JP6039090B2 - Apparatus, system and associated method for forming a porous body for a smoke filter - Google Patents

Description

  The exemplary embodiments described herein relate to an apparatus, system, and related methods for producing a porous body that can be used in a smoke filter. Including.

  The US Centers for Disease Control and Prevention reports that over 300 billion cigarettes and 13 billion cigars were sold in the United States alone in 2012. Thus, there is a sustained demand for cigarettes and cigars worldwide.

  Increasingly, government regulations have the potential to require higher filtration efficiency in removing harmful components from tobacco smoke. In current cellulose acetate, higher filtration efficiency can be achieved by adding particles such as activated carbon at high concentrations to the filter, the concentration of which is increasing. However, increasing the concentration of particulates changes the suction characteristics for smokers.

  One measure of suction characteristics is the enclosed pressure drop. As used herein, the term “enclosed pressure drop” or “EPD” means that the sample is completely enclosed in the measurement device so that air cannot pass through the package and the volume flow rate is at the outlet. The difference in static pressure between the two ends of the sample when the air flow under steady conditions passes through the sample when it is 17.5 ml / sec at the end. EPD is herein referred to as method no. 41. In other words, a higher EPD value is that the smoker must suck the smoking device with greater force.

  Increasing filter effectiveness changed the EPD of the filter, so the general public, and therefore the manufacturer, was slow to adopt a significantly different technology. Thus, despite ongoing research, improved, more efficient, minimizing impact on suction characteristics while removing relatively high levels of certain components in mainstream cigarette smoke There remains an interest in developing compositions. In addition, such a solution must have the large-scale production methods necessary to meet the high consumption market for smoking.

The following figures are presented to illustrate certain specific embodiments of the invention and should not be construed as limiting embodiments. The subject matter disclosed herein is intended to encompass numerous modifications, alternatives, and form and functional equivalents that may occur to those skilled in the art and who may benefit from the disclosed invention. is there.
FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 4 is a non-limiting embodiment (not necessarily to scale) of a system for forming a porous body in accordance with at least one embodiment described herein. FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 4 is a non-limiting embodiment (not necessarily to scale) of a system for forming a porous body in accordance with at least one embodiment described herein. FIG. 3 illustrates a non-limiting embodiment of a system for forming a porous body in accordance with at least one embodiment described herein (not necessarily to scale). FIG. 6 shows an exemplary flow diagram of a method of manufacturing a coalesced filter rod in accordance with at least some embodiments described herein. FIG. 7 illustrates an example flow diagram for at least some methods described herein for forming a filter in accordance with at least some embodiments described herein.

    The exemplary embodiments described herein relate to an apparatus, system, and related methods for producing a porous body that can be used in a smoke filter. Including.

    An exemplary embodiment described herein is a highly productive porous body that can be used in a smoking device filter with enhanced filtration efficacy and acceptable suction characteristics of smoke stream components. Methods and apparatus (and / or systems) for manufacturing are provided.

    Porous bodies (as described in co-pending PCT application number PCT / US11 / 56388, filed October 14, 2011, the entire disclosure of which is incorporated herein by reference) generally have multiple contacts. It includes a plurality of binder particles (eg, polyethylene) and a plurality of active particles (eg, carbon particles or zeolite) that are mechanically bonded at points. The contact point can be an active particle-binder contact point, a binder-binder contact point, an active particle-active particle contact point, and any combination thereof. As used herein, the terms “mechanical coupling”, “mechanically coupled”, “physical coupling” and the like refer to a physical connection that holds two particles at least partially together. The mechanical bond is generally the result of sintering. As such, “mechanically bonding” as described herein includes embodiments in which a plurality of binder particles and a plurality of active particles are mechanically bonded at a plurality of sintered contact points. . The mechanical bond can be rigid or flexible depending on the bonding material. Mechanical bonding may or may not include chemical bonding. As used herein, the terms “particle” and “microparticle” are used interchangeably and include all known shapes of materials, eg, spherical and / or oval, substantially spherical and / or oval. Disc shape and / or thin plate shape, flake shape, ligament shape, needle shape, fiber shape, polygonal shape (for example, cube), irregular shape (for example, crushed stone shape), cut surface shape (for example, crystal shape) Or it should be understood that any of these may be included. Further non-limiting embodiments of the porous body are co-pending applications PCT / US2011 / 043264, PCT / US2011 / 043268, PCT / US2011 / 043269, all filed on July 7, 2012, And PCT / US2011 / 043271, the entire disclosure of which is hereby incorporated by reference.

