BR112020005668A2 - aerosol generating device that has a porous mass - Google Patents

Abstract

It is an aerosol generating device which includes an aerosol generating article comprising an aerosol forming substrate, a support element, an aerosol cooling element and a nozzle. At least one of the aerosol cooling element and the filter comprises a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles.

Description

“AEROSOL GENERATION DEVICE THAT HAS A POROUS MASS” PRIORITY CLAIM

[0001] This application claims priority to Provisional Application No. U.S. 62 / 562,290, filed on September 22, 2017, the content and disclosure of which are incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present disclosure relates, in general, to an aerosol generating device that includes a porous mass comprising a binder and optionally active or inactive particles. In particular, the present invention relates to an aerosol generating device which comprises a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles.

BACKGROUND OF THE INVENTION

[0003] Some smoking articles provide a smoker with an aerosol that is similar to tobacco smoke. Some tobacco articles generate an aerosol vapor from an aerosol generating medium by heating the aerosol generating medium with a fuel source, for example, tobacco. The tobacco is sufficiently heated or burned to vaporize nicotine and produce an aerosol stream containing nicotine. The smoke article may have an external fuel cylinder with satisfactory slow combustion characteristics, preferably cut tobacco or reconstituted tobacco, which surrounds a metal tube containing tobacco, reconstituted tobacco or another source of nicotine and water vapor.

[0004] In other smoking articles, an inhalable aerosol is generated by transferring heat from a heat source to a physically separate aerosol-forming substrate or material, which can be located inside, around or upstream of the heat source . During consumption of the aerosol generating article, volatile compounds are released by heat transfer from the heat source and drawn with the pull through the aerosol generating article. As the released compounds cool by passing through a cooling element, they condense to form an aerosol that is inhaled by the user.

[0005] Synthetic fibers, for example, cellulose esters, are widely used in smoke filters for smoke articles due to the ease with which they can be manufactured to form filter rods in standard cigarette making equipment. Such synthetic fibers generally comprise cellulose acetate in the form of continuous pleated fibers or filaments. Filters made of cellulose ester fibers generally work by removing a portion of the particulate matter from the smoke that passes through the fibers. the pleating or other physical positioning of the fibers within the filter serves to increase the surface area of the filaments that come into contact with the smoke. However, filters consisting of such fibers alone do not significantly cool the high temperature aerosol stream and often require additional components to cool the aerosol.

[0006] Conventional cigarettes burn tobacco by combustion and generate temperatures that release volatile compounds. Temperatures to burn tobacco can reach more than 800 “C and these high temperatures expel much of the water contained in the tobacco smoke. The main smoke produced by conventional cigarettes tends to be perceived by a smoker as having a low temperature due to the fact that it is relatively dry. An aerosol generated by heating an aerosol-forming substrate with or without burning may have a higher water content due to the lower temperatures at which the substrate is heated. Despite the lower temperature of aerosol formation, the aerosol stream generated by such systems can have a perceived temperature higher than that of conventional cigarette smoke. Therefore, the overall length of the aerosol forming article is longer in order to cool the generated aerosol to an acceptable temperature before inhalation.

[0007] Therefore, there is a need for an improved aerosol generating device that enhances cooling efficiency while maintaining desirable smoke characteristics.

SUMMARY OF THE INVENTION

[0008] In some respects, the present disclosure relates to an aerosol generating device comprising an aerosol generating article. The aerosol generating article may include an aerosol-forming substrate, a support element, an aerosol cooling element and a nozzle. In at least a portion of the at least one of the support element, the aerosol cooling element, and the nozzle comprise a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of particles active or inactive. In some embodiments, each of the supporting element, the aerosol cooling element and the nozzle comprises the porous mass. In other embodiments, only one or combinations of two among the support element, the aerosol cooling element and the nozzle comprise the porous mass. The binder can comprise a very high molecular weight polyethylene, an ultra-high molecular weight polyethylene or combinations thereof. In some embodiments, the binder can be selected from the group that includes polyolefins, polyesters, polyamides, polyacrylics, polystyrenes, polyvinyls, cellulosics and combinations thereof. The binder may additionally comprise polyolefins, polyesters, polyamides, polyacrylics, polystyrenes, polyvinyls, cellulosics or combinations thereof.

In some embodiments, the particles are active particles that can be selected from the group that includes ion exchange resins, desiccants, silicates, molecular sieves, silica gels, activated alumina, perlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxides, activated carbon, activated charcoal and combinations thereof.

In other embodiments, the porous mass may include inactive particles that comprise heat-stable materials such as adsorbent carbons.

The adsorbent carbons can be selected from the group that includes porous grade carbons, graphite, low-activity carbons, and non-activated carbons.

In other embodiments, the inactive particles comprise inorganic solids selected from the group that includes ceramics, glass, alumina, vermiculite, clays, bentonite and inert materials.

The porous mass may comprise 30 to 80% by weight of binder and 20 to 70% by weight of active or inactive particles, 30 to 70% by weight of binder and 30 to 70% by weight of active or inactive particles , or 40 to 70% by weight of binder and 30 to 60% by weight of active or inactive particles.

In other embodiments, the porous mass may comprise 70 to 100% by weight of binder and 0 to 30% by weight of active or inactive particles.

In some embodiments, the binder may be a very high molecular weight polyethylene and the active particles may be activated carbon.

The porous mass may have an encapsulated pressure drop of less than 3.0 mm of water / mm in length or of less than 1.0 mm of water / mm in length.

The binder can be configured to go through repeated heat cycles without structural deformation.

The binder can be configured to undergo less than a 10% change in pressure drop.

The binder can be hydrophobic.

