JP7671351B2 - Suction tool and method for manufacturing the atomization unit of the suction tool - Google Patents

Description

The present invention relates to a suction device and a method for manufacturing the atomization unit of the suction device.

Conventionally, a non-combustion heating type inhaler has been known which is characterized in that it comprises an atomization unit having a liquid storage section which stores a predetermined liquid, and an electrical load into which the liquid in the liquid storage section is introduced and which atomizes the introduced liquid to generate an aerosol, and in which tobacco leaf powder is dispersed within the liquid in the liquid storage section (see, for example, Patent Document 1).

Other prior art documents include Patent Document 2 and Patent Document 3. Patent Document 2 discloses the basic configuration of a non-combustion heating type inhaler. Patent Document 3 discloses information regarding tobacco leaf extract.

International Publication No. 2019/211332 JP 2020-141705 A International Publication No. 2015/129679

In the case of conventional inhalers such as that exemplified in Patent Document 1 mentioned above, there is a risk that the tobacco leaves dispersed within the liquid in the liquid storage section may adhere to the electrical load of the inhaler. In this case, there is a risk that the load of the inhaler may deteriorate. In this respect, there is room for improvement in the conventional technology.

The present invention has been made in consideration of the above, and one of its objectives is to provide technology that can suppress deterioration of the load on the suction tool.

(Aspect 1)
In order to achieve the above-mentioned objective, an inhalation device according to one embodiment of the present invention comprises an atomization unit having a liquid storage section that stores an extract of tobacco leaves, and an electrical load into which the extract from the liquid storage section is introduced and which atomizes the introduced extract to generate an aerosol, and a molded body made by solidifying tobacco leaves and forming them into a predetermined shape is placed inside the extract in the liquid storage section.

According to this aspect, a molded body made by solidifying tobacco leaves and forming them into a predetermined shape is placed inside the extract in the liquid storage section, and the molded body and the electrical load of the inhaler are physically separated, so that the tobacco leaves can be prevented from adhering to the load of the inhaler. This makes it possible to prevent the load of the inhaler from deteriorating.

(Aspect 2)
In the above-mentioned aspect 1, the amount of carbonized components contained in 1 g of the extract in the state in which the molded body is disposed is 6 mg or less, and the carbonized components may be components that become carbonized when heated to 250°C.

According to this embodiment, it is possible to enjoy the flavor of the tobacco leaves while minimizing the amount of carbonized components that adhere to the electrical load.

(Aspect 3)
In order to achieve the above-mentioned object, a manufacturing method of an inhalation device according to one aspect of the present invention is a manufacturing method of an atomization unit of an inhalation device according to aspect 1 or 2 above, and includes the following steps: an extraction step of extracting flavor components from tobacco leaves; a molding step of solidifying and molding the tobacco residue, which is the tobacco leaves extracted in the extraction step, into a predetermined shape to manufacture a molded body; an addition step of adding the flavor components extracted in the extraction step to the molded body manufactured in the molding step; and an assembly step of housing the molded body to which the flavor components have been added in the addition step, and a liquid containing one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group, in a liquid storage section.

According to this aspect, it is possible to manufacture the atomization unit of the inhaler while effectively utilizing tobacco residue as a material for the molded body. This makes it possible to suppress deterioration of the load on the inhaler.

(Aspect 4)
In addition, in order to achieve the above-mentioned object, a manufacturing method for an inhalation device according to one aspect of the present invention is a manufacturing method for an atomization unit of an inhalation device according to aspect 1 or 2 above, and includes an extraction process for extracting flavor components from tobacco leaves, a molding process for solidifying and molding the tobacco residue, which is the tobacco leaves extracted in the extraction process, into a predetermined shape to manufacture a molded body, an extract production process for producing a tobacco leaf extract by adding the flavor components extracted in the extraction process to a solvent, and an assembly process for containing the molded body manufactured in the molding process and the tobacco leaf extract manufactured in the extract production process in a liquid storage section.

According to this aspect, it is possible to manufacture the atomization unit of the inhaler while effectively utilizing tobacco residue as a material for the molded body. This makes it possible to suppress deterioration of the load on the inhaler.

(Aspect 5)
In addition, in order to achieve the above-mentioned object, a manufacturing method of an inhalation device according to one aspect of the present invention is a manufacturing method of an atomization unit of an inhalation device according to aspect 1 or 2 above, and includes an extraction step of extracting flavor components from tobacco leaves, a molding step of mixing the flavor components extracted in the extraction step with tobacco residue, which is the tobacco leaves after extraction in the extraction step, to produce a mixture, and solidifying and molding the mixture into a predetermined shape to produce a molded body, and an assembly step of housing the molded body produced in the molding step and a liquid containing one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group, in a liquid storage section.

According to this aspect, it is possible to manufacture the atomization unit of the inhaler while effectively utilizing tobacco residue as a material for the molded body. This makes it possible to suppress deterioration of the load on the inhaler.

