings. Preferably, the inlets and outlets are provided at opposed ends of the housing. Preferably, the cartridge is elongated to enlarge the contact surface between aerosol and flavoring substance. An elongated embodiment further provides a longer dwell time of the aerosol within flavoring device at a given flow rate.

Preferably, the cartridge comprises a mouthpiece. In this embodiment, the cartridge comprises coupling means, which allow detachable coupling to an aerosol generator of a smoking article. In this embodiment, the cartridge is arranged at the mouth end of the smoking article and the user can draw the flavor enriched aerosol directly from the downstream end of the cartridge. The optional mouthpiece at the downstream end of the cartridge could include means for cooling down the flavor enriched aerosol. Along the flow path of the aerosol through the flavoring device the carrier could be separate or combined with further aerosol treatment means.

In a preferred embodiment, the carrier (and the flavoring substance adhered to it) is the only treatment means within the flavoring device. In this embodiment, the inlet and outlet openings are preferably sized and shaped to prevent that the carrier passes through them. Preferably the inlet and/or outlet openings comprise small holes having a diameter smaller than the carrier size. Preferably the holes are part of a net. This is of particular importance in embodiments in which the carrier comprises (small) fibres or granules. To ensure a sufficient aerosol flow rate, the inlet and/or outlet opening preferably comprise a plurality of holes.

In another preferred embodiment, the carrier (and the flavoring substance adhered to it) is combined with at least one other treatment means within the flavoring device. In a preferred embodiment, the carrier is combined with a cellulose acetate filter segment, which is preferably arranged upstream and/or downstream of the carrier. Such a filter segment could prevent carrier particles from leaving the flavoring device and/or the cartridge. Such a filter is preferably arranged at the downstream end of the flavoring device and is preferably a thin filter like a fleece or mesh. Alternatively of in addition thereto, a tobacco component could be arranged upstream and/or downstream of the carrier. Such a further tobacco component could increase the flavor of the aerosol.

The invention is further directed to a method for manufacturing a smoking article. This method comprises the steps of: providing an aerosol generator, providing a flavoring device, which is suitable for releasing a flavoring substance to a stream of aerosol, wherein the flavoring device comprises an inert carrier material and the flavoring substance is releasable adhered to the carrier material, arranging the flavoring device downstream the aerosol generator to allow releasing of the flavoring substance to the stream of aerosol.

The flavoring device could be a separate cartridge, which is provided (or sold to an user) separately from the aerosol generator. This allows selection of a desired flavor from a group of different flavors. Such a cartridge could then be coupled to the aerosol generator and the generated stream of aerosol can take up flavor from the flavoring device. The inert carrier of the flavoring device preferably does not interact with the aerosol chemically. However, energy transfer from the aerosol to the carrier is usually possible.

The step of arranging the flavoring device downstream the aerosol generator could be performed by the end user. In a preferred embodiment the flavoring device is part of a cartridge, which could be combined with the aerosol generator to provide a usable smoking article. When an aerosol is generated in such a smoking article the aerosol is guided through the flavoring device and the flavoring substance is released to the stream of aerosol.

It will be understood that the embodiments explained above are merely a first embodiment of the method and/or system of the invention. In this respect, the disclosure of the invention is not limited to these embodiments.

All the features disclosed in the application documents are claimed as being essential to the invention in so far as they are individually or in combination novel over the prior art.

Further advantages, objectives and features of the present invention will be described, by way of example only, in the following description with reference to the appended figures. In the figures, like components in different embodiments can exhibit the same reference symbols.

The figures show:

Fig. 1 a smoking article 1 according to an embodiment of the invention;

Fig. 2 an enlarged sectional view of one embodiment of the carrier material 6 and the flavoring substance 4 adhered thereto;

Fig. 3a-f different embodiments of the flavoring device 3;

Fig. 4 another embodiment of the smoking article 1 ;

Fig. 5 an enlarged view of the cartridge 12;

Fig. 6 the sequence of steps of the method for manufacturing a smoking article 1.