The porous mass can be configured to provide a multipath air flow. In some embodiments, the porous mass comprises 100% by weight of binder. The support and the aerosol cooling element can be combined into a single unit and the pressure drop can be substantially the same as compared to the support and aerosol cooling elements as separate units.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention will be better understood in view of the attached non-limiting Figures, in which:

[0010] Figure 1 shows a cross-sectional view of an aerosol generating arrangement according to some embodiments of the present invention.

[0011] Figure 2 shows a cross-sectional view of an aerosol generating article according to some embodiments of the present invention;

[0012] Figure 3 shows a cross-sectional view of the aerosol generating device comprising a heating element and the aerosol generating article of Figure 2, according to some embodiments of the present invention;

[0013] Figure 4 shows a cross-sectional view of the nozzle of the aerosol generating device of Figure 2, according to some embodiments of the present invention;

[0014] Figure 5 shows another cross-sectional view of the mouthpiece of the aerosol generating device of Figure 2, according to some embodiments of the present invention;

[0015] Figure 6 shows yet another cross-sectional view of the mouthpiece of the aerosol generating device of Figure 2, according to some embodiments of the present invention;

[0016] Figure 7 shows yet another cross-sectional view of the nozzle of the aerosol generating device of Figure 2, according to some embodiments of the present invention;

[0017] Figure 8 shows yet another cross-sectional view of the nozzle of the aerosol generating device of Figure 2, according to some embodiments of the present invention; and

[0018] Figure 9 shows a photomicrograph of a section of the porous mass, according to some modalities of the present invention.

DETAILED DESCRIPTION OF THE INVENTION I. Introduction

[0019] The present disclosure is directed to an aerosol generating device comprising an aerosol forming substrate, a support element, an aerosol cooling element and a nozzle. At least a portion of the at least one of the support element, the aerosol cooling element, and the nozzle may comprise a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of particles active or inactive. In some respects, a portion of the support element, the aerosol cooling element, and the nozzle each comprise a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of particles active or inactive. The porous mass provides a multipath air flow that improves the temperature reduction for the aerosol cooling element allowing for a reduction in the overall length of the aerosol generating device.

[0020] In some embodiments, the structure of the porous mass provides a minimum encapsulated pressure drop (ie loss of pressure while moving through the porous mass) while maximizing the interaction of the aerosol with the binder and active or inactive particles. The binder helps promote rapid cooling of the aerosol by going through a phase change, but it does so without significant deformation, allowing the heat of the fusion to be used to remove heat without degrading the performance or structure of the filter. The binder will soften to quickly remove heat and then gradually release that heat as it solidifies between blows. This project can be intensified, modified or complemented with an active or inactive material included in the binder to promote the selected filtration or modify the heat adsorption and release profiles.

[0021] Advantageously, with the use of a support element, an aerosol cooling element, and / or a nozzle comprising a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight. weight of active or inactive particles, promotes rapid cooling of the aerosol. Additionally, the pressure drop values of the nozzle or aerosol cooling element are also decreased, causing improvements in the puff while maintaining the desired nozzle hardness and cooling properties by the support element, aerosol cooling element, and / or the nozzle, even after repeated use. Specifically, the structural properties of the porous mass are well suited to undergo melt heat change without significantly changing or deforming the structure. The porous mass performs satisfactorily in reducing heat, but it can also provide positive sensory properties simultaneously if desired.

II. Aerosol Generation Device

[0022] In reference to Figures 1 to 3, some modalities of an aerosol generating device are shown (they are representative, however, not limited to the devices contemplated hereinafter). In some embodiments, the aerosol generating device may, however, include, without limitation, electronic smoking devices, aerosol generating devices that have a fuel source, smokeless smoking devices, etc. Hereafter, reference will be made to aerosol generating devices (unless otherwise specified).

[0023] Figure 1 illustrates an aerosol generating device 1 according to some embodiments of the present invention. The aerosol generating arrangement 1 comprises a rod of smoke material 2 and a nozzle 3. The nozzle 3 may comprise a porous mass comprising from 100% by weight of binder and 0 to 80% by weight of active particles or inactive. The nozzle 3 is fixed to the smoke material rod 2 by a tilting wrap 4. The smoke material rod 2 comprises an outer wrap 5, a coaxially located fuel source 6 and cut smoke material 7 disposed between the source of smoke. fuel 6 and wrapper 5.

[0024] In operation, the aerosol generating device 1 is ignited and burns along the length of the fuel source producing smoke from the side flow that is barely visible. The visible side-flow smoke produced is derived from the organic components in the smoke article and is most visible at the end of a breath. the substantially non-combustible wrap is carbonized to produce a frangible white ash, similar to conventional cigarette ash and which can be removed by the smoker as needed. The non-combustible outer casing 5, by carbonization, also produces a dark firing line that advances along the smoke article as the firing progresses. The smoke article burns backwards along the fuel source 6. As the burning occurs, an aerosol is produced from the aerosol-generated cut smoke material 7, the aerosol of which is swallowed into the smoker's mouth. Due to the rapid cooling properties of the porous mass, the aerosol is cooled before inhalation.

[0025] Figure 2 illustrates an exemplary aerosol generation article 10. The aerosol generating article 10 can comprise four elements arranged in coaxial alignment: an aerosol forming substrate 20, a support element 30, an aerosol cooling element 40 and a nozzle 50. These four elements are arranged sequentially and can be circumscribed by an outer envelope 60 to form the aerosol generating article 10. The support element 30, aerosol cooling element 40 and nozzle 50 can be collectively referred to as a "filter". The aerosol generating article 10 has a proximal or buccal end 70, which a user inserts into his mouth during use, and a distal end 80 located at the opposite end of the aerosol generating article 10 to the buccal end 70 However, it should be understood that the components in the aerosol generation article do not need to be arranged in such a way, and that there may be other possible configurations. In fact, the components in the aerosol generating article can be arranged in alternative arrangements that are not coaxial with other components, for example, a displacement arrangement, an overlap arrangement, combinations thereof, etc. In addition, due to the rapid cooling properties of the porous mass, some of these components can be shortened or removed entirely from the aerosol generating article 10.