(Aspect 6)
In any one of Aspects 3 to 5 above, the extraction step may further include reducing an amount of carbonized components that become carbonized when heated to 250° C., which are contained in the extracted flavor components.

According to this aspect, adhesion of carbonized components to the load can be effectively suppressed.

(Aspect 7)
In any one of Aspects 3 to 6 above, the forming step may include washing the tobacco residue with a washing liquid, and solidifying the washed tobacco residue to form it into the predetermined shape.

According to this embodiment, the amount of carbonized components in the tobacco residue can be reduced as much as possible by washing the tobacco residue with a washing liquid, and the molded body can be manufactured using the tobacco residue with a reduced amount of carbonized components. This makes it possible to effectively prevent the carbonized components from adhering to the load.

According to this aspect of the present invention, deterioration of the load on the suction tool can be suppressed.

1 is a perspective view showing a schematic external appearance of a suction tool according to a first embodiment. FIG. 2 is a schematic cross-sectional view showing a main part of an atomization unit of the suction tool according to the first embodiment. FIG. 3 is a schematic cross-sectional view taken along line A1-A1 in FIG. 2. FIG. 2 is a schematic perspective view of a molded body according to the first embodiment. FIG. 1 is a diagram showing the results of measuring the TPM reduction rate relative to the amount of carbonized components contained in 1 g of the extract according to the embodiment. FIG. 11 is a flow chart for explaining a manufacturing method according to a second embodiment. FIG. 11 is a flow chart for explaining a manufacturing method according to a first modified example of the second embodiment. FIG. 13 is a flow chart for explaining a manufacturing method according to a second modification of the second embodiment.

(Embodiment 1)
Hereinafter, a suction device 10 according to a first embodiment of the present invention will be described with reference to the drawings. Note that the drawings in this application are schematic illustrations to facilitate understanding of the features of the embodiment, and the dimensional ratios of the components are not necessarily the same as those in reality. In addition, the drawings in this application show X-Y-Z orthogonal coordinates as necessary.

Figure 1 is a perspective view showing the appearance of an inhalation device 10 according to this embodiment. The inhalation device 10 according to this embodiment is a non-combustion heating type inhalation device, specifically, a non-combustion heating type electronic cigarette.

The suction tool 10 according to the present embodiment extends in the direction of the central axis CL of the suction tool 10, for example. Specifically, the suction tool 10 has an external shape having a "longitudinal direction (the direction of the central axis CL)", a "width direction" perpendicular to the longitudinal direction, and a "thickness direction" perpendicular to the longitudinal and width directions, for example. The dimensions of the suction tool 10 in the longitudinal, width, and thickness directions decrease in this order. In this embodiment, in the orthogonal coordinate system of X-Y-Z, the direction of the Z axis (Z direction or -Z direction) corresponds to the longitudinal direction, the direction of the X axis (X direction or -X direction) corresponds to the width direction, and the direction of the Y axis (Y direction or -Y direction) corresponds to the thickness direction.

The suction device 10 has a power supply unit 11 and an atomization unit 12. The power supply unit 11 is detachably connected to the atomization unit 12. A battery as a power source, a control device, etc. are arranged inside the power supply unit 11. When the atomization unit 12 is connected to the power supply unit 11, the power supply of the power supply unit 11 and a load 40 of the atomization unit 12, which will be described later, are electrically connected.

The atomization unit 12 is provided with an outlet 13 for discharging air (i.e., air). The air containing the aerosol is discharged from this outlet 13. When using the inhalation tool 10, the user of the inhalation tool 10 can inhale the air discharged from this outlet 13.

The power supply unit 11 is provided with a sensor that outputs the value of the pressure change inside the suction device 10 caused by the user inhaling through the exhaust port 13. When the user starts inhaling air, the sensor detects this start of inhalation of air and notifies the control device, which then starts to supply electricity to the load 40 of the atomization unit 12 described below. When the user stops inhaling air, the sensor detects this end of inhalation of air and notifies the control device, which then stops supplying electricity to the load 40.

The power supply unit 11 may be provided with an operation switch for transmitting a request to start suctioning air and a request to stop suctioning air to the control device by a user's operation. In this case, the user can transmit a request to start suctioning air or a request to stop suctioning air to the control device by operating the operation switch. Then, the control device that receives the request to start suctioning air or the request to stop suctioning air starts or stops supplying electricity to the load 40.

The configuration of the power supply unit 11 as described above is similar to that of the power supply unit of a known suction device, such as that exemplified in Patent Document 2, and therefore will not be described in further detail.

Figure 2 is a schematic cross-sectional view showing the main parts of the atomization unit 12 of the suction device 10. Specifically, Figure 2 shows a schematic cross-section of the main parts of the atomization unit 12 cut along a plane including the central axis CL. Figure 3 is a schematic diagram showing a cross-section along line A1-A1 in Figure 2 (i.e., a cross-section cut along a cutting plane normal to the central axis CL). The atomization unit 12 will be described with reference to Figures 2 and 3.

