Smoking articles and smokable filler material therefor

• US 20070062550A1
• Filed: 10/20/2004
• Published: 03/22/2007
• Est. Priority Date: 10/21/2003
• Status: Active Grant

• Current Assignee: British American Tobacco Limited (British American Tobacco PLC)
• Original Assignee: British American Tobacco Limited (British American Tobacco PLC)
• Inventors: John, Edward, Sutton, Joseph
• Granted Patent: US 7,938,125 B2
• Time in Patent Office: Days
• US Class Current: 131/364
• CPC Class Codes: A24B 15/14 made of tobacco and a binding agent not derived from tobacco
• CPC Class Codes: A24B 15/16 of tobacco substitutes

Abstract

The invention relates to smokable filler materials and a process for making same, the smokable filler material comprising a foaming agent, an agent capable of forming chemical cross-linkages, and a cross-linking agent. A combination of the foaming agent in the foamed state thereof, the agent capable of forming chemical crosslinkages and the cross-linking agent provides a stabilised, foamed material. The invention also provides a smoking article incorporating the smokable filler material of the invention.

Claims

1. A smokable filler material comprising a foaming agent capable of forming chemical cross-linkages, and a cross-linking agent, wherein the foaming agent capable of forming chemical cross-linkages is a foaming alginate, and wherein, when combined, the foaming agent in the foamed state thereof, and the cross-linking agent provided a stabilised, foamed material.

2. A smoking material according to claim 1, wherein the foaming alginate is an esterified alginate.

3. A smoking material according to claim 1, wherein the foaming alginate is propylene glycol alginate.

4. A smoking material according to claim 1, wherein the foaming agent capable of forming chemical cross-linkages is present at between about 30% and about 95% by weight of the dry smokable filler material.

5. A smoking material according to claim 1, wherein the cross-linking agent is an agent which provides free calcium ions in aqueous solution.

6. A smoking material according to claim 5, wherein the cross-linking agent may be a calcium salt which salt is soluble or sparingly soluble at neutral pH (pH 7.0).

7. A smoking material according to claim 5, wherein the cross-linking agent is one or more of calcium sulphate or calcium citrate.

8. A smoking material according to claim 5, wherein the cross-linking agent is a calcium salt which is insoluble at neutral pH, which salt becomes soluble or sparingly soluble at acidic pH.

9. A smoking material according to claim 8, wherein the cross-linking agent is calcium carbonate or calcium phosphate.

10. A smoking material according to claim 5, wherein, the cross-linking agent is a calcium salt which is soluble or sparingly soluble, which salt forms an alkaline solution.

11. A smoking material according to claim 10, wherein the cross-linking agent is calcium hydroxide.

12. A smoking material according to claim 5, wherein the foaming agent capable of forming chemical cross-linkages is present in the range of about 61% to about 90% by weight of the dry smokable filler material.

13. A smoking material according to claim 6, wherein the cross-linking agent is present in the range of between about 1.0% and about 11% by weight of the dry smokable filler material.

14. A smoking material according to claim 5, wherein the cross-linking agent is a tobacco material.

15. A smoking material according to claim 6, wherein the cross-linking agent is further provided by tobacco.

16. A smoking material according to claim 14, wherein the foaming agent capable of forming chemical cross-linkages is present in the range of about 30% to about 80% by weight of the dry smokable filler material.

17. A smoking material. according to claim 14, wherein the tobacco material is present in the range of about 10% to about 60% by weight of the dry smokable filler material.

18. A smoking material according to claim 17, wherein the tobacco is present at about 20% by weight of the dry smokable filler material.

19. A smoking material according to claim 15, wherein the calcium salt is present in the range of about 1.0% to about 6% by weight of the dry smokable filler material.

20. A smoking material according to claim 1 further comprising a non-alginic foaming agent.

21. A smoking material according to claim 20, wherein the non-alginic foaming agent is a foaming agent incapable of forming chemical cross-linkages.

22. A smoking material according to claim 20, wherein the non-alginic foaming agent is a foaming surfactant.

23. A smoking material according to claim 22, wherein the foaming surfactant is one or more of the group including celluloses capable of foaming, for example hydroxylpropyl cellulose, methyl cellulose or ethyl cellulose, starch, proteins, for example egg albumin, sugar esters.

24. A smoking material according to claim 1, further comprising a non-foaming agent capable of forming chemical cross-linkages.

25. A smoking material according to claim 24, wherein the non-foaming agent capable of forming chemical cross-linkages is a soluble alginate.

26. A smoking material according to claim 25, wherein the non-foaming agent capable of forming chemical cross-linkages is one or more of sodium alginate, ammonium alginate and potassium alginate.

27. A smoking material according to claim 1, further comprising a non-alginic foaming agent and a non-foaming agent capable of forming chemical cross-linkages.