[0026] In use, air is sucked through the aerosol generating article 10 by a user from the distal end 80 to the buccal end 70, or the proximal end. The distal end 80 of the aerosol generating article 10 can also be described as the downstream end of the aerosol generating article 10 and the buccal end 70 of the aerosol generating article 10 can also be described as the upstream end of the article aerosol generating element 10. Elements of the aerosol generating article 10 located between the buccal end 70 and the distal end 80 can be described as being downstream of the buccal end 70 or, alternatively, upstream of the distal end 80, as appropriate.

[0027] The aerosol forming substrate 20 is located at the distal end or the extreme downstream of the aerosol generating article 10. In the embodiments illustrated in Figure 2, the aerosol forming substrate 20 may comprise an assembled sheet of tobacco material pleated homogenate circumscribed by a wrap. The pleated sheet of homogenized tobacco material can comprise an aerosol former, such as glycerin.

[0028] The support element 30 can be located immediately upstream of the aerosol forming substrate 20 and is contiguous with the aerosol forming substrate 20. In some aspects, the aerosol forming substrate 20 can be proximal to the support element 30, however, without contiguity. In the embodiments shown in Figure 2, the support element 30 can be a hollow cellulose acetate tube. The support element 30 locates the aerosol forming substrate 20 at the extreme distal end 80 of the aerosol generating article 10 so that it can be penetrated by a heating element of an aerosol generating device. As described further below, the support element 30 acts to prevent the aerosol forming substrate 20 from being forced upstream within the aerosol generating article 10 towards the aerosol cooling element 40 when a heating element of a device aerosol-generating substrate 20 is inserted into the aerosol-forming substrate 20, or as heat may otherwise be applied to the aerosol-forming substrate 20. In some embodiments, the support element 30 also acts as a spacer to space The aerosol cooling element 40 of the aerosol generating article 10 of the aerosol forming substrate 20. In some embodiments, the support element 30 and the aerosol cooling element 40 may form a single unit of the aerosol generating article. 10, which can allow the nozzle to be elongated, and / or can allow the overall overall length of the support element 30, of the aerosol cooling element 40, and d the nozzle 50 is reduced. For example, such a single unit can be formed when the nozzle comprises a filter rod comprising a porous mass. In some respects, when the single unit is formed, the pressure drop is substantially the same as compared to the support element and the aerosol cooling element, each as separate units, for example, within 0.5%.

[0029] As shown in Figure 2, the aerosol cooling element 40 is located immediately upstream of the support element 30 and is contiguous to the proximal end of the support element 30. In other embodiments, the aerosol cooling element 40 does not is contiguous to the proximal end of the support element 30. In use, volatile substances released from the aerosol forming substrate 20 travel upstream along the aerosol cooling element 40 towards the buccal end 70 of the aerosol generating article 10 Volatile substances can cool inside the aerosol cooling element 40 to form an aerosol that is inhaled by the user. The aerosol cooling element can include a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles, circumscribed by a wrap 90. The porous mass can define a plurality of channels for air flow that extends along the length of the aerosol cooling element 40.

[0030] The nozzle 50 is located immediately upstream of the aerosol cooling element 40 and is contiguous to the proximal end of the aerosol cooling element 40. In some embodiments, the nozzle may not be contiguous to the proximal end of the aerosol cooling element. aerosol 40. In some aspects, the aerosol generating arrangement may additionally comprise another support element between the aerosol cooling element 40 and the nozzle 50. As shown in Figure 2, the nozzle 50 comprises a porous mass comprising 20 to 100% by weight of binder and O to 80% by weight of active or inactive particles.

[0031] To assemble the aerosol generating article 10, the four elements described above are aligned and hermetically wrapped inside the outer wrapper 60. In the embodiment illustrated in Figure 2, the outer wrapper is a conventional cigarette paper.

[0032] In some embodiments, a distal end portion of the outer wrap 60 of the aerosol generating article 10 is circumscribed by a tipping paper band (not shown).

[0033] The aerosol generating article 10 shown in Figure 2 is designed to engage with an aerosol generating device that comprises a heating element to form an aerosol that is consumed by a user. In use, the heating element of the aerosol generating device heats the aerosol forming substrate 20 of the aerosol generating article 10 to a temperature sufficient to volatilize compounds that are capable of forming an aerosol, which is swallowed downstream through the aerosol generation article 10 and inhaled by the user.

[0034] Figure 3 illustrates a portion of an exemplary aerosol generating system 100 comprising an aerosol generating device 110 and an aerosol generating article 10 according to the embodiment described above and illustrated in Figure 2.

[0035] In one embodiment, the aerosol generating device 110 comprises a heating element

120. As shown in Figure 3, the heating element 120 is mounted inside an aerosol generating article receiving chamber of the aerosol generating device

110. In use, the user inserts the aerosol generating article into the aerosol generating article receiving chamber of the aerosol generating device 110 so that the heating element 120 is directly inserted into the aerosol forming substrate 20 of the aerosol generating article 10 as shown in Figure 3. In the embodiment shown in Figure 3, the heating element 120 of the aerosol generating device 110 is a heating plate. Of course, other aerosol generating device configurations can be employed without departing from the scope of the present disclosure.

[0036] The aerosol generating device 110 comprises a power supply and electronics (not shown) that allow the heating element 120 to be actuated. Such actuation can be manually operated or can occur automatically in response to a user who brings in an aerosol generating article 10 inserted in the aerosol generating article receiving chamber of the aerosol generating device 110. A plurality of openings are optionally provided in the aerosol generating device to allow air to flow to the aerosol generating article 10. Figure 3 provides an exemplary air flow direction as illustrated by the arrows.

In other respects, the porous mass both in the aerosol cooling element, the support, the nozzle, and in any combination thereof, can provide air flow of multiple trajectories.

