CN219920257U

CN219920257U - Device for producing a nozzle, a filter element or a cooling element for an aerosol-generating article

Info

Publication number: CN219920257U
Application number: CN202320099830.9U
Authority: CN
Inventors: 阿里耶夫·拉赫曼; 罗西·安娜·库尔比; 苏迪尔曼·维达托; 武尔扬托; 苏利什焦·维多多
Original assignee: Essentra Filter Products Development Co Pte Ltd
Current assignee: Philtron Ltd; Zhongyan Yishenghua Xiamen Filter Rod Co ltd
Priority date: 2021-05-13
Filing date: 2021-09-30
Publication date: 2023-10-31
Anticipated expiration: 2031-09-30
Also published as: EP4337039A1; CN115336788A; KR20240007936A; US20240237711A1; WO2022238717A1; JP2024517030A; CN217309139U; CN218921610U; CN218999514U; GB202106836D0

Abstract

The utility model discloses a mouthpiece, filter element or cooling element for an aerosol-generating article, comprising: a first section comprising a longitudinally extending core of filter material having an outer surface and an inner surface, the inner surface defining a channel extending longitudinally from an end of the first section; a second section comprising a longitudinally extending core formed of a filter material; wherein the first section is adjacent to and integral with the second section; wherein the channel has a non-circular transverse cross-section that varies in the longitudinal direction by rotation about the longitudinal axis of the first section. The utility model also relates to a filter comprising a filter element for an aerosol-generating article, a multipart stick comprising a plurality of suction nozzles, filter elements or cooling elements, an aerosol-generating article comprising a suction nozzle, filter element or cooling element or filter, and an apparatus for manufacturing a suction nozzle, filter element or cooling element for an aerosol-generating article.

Description

Device for producing a nozzle, a filter element or a cooling element for an aerosol-generating article

The present utility model is a divisional application of application having application date 2021, 09/30, national application number 202221419408.9, entitled "filter element, filter, multipart stick, aerosol-generating article, apparatus for manufacturing a mouthpiece, filter element or cooling element for an aerosol-generating article".

Technical Field

The present utility model relates to a filter element. The present utility model relates to a filter, a multipart rod, an aerosol-generating article, an apparatus for manufacturing a mouthpiece, a filter element or a cooling element for an aerosol-generating article.

Background

The use of tube filter elements and tube suction nozzles in smoking articles is known in the art. Typically, a candle filter element includes a cylindrical core formed of filter material including channels extending longitudinally from ends of the cylindrical core. A candle filter element is typically included as part of the multi-segment filter, and the candle filter element is typically located at the mouth end of the smoking article to provide a unique end appearance. Thus, existing candle filters require the step of assembling the candle filter element with additional filter segments, which requires a complex assembly process. When incorporated into a smoking article, the tubular filter may cause smoke to leave the filter in a concentrated flow directed towards the tongue of the user during use.

There is a need for a tube filter element that does not require assembly with additional filter segments and that can be manufactured in a single continuous process. There is also a need for a tube filter with different organoleptic properties.

In recent years, non-combustible smoking products have become increasingly popular. Such products include heated tobacco products, also known as tobacco heating products or heated non-combustible products. Heating tobacco products generally include tobacco, a heating element, and a power source. The heating element heats the tobacco to generate an aerosol, which is delivered to a user via the mouthpiece. The mouthpiece may be used to mimic the sensory aspects of a conventional smoking article filter. In addition, some heated non-combustion products include cooling elements that may cool the aerosol before it reaches the mouthpiece. The cooling element is typically a separate element that needs to be assembled with other components that form the non-combustible smoking product.

Disclosure of Invention

In a first aspect of the utility model there is provided a mouthpiece or filter element for an aerosol-generating article comprising: a first section comprising a longitudinally extending core of filter material having an outer surface and an inner surface, the inner surface defining a channel extending longitudinally from an end of the first section; a second section comprising a longitudinally extending core formed of a filter material; wherein the first section is adjacent to and integral with the second section; wherein the channel has a non-circular transverse cross-section that varies in the longitudinal direction by rotation about the longitudinal axis of the first section.

The channel may have the following transverse cross-section: the transverse cross-section is a cross, rectangular or modified circle having one or more projections extending towards the centre of the circle.

The channels are configured such that a transverse cross-section of the channels at a first point along the length of the longitudinally extending core formed of filter material may be rotated relative to adjacent points along the length of the longitudinally extending core formed of filter material. It should be appreciated that the transverse cross-section of the channel may be rotated more or less than 360 degrees along the length of the channel.

Applicants have found that during use, aerosol in the form of smoke passing through a mouthpiece or filter element is caused to take a non-linear path, such as a helical or spiral path, through the channel. It has been found that in use, the mouthpiece or filter element of the present utility model produces a different smoking sensation in which the smoke sensation is more dispersed within the mouth than a standard tube filter element or mouthpiece. Without wishing to be bound by theory, it is believed that non-linear paths taken by smoke, such as helical or spiral paths, can lead to differences in these organoleptic properties.

Applicants have found that having a second section adjacent to and integral with the first section eliminates the need to use an additional separate filter section to impart additional characteristics or functionality to the filter element. The suction nozzle or filter element of the utility model can be manufactured in a single continuous process, which means that no assembly of multiple filter segments is required. However, it should be understood that the suction nozzle or filter element of the present utility model is still compatible with being incorporated into a multi-stage filter, if desired.

The channel may be a tube or a hole. Preferably, the channels are surrounded by a filter material.

The non-circular transverse channel cross-section may be varied in the longitudinal direction by rotation about a longitudinal axis of the channel, for example a central longitudinal axis of the channel.

The second section may comprise a longitudinally extending core formed of a continuous or homogeneously dispersed filter material. Preferably, the second section does not comprise a channel such as a tube or a hole.

The first section may be located at the mouth end of the filter element or nozzle, for example such that the channel is visible when the filter element or nozzle is in use.

The inner surface may comprise one or more ridges extending helically around the longitudinal axis of the first section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel. The one or more ridges protrude from the inner surface. The one or more ridges may be formed in the inner surface. The one or more ridges may be integral with the inner surface.

In the case where the channel has a transverse cross-section that is a modified circle having one or more projections extending from the edges of the circle toward the center of the circle, then the channel has the following generally cylindrical shape: wherein the inner surface defining the channel comprises one or more ridges extending helically around the longitudinal axis of the first section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel.

In the case where the channel has a transverse cross-section that is cross-shaped, the channel has the following generally cylindrical shape: wherein the inner surface defining the channel comprises four ridges extending helically around the longitudinal axis of the first section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel.

The suction nozzle or filter element may comprise: a first section comprising a longitudinally extending core of filter material having an outer surface and an inner surface, the inner surface defining a channel extending longitudinally from an end of the second section; a second section comprising a longitudinally extending core formed of a filter material; wherein the inner surface comprises one or more ridges extending helically about the longitudinal axis of the first section; and wherein the first section is adjacent to and integral with the second section.

The applicant has found that in use, the presence of one or more ridges extending helically around the longitudinal axis of the first section results in a different and improved smoke mouth feel compared to a standard tubular mouthpiece or filter element having a constant transverse cross section in the longitudinal direction.

Applicants have found that during use, aerosol in the form of smoke passing through a mouthpiece or filter element is caused to take a helical or spiral path through the channel. It has been found that in use, the mouthpiece or filter of the present utility model produces a different smoking sensation in which the smoke sensation is more dispersed within the mouth than a standard tube filter element or mouthpiece. Without wishing to be bound by theory, it is believed that the helical path taken by smoke results in differences in these organoleptic properties.