28. A smoking material according to claim 27, wherein the non-alginic foaming agent is a foaming agent incapable of forming chemical cross-linkages.

29. A smoking material according to claim 1, wherein the smokable filler material is a self-supporting foam when dried.

30. A smoking material according to claim 29, wherein, when dried, smokable filler material has a moisture content in the range of 0% to about 30%.

31. A smoking material according to claim 1, further comprising aerosol generating means.

32. A smoking material according to claim 31, wherein the aerosol generating means comprises aerosol forming means.

33. A smoking material according to claim 32, wherein the aerosol forming means is one or more of polyhydric alcohols, glycerol, propylene glycol and triethylene glycol, esters or high boiling point hydrocarbons.

34. A smoking material according to claim 3, wherein the aerosol generating means is present at between 0% and 65% by weight of the dry smokable filler material.

35. A smoking material according to claim 1, further comprising an inorganic filler material.

36. A smoking material according to claim 35, wherein the inorganic filler material is a particulate material.

37. A smoking material according to claim 35, wherein the inorganic filler material is one or more of perlite, zeolite, alumina, vermiculite, diatomaceous earth, colloidal silica, chalk, magnesium oxide, magnesium sulphate or magnesium carbonate.

38. A smoking material according to claim 1 further comprising a colourant and/or a flavourant material.

39. A smoking material according to claim 38, wherein the flavourant and/or colourant is one or more of cocoa, liquorice, caramel, chocolate, toffee, tobacco extract flavours, menthol and vanillin.

40. A smoking material according to claim 38, wherein the flavourant and/or colourant is present in a range of about 0.2% to about 5% by weight of the dry smokable filler material.

41. A smoking material according to claim 1, further comprising a fibrous material.

42. A smoking material according to claim 41, wherein the fibrous material is one or more of tobacco, wood pulp, cellulosic or alginic material.

43. A smoking material according to claim 1, further comprising a carbonaceous material.

44. A smoking material according to claim 1, further comprising a binder material.

45. A smoking article comprising a rod of smoking material enwrapped in a wrapper, the smoking material comprising a blend, which blend incorporates the smokable filler material according to claim 1.

46. A smoking article comprising a rod of smoking material enwrapped in a wrapper, the smoking material consisting essentially of the smokable filler material according to claim 1.

75. A smoking material according to claim 74, wherein when the cross-linking agent is in accordance with claim 38, the non-foaming agent capable of forming chemical cross-linkages is present in the range of about 3% to about 70% by weight of the dry smokable filler material.

76. A smoking material according to claim 74, wherein when the cross-linking agent is in accordance with claim 46, the non-foaming agent capable of forming chemical cross-linkages is present in the range of about 3% to about 55% by weight of the dry smokable filler material.

84. A smoking material according to claim 5, further comprising an inorganic filler material.

85. A smoking material according to claim 84, wherein the inorganic filler material is a particulate material.

86. A smoking material according to claim 84, wherein the inorganic filler material is one or more of perlite, zeolite, alumina, vermiculite, diatomaceous earth, colloidal silica, chalk, magnesium oxide, magnesium sulphate or magnesium carbonate.

94. A smoking article comprising a rod of smoking material enwrapped in a wrapper, the smoking material comprising a blend, which blend incorporates the smokable filler material according to claim 1.

95. A smoking article comprising a rod of smoking material enwrapped in a wrapper, the smoking material consisting essentially of the smokable filler material according to claim 1.

47. A method of producing a foamed smokable filler material comprising the steps of:

a) producing a foam from a foaming agent, which foaming agent is capable of forming chemical cross-linkages, wherein the foaming agent is a foaming alginate;

b) mixing said foam with a cross-linking agent;

c) forming a slurry from said mix;

d) casting said slurry; and

e) drying said slurry to form a foamed sheet material.

48. A method of producing a foamed smokable material comprising the steps of:

a) mixing a foaming agent capable of forming cross-linkages and a cross-linking agent, wherein the foaming agent is a foaming alginate; and

b) extruding said mixture such that upon exiting an extruder die a stabilised foamed material is provided.

49. (canceled)

50. A smokable filler material comprising a foaming agent, an agent capable of forming chemical cross-linkages, and a cross-linking agent, wherein, when combined, the foaming agent in the foamed state thereof, the agent capable of forming chemical cross-linkages and the cross-linking agent provided a stabilised, foamed material wherein the foaming agent and the agent capable of forming chemical cross-linkages are provided by different materials.

51. A smoking material according to claim 50, wherein the smokable filler material comprises a non-alginic foaming agent.

52. A smoking material according to claim 51, wherein the non-alginic foaming agent is incapable of forming chemical cross-linkages.