The structure of the porous mass can include one or more channels for multidirectional air flow.

In conventional aerosol generating devices, air must first pass through the support element which has little to no cooling effect.

The air then passes through the aerosol cooling element and, finally, the nozzle.

Without being limited to theory, it is believed that the porous mass allows such a multidirectional air flow due to the fact that, unlike a pleated fiber that is only oriented parallel to the air flow, the pores of the porous mass are random.

Therefore, the porous mass does not restrict the direction of air flow and instead provides a tortuous trajectory, causing improved cooling.

In this way, the porous mass improves the temperature reduction for the aerosol cooling element, the support element, and / or the nozzle.

Such improved temperature reduction can also allow the aerosol cooling element, the support, and / or the nozzle to be shorter in length when a porous mass is used in one of the elements, as compared to a pleated fiber.

These effects are further amplified by the efficiency of the binder and the optional active or inactive particles.

In addition, the stability of the binder at higher temperatures may allow the filter to function when placed directly against the aerosol generating segment.

The support element 40 of the aerosol generating article 10 resists the penetrating force experienced by the aerosol generating article 10 during the insertion of the heating element 120 of the aerosol generating device 110 into the aerosol forming substrate 20. As a result , the support element 40 of the aerosol generating article 10 resists movement downstream of the aerosol forming substrate within the aerosol generating article 10 during insertion of the heating element of the aerosol generating device into the aerosol generating substrate. aerosol.

[0037] Once the internal heating element 120 is inserted into the aerosol forming substrate of the aerosol generating article 10 and actuated, the aerosol forming substrate 20 of the aerosol generating article 10 is heated to a temperature of less than 400 ° C (or other temperature as discussed in this document) by the heating element 120 of the aerosol generating device 110. At this temperature, volatile compounds are developed from the aerosol forming substrate of the aerosol generating article 10 As a user brings in the buccal end 70 of the aerosol-generating article 10, the volatile compounds developed from the aerosol-forming substrate 20 are swallowed downstream through the aerosol-generating article 10 and condense to form a aerosol which is swallowed through the nozzle 50 of the aerosol generating article 10 in the user's mouth.

[0038] As the aerosol passes downstream through the aerosol cooling element 40, the temperature of the aerosol can be reduced due to the transfer of thermal energy from the aerosol to the aerosol cooling element 40. When the aerosol enters the cooling element aerosol cooling 40, its temperature can be in the range of 60 “C. Due to the cooling inside the aerosol cooling element 40, the temperature of the aerosol as it exits the aerosol cooling element can be in the order of 40ºC. In this way, a temperature reduction of at least 10 ºC, for example, at least 20 ºC or at least 30 ºC, can be achieved.

III. Porous Mass

[0039] As described in this document, the present disclosure relates to a porous mass used in a smoking device, particularly an aerosol generating device. Specifically, the porous mass can form at least a portion of the support element, the aerosol cooling element, the nozzle, or some combination of any or all of the aerosol generating device.

[0040] In the modalities shown in Figures 4 to 8, various dispositions of the nozzle that has the porous mass are shown and described. These modalities are illustrative of any combination of conventional materials, for example, cellulose acetate and the porous mass in the nozzle. It is contemplated that the support element and the aerosol element can also include the porous mass in various arrangements, however, they are not shown in Figures 4 to 8.

[0041] Figures 4 to 8 illustrate various modalities of the nozzle of the aerosol generating device of Figure 2, according to the modalities of the present invention; As described in reference to the nozzle, “filter 51” is different from the nozzle “filter” combination, support, and aerosol cooling element referred to in this document. The nozzle 50 includes a filter 3 which may comprise a porous mass comprising from 20 to 100% by weight of binder and from 0 to 80% by weight of active or inactive particles. For example, in Figure 4, the entire filter 51 of the nozzle 50 may comprise the substantially uniform porous mass.

[0042] In Figure 5, the nozzle 50 has a filter 51 that includes two segments. In this embodiment, the porous mass 53 is located adjacent to the buccal end 70 of the nozzle

50. Conventional filter materials 52 can be located downstream adjacent the aerosol cooling element. It is also contemplated that the porous mass 53 can be located downstream adjacent to the aerosol cooling element 40. For example, Figure 6 illustrates a nozzle embodiment 50 in which conventional filter materials 53 are upstream adjacent to the mouth end 70 , and the porous mass 52 is downstream adjacent to the aerosol cooling element 40.

[0043] In Figure 7, the nozzle 50 includes a multi-segment filter 51 comprising three segments. In that embodiment, conventional filter materials 53 can flank the porous mass 52. For example, a conventional filter material 53 can be provided at a proximal end adjacent to the buccal end 70 and another conventional filter material can be provided downstream proximal to the element of aerosol cooling 40 with porous mass 52 sandwiched between them. Similarly, as shown in Figure 8, one or more porous masses 52 can flank conventional filter materials 53 in a similar arrangement with a porous mass 52 at a proximal end adjacent to the buccal end 70 and another porous mass 52 can be supplied to downstream proximal to the aerosol cooling element 40, and the conventional filter 53 is sandwiched between them. In the embodiments illustrated in Figures 7 and 8, the filter segments can be any combination of conventional materials and porous mass (since at least one of these sections is the porous mass. In some embodiments, the supporting element and the cooling element of aerosol comprise a porous mass and the nozzle may comprise cellulose acetate.

[0044] The aforementioned modalities are representative and not limiting. Of course, inventive filters can have any number of sections, for example, 2, 3, 4, 5, 6, OR More sections. In addition, the sections can be the same or different from each other. For example, sections may have a stacked arrangement of filter materials. The filters can have a diameter in the range of 5 to 10 mm and a length of 5 to 100 mm.