The applicant has also found that the inclusion of one or more ridges extending helically around the longitudinal axis of the or each channel may result in improved filtration compared to a filter element comprising channels having a uniform transverse cross-section in the longitudinal direction. The one or more ridges may increase the surface area of the inner surface of the or each channel, which results in increased surface area for adsorption.

Applicants have found that having a second section adjacent to and integral with the first section eliminates the need to use an additional separate filter section to impart additional characteristics or functionality to the filter element. The suction nozzle or filter element of the utility model can be manufactured in a single continuous process, which means that no assembly of multiple filter segments is required. However, it should be understood that the suction nozzle or filter element of the present utility model is still compatible with being incorporated into a multi-stage filter.

The channel may extend along the entire length of the first section.

Preferably, each longitudinally extending core formed of filter material is generally cylindrical, for example cylindrical. The longitudinally extending core formed of filter material may have a circumference of from 14mm to 25 mm.

The first section may have a non-constant wall thickness due to the presence of one or more ridges on the inner surface of the core. The wall thickness at the narrowest point may be from 0.6mm to 2.3mm, for example 1.8mm to 2.3mm. Wall thickness is defined herein as the distance between the outer and inner surfaces of the longitudinally extending core.

The channel may be substantially cylindrical. It should be appreciated that while the channel may be generally cylindrical, the transverse cross-section will not be circular, e.g., the transverse cross-section may be cross-shaped, rectangular, or a modified circle including one or more protrusions extending from the edges of the circle toward the center of the circle.

Preferably, the channel extends from the mouth end of the core formed of filter material.

The diameter of the channel at its widest point may be from 1.5mm to 6mm, for example 1.5mm to 5mm.

The diameter of the channel at its widest point may be from 2mm to 6mm, for example 3mm to 5mm, for example 3.4mm to 4.8mm, for example from 3.5mm to 4.7mm, for example 3.7mm or 4.5mm.

The one or more ridges may extend along a portion of the length of the inner surface of the core. Preferably, the ridge extends along the full length of the inner surface of the core. The ridge may have a width of 1.0mm to 2mm, for example 1.2mm to 1.7mm, for example 1.5 mm. The ridge may have a height of from 0.2mm to 1.5 mm.

The inner surface of the core may comprise one, two, three or four ridges extending helically around the longitudinal axis of the first section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel. Preferably, the inner surface of the core comprises two ridges extending helically around the longitudinal axis of the first section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel.

The first section may comprise more than one channel extending longitudinally from the end of the core, for example two, three or four channels.

The outer circumference of the suction nozzle or filter element may be between 14mm and 25 mm.

The length of the suction nozzle or filter element may be between 4.0mm and 50mm, for example between 5mm and 32 mm.

The suction nozzle or filter element may comprise a third section comprising a longitudinally extending core formed of filter material; wherein the third section is adjacent to and integral with the first section such that the first section is located between the third section and the second section.

Alternatively, the suction nozzle or filter element may comprise a third section comprising a longitudinally extending core of filter material having an outer surface and an inner surface, the inner surface defining a channel extending longitudinally from an end of the third section.

The third section channel may have a non-circular transverse cross-section that varies in the longitudinal direction by rotation about the longitudinal axis of the third section.

The third section channel may have the following transverse cross-section: the transverse cross-section is a cross, rectangular or modified circle having one or more projections extending towards the centre of the circle. The third section may be adjacent to and integral with the second section such that the second section is located between the first section and the third section.

The inner surface of the third section channel may comprise one or more ridges extending helically around the longitudinal axis of the third section.

The third section may be adjacent to and integral with the second section such that the second section is located between the first section and the third section.

Preferably, the third section channel extends from the free end of the third section. The third section may be substantially identical to the first section. The third section channel is configured such that a transverse cross-section of the third section channel at a first point along the length of the longitudinally extending core formed of filter material may be rotated relative to an adjacent point along the length of the longitudinally extending core formed of filter material. It should be appreciated that the transverse cross-section of the channel may be rotated more or less than 360 degrees along the length of the channel.

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

The inner surface of the third section may comprise one or more ridges extending helically around the longitudinal axis of the third section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel. The one or more ridges protrude from the inner surface. The one or more ridges may be formed in the inner surface. The one or more ridges may be integral with the inner surface.

In the case where the third section channel has a transverse cross-section that is a modified circle having one or more projections extending from the edge of the circle towards the centre of the circle, then the channel has the following generally cylindrical shape: wherein the inner surface defining the channel comprises one or more ridges extending helically around the longitudinal axis of the third section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel.

In the case where the third section channel has a transverse cross-section that is cross-shaped, the channel has the following generally cylindrical shape: wherein the inner surface defining the channel comprises four ridges extending helically around the longitudinal axis of the third section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel.

The third section channel may extend along the entire length of the third section.

The third section may have a non-constant wall thickness due to the presence of one or more ridges on the inner surface of the core. The wall thickness at the narrowest point may be from 0.6mm to 2.3mm, for example 1.8mm to 2.3mm. Wall thickness is defined herein as the distance between the outer and inner surfaces of the longitudinally extending core.

The third section channel may be substantially cylindrical. It should be appreciated that while the channel may be generally cylindrical, the transverse cross-section will not be circular, e.g., the transverse cross-section may be cross-shaped, rectangular, or a modified circle including one or more protrusions extending from the edges of the circle toward the center of the circle.

The diameter of the third section channel at its widest point may be from 1.5mm to 6mm, for example 1.5mm all 5mm.

The diameter of the third section channel at its widest point may be from 2mm to 6mm, for example 3mm to 5mm, for example 3.4mm to 4.8mm, for example from 3.5mm to 4.7mm, for example 3.7mm or 4.5mm.

The one or more ridges may extend along a portion of the length of the inner surface of the core. Preferably, the ridge extends along the full length of the inner surface. The ridge may have a width of 1.0mm to 2mm, for example 1.2mm to 1.7mm, for example 1.5 mm. The ridge may have a height of from 0.2mm to 1.5 mm.

The inner surface of the third section core may comprise one, two, three or four ridges extending helically around the longitudinal axis of the third section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel. Preferably, the inner surface of the third section core comprises two ridges extending helically around the longitudinal axis of the third section, e.g. around the longitudinal axis of the channel, e.g. around the central longitudinal axis of the channel.

In case the filter element or the suction nozzle has only a first section and a second section, the first section may have a length of from 5mm to 10mm, e.g. 7 mm. The second section may have a length of from 15mm to 35mm, for example 10 mm. In case the filter element or the suction nozzle has a first section, a second section and a third section, the length of the first section, the second section and the third section may each independently be from 5mm to 15mm, e.g. 11mm.

Preferably, the first, second and third sections, if present, comprise the same type of filter material.

The filter material may be a material commonly used in the manufacture of tobacco smoke filters, such as a filamentary material, a fibrous material, a mesh material or an extruded material. The filter material may be a natural or synthetic filament tow, for example cotton or a polymer such as polyethylene, polypropylene or cellulose acetate tow.

The filter material may be a thermoplastic or other spinnable polymer such as polypropylene, polyethylene terephthalate, or polylactic acid. For example, the filter material may be natural or synthetic staple fibers, cotton linters, mesh materials such as paper (typically creped paper) and synthetic nonwovens, as well as extruded materials (e.g., starch, synthetic foam). Preferably, the filter material is a material that can be hardened using a plasticizer. Preferably, the filter material comprises cellulose acetate filaments.

The total denier of the filter material may be from about 20,000g/9000m to 100,000g/9000m, for example 20,000g/9000m to 80,000g/9000m, for example 20,000g/9000m to 50,000g/9000m.

Where the filter material is formed from a single bundle of filaments, the total denier of the filter material may be from about 20,000g/9000m to 50,000g/9000m, for example from 30,000g/9000m to 40,000g/9000m, for example from 30,000g/9000m to 38,000g/9000m, for example 30,000g/9000m, 32,000g/9000m, 33,000g/9000m, 37,000g/9000m or 40,000g/9000m.