The atomization unit 12 has a plurality of walls (walls 70a to 70g) extending in the longitudinal direction (the direction of the central axis CL) and a plurality of walls (walls 71a to 71c) extending in the width direction. The atomization unit 12 also has an air passage 20, a wick 30, an electrical load 40, a liquid storage section 50, and a molded body 60.

The air passage 20 is a passage through which air passes when the user inhales air (i.e., when inhaling an aerosol). The air passage 20 in this embodiment includes an upstream passage section, a load passage section 22, and a downstream passage section 23. As an example, the upstream passage section in this embodiment includes a plurality of upstream passage sections, specifically, an upstream passage section 21a ("first upstream passage section") and an upstream passage section 21b ("second upstream passage section").

The upstream passage sections 21a, 21b are arranged upstream of the load passage section 22 (upstream in the air flow direction). The downstream ends of the upstream passage sections 21a, 21b are connected to the load passage section 22. The load passage section 22 is a passage section in which the load 40 is arranged. The downstream passage section 23 is a passage section arranged downstream of the load passage section 22 (downstream in the air flow direction). The upstream end of the downstream passage section 23 is connected to the load passage section 22. In addition, the downstream end of the downstream passage section 23 is connected to the exhaust port 13 described above. Air that has passed through the downstream passage section 23 is discharged from the exhaust port 13.

Specifically, the upstream passage section 21a according to this embodiment is provided in an area surrounded by walls 70a, 70b, 70e, 70f, 71a, and 71b. The upstream passage section 21b is provided in an area surrounded by walls 70c, 70d, 70e, 70f, 71a, and 71b. The load passage section 22 is provided in an area surrounded by walls 70a, 70d, 70e, 70f, 71b, and 71c. The downstream passage section 23 is provided in an area surrounded by the cylindrical wall section 70g.

Wall portion 71a is provided with holes 72a and 72b. Air flows into upstream passage portion 21a from hole 72a and into upstream passage portion 21b from hole 72b. Wall portion 71b is provided with holes 72c and 72d. Air that has passed through upstream passage portion 21a flows into load passage portion 22 from hole 72c, and air that has passed through upstream passage portion 21b flows into load passage portion 22 from hole 72d.

In this embodiment, the air flow direction in the upstream passage sections 21a and 21b is opposite to the air flow direction in the downstream passage section 23. Specifically, in this embodiment, the air flow direction in the upstream passage sections 21a and 21b is the -Z direction, and the air flow direction in the downstream passage section 23 is the Z direction.

Also, referring to Figures 2 and 3, the upstream passage portion 21a and the upstream passage portion 21b in this embodiment are arranged adjacent to the liquid storage portion 50 so that the liquid storage portion 50 is sandwiched between the upstream passage portion 21a and the upstream passage portion 21b.

3, the upstream passage portion 21a according to this embodiment is disposed on one side (the -X direction side) of the liquid storage portion 50 in a cross-sectional view taken along a cutting plane normal to the central axis CL. Meanwhile, the upstream passage portion 21b is disposed on the other side (the X direction side) of the liquid storage portion 50 in this cross-sectional view. In other words, the upstream passage portion 21a is disposed on one side of the liquid storage portion 50 in the width direction of the suction tool 10, and the upstream passage portion 21b is disposed on the other side of the liquid storage portion 50 in the width direction of the suction tool 10.

The wick 30 is a member for introducing the extract from the liquid storage section 50 into the load 40 of the load passage section 22. As long as it has this function, the specific configuration of the wick 30 is not particularly limited, but as an example, the wick 30 according to this embodiment introduces the extract from the liquid storage section 50 into the load 40 by utilizing capillary action.

The load 40 is an electrical load into which the extract from the liquid storage section 50 is introduced and which atomizes the introduced extract to generate an aerosol. The specific configuration of the load 40 is not particularly limited, and for example, a heat generating element such as a heater or an element such as an ultrasonic generator can be used. In this embodiment, a heater is used as an example of the load 40. As this heater, a heat generating resistor (i.e., an electric heating wire), a ceramic heater, a dielectric heating heater, etc. can be used. In this embodiment, a heat generating resistor is used as an example of this heater. In addition, in this embodiment, the heater as the load 40 has a coil shape. That is, the load 40 according to this embodiment is a so-called coil heater. This coil heater is wound around the wick 30.

As an example, the load 40 according to this embodiment is disposed in the wick 30 inside the load passage 22. The load 40 is electrically connected to the power supply of the power supply unit 11 and the control device described above, and generates heat when electricity from the power supply is supplied to the load 40 (i.e., generates heat when energized). The operation of the load 40 is controlled by the control device. The load 40 atomizes the extract in the liquid storage section 50 introduced into the load 40 via the wick 30 by heating it, thereby generating an aerosol.