[0045] In some embodiments, the support element may comprise the porous mass. In other embodiments, the aerosol cooling element comprises the porous mass. In some embodiments, the nozzle comprises the porous mass. In other embodiments, the support element and the aerosol cooling element comprise the porous mass. In other embodiments, the support element and the nozzle comprise the porous mass. In additional embodiments, the aerosol cooling element and the nozzle comprise the porous mass. In other embodiments, the support element, the aerosol cooling element and the nozzle comprise the porous mass.

[0046] The porous mass described in this document can be prepared as a filter rod to be used as a filter in an aerosol generating device. In some embodiments, producing filters and / or filter sections may involve cutting the lengths of the filter rod or filter rods. In some embodiments, producing filter sections may involve cutting lengths of filter rod, filter rods or filters. The lengths of filter rod, filter rods, and / or filter sections may have any cross-sectional shape which includes, but is not limited to, circular, substantially circular, ovular, substantially ovular, polygonal (including those with rounded corners) , or any hybrid thereof.

[0047] In the aforementioned modalities, conventional materials and porous mass are joined. United, as used in this document, means that the porous mass is in line (or in series) with the tobacco column; so that, when the user brings in the heated cigarette, smoke from the tobacco column needs to pass (for example, in series) through the porous mass and, with maximum frequency, through both the porous mass and conventional filter materials. As shown in Figures 5 to 8, the porous mass and conventional filter materials are coaxial, juxtaposed (close, but not in contact), contiguous, and have equivalent cross-sectional areas (or substantially equivalent cross-sectional areas). However, it is understood that the porous mass and conventional materials do not need to be joined in such a way, and that there may be other possible configurations. In addition, although it is anticipated that the porous mass, with maximum frequency, will be used in a combined or multi-segment filter configuration, as shown in Figures 5 to 8; the invention is not so limited and the filter can comprise only the porous mass, as discussed above in relation to Figure 4. In addition, although it is predicted that the porous mass will be juxtaposed to the tobacco column, as shown in Figure 2, the same it is not so limited. For example, the porous mass can be separated from the tobacco by a hollow cavity (for example, a tube or channel).

[0048] The conventional filter materials employed may include, but are not limited to, fibrous tow (for example, cellulose acetate tow, polyolefin tow and combinations thereof), paper, empty chambers (for example, made up of rigid elements , such as paper or plastic), deflected empty chambers and combinations thereof. Also included are fibrous tow and papers with active ingredients (adhered to or impregnated in them or otherwise, incorporated with them). Such active materials include activated carbon (or charcoal), ion exchange resins, desiccants, or other materials adapted to affect tobacco smoke. Empty chambers can be filled (or partially filled) with active ingredients or materials that incorporate the active ingredients. Such active ingredients include activated carbon (or charcoal), ion exchange resins, desiccants, or other materials adapted to affect tobacco smoke. In addition, the conventional material can be a porous mass of binder (i.e., the binder itself without any active particles). For example, this porous mass without active particles can be made with thermoplastic particles (such as polyolefin powders, including the binder discussed below) that are bonded or molded together in a porous cylindrical shape.

[0049] In some embodiments, the porous mass may comprise inactive particles that are heat-stable materials. Inactive particles can comprise carbons - “adsorbents, including, without limitation, porous grade carbons, graphite, low-activity carbons, and non-activated carbons. In other embodiments, inactive particles comprise inorganic solids including, but not limited to, ceramic, glass, alumina, vermiculite, glass, bentonite and inert materials.

[0050] The porous mass comprises active or inactive particles linked together with ligand. For example, Figure 9 shows a photomicrograph of a modality of the porous mass in which active particles (for example, activated carbon particles) 57 are linked to the porous mass by the ligand 58. (The active particles and the ligand are discussed in more detail This porous mass is constructed so that it has a minimal encapsulated pressure drop (ie, loss of pressure while moving through the porous mass) while maximizing the surface area active particles (ie, the functionality of the active particle is increased by exposing the surface area of these particles). Note: in this modality (Figure 9), ligand and active particles are joined at contact points, the contact points are randomly distributed throughout the porous mass, and the ligand retained its original physical shape (or substantially retained its original shape, for example, no more than 10% variation (for example, wrinkling) in original format).

[0051] In terms of ranges, the porous mass may comprise from 0 to 80% by weight of active or inactive particles, for example, from 0.01 to 80% by weight, from 5 to 75% by weight, from 10 to 75% by weight, 20 to 70% by weight, 0 to 30% by weight, 30 to 70% by weight, 30 to 60% by weight, or 40 to 50% by weight. In some aspects, the particles may be present, but the porous mass may comprise less than 80% by weight of active or inactive particles, for example, less than 70% by weight, less than 60% by weight, less than than 50% by weight, less than 40% by weight, less than 30% by weight, less than 20% by weight, less than 10% by weight, or less than 5% by weight. The porous mass may comprise from 20 to 100% by weight of binder, for example, from 70 to 100% by weight, from 20 to 99.9% by weight, from 25 to 95% by weight, from 25 to 90% by weight weight, from 30 to 70% by weight, from 30 to 80% by weight, from 40 to 70% by weight or from 50 to 60% by weight. In some embodiments, the porous mass may comprise 100% by weight of binder.

[0052] In some modalities, the porous mass has a dead volume in the range of 40 to 90%. In another modality, it has a dead volume of 60 to 90%. In yet another modality, it has a dead volume of 60 to 85%. Dead volume refers to the free space between the active particles and the binder after the porous mass is formed.