53. A smoking material according to claim 51, wherein the non-alginic foaming agent may be a foaming surfactant.

54. A smoking material according to claim 53, wherein the foaming surfactant is one or more of the group including celluloses capable of foaming, for example hydroxylpropyl cellulose, methyl cellulose or ethyl cellulose, starch, proteins, for example egg albumin and sugar esters.

55. A smoking material according to claim 51, wherein the non-alginic foaming agent is present in the range of about 0.5% to about 70% by weight of the dry smokable filler material.

56. A smoking material according to claim 50, wherein the cross-linking agent is an agent which provides free calcium ions in aqueous solution.

57. A smoking material according to claim 56, wherein the cross-linking agent is a calcium salt which salt is soluble or sparingly soluble at neutral pH (pH 7.0).

58. A smoking material according to claim 56, wherein the cross-linking agent is one or more of calcium sulphate or calcium citrate.

59. A smoking material according to claim 56, wherein the cross-linking agent is a calcium salt which is insoluble at neutral pH, which salt becomes soluble or sparingly soluble at acidic pH.

60. A smoking material according to claim 59, wherein the cross-linking agent is calcium carbonate or calcium phosphate.

61. A smoking material according to claim 56, wherein, the cross-linking agent is a calcium salt which is soluble or sparingly soluble, which salt forms an alkaline solution.

62. A smoking material according to claim 61, wherein the cross-linking agent is calcium hydroxide.

63. A smoking material according to claim 57, wherein the cross-linking agent is present in a range of between about 0.5% and about 50% by weight of the dry smokable filler material.

64. A smoking material according to claim 56, wherein the cross-linking agent is calcium carbonate, the cross-linking agent being present at between about 40% to about 60% by weight of the dry smokable filler material.

65. A smoking material according to claim 57, wherein the cross-linking agent is further provided by tobacco.

66. A smokable material according to claim 56, wherein the cross-linking agent is a tobacco material.

67. A smoking material according to claim 65, wherein the calcium salt is present in a range of about 0.5% to about 8.0% by weight of the dry smokable filler material.

68. A smoking material according to claim 65, wherein the tobacco is present in the range of about 10% to about 60% by weight of the dry smokable filler material.

69. A smoking material according to claim 57 wherein the non-alginic foaming agent is present in the range of about 0.5% to about 70% by weight of the dry smokable filler material.

70. A smoking material according to claim 65, wherein the non-alginic foaming agent is present in the range of about 2% to about 25% by weight of the dry smokable filler material.

71. A smoking material according to claim 66, wherein the non-alginic foaming agent is present in the range of about 4% to about 35% by weight of the dry smokable filler material.

72. A smoking material according to claim 50, wherein the non-foaming agent capable of forming chemical cross-linkages is a soluble alginate.

73. A smoking material according to claim 72, wherein the soluble alginate is one or more of sodium alginate, ammonium alginate or potassium alginate.

74. A smoking material according to claim 72, wherein the non-foaming agent capable of forming chemical cross-linkages is present in a range of about 3% to about 70% by weight of the dry smokable filler material.

77. A smoking material according to claim 74, wherein, when the cross-linking agent is tobacco the non-foaming agent capable of forming chemical cross-linkages is preferably present in the range of about 6% to about 60% by weight of the dry smokable filler material.

78. A smoking material according to claim 50, wherein the smokable filler material is a self-supporting foam when dried.

79. A smoking material according to claim 78, wherein, when dried, smokable filler material has a moisture content in the range of 0% to about 30%.

80. A smoking material according to claim 50, further comprising aerosol generating means.

81. A smoking material according to claim 80, wherein the aerosol generating means comprises aerosol forming means.

82. A smoking material according to claim 81, wherein the aerosol forming means is one or more of polyhydric alcohols, glycerol, propylene glycol and triethylene glycol, esters or high boiling point hydrocarbons.

83. A smoking material according to claim 80, wherein the aerosol generating means is present at between 0% and 65% by weight of the dry smokable filler material.

87. A smoking material according to claim 50, further comprising a colourant and/or a flavourant material.

88. A smoking material according to claim 87, wherein the flavourant and/or colourant is one or more of cocoa, liquorice, caramel, chocolate, toffee, tobacco extract flavours, menthol and vanillin.

89. A smoking material according to claim 87, wherein the flavourant and/or colourant is present in a range of about 0.2% to about 5% by weight of the dry smokable filler material.

90. A smoking material according to claim 50, further comprising a fibrous material.

91. A smoking material according to claim 90, wherein the fibrous material is one or more of tobacco, wood pulp, cellulosic or alginic material.

92. A smoking material according to claim 50 further comprising a carbonaceous material.

93. A smoking material according to claim 50, further comprising a binder material.

96. (canceled)