CN216796481U - Filter element, filter, multi-rod and smoking article - Google Patents

Abstract

The utility model relates to a filter element, a filter, a multi-rod and a smoking article. A filter element for an aerosol-generating article, the filter element comprising: a longitudinally extending core of filter material, wherein the longitudinally extending core of filter material has an outer surface and an inner surface; a channel extending longitudinally from an end of the core, wherein the channel is defined by an inner surface of the core; wherein the longitudinally extending core of filter material comprises flavour in an amount of 1 to 4mg per filter element; and wherein the filter element has a circumference of from 16.8mm to 24.3 mm.

Description

Filter element, filter, multi-rod and smoking article

Technical Field

The present invention relates to filter elements and filters for aerosol generating articles.

Background

Tubular filter elements for smoking articles are known in the art. Typically, tubular filter elements comprise a cylindrical core of filter material comprising channels extending longitudinally from the ends of the cylindrical core. Tubular filter elements are typically included as part of a multi-segment filter, and are typically located at the mouth-like end of the filter to provide a unique end appearance, which is useful for anti-counterfeiting purposes.

The presence of additives such as flavours in tobacco smoke filters is known in the art. Typically, flavors are not incorporated directly into the tubular filter element due to the difficulty of incorporating the flavor into the filter material and maintaining the flavor within the filter material. The tubular filter element typically forms part of a multi-segment filter, wherein another filter element performs additional filtration or includes additives such as flavors.

Application of additives such as flavors after the filter element is formed may cause contamination problems from the wet filter. In addition, applying the flavors in this manner may result in unacceptable odors and affect the air quality near the manufacturing line.

Accordingly, there is a need for a tubular filter element that includes an additive such as a flavor, such that no additional filter element is needed to provide the additive to the tubular filter.

SUMMERY OF THE UTILITY MODEL

In one aspect of the utility model, there is provided a filter element for an aerosol-generating article, the filter element comprising: a longitudinally extending core of filter material, wherein the longitudinally extending core of filter material has an outer surface and an inner surface; a channel extending longitudinally from an end of the core, wherein the channel is defined by an inner surface of the core; wherein the longitudinally extending core of filter material comprises flavour in an amount of 1 to 4mg per filter element; and wherein the filter element has a circumference of from 16.8mm to 24.3 mm.

The channel may be a tube or a bore. Preferably, the channel is surrounded by filter material.

The longitudinally extending core of filter material may have a generally circular cross-section. Preferably, the longitudinally extending core has a circular transverse cross-section. It will be appreciated that a generally circular transverse cross-section will correspond to a generally cylindrical core.

The channel may extend through a portion of the length of the longitudinally extending core or through the entire length of the longitudinally extending core.

The channel may have a generally circular transverse cross-section, an elliptical transverse cross-section, a triangular transverse cross-section, a trilobal transverse cross-section, or a star transverse cross-section. Preferably, the channel has a substantially circular transverse cross-section.

The filter material may be, for example, any of those materials (typically filamentary, fibrous, web or extruded) typically used in the manufacture of smoke filters for tobacco. The filter material may be a natural filament tow or a synthetic filament tow made of, for example, cotton or a plastic such as polyethylene or polypropylene, or a cellulose acetate filament tow. The filter material may be a thermoplastic or otherwise spinnable polymer such as polypropylene, polyethylene terephthalate or polylactic acid. The filter material can be, for example, natural or synthetic staple fibres, cotton linters, web materials such as paper (usually crepe paper) and synthetic nonwovens, and extruded materials (e.g. starch, synthetic foams). Preferably, the filter material comprises cellulose acetate filament tow.

The filter material may optionally include a binder material. The filter material may optionally include a water-soluble binder material. Examples of water-soluble binder materials include: water-soluble polymer materials such as polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl ether, starch, polyethylene glycol, and polypropylene glycol; mixtures of water-soluble binders with plasticizers such as triacetin, triethylene glycol diacetate (TEGDA) or polyethylene glycol (PEG); and a hot melt water soluble binder in the form of particles. The inclusion of a water-soluble binder material may further enhance the ability of the filter to readily and rapidly degrade, for example, under ambient conditions.