Where the filter material is formed from two bundles of filaments, the filter material may have a total denier of from about 40,000g/9000m to 100,000g/9000m, for example from 60,000g/9000m to 80,000g/9000m, for example from 60,000g/9000m to 76,000g/9000m, for example 60,000g/9000m, 64,000g/9000m, 66,000g/9000m, 74,000g/9000m or 80,000g/9000m.

The filament denier may be from 5g/9000m to 9g/9000m, for example 5g/9000m, 7.3g/9000m, 8g/9000m or 9.0g/9000m.

Filter materials are generally described with reference to filament denier, total denier and fiber cross section. For example, the filter material may comprise a tow having the following denier: 8.0Y40, 8.0Y32, 7.3Y33 or 9.0Y37. For example, a filter material of denier 8.0Y40 means: the filament denier was 8.0g/9000m, the total denier was 40000g/9000m, and the filament had a Y-shaped cross section.

The filter material may include a plasticizer. The filter material may include a plasticizer in an amount of about 12% to 24% by weight of the filter material and plasticizer, such as in an amount of about 14% to 22%, such as about 16% to 20%, such as about 17% to 19%, such as about 18% by weight of the filter material and plasticizer.

The amount of plasticizer present in the mouthpiece or filter element is calculated by the general formula set forth below as a percentage of the total weight of filter material and plasticizer.

In the case of fibrous filter materials such as filament tows, plasticizers are used to rigidify the fibers of the filter material. Stiffening the fibers of the filter material may improve the shape definition (shape definition) of the filter element, and in particular the definition of the channels. For example, the filter material may include plasticized fibers such as plasticized tows, such as plasticized cellulose acetate tows. The formation of plasticized tows is known in the art. The plasticizer may be, for example, glyceryl triacetate, 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 filter material may optionally include an adhesive material. The filter material may optionally include a water-soluble adhesive material. Examples of the water-soluble material include water-soluble polymer materials such as polyvinyl alcohol, polyvinylpyrrolidone, polyvinyl ether, starch, polyethylene glycol, and polypropylene glycol; mixtures of water-soluble binders with plasticizers such as glyceryl triacetate, triethylene glycol diacetate (TEGDA) or polyethylene glycol (PEG); a hot melt water soluble adhesive in particulate form. Inclusion of a water-soluble binder material may further enhance the ability of the filter to degrade easily and rapidly, for example, under ambient conditions.

The filter material may include additives. The additive may be a particulate additive. The particulate additive may be any particulate additive suitable for use in a smoke filter, such as activated carbon, zeolite, ion exchange resins (e.g., weakly basic anion exchange resins), sepiolite, silica gel, alumina, molecular sieves, carbonaceous polymer resins, and diatomaceous earth. The particulate additive may be a mixture of two or more materials. The additive may be a pigment, such as a pearlescent pigment or a thermochromatic pigment.

The additive may comprise a smoke modifying agent (e.g. a flavouring agent). The flavoring agent may be menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc. The smoke modifying agent (e.g. flavouring agent) may be applied to the filter material in liquid form. The smoke modifying agent (e.g. flavouring agent) may be liquefied, for example by heating above the melting point, for example by mixing with a liquid carrier, prior to application to the filter material. The smoke modifying agent (e.g. flavouring agent) may be mixed with the plasticiser and applied together with the plasticiser, for example by spraying the mixture of smoke modifying agent (e.g. flavouring agent) and plasticiser onto the filter material. Preferred smoke modifying agents (e.g. flavouring agents) are menthol or clove.

The mouthpiece or filter element may be used as part of a tobacco smoke filter or a filter for non-tobacco smokable material. The mouthpiece or filter element may be used as part of a non-combustible tobacco product, such as a tobacco heating product device.

The mouthpiece or filter element of the present utility model may be incorporated into smoking articles such as cigarettes, cigarillos, cigars and the like. The mouthpiece or filter element of the present utility model may be incorporated into a tobacco heating product or an electronic cigarette. The mouthpiece or 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.

The suction nozzle or filter element of the present utility model may be incorporated into a multi-segment filter as a single segment. For example, a suction nozzle or filter element according to any of the statements listed above may be connected with a further filter element comprising an additive, such as a particulate additive, e.g. activated carbon particles. The mouthpiece or filter element of the present utility model may be connected to a filter element comprising a capsule, e.g. a frangible capsule, e.g. a capsule containing a flavouring agent. The mouthpiece or filter element of the present utility model may be coupled to a filter element containing a flavoring agent (e.g., menthol) or multiple flavoring agents.

In another aspect of the utility model there is provided a filter for an aerosol-generating article, such as a tobacco smoke filter, the filter comprising a filter element according to any of the statements set out above. Filters, such as tobacco smoke filters, may also include one or more additional filter elements. Such a filter comprising more than one filter element may be referred to as a multi-stage filter.

The one or more further filter elements may comprise a longitudinally extending core formed of filter material as defined above. The one or more additional filter elements may include additives.

The one or more additional filter elements may include a fully encapsulated (e.g., embedded) pocket of additive embedded therein. The additive may be a particulate additive such as activated carbon (see above), for example encapsulated within the filter material in a separate pocket or pod formed from particles of the particulate additive, the separate pocket or pod being substantially separate from and completely encapsulated within the filter material. In another example, the fully encapsulated (e.g., embedded) pouch of additive may be a frangible capsule or capsules or one or more frangible microcapsules. The capsules or microcapsules may contain a variety of media-for example smoke modifiers such as flavourants (e.g. those disclosed above) and/or liquids, solids or other materials, for example materials to assist in smoke filtration.

The one or more further filter elements may comprise a flavouring agent provided in and/or on the thread. "flavor wire" filter elements are known in the art. Such filter elements incorporate a generally longitudinally aligned string or belt element therein which carries an aerosol modifying agent such as a flavoring agent.

The filter may comprise an outer wrapper, such as plugwrap (plugwrap), around the filter element or elements. The wrapper may be paper, for example, breathable paper. The wrapper may have a weight of from 20 to 50 grams per square meter, for example from 27 to 35 grams per square meter. Particulate additives such as those described above may be applied to a wrapper or plug wrap surrounding the filter material, for example as described in GB 2261152. The further filter element may be wrapped by an outer wrapper, such as plug wrap, surrounding the further filter element. The filter element defined according to any of the statements set out above and the further filter element may be together wrapped by an outer wrapper, such as plugwrap. An overwrap may be used to connect the filter elements and secure the filter elements in place.

In another aspect of the utility model there is provided an aerosol-generating article comprising a filter, filter element or mouthpiece 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 formed from a smoking material, such as a tobacco smoking material. Generally, in the case of a smoking article comprising a smoking material, the smoking article comprises a mouthpiece according to any statement listed above. The smoking article may further comprise a tipping wrapper, such as tipping paper. The tipping wrapper connects the wrapped rod formed of smoking material to the rod of smoking material to the filter or mouthpiece by engaging around the filter or mouthpiece and the adjacent end of the wrapped rod formed of smoking material. The tipping wrapper may be configured to expose a portion of the exterior surface of the filter/nozzle or filter wrapper. The filter may be connected to a wrapped rod formed of smoking material by a complete tipping wrapper that engages around the entire filter or mouthpiece length and adjacent ends of the rod formed of smoking material.