[0053] As used in this document, the term "encapsulated pressure drop" or "EPD" refers to the difference in static pressure between the two ends of a specimen when it is traversed by an air flow under immediate conditions when the volume flow is 17.5 ml / sec. at the outlet end when the specimen is completely encapsulated in a measuring device so that no air can pass through the enclosure. EPD was measured in this document under CORESTA (“Cooperation Center for Scientific Research on Tobacco” Recommended Method No. 41, dated June 2007. Higher EPD values translate into the smoker having to swallow a smoking device with The porous mass optionally has an encapsulated pressure drop (EPD) of less than 3.0 mm of water per mm of porous mass. In another embodiment, the porous mass has an EPD of less than 1, 0 mm of water per mm of porous mass, and in yet another embodiment, the porous mass has an EPD equal to or less than 0.6 mm of water per mm of porous mass (or no greater than 0 , 6 mm of water per mm of porous mass) or less than or equal to 0.5 mm of water per mm of porous mass (or no greater than 0.5 mm of water per mm of mass) In some embodiments, to obtain the desired EPD, the active particles must have a particle size la greater than the ligand. In one embodiment, the ratio of binder particle size to active particle size is in the range of 1: 1.5 to 4.0.

[0054] In some embodiments, the porous mass has a length of 2 to 25 mm, for example, from 5 to 20 mm or from 15 to 20 mm.

[0055] The porous mass can have any physical shape; in one mode, the same is in the shape of a cylinder.

[0056] The active or inactive particles can be any material adopted to intensify the smoke that flows through it and facilitate the removal of heat or heat dissipation, for example, materials with high heat capacity. By "adopted (a) to intensify the smoke that flows through it" is meant any material that can remove or add components for smoke. Removal can be selective. In tobacco smoke from a cigarette, carbonyls (eg formaldehyde, acetaldehyde, acetone, propionaldehyde, crotonaldehyde, butyraldehyde, methyl ethyl ketone, acrolein) and other compounds (eg benzene, 1,3 butadiene, and benzo [a] pyrene ( or BaPyrene)), for example, can be selectively removed. An example of such a material is activated carbon (or activated charcoal or activated carbon). Activated carbon can be low activity (50 to 75% absorption of CClas) or high activity (75-95% absorption of CCla) or a combination of both. Other examples of such materials include ion exchange resins, desiccants, silicates, molecular sieves, silica gels, activated alumina, perlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxides (for example, iron oxide), and combinations of the above (including activated carbon). Ion exchange resins include, for example, a polymer with a backbone, such as styrene-divinyl benzene copolymer (DVB), acrylates, methacrylates, phenol formaldehyde condensates, and epichlorohydrin amine condensates; and a plurality of electrically charged functional groups attached to the polymer backbone. In one embodiment, the active particles are a combination of several active particles.

[0057] In some embodiments, the active particles have an average particle size of 0.5 to 5,000 microns, for example, 10 to 1,000 microns, or 200 to 900 microns, or a mixture of particle sizes. In additional embodiments, the active particles can be a mixture of various particle sizes that have an average particle size of 0.5 to 5,000 microns, for example, from 1,000 microns, or from 200 to 900 microns.

[0058] The binder can be any binder that overcomes the heat cycles that occur during the use of the aerosol generating device, for example, repeated heating at temperatures up to 300 ºC. As used in this document, the "heat cycles" in an aerosol generating device can be 14 "breaths" or swallowed in the device, or the use of the device for 6 minutes (whichever comes first). In one embodiment, the binder exhibits virtually no flow at its melting temperature. This means a material that, when heated to its melting temperature, exhibits little to no polymer flow. Little or no polymer flow is advantageous due to the fact that even at temperatures higher than the melting point of the binder, the binder will not be significantly repositioned or moved within the aerosol generating device. Materials that meet these criteria include, without limitation, ultra-high molecular weight polyethylene, very high molecular weight polyethylene, high molecular weight polyethylene and combinations thereof. The binder is configured to undergo repeated heat cycles without structural deformation at 350 “C or less. For example, the structure of the binder undergoes less than a 10% pressure change during repeated heat cycles. The binder can also be hydrophobic, which allows condensation of water vapor to facilitate the removal of heat and, advantageously, some selective filtration of phenols.

[0059] In some embodiments, the binder has a melt flow index (MFI, ASTM D1238 2013) less than or equal to 3.5 g / 10 min at 190 ºC and 15 kg (or O at 3.5 g / 10 min at 190 ºC and 15 Kg). In some embodiments, the binder has a melt flow index (MFI) of less than or equal to 2.0 g / 10 min at 190 ºC and 15 kg (or O at 2.0 9/10 min at 190 ºC and 15 kg ). An example of such a material is ultra-high molecular weight polyethylene, UHMWPE, which has no polymer flux, MFI of approximately 0 g / 10 min at 190 ºC and 15 kg, or a

MFI of O at 1.0 g / 10 min at 190 ºC and 15 Kg. Another material can be very high molecular weight polyethylene, VHMWPE, which can have MFIS in the range, for example, 1.0 to 2.0 9 / 10 min at 190 ºC and 15 Kg. Still another material is high molecular weight polyethylene, HMWPE, which can have MFIsS of, for example, 2.0 to 3.5 9g / 10 min at 190 ºC and 15 Kg. For example, the porous mass may comprise a binder and active particles, where the binder is a very high molecular weight polyethylene and the active particles are activated carbon. The binder is configured to undergo repeated heat cycles without structural deformation.

[0060] In terms of molecular weight, "ultra-high molecular weight polyethylene" as used in this document refers to polyethylene compositions with an average molecular weight of at least about 3x10º g / mol. In some embodiments, the molecular weight of the ultra-high molecular weight polyethylene composition is between about 3x10º g / mol and about 30x10º g / mol, or between about 3x10º g / mol and about 20x10º g / mol, or between about 3x10º g / mol and about 10x10º g / mol, or between about 3x10º g / mol and about 6x10º g / mol. "Very high molecular weight polyethylene" refers to polyethylene compositions with an average molecular weight of less than 3x1056 g / mol and greater than 1x10 ° g / mol. In some embodiments, the molecular weight of the very high molecular weight polyethylene composition is between 2x10º g / mol and 3x10º g / mol. "High molecular weight polyethylene" refers to polyethylene compositions with an average molecular weight of at least 3x10 * g / mol and can vary from 3x10º g / mol to 1x10º g / mol. For the purposes of this specification, the molecular weights referred to in this document are determined according to the Margolies equation ("Margolies molecular weight").