The total denier of the filter material may be about 12,000 to 100,000g per 9000m, such as 20,000 to 80,000g per 9000m, such as 20,000 to 50,000g per 9000 m.

Where the filter material is formed from a tow bale, the total denier of the filter material may be about 12,000g to 50,000g per 9000m, such as 30,000g to 40,000g per 9000m, such as 30,000g to 38,000g per 9000m, such as 30,000g, 32,000 g, 33,000g, 37,000g or 40,000g per 9000 m.

Where the filter material is formed from two bundles of tow, the total denier of the filter material may be about 20,000g to 100,000g per 9000m, for example 60,000g to 80,000g per 9000m, for example 60,000g to 76,000g per 9000m, for example 60,000g, 64,000 g, 66,000g, 74,000g or 80,000g per 9000 m.

The filament denier may be 1.5g to 12g per 9000m, such as 1.5g to 9g per 9000m, such as 5g, 7.3g, 8g, or 9.0g per 9000 m.

The filter material is generally described by reference to filament denier, total denier, and fiber cross-section. For example, the filter material may comprise tow having the following denier: 8.0Y40, 8.0Y32, 7.3Y33, or 9.0Y 37. For example, a filter material having a denier of 8.0Y40 means a filament denier of 8.0g per 9000m, a total denier of 40000g per 9000m, and a filament having a Y-shaped cross-section.

The filter material may include a plasticizer. The filter material may include a plasticizer in an amount of about 8% to 24% by weight of the filter material and the plasticizer, for example about 12% to 24%, for example about 14% to 22%, for example about 16% to 20%, for example about 17% to 19%, for example about 18% by weight of the filter material and the plasticizer. The plasticizer may be applied to the filter material, for example to a surface of the filter material.

The amount of plasticizer present in the filter element is calculated as a percentage of the total weight of filter material and plasticizer via the general equation given below.

The plasticizer is used to harden the filter material. Stiffening the filter material may improve the shape definition of the filter element, and in particular the definition of the channels. For example, the filter material may comprise plasticized fibers, such as plasticized tow, e.g., plasticized cellulose acetate tow. The plasticizer may be, for example, triacetin, triethylene glycol diacetate (TEGDA), or polyethylene glycol (PEG). The plasticizer may be applied to the filter material by spraying onto the surface of the filter material using methods known in the art.

The flavoring agent may be one or more of menthol, spearmint, clove, nutmeg, cinnamon, lemon, chocolate, peach, strawberry, vanilla, etc. Preferably, the flavoring agent is menthol or clove.

The flavour agent may be present in an amount of from 1mg to 3.5mg, for example from 2mg to 3.5mg, for example from 2.5mg to 3.5mg, for example 3 mg.

A flavoring may be applied to the inner surfaces defining the channel. Applicants have found that most of the additive applied to the filter material remains intact after the filter element is manufactured. Applicants have found that the filter elements of the present invention exhibit excellent additive loading and exhibit additive levels that are maintained for a long period of time after filter element production. This means that a tubular filter may be provided which does not require an additional filter section to add flavour to the smoke or other aerosol produced by an aerosol generating article, such as a smoking article.

The circumference of the filter element may be from 18mm to 23mm, for example 22.45 mm. The channel may have a diameter of from 3mm to 5mm, for example from 4mm to 5mm, for example 4.1 mm.

The length of the filter element may be between 5mm and 20mm, for example 7 mm.

The distance between the outer surface and the inner surface may be from 0.8mm to 2mm, such as from 1mm to 1.8mm, such as 1.4 mm. The distance between the outer surface and the inner surface is also referred to as the wall thickness.

The filter element may have a pressure drop from 5mm/Wg to 8.7 mm/Wg.

The unit mm/Wg is also referred to as millimeter water column, and is the pressure exerted by a 1 millimeter high water column at 4 ℃. 1mm/Wg corresponds to 9.80665 Pa.