    The porous body can be manufactured by various methods. For example, some embodiments include forming a matrix material (eg, active particles and binder particles) into a desired shape (eg, using a mold), heating the matrix material to bring the matrix material together A step of mechanically bonding and a step of finishing the porous body (for example, a step of cutting the porous body to a desired length) can be included. Among the various processes / steps involved in the production of porous bodies, the step of forming the matrix material into the desired shape while maintaining uniform dispersion and the heating step are two steps that limit the production of high productivity It may be. Accordingly, methods using a high concentration phase air feed can provide high productivity production of the porous bodies described herein (eg, from about 1 m / min to about 800 m / min, or from about 300 m / min to about 800 m / min. A preferred method for (min linear flow rate) can be included. In addition, methods that use rapid heating (eg, microwave heating, and optionally including microwave-enhancing additives and microwave heating in the matrix material), and optionally a preheating step (eg, indirect heating or heating) Can be included in several preferred methods for high productivity production of porous bodies as described herein. Further, in an additional preferred high productivity manufacturing embodiment, the rapid heating portion of the method is designed to sinter or mechanically bond a portion of the matrix material (eg, the outer portion). In some cases, secondary sintering or secondary heating can be used for quality control or to complete the sintering.

    As used herein, the term “smoking tool” refers to an article or tool that includes a cigarette, cigarette holder, cigar, cigar holder, pipe, water pipe, hookah, electronic smoking tool, hand-rolled cigarette and / or cigar. However, it is not limited to these.

    It should be noted that where “about” is provided herein for a number in a numerical list, the term “about” modifies each number in the numerical list. It should be noted that in the enumeration of some numbers of ranges, some listed lower limits may be greater than some listed upper limits. One skilled in the art will recognize that the selected sub-combination requires selection of an upper limit that exceeds the selected lower limit.

I. Methods and Apparatus for Forming Porous Materials Methods for forming porous materials can include continuous processing methods, batch processing methods, or continuous-batch hybrid processing methods. As used herein, “continuous processing” refers to the production or manufacture of materials without interruption. The material flow can be continuous, intermittent, or a combination of both. As used herein, “batch processing” refers to the production or manufacture of a material as a single component or group of components at a separate process location, after which the single component or group of components is It means to go to the process place. As used herein, “continuous-batch processing” refers to a mixture of continuous and batch, where several steps or series of steps are performed sequentially and the remaining steps are performed for each batch. .

  Generally, the porous body can be formed from a matrix material. As used herein, “matrix material” refers to precursors used to form a porous body, such as binder particles and active particles. In some embodiments, the matrix material can comprise, consist of, or consist essentially of binder particles and active particles. In some embodiments, the matrix material may include binder particles, active particles, and additives. Non-limiting examples of suitable binder particles, active particles and additives are presented herein.

  Forming the porous body generally involves forming the matrix material into a desired shape (eg, a shape suitable for incorporation into a smoking device filter, water filter, air filter, etc.) and at a plurality of contact points. A step of mechanically bonding (eg, sintering) at least a portion of the matrix material may be included.

  The step of forming the matrix material into a shape can include a mold. In some embodiments, the mold is a single piece or a collection of single pieces, which may or may not include a back end cap, plate or plug. In some embodiments, the mold may be a plurality of mold parts that when combined form a mold. In some embodiments, the mold parts may be joined together by a conveyor, belt, etc. In some embodiments, the mold parts are stationary along the material path, configured such that a conveyor, belt, etc. pass therethrough, and the mold expands and contracts radially to achieve the desired A degree of compression can be applied to the matrix material.

  The mold can have any cross-sectional shape, for example, round, substantially circular, oval, substantially oval, polygonal (eg, triangle, square, rectangle, pentagon, etc.), rounded Including but not limited to polygons with ends, donut shapes, etc., or any blended form thereof. In some embodiments, the porous body can have a cross-sectional shape that includes holes, the holes using one or more dies, by machining, by a suitably shaped mold, or any It can be formed by other suitable methods (e.g. decomposition of degradable materials). In some embodiments, the porous body can have a specific shape for a cigarette holder or pipe that is adjusted to fit within the cigarette holder or pipe to filter the smoke flow. Allowing consumers to reach through. When considering the shape of the porous body herein, for a conventional smoking device filter, the shape is the diameter or circumference of the cross section of the cylinder (where the circumference is the length of the circumference of the circle). Can be referred to). However, in embodiments where the porous body described herein is in a shape other than a precise cylinder, the term “circumference” means the perimeter of any shape of cross section, including circular cross sections. Must be understood as used.