In figure 1 a smoking article 1 according to one embodiment of the invention is depicted. The smoking article 1 comprises an aerosol generator 2. The aerosol generator 2 generates an aerosol, which is entrained in an aerosol stream 5. The aerosol generator 2 preferably comprises a liquid reservoir 2a, liquid transport means and a heating unit 2b. The liquid transport means can be integral to the liquid reservoir 2a (e.g. a plurality of small orifices on a surface of the liquid reservoir 2a that directs liquid in a controlled amount to the heating unit 2b) and/or to the heating unit (e.g. the heating unit 2b comprises a porous body that draws liquid from the liquid reservoir 2a). The liquid transport means can also be a separate element. For example, the liquid transport means can be a wick with one or more sections in fluid communication with the liquid inside the liquid reservoir 2a and one or more sections in contact with the heating unit 2b. A capillary tube may be used instead of a wick. The heating unit 2b preferably comprises a heater with which a liquid from the liquid reservoir 2a can be aerosolized. In this embodiment, the liquid reservoir 2a is an annular liquid reservoir arranged downstream of the heating unit 2b. The annular liquid reservoir 2a comprises an inner channel through which the aerosol stream 5 can flow. The heating unit 2b may be arranged within the inner channel of the annular liquid reservoir 2a or even downstream of the liquid reservoir 2a in alternative embodiments. The liquid reservoir 2a may not be annular in other embodiments, which may cause the aerosol stream 5 to go around the liquid reservoir in embodiments where the liquid reservoir is in the aerosol stream 5. The liquid may be enclosed within a housing such that the liquid reservoir 2a is a container that can be replaced. Alternatively, the liquid may be retained in one or more porous elements, such as a cotton wadding, that is fitted inside the smoking article 1, typically against an inner wall of an outer housing of the smoking article 1. In such case, the liquid reservoir is the porous element soaked in liquid. The porous element may be rolled up into a cylinder to provide an airflow or aerosol channel through it.

The aerosolized liquid, i.e. the aerosol, is transferred from the aerosol generator 2 into the flavoring device 3 in the aerosol stream 5. The flavoring device 3 comprises an aerosol inlet 9, through which the aerosol stream 5 enters the flavoring device 3, and an aerosol outlet 10, through which the aerosol stream 5 leaves the flavoring device 3. Between the aerosol inlet 9 and the aerosol outlet 10 an aerosol passageway 11 is arranged along which the aerosol stream 5 travels through the flavoring device 3.

Preferably, the aerosol inlet 9 and the aerosol outlet 10 are arranged on opposing ends 3a, b of the flavoring device 3. Preferably, the aerosol inlet 9 is arranged towards the aerosol generator 2, preferably directly facing an aerosol outlet of the aerosol generator 2. Preferably, the aerosol outlet 10 is arranged at the downstream end 8 of the smoking article 1. Preferably, the downstream end 8 of the smoking article 1 is located in a mouthpiece 14. The downstream end 8 of the smoking article 1 defines the point at which the aerosol exits the smoking article 1. In the flavoring device 3 a carrier material 6 is arranged. The carrier material 6 itself is an inert material. To the carrier material 6 a flavoring substance 4 is releasably adhered. The flavoring substance 4 comprises tobacco particles 7. The carrier material 6 comprising the flavoring substance 4 is arranged along the aerosol passageway 11 of the flavoring device 3. This means, that the aerosol stream 5 flowing along the aerosol passageway 11 is in contact with the carrier material 6 and the flavoring substance 4. When the aerosol flow 5 passes the carrier material 6 with the flavoring substance 4, the flavoring substance 4 flavors the aerosol stream 5. The flavored aerosol stream 5 then leaves the flavoring device 3 through the aerosol outlet 10 and preferably also leaves the smoking article 1 at the downstream end 8 preferably through the mouthpiece 14.

Figure 2 shows an enlarged sectional view of one embodiment of the carrier material 6 and the flavoring substance 4 adhered thereto. In this embodiment the carrier material 6 is a sheet comprising a surface 6a. The flavoring substance 4 is adhered to the surface 6a. In particular, the flavoring substance 4 are tobacco particles 7 adhered to the surface 6a of the carrier material 6.

Figures 3 a-f show different embodiments of the flavoring device 3. Figure 3a shows an embodiment of the flavoring device 3 comprising the sheet carrier material 6 from the embodiment of fig. 2. The carrier material 6 comprising the flavoring substance 4 is folded in an accordion manner, i.e. like a leporello-fold, then rolled up 15 into a cylindrical shape and placed in a cartridge 12 comprising an aerosol inlet 9 and aerosol outlet 10. In this way, the aerosol passageway 11 is created not only in a center of the rolled-up carrier material 6 but also between the leporello-folds through which the respective layers of the rolled-up carrier material 6 are distanced from each other. In this way, the aerosol stream 5 is brought in contact with the surface 6a of the carrier material 6 and thus in contact with the flavoring substance 4 very effectively.