The mouthpiece, filter element, filter or smoking article according to the utility model may be unvented or may be aerated by methods known in the art, for example by using a pre-perforated or air permeable filter wrap (plugwrap) or tipping wrapper (tipping paper) and/or by laser perforation of the filter wrap and/or tipping wrapper. A mouthpiece, filter element or smoking article according to the present utility model may be ventilated by laser perforation of a longitudinally extending core formed of filter material, and, if present, a wrapper (plugwrap) and tipping wrapper (tipping paper). The vented complete tipping wrapper (tipping paper) may also be inherently air-permeable or may be provided with ventilation holes, and for aerated products in which both a filter wrapper (plug wrap) and a tipping wrapper (tipping paper) are present, the ventilation through the tipping wrapper (tipping paper) will generally be aligned with the ventilation through the filter wrapper (plug wrap). The ventilation holes through the filter wrap (plugwrap) or through the tipping wrapper (tipping paper) or both can be made during production of the mouthpiece, filter or filter element by laser perforation.

In another aspect of the utility model, a multipart wand is provided comprising a plurality of suction nozzles or filter elements according to the utility model arranged end to end in mirrored relationship.

The aerosol-generating article may be a heated aerosol-generating system.

According to any of the statements set forth above, the heated aerosol-generating system may comprise a rod formed from tobacco material, a heating element, a power source, one or more cooling elements, and a mouthpiece or filter element. The one or more cooling elements may be positioned downstream of the heating element and the tobacco rod. In use, the tobacco rod is heated to thereby produce a heated aerosol. The heated aerosol then passes through the one or more cooling elements, which serve to cool the aerosol before it passes through the mouthpiece and into the user's mouth.

In this context, aerosol-generating articles may include smoking articles, such as cigarettes, cigars, cigarillos, self-wrapping cigarettes, and the like; heating tobacco products, such as heating non-combustion devices, tobacco heating devices, and the like; and E-cigarettes.

In another aspect of the utility model, there is provided a cooling element for an aerosol-generating article comprising: a first section comprising a longitudinally extending core of filter material having an outer surface and an inner surface, the inner surface defining a channel extending longitudinally from an end of the first section; a second section comprising a longitudinally extending core formed of a filter material; wherein the first section is adjacent to and integral with the second section; wherein the channel has a non-circular transverse cross-section that varies in the longitudinal direction by rotation about the longitudinal axis of the first section.

Applicants have found that during use, the heated aerosol passing through the cooling element is caused to take a helical or spiral path through the or each passage. Without wishing to be bound by theory, it is believed that the helical path taken by the heated aerosol cools the aerosol.

The cooling element may comprise: a first section comprising a longitudinally extending core of filter material having an outer surface and an inner surface, the inner surface defining a channel extending longitudinally from an end of the second section; a second section comprising a longitudinally extending core formed of a filter material; wherein the inner surface comprises one or more ridges extending helically about the longitudinal axis of the first section; and wherein the first section is adjacent to and integral with the second section.

The channel may extend along the entire length of the first section.

The cooling element may comprise more than one channel extending longitudinally from the end of the core, for example two, three or four channels.

The cooling element may be between 14mm and 25 mm.

The length of the cooling element may be between 4.0mm and 50mm, for example between 5mm and 32 mm.

The cooling element may comprise a third section comprising a longitudinally extending core formed of filter material; wherein the third section is adjacent to and integral with the first section such that the first section is located between the third section and the second section.

The third section channel may have a non-circular transverse cross-section that varies in the longitudinal direction by rotation about the longitudinal axis of the third section. The channel may have the following transverse cross-section: the transverse cross-section is a cross, rectangular or modified circle having one or more projections extending towards the centre of the circle. The third section may be adjacent to and integral with the second section such that the second section is located between the first section and the third section.

The diameter of the third section channel at its widest point may be from 1.5mm to 6mm, for example 1.5mm to 5mm.

The channel in the first or third section may for example comprise a housing, a heating element.

The applicant has found that a cooling element comprising a first section, a second section and a third section as described herein can house a heating element within a channel in the first section or the third section. In this case, the second and remaining sections may be used to cool the aerosol formed by the heating element.

In the case of a cooling element having only a first section and a second section, the first section may have a length of from 5mm to 10mm, for example 7 mm. The second section may have a length of from 15mm to 35mm, for example 10 mm. In case the filter element or the suction nozzle has a first section, a second section and a third section, the length of the first section, the second section and the third section may each independently be from 5mm to 15mm, e.g. 11mm.

In the case of fibrous filter materials such as filament tows, plasticizers are used to rigidify the fibers of the filter material. Stiffening the fibers of 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 include plasticized fibers such as plasticized tows, such as plasticized cellulose acetate tows. The formation of plasticized tows is well known in the art. For example, the plasticizer may be, for example, glyceryl triacetate, 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 filter material may include additives. The additive may be a pigment, such as a pearlescent pigment or a thermochromatic pigment.

The additive may include an aerosol modifier (e.g., a flavoring agent). The flavoring agent may be menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc. Aerosol modifiers (e.g., flavoring agents) may be applied to the filter material in liquid form. The aerosol modifier (e.g., flavoring agent) may be liquefied prior to application to the filter material, e.g., by heating above the melting point, e.g., by mixing with a liquid carrier. The aerosol modifier (e.g., flavoring agent) may be mixed with the plasticizer and applied with the plasticizer, for example, by spraying a mixture of the aerosol modifier (e.g., flavoring agent) and plasticizer onto the filter material. Preferred aerosol modifiers (e.g. flavouring agents) are menthol or clove.

The cooling element of the present utility model may be used as part of an aerosol-generating article, for example, the cooling element may form part of a heated tobacco product.

In another aspect of the utility model, an aerosol-generating article is provided that includes a cooling element according to any of the statements set forth herein.

The aerosol-generating article may be a heated aerosol-generating system. The heating aerosol-generating system may comprise a rod formed from tobacco material, a heating element, a power source, one or more cooling elements according to any of the statements listed above, and a mouthpiece or filter element, for example, according to any of the statements listed herein. The one or more cooling elements may be positioned downstream of the heating element and the tobacco rod. In use, the tobacco rod is heated to thereby produce a heated aerosol. The heated aerosol then passes through the one or more cooling elements, which serve to cool the aerosol before it passes through the mouthpiece and into the user's mouth.

In the case where the cooling element comprises a first section, a second section and a third section, the heating element may be housed within a channel in the first section or the third section. The second and remaining sections are for cooling the heated aerosol in use.

In another aspect of the utility model, a multi-part rod is provided comprising a plurality of cooling elements according to the utility model arranged end-to-end in mirrored relation.

In another aspect of the utility model, there is provided an apparatus for manufacturing a mouthpiece, a filter element or a cooling element for an aerosol-generating article, the apparatus comprising: a forming chamber having an inlet for receiving filter material and an outlet for discharging rods formed of filter material; forming a rod; wherein the forming bar is configured to rotate; wherein the forming chamber includes a curing zone extending longitudinally along at least a portion of the length of the forming chamber; and wherein the forming bar is configured to move longitudinally (reciprocate) between a first position in which an end of the forming bar is at an end of the curing zone and the forming bar extends along the entire length of the curing zone and a second position in which the end of the forming bar is longitudinally spaced from the first position and the forming bar does not extend along the entire length of the curing zone. It should be appreciated that the forming bar may also be configured to move between the second position and the first position such that the forming bar is configured to reciprocate between the first position and the second position.

The curing zone extends transversely along the width of the forming chamber.

The shaped rod may be configured to rotate about a central longitudinal axis of the shaped rod.

In the second position, the shaped rod may be configured not to extend into the curing zone.

The forming chamber may include a generally cylindrical hollow element, such as a cylindrical hollow element, an inner surface of which is configured to shape the filter material to form a cylindrical rod formed from the filter material. The forming chamber inlet may be longitudinally spaced from the forming chamber outlet.

The curing zone may extend along the entire width and the entire length of the forming chamber. Alternatively, the curing zone may extend along the entire width and part of the length of the forming chamber.