The pressure drop can be measured using a Cerulean QTM module #6 device and is defined as a volumetric flow rate of 17.5ml s at the output^-1The static pressure difference between the two ends of the sample as the gas stream passes through the sample under steady conditions.

The longitudinally extending core of filter material may be wrapped with a wrapper or plug wrap, a wrapper such as paper, a wrapper such as air permeable paper.

The filter element may be used as part of a tobacco smoke filter or a filter for a non-tobacco smokable material.

The filter element of the present invention may be incorporated into an aerosol generating article. The filter elements of the present invention may be incorporated into smoking articles such as cigarettes, cigarillos, cigars and the like. The filter element of the present invention may be incorporated into a tobacco heating product or an electronic cigarette. The filter element may also be used alone or as part of a filter that is assembled by a user to form a smoking article, such as a self-rolling smoking article.

In another aspect of the utility model, there is provided a filter, for example a tobacco smoke filter, comprising a filter element according to the utility model.

The filter may comprise an overwrap, such as a plug wrap surrounding the filter element. The wrapper may be paper, such as breathable paper. The wrapper may have a weight of 20 to 100 grams per square meter, for example 20 to 50 grams per square meter, for example 27 to 35 grams per square meter.

The filter may comprise one or more further filter elements connected to the filter element of the utility model.

The first further filter element may comprise: a longitudinally extending core of filter material, wherein the longitudinally extending core has an outer surface and an inner surface; and a channel extending longitudinally from an end of the core, wherein the channel is defined by an inner surface of the core; wherein the filter element has a circumference of from 16.8mm to 24.3 mm.

The first additional filter element may be free of flavoring.

The second additional filter element comprises: a longitudinally extending core of filter material; and wherein the second further filter element has a circumference of from 16.8mm to 24.3 mm. The second additional filter element may not include a channel defined by an inner surface of the longitudinally extending core of filter material.

In an embodiment, the filter may include: a first filter element according to the utility model as defined herein; a second filter element comprising a longitudinally extending core of filter material, wherein the longitudinally extending core of filter material has an outer surface and an inner surface; and a channel extending longitudinally from an end of the core, wherein the channel is defined by an inner surface of the core; wherein the second filter element has a circumference of from 16.8mm to 24.3 mm; and a third filter element comprising a longitudinally extending core of filter material. In such a filter, the second filter element may be positioned between the first filter element and the third filter element. If assembled into a smoking article, the first filter element may be adjacent to a smoking material (such as tobacco) and the third filter element may be located at the mouth-shaped end of the smoking article.

Here, the aerosol-generating article may comprise a smoking article such as a cigarette, cigar, cigarillo, self-rolling cigarette or the like; heated tobacco products such as heated non-combustible devices, tobacco heating devices, and the like; and an electronic cigarette.

In another aspect of the utility model there is provided an aerosol-generating article comprising a filter or filter element as described above. The aerosol generating article may be a smoking article.

The smoking article may comprise a filter as described above attached to a wrapped rod of smoking material, such as tobacco smoking material. The smoking article may further comprise a tipping wrapper, such as tipping paper. The tipping wrapper connects the wrapped rod of smoking material to the filter by engaging around the adjacent end of the filter and the wrapped rod of smoking material. The tipping wrapper may be configured to expose the filter or some of the outer surface of the filter wrapper. The filter may be attached to the wrapped rod of smoking material by a complete tipping wrapper which is engaged around the entire filter length and adjacent end of the rod of smoking material.