  In general, the mold has a major axis direction and a radial direction perpendicular to the major axis direction, and can have a substantially cylindrical shape, for example. Those skilled in the art should understand how the embodiments presented herein can be replaced, where applicable, by types that cannot define the major axis and radial direction, for example, spheres and cubes. In some embodiments, the mold may have a cross-sectional shape that varies along the longitudinal direction, such as a conical shape, a shape that transitions from a square to a circle, or a helical shape. In some embodiments for a sheet-shaped mold (eg, a mold formed by an opening between two plates), the major axis direction is the machine direction or the flow direction of the matrix material. In some embodiments, the mold can be paper that is rolled or of a desired cross-sectional shape, such as a cylindrical shape. In some embodiments, the mold may be a paper cylinder glued with a longitudinal seam.

  In some implementations, the mold has a major axis that can have openings as a first end and a second end along it. In some embodiments, the matrix material can pass along the long axis of the mold while being processed. As a non-limiting example, FIG. 1 shows a mold 120 having a long axis along the material path 110.

  In some embodiments, the mold has a long axis that has an opening as a first end and a second end along at least one end that is closed. Also good. In some embodiments, the closed end may be openable.

  In some embodiments, individual molds can be filled with matrix material prior to being mechanically bonded. In some embodiments, a single mold is used to continuously pass the porous body by passing matrix material continuously therethrough prior to and / or during mechanical bonding. Can be manufactured. In some embodiments, a single mold can be used to produce individual porous bodies. In some embodiments, the single mold can be reused and / or continuously reused to produce a plurality of individual porous bodies.

  In some embodiments, the mold can be at least partially lined with a wrapper and / or coated with a release agent. In some embodiments, the wrapper can be an individual wrapper, such as a piece of paper. In some embodiments, the wrapper can be a rollable length wrapper, such as a 50 foot (15.2 meter) roll of paper.

  In some implementations, the mold can be lined with multiple wrappers. In some embodiments, forming the porous body can include lining the mold (s) with the wrapper (s). In some embodiments, forming the porous body can include wrapping the matrix material with a wrapper such that the wrapper effectively forms a mold. In such embodiments, the wrapper may be pre-formed as a mold, may be formed as a mold in the presence of a matrix material, or in a pre-formed shape (eg, with a tackifier). You may wrap around the matrix material. In some embodiments, the wrapper can be fed continuously into the mold. The wrapper can hold the porous body in a certain shape, can release the porous body from the mold, can help the matrix material pass through the mold, and during processing or shipping The porous body can be protected, or any combination thereof can be made.

  Suitable wrappers include paper (eg wood based paper, flax-containing paper, flax paper, paper made from other natural or synthetic fibers, functional paper, special marking paper, colored paper), plastic (Eg, fluorinated polymers, eg, polytetrafluoroethylene, silicone), films, coated papers, coated plastics, coated films, and the like, and any combination thereof. In some embodiments, the wrapper can be paper suitable for use in a smoking device filter.

  In some embodiments, the wrapper can be glued (eg glued) to itself to help maintain the desired shape, eg, a substantially cylindrical structure. In some embodiments, the step of mechanically bonding the matrix material can also be the step of mechanically bonding (or sintering) the matrix material to the wrapper, which means that the wrapper is attached to itself. The need for gluing can be reduced.

  Suitable release agents can be chemical release agents or physical release agents. Non-limiting examples of chemical release agents include oils, oily solutions and / or suspensions, soap solutions and / or suspensions, coating agents bound to the mold surface, and any combination thereof. . Non-limiting examples of physical release agents include paper, plastic, and any combination thereof. Physical release agents are sometimes referred to as release wrappers, which can also be used in the same manner as the wrappers described herein.

  Once formed in the mold in the desired cross-sectional shape, the matrix material can be mechanically bonded at multiple contact points. The mechanical bonding step can be performed while and / or after the matrix material is in the mold. The mechanical bonding process can be accomplished using heat and / or pressure (ie, forming a sintered contact point) and without using an adhesive. In some embodiments, an adhesive may optionally be included.