The forming bar may be configured to extend at least partially within the forming chamber. For example, the forming bar may be configured to protrude from the forming chamber. The forming bar may be configured to extend along the entire length of the forming chamber. For example, in the first position, the forming bar may be configured to extend along the entire length of the forming chamber, while in the second position, the forming bar may be configured to extend along a portion of the length of the forming chamber. In the second position, the forming bar may be configured not to extend into the forming chamber.

In the second position, the shaped rod may be configured to extend along a portion of the length of the curing zone. Alternatively, in the second position, the shaped rod may be configured to extend up to the curing zone but not into the curing zone.

Applicants have found that an apparatus comprising a forming rod configured to rotate about a longitudinal axis of a forming chamber and also configured to reciprocate longitudinally as described herein enables the production of a filter element or nozzle as described herein. It will be appreciated that controlling the rate at which the filter material advances into the forming chamber and the frequency of the forming rod reciprocation can control the relative lengths of the first, second and third sections (if present) forming the filter element or mouthpiece of the present utility model.

The forming bar may be coupled to a first motor for rotating the forming bar. The motor may be configured to rotate the forming bar.

The forming bar may be coupled to a second motor for moving the forming bar between the first position and the second position. The motor may be configured to move the forming bar between the first position and the second position. The forming bar may be coupled to the second motor via a cam.

Preferably, the shaped bar has a non-circular transverse cross-section. The non-circular transverse cross-section may be cross-shaped, rectangular, or a modified circular shape with one or more recesses.

Preferably, the apparatus comprises a heating element for applying heat to the filter material to thereby cure the filter material. Preferably, the forming chamber includes a heating element such that heat is applied to the filter material within the curing zone. The heating element may apply heat in the form of a jet of hot air, infrared radiation or steam. Preferably, the heating element comprises a steam element for applying steam to (or configured to apply steam to) the filter material. The forming chamber may include a vapor element for applying vapor (or configured to apply vapor) to the filter material within the curing zone. The vapor element may be used to apply vapor (or be configured to apply vapor) directly to the filter material within the curing zone. The forming chamber may include a vapor inlet for applying vapor to (or configured to apply vapor to) a filter material within the forming chamber, such as a filter material within a curing zone.

The apparatus may include a further heating element (e.g. in the form of a steam element) for applying heat (e.g. in the form of steam) to the rod formed from the filter material. Additional heating elements or steam elements may be longitudinally spaced from the outlet of the forming chamber.

The apparatus may include a filling nozzle for collecting the filter material before it enters the forming chamber (or configured to collect the filter material before it enters the forming chamber). The filling nozzle may comprise an inlet for applying fast moving air, such as compressed air, to the filter material.

The apparatus may include a filter material expansion element for or configured to expand the filter material prior to entering the forming chamber. For example, the filter material expansion element is used or configured to open the filter material. The shaped rod may extend through the filter material expansion element. Applicants have found that the inclusion of a filter material expansion element enables the filter material to twist as the forming rod rotates, which begins to form channels before the filter material enters the forming chamber and thereby helps to improve the definition of the channels.

The filter material expansion element may be located between the filling nozzle and the forming chamber. The filling nozzle and the forming chamber may be longitudinally spaced apart such that the filter material expands into the space between the filling nozzle and the forming chamber. The apparatus may include one or more air ejection elements for (or configured to) apply fast moving air, such as compressed air, to the filter material after it exits the forming chamber.

The apparatus may include a plasticizing element for (or configured to) apply a plasticizer to the filter material prior to the filter material entering the forming chamber. The plasticizing element may be positioned longitudinally away from the inlet of the forming chamber.

The apparatus may comprise a wrapping element for (or configured to) wrapping the longitudinally extending rods with a wrapper, such as plugwrap.

The apparatus may include a cutting element for (or configured to) cut a rod formed from the filter material.

In another aspect of the utility model, there is provided a method of manufacturing a mouthpiece, a filter element or a cooling element for an aerosol-generating article, the method comprising: advancing the filter material in a longitudinal direction; pulling the filter material into and through a forming chamber having an inlet for receiving the filter material and an outlet through which a rod formed of the filter material exits the forming chamber; wherein the forming chamber includes a curing zone extending longitudinally along at least a portion of the length of the chamber; longitudinally moving (e.g., reciprocally moving) the forming bar between a first position in which an end of the forming bar is at an end of the curing zone and the forming bar extends along the entire length of the curing zone and a second position in which the end of the forming bar is longitudinally spaced from the first position and the forming bar does not extend along the entire length of the curing zone; rotating the forming bar; such that in a first position the advancing filter material advances through a space defined by the inner surface of the forming chamber and the forming bar to form a first section comprising a longitudinally extending core formed of filter material having an outer surface and an inner surface, the inner surface defining a longitudinally extending channel having a non-circular transverse cross section that varies in the longitudinal direction by rotation about the longitudinal axis of the first section, and such that in a second position the filter material travels into a space defined by the end of the forming bar, the inner surface of the chamber and the end of the curing zone to form a second section comprising a longitudinally extending core formed of filter material; to thereby form a longitudinally extending rod of filter material having alternating first and second sections. It will be appreciated that the forming bar may also be movable between the second position and the first position such that the forming bar reciprocates between the first position and the second position.

The filter material may continue to advance.

Preferably, the curing zone extends along the width of the forming chamber.

The forming chamber may include a generally cylindrical (e.g., cylindrical) hollow element, such as a cylindrical hollow element, with an inner surface configured to shape the filter material into a cylindrical rod formed from the filter material. The generally cylindrical hollow element includes a curing zone extending laterally along a width of the generally cylindrical element and longitudinally along at least a portion of the generally cylindrical hollow element.

The outlet of the forming chamber may be longitudinally spaced from the inlet of the forming chamber.

The curing zone may extend along the entire length of the forming chamber. Alternatively, the curing zone may extend along part of the length of the forming chamber.

The forming bar may extend at least partially within the forming chamber. For example, the forming bar may protrude from the forming chamber. The forming bar may extend along the entire length of the forming chamber. For example, in the first position, the forming bar may extend along the entire length of the forming chamber, while in the second position, the forming bar may extend along a portion of the length of the forming chamber. In the second position, the forming bar may not extend into the forming chamber.

In the second position, the shaped rod may extend along a portion of the length of the curing zone. Alternatively, in the second position, the shaped rod may extend up to the curing zone but not into the curing zone.

It will be appreciated that controlling the rate at which the filter material advances into the forming chamber and the frequency of the forming rod reciprocation can control the relative lengths of the first, second and third sections forming the filter element or mouthpiece of the present utility model. The relative rate of advancement of the filter material and the frequency of reciprocation of the forming rod may be controlled by a controller using techniques known in the art.

The forming bar may be rotated by a first motor coupled to the forming bar.

The forming bar may be longitudinally moved (reciprocated) between the first and second positions by a second motor coupled to the forming bar.

Preferably, heat is applied to the filter material in the solidified region. The heat may be applied in the form of steam, hot air or infrared radiation. Preferably, the steam is applied directly to the filter material in the curing zone.

The heat is used to cure the filter material within the cure zone to thereby form a longitudinally extending rod of filter material, such as a longitudinally extending rod of filter material including longitudinally extending channels as described herein.

The method may include the step of applying a plasticizer to the filter material before the filter material is pulled into the forming chamber. A plasticizer may be applied to the filter material at the plasticizing station. The plasticizer may be sprayed onto the filter material using techniques known in the art. Alternatively, the filter material may be pre-plasticized by a separate plasticizing process.