The filter element, filter or smoking article according to the utility model may be unventilated or may be ventilated by methods known in the art, for example by using a pre-perforated or air-permeable filter wrapper (plug wrap) or tipping wrapper (tipping paper) and/or laser perforating the filter wrapper and/or tipping wrapper. Filters, filter elements or smoking articles according to the utility model may be ventilated by laser perforation of a longitudinally extending core of filter material (and of a wrapper (plug wrap) and tipping wrapper (tipping paper), if present). The ventilated full tipping wrapper (tipping paper) may also be inherently air permeable or may be provided with ventilation holes, and for ventilated products in which both the filter wrapper (plug wrap) and the tipping wrapper (tipping paper) are present, ventilation through the tipping wrapper (tipping paper) will generally coincide with ventilation through the filter wrapper (plug wrap). Ventilation holes through the filter wrapper (plug wrap) or through the tipping wrapper (tipping paper) or both may be made during filter or filter element production by laser perforation.

In another aspect of the utility model, a multi-rod is provided comprising a plurality of filter elements according to the utility model arranged end-to-end in mirror image relationship.

Drawings

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

FIG. 1 is a schematic view of a method of making a filter element according to the present disclosure;

FIG. 2 is a perspective view of a forming element used in a method of making a filter element;

FIG. 3 is a perspective view of a filter element according to the present invention;

FIG. 4 is a perspective view of a filter according to the present invention;

fig. 5 is a cross-sectional view of a filter according to the present invention.

Detailed Description

Fig. 1 shows a schematic representation of a method according to the utility model for producing a filter element.

Filament bundle 100 is simultaneously withdrawn from both bundles 102a and 102b and continuously advanced in longitudinal direction L. Each advancing web of tows 100a and 100b is bloomed by a blooming apparatus 104, the blooming apparatus 104 spreading the fibers in the cross direction. Each web of transversely spread fibers then enters a plasticizing station 106, which plasticizing station 106 sprays a plasticizer onto each web of advancing transversely spread fiber tows to form two webs of plasticized filament tows. The plasticizer is sprayed onto the surface of the fibers that make up the filament bundle. The plasticizer is triacetin, but it should be understood that other plasticizers are also suitable. The two webs of plasticized filament tow are gathered together in gathering device 108 to form a single web of plasticized filament tow. The web of plasticized filament strands continues to advance longitudinally and into the forming element 110. The shaping element 110 shapes the tow into a longitudinally extending rod of filter material through which longitudinally extending channels extend.

The forming element comprises a hollow cylindrical chamber (die) formed of a metallic material, such as brass or stainless steel, into which the plasticized tow is advanced. The chamber has an inner surface defining a hollow cylindrical member extending in the longitudinal direction L. The inner surface may have a circumference between 14mm and 27 mm. As the tow advances into the chamber, the tow is shaped against the inner surface of the chamber to form a longitudinally extending cylindrical rod of filter material.

The forming element 110 further comprises a mandrel, as shown in fig. 1 and 2. The core rod extends in the longitudinal direction L in the center of the chamber.

As shown in fig. 2, a forming rod (mandrel) 200 includes a tapered section 202 with a cylindrical rod 204 extending from the tapered section 202. The cylindrical rod 204 has an outer surface 206 and a cavity (not shown). A portion of the cylindrical rod positioned proximate the free end of the cylindrical rod 204 includes a plurality of holes 208 (e.g., four sets of six equally spaced holes), the plurality of holes 208 extending through the outer surface 206 into the cavity. The plurality of holes are regularly spaced around the entire circumference of the outer surface of the mandrel. The mandrel may be made of any suitable metal, such as brass or stainless steel.

Returning to fig. 1, as the web of plasticized tow advances into the forming element 110, the plasticized tow is pressed against the outer surface of the cylindrical rod 204. Thus, the cylindrical rod 204 forms a cylindrical channel within a longitudinally extending rod of filter material. The cylindrical rod 204 is cylindrical, which means that a substantially cylindrical channel is formed within the rod of filter material. It will be understood that other shapes of the rod 204 are possible, such as a rod having a triangular, elliptical, or star-shaped cross-section. The cross-sectional shape and diameter of the rod 204 will determine the cross-sectional shape and diameter of the channel formed in the longitudinally extending rod of filter material.

The mandrel 200 may be centrally aligned within the chamber of the forming element 110. The centered alignment of the plug 200 will mean that the channel formed in the longitudinally extending rod is centrally located within the longitudinally extending rod of filter material.