  The heat can be radiant heat, conduction heat, convection heat, and any combination thereof. As the heating, secondary radiation from a heat source such as a heating fluid inside the mold, a heating fluid outside the mold, steam, a heated inert gas, and a porous body component (for example, nanoparticles, active particles, etc.) , Ovens, furnaces, flames, conductive or thermoelectric materials, ultrasonics, and the like, and any combination thereof. As a non-limiting example, heating includes a convection oven or a heating block. Another non-limiting example is heating by microwave energy (single mode or multimode heater). In another non-limiting example, heating may cause heated air, nitrogen, or other gas to pass through the matrix material while the matrix material is in the mold. In some embodiments, a heated inert gas can be used to mitigate any undesirable oxidation of the active particles and / or additives. Another non-limiting example is a mold made of a thermoelectric material so that the mold generates heat. In some embodiments, heating includes a combination of the above, eg, passing a heated gas through the matrix material while the matrix material passes through the microwave oven.

  Secondary radiant heat from components of the porous body (eg, nanoparticles, active particles, etc.), in some embodiments, is electromagnetic radiation, such as gamma rays, X-rays, ultraviolet rays, visible rays, infrared rays, microwaves, radio waves And / or by irradiating the component with long radio waves. As a non-limiting example, the matrix material can include carbon nanotubes that release heat when irradiated with high frequencies. In another non-limiting example, the matrix material can include active particles such as carbon particles that are capable of converting microwave radiation into heat, which heats the binder particles together mechanically. Or mechanically bond (eg, sinter). In some embodiments, the electromagnetic radiation can be tuned in frequency and intensity to properly interact with the desired component. For example, activated carbon may be used in combination with microwaves at a fixed or adjustable set intensity selected to match the target heating rate and at a frequency in the range of about 900 MHz to about 2500 MHz. Can do.

  Those of ordinary skill in the art having the benefit of the present disclosure should understand that electromagnetic radiation of different wavelengths penetrates to different depths of the material. Thus, when using primary or secondary radiation methods, the mold material, arrangement and configuration, the composition of the matrix material, the components that convert electromagnetic radiation into heat, the wavelength of electromagnetic radiation, the intensity of electromagnetic radiation, the irradiation method, and The desired amount of secondary radiation, eg heat, must be considered.

  Causes residence time and / or mechanical coupling (eg, sintered contact points) for heating (including by any method described herein, eg, exposure to convection ovens or electromagnetic radiation). The residence time for the applied pressure is about 30 minutes, 15 minutes, 5 minutes, 1 minute from the lower limit of about 1 / 100th, 1 / 10th, 1 second, 5 seconds, 30 seconds, or 1 minute. It can be minutes, or a time in the range up to an upper limit of 1 second, and the residence time can range from any lower limit to any upper limit, including any sub-combination in between. . For faster heating methods, such as continuous methods that utilize exposure to electromagnetic radiation such as microwaves, a short residence time is preferred, for example about 10 seconds or less, or more preferably about 1 second or less. You must keep in mind. Furthermore, processing methods using methods such as convection heating can provide longer residence times on a time scale of minutes, which can include residence times in excess of 30 minutes. A longer time can be applied, for example from a few seconds to a few minutes, a few hours or more, provided that an appropriate temperature and heating profile can be selected for a given matrix material. Those skilled in the art should understand. Note that preheating or pretreatment methods and / or steps that are not up to a temperature and / or pressure sufficient to allow mechanical coupling are not considered part of the residence time used herein. Must.

  In some embodiments, the heating to promote mechanical bonding can be up to the softening temperature of the components of the matrix material. As used herein, the term “softening temperature” refers to the temperature at which a material becomes soft above that temperature, which is typically below the melting point of the material.

  In some embodiments, the mechanically bonding step includes a lower limit of about 90 ° C, 100 ° C, 110 ° C, 120 ° C, 130 ° C, or 140 ° C to about 300 ° C, 275 ° C, 250 ° C, 225 ° C. , 200 ° C., 175 ° C., or 150 ° C., which can be achieved at temperatures ranging from any lower limit to any upper limit, and any subcombination therebetween Can be included. In some embodiments, heating can be achieved by subjecting the material to a single temperature. In another embodiment, the temperature profile can change over time. As a non-limiting example, a convection oven may be used. In some embodiments, the heating may be localized within the matrix material. As a non-limiting example, secondary radiation from nanoparticles can only heat the matrix material proximate to the nanoparticles.