The plasticizer may be applied such that the filter material includes plasticizer in an amount of about 12% to 24% by weight of the filter material and plasticizer, such as plasticizer in an amount of about 14% to 22% by weight of the filter material and plasticizer, such as about 16% to 20%, such as about 17% to 19%, such as about 18%.

The amount of plasticizer present in the filter material is calculated as a percentage of the total weight of filter material and plasticizer by the general formula set forth below.

The plasticizer may be, for example, glyceryl triacetate, triethylene glycol diacetate (TEGDA) or polyethylene glycol (PEG).

The filter material used in the method of the utility model may be defined in accordance with any statement herein.

The method may include the step of expanding the filter material prior to entering the forming chamber. The filter material may be expanded into a space prior to entering the forming chamber. The filter material may expand from a narrow stream formed by the filter material to a wider (more dispersed) stream formed by the filter material. The forming chamber may condense the expanded filter material to thereby form a rod of filter material as described above.

The shaped rod may extend through the expanded filter material.

The method may include the step of pulling the filter material into the filling nozzle prior to entering the forming chamber. The filter material may be pulled into the filling nozzle prior to the step of expanding the filter material. In this configuration, the step of expanding the filter material may include expanding the filter material into a space between the filling nozzle and the forming chamber. The filler jet may condense the filter material into a narrow stream formed by the filter material. Upon exiting the fill nozzle, the filter material may expand to form a wider (more dispersed) stream formed by the filter material.

The applicant has found that the step of expanding the filter material before it enters the forming chamber helps the filter material to twist as the forming rod rotates, which begins to form channels before the filter material enters the forming chamber and helps to improve the definition of the channels.

The method may include the step of cutting a longitudinally extending rod formed of filter material to form one or more filter elements or nozzles. It will be appreciated that longitudinally extending rods of filter material may be cut at regular intervals to form filter elements, suction nozzles or cooling elements according to the utility model. The cutting frequency may be determined according to the type of filter. The cutter may be controlled by a controller using techniques known in the art.

The cutting step may form a filter element, a suction nozzle or a cooling element having two or three sections as described herein. It will be appreciated that the timing of the cutting step, in combination with the speed at which the filter material advances, will determine whether the filter element, suction nozzle or cooling element being formed comprises two or three sections and the configuration of these sections.

The method may comprise the step of wrapping the longitudinally extending rod with a wrapper, for example, prior to the cutting step.

The method may include the step of applying fast moving air, such as compressed air, to the rod of filter material after the rod of filter material leaves the forming chamber. The applicant has found that applying rapidly moving air to the rods formed of filter material helps to further cure and harden the rods formed of filter material.

Drawings

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

fig. 1 is a perspective view of a suction nozzle, a filter element or a cooling element according to the utility model.

Fig. 2 is an end view of a suction nozzle, filter element or cooling element according to the present utility model.

Fig. 3 is a perspective view of a suction nozzle, a filter element or a cooling element according to the utility model.

Fig. 4 is a side view of a suction nozzle, a filter element or a cooling element according to the utility model.

Fig. 5 is a cross-sectional view of the suction nozzle, filter element or cooling element shown in fig. 3.

Fig. 6 is a cross-sectional view of a suction nozzle, a filter element or a cooling element according to the utility model.

Fig. 7 is a cross-sectional view of a suction nozzle, a filter element or a cooling element according to the utility model.

Fig. 8 is an end view of a suction nozzle, filter element or cooling element according to the present utility model.

Fig. 9 is a cross-sectional view of a suction nozzle, a filter element or a cooling element according to the utility model.

Fig. 10 is an end view of a suction nozzle, filter element or cooling element according to the present utility model.

Fig. 11 is a cross-sectional view of a suction nozzle, a filter element or a cooling element according to the utility model.

Fig. 12 is a perspective view of a suction nozzle, a filter element or a cooling element according to the present utility model.

Fig. 13 is a schematic view of an apparatus for manufacturing a suction nozzle, a filter element or a cooling element in use.

Fig. 14a and 14b are cross-sectional views of a part of an apparatus for manufacturing a suction nozzle, a filter element or a cooling element in use.

Detailed Description

Fig. 1 shows a perspective view of a mouthpiece, filter element or cooling element 100 for an aerosol generating device according to an embodiment of the utility model. The suction nozzle, filter element or cooling element 100 comprises a first section 110 and a second section 120. The first section 110 includes a longitudinally extending core 112 formed of filter material in the form of a cylindrical core formed of filter material. The filter material may be cellulose acetate, but it should be understood that other filter materials are suitable. The cylindrical core 112 formed of filter material forming the first section includes an outer surface 116 and an inner surface (shown at 118 in fig. 2). The outer surface 116 defines a cylindrical core and the inner surface 118 defines the channel 114. The channel 114 extends from the free end of the first section 110 and along the entire length of the first section 110. In the case of a filter element or a suction nozzle, the channel 114 extends from the mouth end. The channel 114 has a non-circular transverse cross-section and, as shown in fig. 1, is a modified circular shape with two protruding portions 119. The transverse cross-section varies in the longitudinal direction by rotation about the longitudinal axis of the first section 110, for example about the longitudinal axis of the channel 114. The protruding portion 119 is formed as a ridge extending helically around the longitudinal axis L (as shown in fig. 2). The ridge 119 extends along and protrudes from an inner surface 118 defining the channel 114. Two ridges 119 are integral with the inner surface 118 and are defined by the filter material constituting the core. As shown in fig. 1, the channel is centrally located with respect to the core 112.

The second section 120 is integral with the first section 110. The second section 120 comprises a longitudinally extending core 122 of filter material in the form of a cylindrical core of filter material. The filter material may be cellulose acetate, but it should be understood that other filter materials are suitable. The filter material forming the second section 120 is continuous and homogeneous. The filter material forming the second section 120 is the same type of filter material as the first section. The second section does not include a channel. A cylindrical core 122 formed of filter material is defined by an outer surface 126.

Fig. 2 shows an end view of the suction nozzle, filter element or cooling element shown in fig. 1, which also corresponds to an end view of the first section 110. Figure 2 shows the ridge 119 in more detail.

Fig. 3 shows a perspective view of the first section as shown in fig. 1. As shown in fig. 3, the core 112 extends along a longitudinal axis (L), and the channels 114 extend along the longitudinal axis L of the core 112.

Fig. 4 shows a side view of the first section along a plane defined by the y-axis and the L-axis in fig. 3.

Fig. 5 shows a cross-sectional view of the first section along the line A-A as shown in fig. 4. The channel transverse cross-section shown in fig. 5 comprises a modified circle having two diametrically opposed projections extending from the edges of the circle towards the centre of the circle. The diametrically opposed projections correspond to ridges 119 extending helically around the longitudinal axis of the first section 110. As shown in fig. 5, the transverse cross-section of the channel 114 is rotated relative to the channel cross-section shown at the end of the first section as shown in fig. 3.

The ridge 119 extends helically with respect to the longitudinal axis (L) of the first section 110, so that the position of the ridge 119 with respect to the outer circumference of the channel 114 varies along the length of the first section 110.

Fig. 6 shows another cross-sectional view of the first section 110 along line B-B as shown in fig. 4. As shown in fig. 6, the transverse cross-section of the channel 114 is rotated relative to both the transverse cross-section shown in fig. 5 and the end cross-section shown in fig. 3.

Fig. 7 shows a cross-sectional view of a first section of another filter element, suction nozzle or cooling element 200 according to the utility model. The filter element or nozzle 200 shown in fig. 7 is similar to the filter element or nozzle shown in fig. 5 and 6, but the filter element or nozzle 200 comprises four ridges 219, which ridges 219 extend helically around the longitudinal axis of the first section along the inner surface of the core 214.