[0061] Suitable polyethylene materials are commercially available from several sources including GURE UHMWPE from Ticona Polymers LLC, a division of Celanese Corporation of Dallas, Tex., And DSM (Netherlands), Braskem (Brazil), Beijing Factory No. 2 ( BAAF), Shanghai Chemical, and Qilu (People's Republic of China), Mitsui and Asahi (Japan). Specifically, GUR polymers can include: GUR 2000 series (2105, 2122, 2122-5, 2126), GUR 4000 series (4120, 4130, 4150, 4170, 4012, 4122-5, 4022-6, 4050- 3/4150 -3), GUR 8000 series (8110, 8020), and GUR X series (X127, X143, X184, X168, X172, X192).

[0062] An example of a suitable polyethylene material is that, having an intrinsic viscosity in the range of dl / g to 30 dl / g and a degree of crystallinity of 80% or more as described in US Patent Application Publication 2008/0090081 . Another example of a suitable polyethylene material is that having a molecular weight in the range of 300,000 g / mol to 2,000,000 g / mol as determined by ASTM-D 4020 (2011), an average particle size, Dso, 300 and 1500 µm, and an apparent density of 0.25 to 0.5 g / ml as described in WO No. 2011/140053.

[0063] In one embodiment, the ligand is a combination of several ligands. In one embodiment, the binder has a particle size in the range of 0.5 to 5,000 microns, for example, 10 to 1,000 microns, 20 to 600 microns, 125 to 5,000 microns, 125 to 1,000 microns, 150 at 600 microns, from 200 to 600 microns, from 250 to 600 microns, or from 300 to 600 microns. In another embodiment, the binder can be a mixture of several particle sizes. In another embodiment, the binder can be a mixture of various particle sizes with an average particle size in the range of 125 to 5,000 microns, for example, 125 to 1,000 microns or 125 to 600 microns.

[0064] Additionally, the binder can have an apparent density in the range of 0.10 to 0.55 g9 / cm ?, for example, from 0.17 to 0.50 g / cm? º or from 0.20 to 0 , 47 g / cmº ?.

[0065] In addition to the aforementioned binder, other conventional thermoplastics can be used as the binder. Such thermoplastics may include, for example: polyolefins, polyesters, polyacrylic polyamides (or nylon), polystyrenes, polyvinyls and cellulosics. However, polyolefins include, without limitation, polyethylene, polypropylene, polybutylene, polymethylpentene, copolymers thereof, mixtures thereof and the like.

[0066] Polyethylenes additionally include low density polyethylene, linear low density polyethylene, high density polyethylene, copolymers thereof, mixtures thereof and the like. Polyesters include polyethylene terephthalate, polybutylene terephthalate, polycyclohexylene dimethylene terephthalate, polytrimethylene terephthalate, copolymers thereof, mixtures thereof, and the like. Polyacrylics include, without limitation, polymethyl methacrylate, copolymers thereof, modifications thereof and the like. Polystyrene, however, includes, without limitation, polystyrene, acrylonitrile-butadiene-styrene, styrene-acrylonitrile, styrene-butadiene, styrene-maleic anhydride, copolymers thereof, mixtures thereof and the like. However, polyvinyls include, without limitation, ethylene vinyl acetate, ethylene vinyl alcohol, polyvinyl chloride, copolymers thereof, mixtures thereof, and the like. Cellulosics include, without limitation, cellulose acetate, cellulose butyrate acetate, cellulose propionate, ethyl cellulose, copolymers thereof, mixtures thereof and the like.

[0067] The ligand can take any shape. Such formats include spherical, hyperion, asteroidal, crondular or interplanetary, pelleted, potato, irregular, or combinations thereof.

[0068] The porous mass is preferably effective in removing components from tobacco smoke. A porous mass can be used to reduce the delivery of certain components of tobacco smoke targeted by the World Health Organization (WHO) or certain compounds categorized by the Food and Drug Administration (FDA) as HPHCs (Harmful or Potentially Harmful Compounds). For example, a porous mass comprising a binder and active particles, such as activated carbon, reduces the delivery of certain components of tobacco or aerosol smoke to levels below WHO recommendations.

[0069] The porous mass can be produced by any means. In one embodiment, the active particles and binder are mixed together and introduced into a mold. The mold is heated to a temperature above the binder's melting point, for example, in a mode around 200 ºC and kept at the temperature for a period of time (in a mode 40 + 10 minutes). Then, the dough is removed from the mold and cooled to room temperature. In one embodiment, this process is characterized as a free sintering process, due to the fact that the binder does not flow (or flows very little) at its melting temperature and no pressure is applied to the materials mixed in the mold. In this modality, point bonds are formed between the active particles and the ligand. This allows for superior bonding and maximizes interstitial space, while minimizing the blinding of the surface of active particles by free flowing fused ligand. See also U.S. Patent Nos. 6,770,736, 7,049,382, 7,160,453, incorporated herein by reference.

[0070] Alternatively, the porous mass could be produced using a sintering process under pressure. As the mixture of the active particles and the binder is heated (or at a temperature that may be below,

at, or above the melting temperature of the binder) a pressure is exerted on the mixture to facilitate the coalescence of the porous mass.

[0071] In addition, the porous mass can be produced by an extrusion sintering process in which the mixture is heated in an extruder barrel and extruded into the porous mass.

[0072] The present invention will be better understood in view of the following non-limiting examples.