Figure 3b shows a different embodiment of the flavoring device 3. In this embodiment, the carrier material 6 is a filter, similar to a conventional cigarette filter, wherein the flavoring substance 4 is homogeneously distributed in the filter material. Preferably, the filter is a conventional cigarette filter. Preferably, the filter material is cellulose acetate. But also other materials comprising a porous or fibrous structure are possible. Preferably, the flavoring substance 4 is mixed with the filter material before the filter material is formed into the filter. In alternative to that, the readymade filter is soaked in the flavoring material 4, thereby soaking up flavoring material 4 into the porous structure of the filter until the filter is saturated with the flavoring material 4. The filter may subsequently be dried to prevent dripping, but it is also conceivable that the filter is used in the flavoring device 3 in a wet state. The porous and/or fibrous nature of the filter material forms an aerosol passageway 11 through the filter material. Due to the very large inner surface of the filter, the interaction of the aerosol stream with the flavoring substance 4 is very effective.

Figure 3c shows another embodiment of the flavoring device 3. In this embodiment the carrier material 6 comprises the shape of a hollow cylinder or, in other words, a tube. In this way, the carrier material 6 comprises a through-hole 16 in which the aerosol passageway 11 is arranged. The through-hole 16 is confined by an inner lateral area 17 of the carrier material 6. The flavoring substance 4 is preferably arranged on at least a part of the inner lateral area 17. Preferably, the flavoring substance 4 is arranged on the complete inner lateral area 17. It is however also conceivable that the flavoring substance 4 is arranged on the whole surface 6a of the carrier material 6.

Figure 3d shows a similar embodiment of the flavoring device 3 as shown in fig. 3c.

However, in this embodiment the inner lateral area 17 comprises protrusions 18, protruding radially inwards from the inner lateral area 17 to a center axis 19, wherein the center axis 19 is a longitudinal axis of the hollow cylindrical shape. The protrusions 18 increase the surface area of the inner lateral area 17. Preferably, the protrusions 18 are coated with the flavoring substance 4. Preferably, the protrusions 18 are arranged alternatingly protruding from opposite sides 20, 21 of the inner lateral area 17 thereby forming a maze-like arrangement with a meandering aerosol passageway 11. In this way, the surface area 6a can be increased, which in turn allows more flavoring substance 4 be arranged in the flavoring device 3. In addition to that, the meandering aerosol passageway 11 increases the dwell time of the aerosol in the flavoring device 3, which can lead to a better transfer of the flavor from the flavoring substance 4 to the aerosol stream 5.

Figure 3e shows another embodiment of the flavoring device 3. In this embodiment, the carrier material 6 comprises the form of particles. The particles surface 6a is coated with the flavoring material 4 comprising the tobacco particles 7. The coated particles are comprised in a cartridge 12 having an aerosol inlet 9 and aerosol outlet 10. The aerosol stream 5 circulates around the coated particles along a multi-branched aerosol passageway 11. In this embodiment the overall surface area 6a of all particles is large which promotes the interaction between the aerosol stream 5 and the flavoring material 4 arranged on the surface area 6a of the particles. This is further enhanced by the multi-branched aerosol passageway 11.

Figure 3f shows another embodiment of the flavoring device 3. In this embodiment, the carrier material 6 consists of multiple tubes arranged parallel to each other. The inside surfaces of the tubes are coated with the flavoring substance 4. Each tube comprises an individual aerosol passageway 22, wherein all individual aerosol passageways 22 together form the aerosol passageway 11 of the flavoring device 3. The entirety of the tubes may be wrapped in a wrapper 23 to provide a stable shape of all tubes of the flavoring device 3 in order to ensure proper machine handling.

Figure 4 shows another embodiment of the smoking article 1. The smoking article 1 comprises the same aerosol generator 2 as in the embodiment shown in fig. 1. But in the current embodiment, the flavoring device 3 is comprised in a cartridge 12 and comprises a mouthpiece 14. The flavoring device 3 can be arranged in a cartridge support 13 of the smoking article 1. The flavoring device 3 is arranged downstream of the aerosol generator 2. This means that the aerosol stream 5, which originates at the aerosol generator 2, flows from the aerosol generator 2 through the flavoring device 3 to the consumer. In other words, the term “downstream” refers to a respective position arranged nearer to the downstream end 8 of the smoking article 1 and farther away from the aerosol generator 2 than a reference position. Preferably, the cartridge support 13 securely arranges the aerosol inlet 9 of the flavoring device 3 on an aerosol outlet of the aerosol generator 2. Preferably, only the cartridge 12 is arranged in the cartridge support 13 wherein the mouthpiece 14 protrudes from the cartridge support 13.