The configuration of the wick 30 and the load 40 is similar to that of the wicks and loads used in known suction devices, such as those exemplified in Patent Document 2, and therefore further detailed explanation is omitted.

The liquid storage portion 50 is a portion for storing tobacco leaf extract (Le). The liquid storage portion 50 according to this embodiment is provided in an area surrounded by walls 70b, 70c, 70e, 70f, 71a, and 71b. In this embodiment, the downstream passage portion 23 described above is provided so as to penetrate the liquid storage portion 50 in the direction of the central axis CL.

In this embodiment, a specified solvent containing flavor components of tobacco leaves is used as the tobacco leaf extract. The specific type of specified solvent is not particularly limited, but for example, a substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or a liquid containing two or more substances selected from this group, can be used. In this embodiment, glycerin and propylene glycol are used as an example of the specified solvent.

Specific examples of flavor components in tobacco leaves include nicotine and neophytadiene.

Figure 4 is a schematic perspective view of the molded body 60. With reference to Figures 2, 3, and 4, the molded body 60 is formed by solidifying tobacco leaves and molding them into a predetermined shape. Two molded bodies 60 according to this embodiment are disposed inside the extract in the liquid storage section 50. However, the number of molded bodies 60 is not limited to this, and may be one, or three or more.

The shape of the molded body 60 is not particularly limited, and may be, for example, a rod shape extending in a specific direction (i.e., a shape in which the length is longer than the width), a cubic shape (a shape having sides of the same length), a sheet shape, or some other shape.

The shape of the molded body 60 according to this embodiment is, for example, rod-shaped. Specifically, the rod-shaped molded body 60 according to this embodiment has, for example, a rod-shaped polyhedron shape, and for example, a cylindrical shape with a circular cross section. The cross-sectional shape of the molded body 60 is not limited to a circle, and may be, for example, a polygon (triangle, square, pentagon, or a polygon with six or more corners). In addition, when a sheet-shaped molded body 60 is used, specifically, a tobacco leaf paper sheet, a tobacco leaf cast sheet, a tobacco leaf rolled sheet, etc. can be used as the molded body 60.

The specific values of the width (i.e., outer diameter) (W), which is the length in the short direction of the molded body 60, and the total length (L), which is the length in the longitudinal direction of the molded body 60, are not particularly limited, but examples of numerical values are as follows. That is, as the width (W) of the molded body 60, a value selected from the range of, for example, 2 mm or more and 20 mm or less can be used. As the total length (L) of the molded body 60, a value selected from the range of, for example, 5 mm or more and 50 mm or less can be used. However, these values are merely examples of the width (W) and total length (L) of the molded body 60, and the width (W) and total length (L) of the molded body 60 may be set to appropriate values depending on the size of the suction device 10.

In the present embodiment, the density (mass per unit volume) of the molded body 60 is, for example, 1100 mg/cm ³ or more and 1450 mg/cm ³ or less. However, the density of the molded body 60 is not limited to this, and may be less than 1100 mg/cm ³ or may be greater than 1450 mg/cm ³ .

Inhalation using the inhaler 10 is performed as follows. First, when a user starts inhaling air, the air passes through the upstream passages 21a and 21b of the air passage 20 and flows into the load passage 22. Aerosol generated in the load 40 is added to the air that has flowed into the load passage 22. This aerosol contains flavor components contained in the tobacco leaf extract and flavor components eluted from the molded body 60 placed in the extract. The air to which this aerosol has been added passes through the downstream passage 23 and is discharged from the outlet 13, and is inhaled by the user.

According to the inhalation device 10 according to the present embodiment as described above, the aerosol generated by the load 40 can be supplemented with the flavor components of the tobacco leaves contained in the molded body 60 in addition to the flavor components of the tobacco leaves contained in the extract. This allows the flavor of the tobacco leaves to be fully enjoyed.

In addition, according to the inhalation device 10 of this embodiment, a tobacco leaf molded body 60 is disposed inside the extract in the liquid storage section 50, and the molded body 60 and the electrical load 40 of the inhalation device 10 are physically separated, so that the tobacco leaves can be prevented from adhering to the load 40 of the inhalation device 10. This can prevent the load 40 of the inhalation device 10 from deteriorating.

In addition, the amount (mg) of carbonized components contained in 1 g of extract in which the molded body 60 is disposed is preferably 6 mg or less, and more preferably 3 mg or less.

This configuration allows the flavor of the tobacco leaves to be enjoyed while minimizing the amount of carbonized components that adhere to the electrical load 40. This allows the flavor of the tobacco leaves to be enjoyed while minimizing the occurrence of scorching on the load 40.

In addition, the "carbonized components contained in the extract when the molded body 60 is placed" specifically corresponds to the sum of the amount of carbonized components contained in the extract before the molded body 60 is placed and the amount of carbonized components dissolved into the extract from the molded body 60 placed in the extract.