Fig. 8 shows an end view and fig. 9 shows a cross-sectional view of a first section of another filter element, suction nozzle or cooling element 300 according to the utility model. The first section shown in fig. 7 and 8 is similar to the first section shown in fig. 1-6, but the first section shown in fig. 7 and 8 includes a channel 314 having a rectangular transverse cross-section. The transverse cross-section of the channel is varied in the longitudinal direction of the core by rotation about the longitudinal axis of the first section.

Fig. 10 shows an end view and fig. 11 shows a cross-sectional view of a first section of another filter element, suction nozzle or cooling element 400 according to the utility model. The first section shown in fig. 10 is similar to the first section shown in fig. 1-8, but the first section shown in fig. 10 and 11 includes a channel 414 having a cross-shaped transverse cross-section. The transverse cross-section of the channel is varied in the longitudinal direction of the core by rotation about the longitudinal axis of the first section.

Fig. 12 shows another filter element, suction nozzle or cooling element 500 according to the utility model. The filter element, nozzle or cooling element 500 is similar to the filter element, nozzle or cooling element shown in fig. 1, but includes a third section 130 integral with the second section. The first section 110 and the second section 120 are the same as described above with respect to fig. 1-6. The third section 130 is similar to the first section 110 and includes a longitudinally extending core of filter material in the form of a cylindrical core 132 of filter material. The cylindrical core 132 formed of filter material forming the third section includes an outer surface 136 and an inner surface. The outer surface 136 defines the cylindrical core 132 and the inner surface defines the channel 134. The channel 134 extends from the free end of the third section 130 and along the entire length of the third section 130. In the case of a filter element or a suction nozzle, the first section channel 114 extends from the mouth end. The channel 134 has a non-circular transverse cross-section and, as shown in fig. 1, is a modified circular shape with two protruding portions 139. The transverse cross-section is varied in the longitudinal direction by rotation about the longitudinal axis of the third section, for example about the longitudinal axis of the channel 134. The protruding portion 139 is formed as a ridge extending helically around the longitudinal axis. Ridge 139 extends along an inner surface defining channel 134, and ridge 139 protrudes from the inner surface. Two ridges 139 are integral with the inner surface and are defined by the filter material comprising the core. As shown in fig. 12, the channel is centrally located with respect to the core 132.

The applicant has found that the filter element shown in fig. 12 may be particularly suitable for heating tobacco products, as the channels in the first or third sections may contain heating elements, while the second and remaining sections, which do not contain heating elements, may provide for filtration of the aerosol and act as cooling elements for cooling the aerosol.

Any of the mouthpieces or filter elements shown in fig. 1-12 can form part of a filter that is included in a smoking article, such as a cigarette. Some smoking articles comprise a mouthpiece as described herein.

During use, the smoke travels through the nozzle or filter element and the smoke adopts a helical path within the channel, which means that the smoke emerging from the nozzle or filter element will continue to follow a helical path, for example in the mouth of the user. The spiral path taken by the smoke affects the taste of the smoke. The second section provides additional filtration of the smoke and may include additives to alter the characteristics of the smoke.

Any of the mouth or filter elements shown in fig. 1-12 may also form part of a heated tobacco product or an electronic cigarette.

The cooling element as shown in fig. 1-12 may form part of a heated aerosol-generating system that may form part of a non-combustible product such as a heated tobacco product. Heating aerosol-generating systems typically include a heating element, a power source, a tobacco rod, one or more cooling elements, and a mouthpiece. The cooling elements described herein may be incorporated into a heated aerosol-generating system between a mouthpiece and a tobacco rod. During use, the heating element heats the tobacco rod to form an aerosol. The aerosol then enters the cooling element and is cooled by the cooling element. Due to the configuration of the channels, the aerosol follows a spiral path through the cooling element, which reduces the temperature of the aerosol. In the case of the cooling element shown in fig. 12, the first or third section may house a heating element, thereby enabling the heating element and the cooling element to be included in a single product.

Fig. 13 is a schematic view of a method and apparatus for manufacturing a filter element, a suction nozzle or a cooling element as described in relation to fig. 1 to 12.

Referring to fig. 13, the apparatus includes a fill nozzle 20 configured to receive the filter material 10. A forming chamber 30 is longitudinally spaced from the filling nozzle. The space between the filling nozzle and the forming chamber defines a filter material expansion element in the form of a tow opening section (tow blooming section) 25 into which the filter material expands as it exits the filling nozzle 20. A forming rod in the form of a mandrel 60 extends longitudinally through the center of the filling nozzle 20, the tow opening section 25 and into the forming chamber 30. The spindle 60 is coupled to a first motor 70, the first motor 70 being configured to rotate the spindle about a central longitudinal axis of the spindle. The spindle is coupled with a second motor 80, and the second motor 80 is configured to reciprocate the spindle 60 in the longitudinal direction. It should be appreciated that to achieve rotation of the second motor 80 while reciprocating the spindle 60, the second motor 80 is coupled to the first motor 70 such that the second motor 80 will cause the first motor 70 to reciprocate with the spindle 60. Longitudinally spaced from the forming chamber 30 are air jet members 40, the air jet members 40 being configured to apply a rapidly moving air stream, such as a compressed air stream, to the rod 50 of filter material after the rod 50 of filter material exits the forming chamber 30. Longitudinally spaced from the air jet elements 40 are cutters 90, the cutters 90 being configured to cut the rods 50 formed of filter material into one or more filter elements, suction nozzles or cooling elements 100. The mandrel 60, filling nozzle 20, tow opening section 25, and forming chamber 30 are described in more detail below with reference to fig. 14a and 14 b.

A method of manufacturing the filter element, the suction nozzle or the cooling element 100 will now be described with reference to fig. 13. The tow 10 continues to advance in the longitudinal direction L. The tow may be cellulose acetate or other suitable filter material. The tow may be pulled from the bundle and may be pre-treated. For example, the plasticizer may be sprayed directly onto the tow at a plasticizing station (not shown) using methods known in the art. Alternatively, the plasticizer may have been applied to the tow bundle using a separate process prior to forming the tow bundle.

The tow 10 is advanced and flattened prior to entering the filling nozzle 20. The filling nozzle 20 is configured to pull and gather the tow. As the tow exits the filling nozzle 20 via the filling nozzle outlet, the tow expands into the gap between the outlet of the filling nozzle 20 and the inlet of the forming chamber 30. The tow 10 continues into the forming chamber 30, where the forming chamber 30 forms the tow into a longitudinally extending cylindrical rod 50 of filter material. The mandrel 60 extends longitudinally through the center of the filling nozzle 20, the tow expansion section 25 and into the forming chamber 30. The tow 10 is advanced around the mandrel 60 such that the mandrel 60 forms a longitudinally extending channel within the formed tow bar.

As the tow 10 passes through the forming chamber 30, rotation of the mandrel 60 forms a longitudinally extending channel, wherein the channel cross-section varies in the longitudinal direction by rotation about the central longitudinal axis of the channel.

The reciprocation of the mandrel 60 creates alternating first and second sections in a rod formed of filter material. The first section includes a longitudinally extending core formed of filter material, the core including an outer surface defining the core and an inner surface defining the channel, as described with respect to fig. 1-12. The second section includes a longitudinally extending core formed of filter material that is continuous and homogeneous and does not include channels.

The tow 10 is cured by steam in the forming chamber 30.

After the rod of filter material leaves the forming chamber 30, the rod of filter material is treated by the air jet member 40 by a fast moving air stream to further solidify the rod of filter material 50. The rod of filter material is then cut into individual filter elements, suction nozzles or cooling elements by a cutter 90.

The method and apparatus for shaping the rods formed of filter material, shaping the channels and forming the alternating first and second sections will now be described in more detail with reference to fig. 14a and 14 b.