Figure 5 shows the cartridge 12 of the previous embodiment in an enlarged version. In this embodiment the aerosol outlet 10 of the flavoring device 3 is arranged in the mouthpiece 14. The carrier material 6 comprising the flavoring substance 4 is arranged in the cartridge 12. It is possible to use any of the previously described embodiments of the carrier material 6 with the flavoring substance 4 in this embodiment of the cartridge 12. Preferably, the carrier material 6 does not occupy the whole inner space of the cartridge 12. Preferably, the carrier material 6 only occupies an upstream section 23 of the cartridge 12, whereas a downstream section 24 is occupied by a filter material 25 not comprising the flavoring substance 4. This prohibits tobacco particles 7 from leaving the flavoring device 3 and being accidentally inhaled by the consumer. Preferably, the aerosol inlet 9 and outlet 10 of the flavoring device 3 are covered by a sheet material being permeable to aerosols but impermeable to solid particles. This may e.g. be achieved with a tissue material or a net-like material comprising an accordingly small mesh size. Preferably, a second filter material is arranged upstream of the carrier material 6 in the cartridge 12.

Figure 6 shows the sequence of steps of the method for manufacturing a smoking article 1. At first an aerosol generator 2 is provided 100. Subsequently, a flavoring device 3 is provided 101 . The flavoring device 3 comprises the carrier material 6 and the flavoring substance 4. The flavoring device 3 may be a flavoring device 3 according to any of the previously described embodiments. The flavoring device 3 is then arranged 102 at the aerosol generator 2 thereby forming the smoking article 1. The flavoring device 3 is positioned downstream of the aerosol generator 2. In this way, the aerosol stream 5 can flow along an aerosol passageway 11 from the aerosol generator 2 through the flavoring device 3, in which it is flavored by the flavoring material 4, to the downstream end 8 of the smoking article 1 at which the aerosol stream 5 exits the smoking article 1. Preferably, the arranging 102 is a releasable arranging, meaning that the flavoring device 3 can be removed from the smoking article 1 if desired. In other words, the flavoring device 3 is interchangeable. The flavoring device 3 is preferably arranged in the cartridge support 13.

The applicant reserves his right to claim all features disclosed in the application document as being an essential feature of the invention, as long as they are new, individually or in combination, in view of the prior art. Furthermore, it is noted that in the figures features are described, which can be advantageous individually. Someone skilled in the art will directly recognize that a specific feature being disclosed in a figure can be advantageous also without the adoption of further features from this figure. Furthermore, someone skilled in the art will recognize that advantages can evolve from a combination of diverse features being disclosed in one or various figures. List of reference symbols smoking article aerosol generator a liquid reservoir b heating unit flavoring device a, b ends flavoring substance aerosol stream carrier material a surface tobacco particles downstream end aerosol inlet 0 aerosol outlet 1 aerosol passageway 2 cartridge 3 cartridge support 4 mouthpiece 5 rolling up 6 through-hole 7 inner lateral area 8 protrusion 9 center axis 0 opposite side 1 opposite side 2 individual aerosol passageway 3 upstream section 4 downstream section 5 filter material 00 providing an aerosol generator 01 providing a flavoring device 02 arranging the flavoring device

Claims

Smoking article comprising a particulate tobacco substituent Claims

1. A smoking article (1 ) comprising an aerosol generator (2) and a flavoring device (3), which is suitable for releasing a flavoring substance (4) to a stream (5) of aerosol generated by the aerosol generator (2), wherein the flavoring device (3) comprises an inert carrier material (6), characterized in that the flavoring substance (4) is releasably adhered to the carrier material (6) and comprises tobacco particles (7) having an average particle size (sD₅o laser diffraction) < 30 pm.

2. The smoking article (1) according to claim 1 , characterized in that releasing of the flavoring substance (4) from the carrier material (6) is initiable by an activation signal.

3. The smoking article (1) according to claim 1 or 2, characterized in that the activation signal is selected from a group comprising temperature change, humidity change, moisture change, water contact, contact to liquids, contact to an aerosol, pressure change, electric signal, light and electromagnetic radiation.