In this embodiment, the term "carbonized component" refers to a component that becomes a carbonized material when heated to 250°C. Specifically, the term "carbonized component" refers to a component that does not become a carbonized material at temperatures below 250°C, but becomes a carbonized material when maintained at a temperature of 250°C for a predetermined period of time.

The "amount (mg) of carbonized components contained in 1 g of the extract in which the molded body 60 is disposed" can be measured, for example, by the following method. First, a predetermined amount (g) of the extract in which the molded body 60 is disposed is prepared. Next, this extract is heated to 180°C to volatilize the solvent (liquid components) contained in the extract, thereby obtaining a "residue consisting of non-volatile components". Next, this residue is carbonized by heating to 250°C to obtain a carbonized product. Next, the amount (mg) of this carbonized product is measured. By the above method, the amount (mg) of carbonized products contained in a predetermined amount (g) of the extract can be measured, and the amount of carbonized products (i.e., the amount (mg) of carbonized products) contained in 1 g of the extract can be calculated based on this measurement value.

Next, the relationship between the amount of carbonized components contained in 1 g of extract and the TPM reduction rate will be described. Fig. 5 is a diagram showing the results of measuring the TPM reduction rate relative to the amount of carbonized components contained in 1 g of extract. The horizontal axis of Fig. 5 shows the amount of carbonized components contained in 1 g of extract, and the vertical axis shows the TPM reduction rate ( _RTPM ) (%).

The TPM reduction rate (R _TPM : %) in Figure 5 was measured by the following method. First, a plurality of suction device samples were prepared, each of which had a different amount of carbonized components contained in 1 g of extract. Specifically, five samples (sample SA1 to sample SA5) were prepared as the plurality of suction device samples. These five samples were prepared by the following process.

(Step 1)
To a tobacco raw material consisting of tobacco leaves, 20 wt % of potassium carbonate was added in terms of dry weight, and then a heat distillation treatment was performed. The distillation residue after this heat distillation treatment was immersed in water in an amount 15 times the weight of the tobacco raw material before the heat distillation treatment for 10 minutes, dehydrated in a dehydrator, and then dried in a dryer to obtain a tobacco residue.

(Step 2)
Next, a portion of the tobacco residue obtained in step 1 was washed with water to prepare a tobacco residue containing a low amount of carbonized matter.

(Step 3)
Next, 25 g of immersion liquid (propylene glycol 47.5 wt%, glycerin 47.5 wt%, water 5 wt%) as an extraction liquid was added to 5 g of the tobacco residue obtained in step 2, and the temperature of the immersion liquid was set to 60° C. and the mixture was allowed to stand. By varying the standing time (i.e., the immersion time in the immersion liquid), the amount of carbonized components dissolved in the immersion liquid (extraction liquid) was varied.

Using the above process, several samples were prepared with different amounts of carbonized components contained in 1 gram of immersion liquid (extraction liquid).

Next, the samples prepared in the above steps were subjected to automatic smoking using an automatic smoking machine (Borgwaldt's "Analytical Vaping Machine") under the "CRM (Coresta Recommended Method) 81 smoking conditions." The CRM 81 smoking conditions involve inhaling 55 cc of aerosol over 3 seconds, multiple times every 30 seconds.

Next, the amount of total particulate matter trapped in the Cambridge filter of the automatic smoking machine was measured. Based on the measured amount of total particulate matter, the TPM reduction rate ( _RTPM ) was calculated using the following formula (1). The TPM reduction rate ( _RTPM ) in Figure 5 was measured using the above method.

R _TPM (%) = (1-TPM (201puff ~ 250puff) / TPM (1puff ~ 50puff)) x 100... (1)

Here, TPM (Total Particle Molecule) indicates the total particulate matter captured by the Cambridge filter of the automatic smoking machine. "TPM (1 puff to 50 puff)" in formula (1) indicates the amount of total particulate matter captured by the Cambridge filter from the 1st puff to the 50th puff of the automatic smoking machine. "TPM (201 puff to 250 puff)" in formula (1) indicates the amount of total particulate matter captured by the Cambridge filter from the 201st puff to the 250th puff of the automatic smoking machine.

In other words, the TPM reduction rate (R _TPM ) in equation (1) is calculated by subtracting from 1 the value obtained by dividing the amount of total particulate matter trapped by the Cambridge filter of the automatic smoking machine between the 201st and 250th puffs by the amount of total particulate matter trapped by the Cambridge filter of the automatic smoking machine between the 1st and 50th puffs, and multiplying this value by 100.

As can be seen from Figure 5, the amount of carbonized components contained in 1 g of extract is proportional to the TPM reduction rate. And, as can be seen from Figure 5, particularly from samples SA1 to SA4, when the amount of carbonized components contained in 1 g of extract is 6 mg or less, the TPM reduction rate can be suppressed to 20% or less.