The plug 200 may include more than one cylindrical rod 204, such as two, three, or four cylindrical rods, whereby multiple channels will be formed in the rod of filter material. In such a configuration, the plug may comprise two, three or four cylindrical rods protruding longitudinally, thereby enabling the formation of two, three or four channels in the filter material.

The plug 200 additionally applies an additive in the form of a menthol composition to the continuously advancing filter material. Additive is pumped from an external reservoir 112 and carried by a conduit 114 to the mandrel. The tube 114 is connected to the tapered section 202 of the mandrel 200. The additive passes through the cavity in the mandrel and exits the mandrel through the plurality of holes 208. As the additive exits the apertures 208, the additive forms a spray. The additive spray is directed towards the filter material and the additive penetrates the entire filter material. The additive may also form a layer on the inner surface of the filter material defining the channel.

As mentioned above, the plurality of holes extend around the entire circumference of the cylindrical rod 204, which means that the additive may be applied in multiple directions such that the additive is applied over the entire filter material.

The menthol composition includes menthol and a solvent such as propylene glycol. It will be appreciated that the menthol composition may also include pure menthol without solvent.

Superheated steam is applied directly to the filter material within the forming element chamber via a steam inlet duct through the exterior of the forming element. The superheated steam is used to solidify the plasticized filter material as it is being formed by the forming element. The curing hardens the filter material so that the shape of the rod made of filter material and the channel is well defined. When the outer surface of the longitudinally extending rod of filter material is formed by the forming element chamber, superheated steam is applied directly to the outer surface.

Surprisingly, the applicant has found that a high menthol loading can be achieved despite the presence of steam in the shaped element, and that menthol remains incorporated into the filter material over time.

After the longitudinally extending rod of filter material exits the forming element, the rod proceeds on and is cooled by air jets 116 and cut by rotary cutter 118 to form filter elements such as shown in fig. 3.

The longitudinally extending rod of filter material may be wrapped with a paper wrapper before being cut.

The filter elements may be assembled into a multi-rod comprising a plurality of filter elements or mouthpieces connected end-to-end in mirror image relationship.

The filter elements may be assembled into aerosol-generating articles, such as smoking articles, using techniques known in the art.

The filter element may also be assembled into a multi-segment filter, such as the filter shown in FIG. 4.

Fig. 3 is a perspective view of a filter element according to the present invention.

The filter element 300 shown in fig. 3 may be manufactured by the above-described method.

The filter element 300 includes a longitudinally extending cylindrical core 302 of filter material, wherein the longitudinally extending cylindrical core 302 has an outer surface 304 and an inner surface 306. The filter material comprises cellulose acetate filament tow and a plasticizer such as triacetin. The filter element also includes a cylindrical passage 308 extending from the end of the core along the entire length of the core, the passage being defined by the inner surface 306 of the core 302. The core 302 includes menthol dispersed throughout the filter material. The filter elements included menthol in an amount of 3mg per filter element. The filter element had a circumference of 22.45mm, a length of 7mm, a wall thickness of 1.4mm, and a channel diameter of 4.1 mm. The pressure drop of the filter element is in the range from 5mm/Wg to 8.7 mm/Wg.

The filter element 300 may form part of a smoke filter suitable for use in a tobacco smoking article or a non-tobacco smokable material. Further, the filter element may be used in a heated non-burning or e-cigarette type device.

Figure 4 shows a perspective view of a filter for an aerosol generating article, such as a smoking article, according to the present invention. The filter 600 shown in fig. 4 includes the same first filter element 300 as described above with reference to fig. 3. Adjacent to the end of the first filter element 300 is a second filter element 400, and adjacent to the end of the second filter element 400 is a third filter element 500. Second filter element 400 is positioned between first filter element 300 and third filter element 500.

As shown in fig. 5, the first filter element 300 is the same as the filter element described above with reference to fig. 3.