EXAMPLE 1

[0073] An aerosol generating device was constructed using a porous mass for the aerosol cooling element and / or supporting element compared to an aerosol generating device without any aerosol cooling element. The aerosol generating devices were tested with a Cerulean SM450 smoke machine using the Canadian Health Protocol of December 1999 for “Determination of Tar, Nicotine, and Carbon Monoxide in Mainstream Tobacco Smoke”. The maximum blowing temperature was measured in 11 breaths using a thermocouple thermometer inserted in the nozzle. The porous mass in Samples A to C consisted of ultra-high molecular weight polyethylene and adsorbent carbon. The porous mass was fixed to an aerosol generating substrate with the support element in Samples A and B and without the support element in Sample C. In samples B and C, the porous mass was placed immediately after the substrate and in the Sample. A, the porous mass was placed after the support element. Samples with a porous mass (A to C) were compared to a device without any cooling elements (Sample D). The maximum blowing temperatures for each construction are shown in Table 1 below.

TABLE 1 Sample Construction Maximum Temperature (ºC) A Support element, porous mass, nozzle 57.8 B Porous mass, support element, nozzle 59.0 Cc Porous mass, nozzle 57.7 D Support element, nozzle 63.0

[0074] As shown in Table 1, Sample D, which does not include a porous mass, had a maximum blowing temperature higher than Samples A and B, which included the same components as Sample D, but with the addition of a porous mass. Sample D also had a maximum blowing temperature higher than Sample C, which included a porous mass and nozzle, but did not include a support element. Consequently, the inclusion of a porous mass resulted in a reduction in maximum and even allowed blowing temperature for the support element to be omitted in Sample D.

EXAMPLE 2:

[0075] A porous mass was produced using the components shown below in Table 2. The encapsulated pressure drop of the porous mass was measured using a Cerulean Quantum Solo V bench pressure drop tester. The results are shown below in Table 2.

TABLE 2 Sample Porous Mass Encapsulated Pressure Drop (mm of water / mm in length) 4 60% ultra-high molecular weight 0.82 polyethylene, 40% carbon

TABLE 2 Sample Porous Mass Encapsulated Pressure Drop (mm of water / mm in length) 100% polyethylene of 1.27 ultra-high molecular weight 6 100% plastic acetate 0.18 of plasticized cellulose

[0076] As shown in Table 2, the encapsulated pressure drop was decreased from Sample 5 to 4 by adding 40% carbon. The encapsulated pressure drop of the porous mass containing plasticized cellulose acetate plastic was even lower than that of Samples 4 and 5.

[0077] Although the invention has been described in detail, changes within the spirit and scope of the invention will be readily apparent to elements skilled in the art. It is to be understood that aspects of the invention and portions of various modalities and various features cited above and / or in the appended claims can be combined or exchanged both at the top and in part. In the preceding descriptions of the various modalities, those modalities that refer to another modality can be appropriately combined with other modalities as will be verified by an element of common skill in the art. In addition, elements of ordinary skill in the art will note that the foregoing description is by way of example only, and is not intended to limit the invention. All American scooters and publications mentioned in this document are incorporated by reference in their entirety.

Claims (20)

1. Aerosol generating device characterized by comprising: an aerosol generating article, wherein the aerosol generating article comprises: an aerosol forming substrate; a support element; an aerosol cooling element; and a nozzle, wherein at least one of the support element, the aerosol cooling element and the nozzle comprises a porous mass comprising from 20 to 100% by weight of binder and from 0 to 80% by weight of active particles or inactive. Device according to claim 1, characterized in that the support element comprises the porous mass. Device according to claim 1, characterized in that the aerosol cooling element comprises the porous mass. Device according to claim 1, characterized in that the nozzle comprises the porous mass. Device according to claim 1, characterized in that the support element and the aerosol cooling element comprise the porous mass. Device according to claim 1, characterized in that the support element and the nozzle comprise the porous mass. Device according to claim 1, characterized in that the aerosol cooling element and the nozzle comprise the porous mass. Device according to claim 1, characterized in that the support element, the aerosol cooling element and the nozzle comprise the porous mass. Device according to any one of claims 1 to 8, characterized in that the binder comprises a very high molecular weight polyethylene, an ultra-high molecular weight polyethylene or combinations thereof. Device according to any one of claims 1 to 8, characterized in that the binder is selected from the group consisting of polyolefins, polyesters, polyamides, polyacrylics, polystyrenes, polyvinyls, cellulosic and combinations thereof. Device according to claim 9, characterized in that the binder additionally comprises polyolefins, polyesters, polyamides, polyacrylics, polystyrenes, polyvinyls, cellulosics or combinations thereof. 12. Device according to any one of claims 1 to 11, characterized in that the active particles are selected from the group consisting of ion exchange resins, desiccants, silicates, molecular sieves, silica gels, activated alumina, perlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxides, activated carbon, activated charcoal and combinations thereof. Device according to any one of claims 1 to 11, characterized in that the inactive particles comprise heat-stable materials. Device according to any one of claims 1 to 11, characterized in that the inactive particles comprise adsorbent carbons selected from the group consisting of porous grade carbons, graphite, low-activity carbons and non-activated carbons. Device according to any one of claims 1 to 11, characterized in that the inactive particles comprise inorganic solids selected from the group consisting of ceramics, glass, alumina, vermiculite, clays, bentonite and inert materials. 16. Device according to any one of claims 1 to 15, characterized in that the porous mass has an encapsulated pressure drop of less than 3.0 mm of water / mm in length. Device according to any one of claims 1 to 16, characterized in that the binder is configured to undergo repeated heat cycles without structural deformation. 18. Device according to claim 17, characterized in that the binder is configured to undergo less than 10% change in pressure drop. 19. Device according to any one of claims 1 to 18, characterized in that the porous mass is configured to provide a multipath air flow. Device according to any one of claims 1 to 19, characterized in that the support and the aerosol cooling element are combined in a single unit and in which the pressure drop is substantially the same as compared to the support and cooling elements aerosol dispensers as separate units.