(Embodiment 2)
Next, a description will be given of embodiment 2. This embodiment is an embodiment of a manufacturing method for the atomization unit 12 of the suction tool 10. Fig. 6 is a flow diagram for explaining the manufacturing method according to this embodiment.

In the extraction process in step S10, flavor components are extracted from the tobacco leaves. The specific method of this step S10 is not particularly limited, but the following method can be used, for example. First, an alkaline substance is applied to the tobacco leaves (referred to as alkaline treatment). The alkaline substance used here can be, for example, a basic substance such as an aqueous solution of potassium carbonate.

Next, the tobacco leaves that have been subjected to the alkali treatment are heated at a predetermined temperature (for example, a temperature of 80°C or higher and lower than 150°C) (referred to as heat treatment). During this heat treatment, the tobacco leaves are brought into contact with one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or with two or more substances selected from this group.

This heat treatment causes the released components (which include flavor components) released from the tobacco leaves into the gas phase to be collected in a specified collection solvent. The collection solvent can be, for example, one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group. This makes it possible to obtain a collection solvent containing the flavor components (i.e., the flavor components can be extracted from the tobacco leaves).

Alternatively, step S10 may be configured not to use the collection solvent as described above. Specifically, in this case, after the alkali-treated tobacco leaves are subjected to the heat treatment described above, they may be cooled using a condenser or the like to condense the released components released from the tobacco leaves into the gas phase, thereby extracting the flavor components.

Alternatively, step S10 may be configured not to involve the alkaline treatment described above. Specifically, in this case, in step S10, one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group, are added to tobacco leaves (tobacco leaves that have not been subjected to an alkaline treatment). The tobacco leaves to which this substance has been added are then heated, and the components released during this heating are collected in a collection solvent or condensed using a condenser or the like. Flavor components can also be extracted by such a process.

Alternatively, in step S10, an aerosol of one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or an aerosol of two or more substances selected from this group, is passed through tobacco leaves (tobacco leaves that have not been treated with alkali), and the aerosol that has passed through the tobacco leaves is collected in a collection solvent. Flavor components can also be extracted by such a process.

Furthermore, step S10 (extraction process) according to this embodiment may further include reducing the amount of carbonized components that become carbonized when heated to 250°C, which are contained in the flavor components extracted by the method described above. This configuration can effectively prevent the carbonized components from adhering to the load 40. As a result, the occurrence of scorching on the load 40 can be effectively prevented.

The specific method for reducing the amount of carbonized components contained in the extracted flavor components is not particularly limited, but for example, the amount of carbonized components contained in the extracted flavor components may be reduced by cooling the extracted flavor components and filtering the precipitated components with filter paper or the like. Alternatively, the amount of carbonized components contained in the extracted flavor components may be reduced by centrifuging the extracted flavor components with a centrifuge. Alternatively, the amount of carbonized components contained in the extracted flavor components may be reduced by using a reverse osmosis membrane (RO filter).

After step S10, the molding process relating to step S20 and the concentration process relating to step S30 are carried out as described below.

In step S20, the "tobacco residue", which is the tobacco leaves extracted in the extraction process in step S10, is solidified and molded into a predetermined shape (in this embodiment, a rod shape as an example) to produce the molded product 60. A specific example of step S20 is as follows.

For example, in step S20, the tobacco residue is solidified into a predetermined shape to produce a molded body 60, and then the surface of the molded body 60 is coated with a coating material. This makes it possible to produce a molded body 60 in which the surface of the tobacco residue solidified into a predetermined shape is covered with a coating material.

For example, wax can be used as the coating material. Examples of wax that can be used include Microcristan WAX (model number: Hi-Mic-1080 or model number: Hi-Mic-1090) manufactured by Nippon Seiro Co., Ltd., water-dispersed ionomer (model number: Chemipearl S120) manufactured by Mitsui Chemicals, Inc., and Hiwax (model number: 110P) manufactured by Mitsui Chemicals, Inc.

Alternatively, corn protein can be used as the coating material. A specific example of this is zein (model number: Kobayashi Zein DP-N) manufactured by Kobayashi Fragrance Co., Ltd.

Alternatively, polyvinyl acetate can be used as a coating material.

It is preferable that the coating material covering the surface of the molded body 60 has a plurality of holes (fine holes) that prevent the tobacco residue from passing through while allowing the flavor components remaining in the tobacco residue to pass through. In other words, the holes in the coating material need only be larger than the flavor components and smaller than the tobacco residue. With this configuration, it is possible to prevent the tobacco residue from dissolving into the extract while allowing the flavor components remaining in the tobacco residue to dissolve into the extract.

The specific size (diameter) of the holes in this coating material is not particularly limited, but as a specific example, a value selected from the range of 10 μm or more and 3 mm or less can be used.

