Smoking articles and smokable filler material therefor

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.

1 . A smokable filler material having a stabilised foam structure, obtainable by drying a stabilised foam, wherein the foam comprises a foaming agent and a non-foaming, chemically cross-linkable agent that has been cross-linked in its foamed state with a cross-linking agent, wherein the foaming agent and the cross-linkable agent are different materials. 
     
     
         2 . A smokable filler material according to  claim 1 , wherein the foaming agent is non-alginic. 
     
     
         3 . A smokable filler material according to  claim 2 , wherein the non-alginic foaming agent is non-cross-linkable. 
     
     
         4 . A smokable filler material according to  claim 2 , wherein the non-alginic foaming agent may be a foaming surfactant. 
     
     
         5 . A smokable filler material according to  claim 4 , 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. 
     
     
         6 . A smokable filler material according to  claim 2 , 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. 
     
     
         7 . A smokable filler material according to  claim 1 , wherein the cross-linking agent is an agent which provides free calcium ions in aqueous solution. 
     
     
         8 . A smokable filler material according to  claim 7 , wherein the cross-linking agent is a calcium salt which salt is soluble or sparingly soluble at neutral pH (pH 7.0). 
     
     
         9 . A smokable filler material according to  claim 7 , wherein the cross-linking agent is one or more of calcium sulphate or calcium citrate. 
     
     
         10 . A smokable filler material according to  claim 7 , 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. 
     
     
         11 . A smokable filler material according to  claim 10 , wherein the cross-linking agent is calcium carbonate or calcium phosphate. 
     
     
         12 . A smokable filler material according to  claim 7 , wherein, the cross-linking agent is a calcium salt which is soluble or sparingly soluble, which salt forms an alkaline solution. 
     
     
         13 . A smokable filler material according to  claim 12 , wherein the cross-linking agent is calcium hydroxide. 
     
     
         14 . A smokable filler material according to  claim 8 , 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. 
     
     
         15 . A smokable filler material according to  claim 7 , 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. 
     
     
         16 . A smokable filler material according to  claim 8 , wherein the cross-linking agent is further provided by tobacco. 
     
     
         17 . A smokable filler material according to  claim 7 , wherein the cross-linking agent is a tobacco material. 
     
     
         18 . A smokable filler material according to  claim 16 , 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. 
     
     
         19 . A smokable filler material according to  claim 16 , wherein the tobacco is present in the range of about 10% to about 60% by weight of the dry smokable filler material. 
     
     
         20 . A smokable filler material according to  claim 8  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. 
     
     
         21 . A smokable filler material according to  claim 16 , 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. 
     
     
         22 . A smokable filler material according to  claim 17 , 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. 
     
     
         23 . A smokable filler material according to  claim 1 , wherein the non-foaming agent capable of forming chemical cross-linkages is a soluble alginate. 
     
     
         24 . A smokable filler material according to  claim 23 , wherein the soluble alginate is one or more of sodium alginate, ammonium alginate or potassium alginate. 
     
     
         25 . A smokable filler material according to  claim 23 , 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. 
     
     
         26 . A smokable filler material according to  claim 25 , wherein when the cross-linking agent is an agent which provides free calcium ions in aqueous solution, 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. 
     
     
         27 . A smokable filler material according to  claim 25 , wherein when the cross-linking agent is Tobacco and a Calcium salt which is soluble or sparingly soluble at neutral PH (PH7.0), 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. 
     
     
         28 . A smokable filler material according to  claim 25 , 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. 
     
     
         29 . A smokable filler material according to  claim 1 , wherein the smokable filler material is a self-supporting foam when dried. 
     
     
         30 . A smokable filler 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 smokable filler material according to  claim 1 , further comprising aerosol generating means. 
     
     
         32 . A smokable filler material according to  claim 31 , wherein the aerosol generating means comprises aerosol forming means. 
     
     
         33 . A smokable filler 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 smokable filler material according to  claim 31 , wherein the aerosol generating means is present at between 0% and 65% by weight of the dry smokable filler material. 
     
     
         35 . A smokable filler material according to  claim 1 , further comprising an inorganic filler material. 
     
     
         36 . A smokable filler material according to  claim 35 , wherein the inorganic filler material is a particulate material. 
     
     
         37 . A smokable filler 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 smokable filler material according to  claim 1 , further comprising a colourant and/or a flavourant material. 
     
     
         39 . A smokable filler 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 smokable filler 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 smokable filler material according to  claim 1 , further comprising a fibrous material. 
     
     
         42 . A smokable filler material according to  claim 41 , wherein the fibrous material is one or more of tobacco, wood pulp, cellulosic or alginic material. 
     
     
         43 . A smokable filler material according to  claim 1  further comprising a carbonaceous material. 
     
     
         44 . A smokable filler 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 .