4. The smoking article (1) according to any preceding claim, characterized in that the flavoring device (3) is arranged downstream the aerosol generator (2), preferably at the downstream end (8) of the smoking article (1).

5. The smoking article (1) according to any preceding claim, characterized in that the flavoring device (3) comprises an aerosol inlet (9) and an aerosol outlet (10), which are preferable arranged at opposed ends (3a, 3b) of the flavoring device (3).

6. The smoking article (1) according to any preceding claim, characterized in that the flavoring device (3) comprises an aerosol passageway (11) along which the flavoring substance (4) bearing carrier material (6) is arranged.

7. The smoking article (1) according to any preceding claim, characterized in that the flavoring device (3) is arranged in a replaceable cartridge (12).

8. The smoking article (1) according to any preceding claim, characterized in that a carrier material (6) is selected from a group comprising fibres, filtering material, cellulose acetate, fibre tow, or staple fibres, randomly oriented staple fibres, sheets, paper sheet, folded sheet, rolled sheet, crimped sheet, labyrinth, matrix material, sponge type, ceramic material, fleece, multiple tubes, a single tube, granulate, spherical particles, cubes, cuboids and parallelepipeds.

9. The smoking article (1) according to any preceding claim, characterized in that the flavoring substance (4) is adhered to a surface (6a) of the carrier material (6).

10. The smoking article (1) according to any preceding claim, characterized in that the flavoring substance (4) is a dispersion and comprises one or more dispersion medium selected from a group comprising water, monovalent alcohol, monovalent aliphatic alcohol, methanol, ethanol, 1 -propanol, 2-propanol, 1 -butanol, 2-butanol, 2- methyl-1 -propanol, 2,2-dimethylethanol, cyclohexanol, monovalent alcohol having an aromatic substituent, benzyl alcohol, monovalent alcohol containing one or more halogen element monovalent alcohol having one or more ether bond, polyvalent alcohol, glycerol, propylene glycol, sugar alcohol, sorbitol, maltitol, xylitol, erythritol, lactitol, sorbitan, xylose, arabinose, mannose, trehalose, sugar, lactose, sucrose, coupling sugar, glucose, enzyme-saccharified starch syrup, acid-saccharified starch syrup, maltose starch syrup, maltose, isomerized sugar, fructose, reduced maltose, reduced starch syrup, honey, polyvalent alcohol ester, fatty acid polyvalent alcohol ester and fatty acid triglyceride, wherein preferably the ratio of the tobacco particles is >0,5 % (w/w), preferably > 1 % (w/w), > 2 % (w/w) or > 5 % (w/w), more preferably > 10 % (w/w), most preferably > 20 % (w/w) and < 95 % (w/w), preferably < 90 % (w/w), < 80 % (w/w) or < 70 % (w/w), more preferably < 60 % (w/w), most preferably < 50 % (w/w). A replaceable cartridge (12) for a smoking article, comprising an aerosol generator (2), characterized in that the cartridge (12) comprises a flavoring device (3), which is suitable for releasing a flavoring substance (4) to a stream (5)of aerosol generated by the aerosol generator (2), wherein the flavoring device (3) comprises an inert carrier material (6) and the flavoring substance (4) comprising tobacco particles (7) having an average particle size (SD₅O laser diffraction) < 30 pm is releasable adhered to the carrier material (6). The replaceable cartridge (12) according to claim 11 , characterized by the characterizing feature of any of claims 2-10. A method for manufacturing a smoking article (12) comprising the steps of:

Providing (100) an aerosol generator (2),

- providing (101 ) a flavoring device (3), which is suitable for releasing a flavoring substance (4) to a stream (5) of aerosol, wherein the flavoring device (3) comprises an inert carrier material (6) and the flavoring substance (4) is releasable adhered to the carrier material (6),

- arranging (102) the flavoring device (3) downstream the aerosol generator (2) to allow releasing of the flavoring substance (4) to the stream (5) of aerosol. The method according to claim 13, characterized in that the flavoring device (3) is arranged in a cartridge (12), which is releasably held by a cartridge support (13) of the smoking article (1). -21 - The method according to claim 13 or 14, characterized in that releasing of the flavoring substance (4) to the stream (5) of aerosol is initiated by application of an activation signal selected from a group comprising temperature change, humidity change, moisture change, water contact, contact to liquids, contact to an aerosol, pressure change, electric signal, light and electromagnetic radiation.