A net-like mesh member can also be used as the coating material. In this case, it is possible to suppress the dissolution of the tobacco residue into the extract while allowing the flavor components remaining in the tobacco residue to dissolve into the extract.

In addition, in the molding process of step S20, the tobacco residue can be mixed with a resin to solidify the tobacco residue and produce the molded body 60. In this case, too, it is possible to dissolve flavor components remaining in the tobacco residue into the extract while suppressing dissolution of the tobacco residue into the extract.

Alternatively, in the molding process of step S20, the tobacco residue can be washed with a cleaning solution, and the washed tobacco residue can be molded by the above-mentioned method to produce the molded body 60. With this configuration, the amount of carbonized components contained in the tobacco residue can be reduced as much as possible by washing, and the molded body 60 can be produced using the tobacco residue with a reduced amount of carbonized components. This can effectively prevent the carbonized components from adhering to the load 40. As a result, the occurrence of scorching on the load 40 can be effectively prevented.

On the other hand, in the concentration process in step S30, the flavor components extracted in step S10 are concentrated. Specifically, in step S30 according to this embodiment, the flavor components contained in the collection solvent containing the flavor components extracted in step S10 are concentrated.

After steps S20 and S30, an addition step related to step S40 is carried out. In step S40, the flavor components extracted in the extraction step related to step S10 (specifically, in this embodiment, the flavor components after further concentration in step S30) are added to the molded body 60 produced in step S20.

After step S40, an assembly process according to step S50 is performed. Specifically, in step S50, the atomization unit 12 is prepared without the molded body 60, and the molded body 60 after step S40 is accommodated in the liquid storage section 50 of the atomization unit 12, and a liquid containing one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group is stored. In this case, a flavor component may be further added to the liquid stored in the liquid storage section 50 in addition to the flavor component added to the molded body 60 in the above-mentioned step S40. Through the above steps, the atomization unit 12 of the suction tool 10 according to this embodiment is manufactured.

This embodiment may also be configured not to include step S30. In this case, in step S40, the flavor components extracted in the extraction process related to step S10 may be added to the molded body 60 produced in step S20. However, the case where this embodiment includes step S30 is preferable in that the amount of flavor components contained in the molded body 60 can be increased compared to the case where this embodiment does not include step S30.

According to the manufacturing method of the present embodiment as described above, the atomization unit 12 of the inhaler 10 can be manufactured while effectively utilizing tobacco residue as a material for the molded body 60. This makes it possible to suppress deterioration of the load 40 of the inhaler 10.

(Variation 1 of the second embodiment)
Fig. 7 is a flow diagram for explaining a manufacturing method of the atomization unit 12 of the inhaler 10 according to the first modified example of the second embodiment. In the extraction process according to step S10 in Fig. 7, flavor components are extracted from tobacco leaves. This step S10 is similar to step S10 described in Fig. 6, and therefore a detailed description thereof will be omitted.

After step S10, a molding process in step S20 and a concentration process in step S30 are carried out. Steps S20 and S30 in this modified example are similar to steps S20 and S30 described in FIG. 6, respectively, and therefore will not be described in detail.

In this modified example, after step S30, an extract liquid production process relating to step S45 is carried out. Specifically, in step S45, the flavor components extracted in step S10 (specifically, in this modified example, the flavor components after further concentration in step S30) are added to a predetermined solvent to produce a tobacco leaf extract liquid. The specific type of the predetermined solvent is not particularly limited, but for example, one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group, can be used.

After step S45, the assembly process of step S50A is carried out. Specifically, in step S50A, the atomization unit 12 is prepared without the molded body 60 contained therein, and the molded body 60 produced in step S20 and the "tobacco leaf extract" produced in step S45 are contained in the liquid storage section 50 of this atomization unit 12. Through the above steps, the atomization unit 12 of the inhaler 10 according to this modified example is manufactured.

In the manufacturing method according to this modified example as described above, the atomization unit 12 of the inhaler 10 can be manufactured while effectively utilizing tobacco residue as a material for the molded body 60. This makes it possible to suppress deterioration of the load 40 of the inhaler 10.

This modified example may be configured not to include step S30, as in the second embodiment described above. In this case, in step S45, the flavor components extracted in step S10 are added to a specified solvent to produce a tobacco leaf extract. However, the case where this modified example includes step S30 is preferable in that the amount of flavor components contained in the tobacco leaf extract can be increased compared to the case where it does not include step S30.

(Modification 2 of the second embodiment)
Fig. 8 is a flow diagram for explaining a manufacturing method of the atomization unit 12 of the inhaler 10 according to the second modification of the second embodiment. In the extraction process according to step S10 in Fig. 8, flavor components are extracted from tobacco leaves. This step S10 is similar to step S10 described in Fig. 6, and therefore a detailed description thereof will be omitted.

After step S10, a molding process in step S20B and a concentration process in step S30 are carried out. Step S30 in this modified example is similar to step S30 described in FIG. 6, so a detailed description is omitted.