Fig. 14a and 14b show the configuration of the filling nozzle, the tow expansion element and the forming chamber in use and in the first and second configurations.

Fig. 14a shows the spindle 60 in a first position. Fig. 14a shows a filling nozzle 20, the filling nozzle 20 being a funnel-shaped element with an inlet 24 and an outlet 26 for filter material, such as a tow 10, and an air inlet 22 for applying fast moving air to the tow 10. The inlet 24 of the filling nozzle 20 has a larger diameter than the outlet 26 such that the filling nozzle 20 is tapered. Fast moving air enters the filling nozzle 20 via the air inlet 22 and advances the tow longitudinally into the filling nozzle 20 and through the filling nozzle 20, where the tow is compressed into a cylinder. After the tow exits the filling nozzle via outlet 26, the tow 10 expands into a gap 25 between the filling nozzle outlet 26 and the inlet of the forming chamber, which is longitudinally spaced from the outlet 26 of the filling nozzle 20. The expanded tow continues longitudinally forward and into the forming chamber 30. The forming chamber includes an inlet into which the expanded tow enters and an outlet from which longitudinally extending rods 50 formed of filter material exit the forming chamber 30. The forming chamber 30 includes a steam inlet 32 through which steam enters the forming chamber 32. As shown in fig. 14a, the forming chamber includes a curing zone 35, the curing zone 35 extending along the longitudinal length of the forming chamber and across the width of the forming chamber 30. The mandrel 60 extends longitudinally through the center of the filling nozzle 20, the tow expansion element 25, and within the forming chamber 30 along the entire length of the curing zone 35 such that the ends of the mandrel 60 are in line with the ends of the curing zone 35.

In this first configuration, the tow 10 passes through the annular space between the mandrel 60 and the inner surface of the forming chamber 30, thereby forming a channel extending along the length of the curing zone 35. Steam is applied to the filter material within the forming chamber 30, thereby curing the filter material by hardening the filter material such that the following first section is formed: the first section includes a longitudinally extending core formed of filter material having an outer surface defining a longitudinally extending core formed of filter material and an inner surface defining a longitudinally extending channel.

Fig. 14b shows the spindle 60 in a second position, wherein the spindle 60 is located behind the spindle shown in fig. 14 a. In the second position, the end of the mandrel 60 is longitudinally distal from the first position in which the mandrel is shown in fig. 14a, and the mandrel 60 does not extend along the entire length of the cure zone 35. As shown in fig. 14b, mandrel 60 is withdrawn outside of curing zone 35. In the second position, the tow 10 enters the space defined by the end of the mandrel 60 and the inner surface of the forming chamber 30 to form a second section comprising a longitudinally extending core formed of filter material without channels.

As shown in fig. 14b, the first section has been advanced and retains the shape of the first section, including the channels, due to the steam applied to the filter material within the curing zone 35. Thus, the method forms alternating first and second sections. It will be appreciated that the filter material advances at a rate related to the speed at which the mandrel reciprocates such that alternating first and second sections are formed. The relative speeds of the advancing filter material and the mandrel may be controlled by a controller (not shown).

The shape of the mandrel determines the cross-sectional shape of the channel. For example, the rods used to manufacture the suction nozzle, filter element or cooling element shown in fig. 1-6 are cylinders comprising two diametrically opposed grooves extending along the length of the mandrel. The mandrel used to manufacture the suction nozzle, filter element or cooling element shown in fig. 7 is a cylinder with two pairs of diametrically opposed grooves. The mandrel used to manufacture the suction nozzle, filter element or cooling element shown in fig. 8 and 9 has a rectangular cross-section, and the mandrel used to form the suction nozzle, filter element or cooling element shown in fig. 10 and 11 has a cross-shaped cross-section.

The channel shape is defined by the mandrel as described above. During this method, the spindle is always rotating. The rotation of the mandrel as the filter material passes through the forming chamber forms a longitudinally extending channel, wherein the channel cross-section varies in the longitudinal direction by rotation about the central longitudinal axis of the channel. In the case of a spindle comprising grooves, such as in the case of a spindle for manufacturing a suction nozzle, a filter element or a cooling element as shown in fig. 1 to 6, the grooves in the spindle define ridges on the inner surface of the core defining the channels. Rotation of the spindle and thus rotation of the grooves causes ridges to be formed on the inner surface of the core defining the channels. The ridge extends along the inner surface and follows a helical path about the longitudinal axis of the channel. The pitch of the ridges can be varied by controlling the rotational speed of the spindle and the speed at which the tow is pulled through the forming chamber. The depth and width of each ridge may be modified by varying the depth and width of each groove in the mandrel. If additional ridges are desired, the mandrel may include additional grooves. For example, the suction nozzle, filter element, or cooling element shown in fig. 7 uses a spindle having four grooves.

The diameter of the channel at its widest point may be varied by varying the diameter of the rod at its widest point. Similarly, the diameter and shape of the core formed of the filter material may be changed by modifying the diameter and shape of the forming chamber.

The applicant has found that the inclusion of a tow expansion element can improve channel definition because the expanded tow can twist prior to entering the forming chamber, which aids in the formation of the channels as described above.

It should be appreciated that while the mandrel extends through the filler nozzle and tow opening sections in which channels may begin to form, the filter material does not cure because no heat is applied. This means that when the mandrel is withdrawn to the second position, a second section may still be formed which does not comprise a channel.

The cutting step is timed according to the type of filter element, suction nozzle or cooling element desired. For example, the cutting step may be timed to form a filter element, a suction nozzle or a cooling element comprising a first section and a section as shown in fig. 1. A rod formed of filter material may be cut through the center of each first section to thereby form a filter element, a suction nozzle, or a cooling element having first, second, and third sections, wherein the first and third sections are shorter than the second section. The rod may be cut such that each filter element, suction nozzle or cooling element comprises a first section, a second section and a third section having the same length.

Claims

1. An apparatus for manufacturing a mouthpiece, a filter element or a cooling element for an aerosol-generating article, the apparatus comprising:

a forming chamber having an inlet for receiving filter material and an outlet for discharging rods formed from the filter material; and

forming a rod;

wherein the forming bar is configured to rotate;

wherein the forming chamber includes a curing zone extending longitudinally along at least a portion of a length of the forming chamber;

and wherein the forming bar is configured to move longitudinally between a first position in which an end of the forming bar is at an end of the curing zone and the forming bar extends along the entire length of the curing zone and a second position in which the end of the forming bar is longitudinally spaced from the first position and the forming bar does not extend along the entire length of the curing zone.

2. The apparatus of claim 1, wherein the forming bar is coupled to a first motor for rotating the forming bar.

3. The apparatus of claim 1 or 2, wherein the forming bar is coupled to a second motor for moving the forming bar between the first position and the second position.

4. Apparatus according to claim 1 or 2, wherein the forming chamber comprises a hollow substantially cylindrical element for forming the filter material.

5. The apparatus of claim 1 or 2, wherein the shaped rod has a non-circular transverse cross section.

6. The apparatus of claim 5, wherein the non-circular transverse cross-section is cross-shaped, rectangular, or a modified circular shape having one or more recesses.

7. An apparatus according to claim 1 or 2, characterized in that the apparatus comprises a heating element for applying heat to the filter material.

8. An apparatus according to claim 1 or 2, characterized in that the apparatus comprises a steam element for applying steam to the filter material.

9. The apparatus of claim 8, wherein the forming chamber includes a vapor element for applying vapor to the filter material within the curing zone.

10. The apparatus according to claim 1 or 2, characterized in that the apparatus comprises a cutting element for cutting a rod formed of filter material.

11. An apparatus according to claim 1 or 2, characterized in that the apparatus comprises a plasticizing element for applying a plasticizer to the filter material before the filter material enters the forming chamber.