The second filter element 400 includes a longitudinally extending cylindrical core 402 of filter material having an outer surface and an inner surface. The filter material comprises cellulose acetate filament tow and a plasticizer such as triacetin. A cylindrical passage 408 extends centrally along the entire length of the second filter element, the cylindrical passage being defined by the inner surface of the longitudinally extending core 402 of filter material. While the first filter element 300 includes menthol, the second filter element 400 does not include menthol or any flavoring.

The third filter element 500 includes a longitudinally extending core 502 of filter material. The filter material comprises cellulose acetate filament tow. As with the first and second filter elements, the third filter element 500 does not include channels. The third filter element comprises a continuous and uniformly dispersed filter material. The third filter element 500 may be referred to as a single acetate filter element.

A wrapper in the form of plug wrap 550 surrounds and holds together the first, second and third filter elements.

The second filter element and the third filter element may be manufactured according to techniques known in the art.

Claims (22)

1. A filter element for an aerosol generating article, the filter element comprising:

a longitudinally extending core of filter material, wherein the longitudinally extending core of filter material has an outer surface and an inner surface;

a channel extending longitudinally from an end of the core, wherein the channel is defined by the inner surface of the core;

wherein the longitudinally extending core of filter material comprises a flavour; and is

Wherein the filter element has a circumference of from 16.8mm to 24.3 mm.

2. The filter element of claim 1, wherein the flavoring is applied to the inner surface of the longitudinally extending core of filter material.

3. A filter element as claimed in claim 1 or 2 wherein the flavour is menthol, spearmint, clove, nutmeg, cinnamon, lemon, chocolate, peach, strawberry or vanilla.

4. The filter element of claim 1 or 2, wherein the filter element has a circumference of 22.45 mm.

5. A filter element according to claim 1 or 2, wherein the longitudinally extending core of filter material has a circular transverse cross-section.

6. The filter element of claim 1 or 2, wherein the channel has a circular transverse cross-section, an elliptical transverse cross-section, a triangular transverse cross-section, a trilobal transverse cross-section, or a star transverse cross-section.

7. The filter element of claim 1 or 2, wherein the filter material comprises a plasticizer.

8. The filter element of claim 1 or 2, wherein the filter element has a length of from 5mm to 20 mm.

9. The filter element of claim 8, wherein the filter element has a length of 7 mm.

10. The filter element of claim 1 or 2, wherein the distance between the outer surface and the inner surface is 0.8mm to 2 mm.

11. The filter element of claim 10, wherein the distance between the outer surface and the inner surface is 1.4 mm.

12. The filter element of claim 1 or 2, wherein the channels have a diameter of from 3mm to 5 mm.

13. The filter element of claim 12, wherein the channel has a diameter of 4.1 mm.

14. The filter element of claim 1 or 2, wherein the filter element has a pressure drop of from 5mm/Wg to 8.7 mm/Wg.

15. A filter, characterized in that it comprises a filter element according to any one of claims 1 to 14.

16. The filter of claim 15, comprising one or more additional filter elements.

17. The filter of claim 16, wherein the first additional filter element comprises:

a longitudinally extending core of filter material, wherein the longitudinally extending core of filter material has an outer surface and an inner surface;

a channel extending longitudinally from an end of the core, wherein the channel is defined by the inner surface of the core;

wherein the filter element has a circumference of from 16.8mm to 24.3 mm.

18. The filter of claim 17, wherein the first additional filter element is flavor-free.

19. A filter according to claim 17 or 18, comprising a second further filter element, wherein the second further filter element comprises a longitudinally extending core of filter material; and wherein the second further filter element has a circumference of from 16.8mm to 24.3 mm.

20. The filter of claim 19, wherein the second additional filter element does not include a channel defined through the inner surface of the longitudinally extending core made of filter material.

21. A multi-rod comprising a plurality of filter elements according to any one of claims 1 to 14 end-to-end in mirror image relationship.

22. A smoking article comprising a filter element according to any one of claims 1 to 14 or a filter according to any one of claims 16 to 20, the filter element or filter being connected to a rod of smokable material.

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