In step S20B of this modified example, the flavor components extracted in step S10 (specifically, in this modified example, the flavor components after further concentration in step S30) are mixed with the "tobacco residue," which is the tobacco leaves extracted in the extraction process in step S10, to produce a mixture, which is then solidified and molded into a predetermined shape (in this modified example, a rod shape is used as an example) to produce the molded body 60.

After step S20B, an assembly process according to step S50B is performed. In step S50B, the atomization unit 12 is prepared without the molded body 60 contained therein, and the molded body 60 produced in step S20B and a liquid containing one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group, are contained in the liquid storage section 50 of the atomization unit 12. In this case, a flavor component may be further added to the liquid contained in the liquid storage section 50, in addition to the flavor component mixed with the tobacco residue in the above-mentioned step S20B. Through the above steps, the atomization unit 12 of the inhaler 10 according to this modified example is manufactured.

This modified example may also be configured not to include step S30, as in the second embodiment described above. In this case, in step S20B, the flavor components extracted in step S10 are mixed with the tobacco residue to produce a mixture, and the mixture is solidified and molded into a predetermined shape to produce the molded body 60. However, the case in which this modified example includes step S30 is preferable in that the amount of flavor components contained in the molded body 60 can be increased compared to the case in which it does not include step S30.

In the manufacturing method according to this modified example as described above, the atomization unit 12 of the inhaler 10 can be manufactured while effectively utilizing tobacco residue as a material for the molded body 60. This makes it possible to suppress deterioration of the load 40 of the inhaler 10.

Although the embodiments and variations of the present invention have been described in detail above, the present invention is not limited to such specific embodiments and variations, and various modifications and variations are possible within the scope of the gist of the present invention as described in the claims.

10 suction tool 12 atomization unit 20 air passage 40 load 50 liquid storage section 60 molded body Le extract

Claims (7)

a liquid storage section for storing tobacco leaf extract;
an atomization unit having an electric load into which the extract liquid of the liquid storage section is introduced and which atomizes the introduced extract liquid to generate an aerosol;
A molded body obtained by solidifying tobacco leaves and molding them into a predetermined shape is disposed inside the extract in the liquid storage section ,
The suction tool , wherein the surface of the molded body is coated with a coating material . the amount of carbonized components contained in 1 g of the extract in a state in which the molded body is disposed is 6 mg or less;
The suction tool according to claim 1 , wherein the carbonizable component is a component that becomes a carbonized material when heated to 250° C. A method for manufacturing the atomization unit of the suction tool according to claim 1 or 2, comprising the steps of:
An extraction step of extracting flavor components from tobacco leaves;
a molding step in which the tobacco residue, which is the tobacco leaves extracted in the extraction step, is solidified and molded into a predetermined shape to produce a molded body , the surface of the molded body being coated with a coating material;
an adding step of adding the flavor component extracted in the extracting step to the molded body produced in the molding step;
A method for manufacturing an atomization unit of an inhaler, comprising: an assembly process for housing in a liquid housing section the molded body to which the flavor component has been added in the adding process, and a liquid containing one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or two or more substances selected from this group. A method for manufacturing the atomization unit of the suction tool according to claim 1 or 2, comprising the steps of:
An extraction step of extracting flavor components from tobacco leaves;
a molding step in which the tobacco residue, which is the tobacco leaves extracted in the extraction step, is solidified and molded into a predetermined shape to produce a molded body , the surface of the molded body being coated with a coating material;
an extract production step of producing an extract of tobacco leaves by adding the flavor components extracted in the extraction step to a solvent;
A method for manufacturing an atomization unit of an inhalation tool, comprising: an assembly process for housing the molded body produced in the molding process and the tobacco leaf extract produced in the extract production process in a liquid storage section. A method for manufacturing the atomization unit of the suction tool according to claim 1 or 2, comprising the steps of:
An extraction step of extracting flavor components from tobacco leaves;
a molding step of mixing the flavor components extracted in the extraction step with tobacco residue, which is the tobacco leaves extracted in the extraction step, to produce a mixture, and then solidifying and molding the mixture into a predetermined shape to produce a molded body, the surface of which is coated with a coating material;
A manufacturing method for an atomization unit of an inhaler, comprising: an assembly process for housing the molded body manufactured in the molding process and a liquid containing one substance selected from the group consisting of glycerin, propylene glycol, triacetin, 1,3-butanediol, and water, or a liquid containing two or more substances selected from this group, in a liquid storage section. The method for manufacturing an atomization unit for an inhaler according to any one of claims 3 to 5, wherein the extraction step further includes reducing the amount of carbonized components contained in the extracted flavor components that become carbonized when heated to 250°C. The method for manufacturing the atomization unit of an inhaler according to any one of claims 3 to 6, wherein the forming step includes washing the tobacco residue with a washing liquid and solidifying the washed tobacco residue to form it into the predetermined shape.