  In some embodiments, the matrix material can be preheated before being inserted into the mold. In some embodiments, the matrix material can be preheated to a temperature below the softening temperature of the components of the matrix material. In some embodiments, the matrix material can be preheated to a temperature that is about 10%, about 5%, or about 1% below the softening temperature of the components of the matrix material. In some embodiments, the matrix material can be preheated to a temperature about 10 ° C., about 5 ° C., or about 1 ° C. below the softening temperature of the components of the matrix material. Preheating can include, but is not limited to, a heat source, such as those listed above as a heat source to accomplish the mechanical coupling step.

  In some embodiments, bonding the matrix material can result in a porous body or an elongated porous body. As used herein, the term “elongate porous body” refers to a continuous porous body (ie, does not last indefinitely but is longer than a porous body and is continuously produced). Stuff). As a non-limiting example, an elongate porous body can be produced by continuously passing a matrix material through a heated mold. In some embodiments, the binder particles have their original physical shape (or substantially retained original shape, eg, no more than 10% shape change from the original shape) during the mechanical bonding process. (E.g., a contracted shape), i.e., the binder particles can be substantially the same shape in the matrix material and in the porous body (or elongate body). For the sake of brevity and readability, unless otherwise specified, the term “porous body” refers to a porous body compartment, a porous body, an elongated porous body (encapsulated or not) Is included.

  In some embodiments, the elongated porous body can be cut to yield a porous body. Cutting can be accomplished using a cutter. Suitable cutters include blades, hot blades, carbide blades, stellite blades, ceramic blades, hardened steel blades, diamond blades, smooth blades, saw blades, lasers, pressurized fluids, liquid lances, gas lances, cutters, etc., and Any combination of these can be mentioned, but is not limited to these. In some embodiments involving high speed processing, the cutting blade or similar tool can be positioned at an angle that matches the processing speed to provide a porous body having an end perpendicular to the long axis. . In some embodiments, the cutter can change its position relative to the elongate porous body along the long axis of the elongate porous body.

  In some embodiments, the porous body and / or the elongated porous body can be extruded. In some embodiments, a die can be used for extrusion. In some embodiments, the die can have a plurality of holes through which the porous body and / or the elongated porous body can be extruded.

  Some embodiments can include cutting the porous body and / or the elongated porous body radially to provide a porous body and / or a porous body compartment. One of ordinary skill in the art will recognize what sheet-like shape the radial cut will be, and what sheet-like shape the cut will encompass. Cutting can be accomplished by any known method using any known device, including those described above with respect to cutting a long porous body into a porous body. It is not limited to.

  The length of the porous body or its compartment ranges from a lower limit of about 2 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, or 30 mm to an upper limit of about 150 mm, 100 mm, 50 mm, 25 mm, 15 mm, or 10 mm. The length can range from any lower limit to any upper limit, and can include any sub-combination in between.

  The outer circumference of the elongated porous body, porous body, or compartment (wrapped or not) is about 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, From the lower limit of 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm, 25 mm, or 26 mm, about 60 mm, 50 mm, 40 mm, 30 mm, 20 mm, 29 mm, 28 mm, 27 mm, 26 mm, 25 mm, 24 mm, 23 mm , 22 mm, 21 mm, 20 mm, 19 mm, 18 mm, 17 mm, or 16 mm, and the outer circumference ranges from any lower limit to any upper limit, and any subordinate in between Combinations can be included.

  One skilled in the art will recognize the dimensional requirements of a porous body configured for a filtration device other than a smoking article. As a non-limiting example, a porous body configured for a concentric fluid filter can be a hollow cylinder having an outer diameter of about 250 mm or more. As another non-limiting example, a porous body configured for a sheet in an air filter may have a length and width of several tens of centimeters and a relatively thin thickness (eg, about 5 mm to about 50 mm). it can.

  Some embodiments may include wrapping the porous body with a wrapper after the matrix material is mechanically bonded, eg, after the porous body exits the mold or exits the extrusion die. it can. Suitable wrappers include those described above.

  Some embodiments can include cooling the porous body. The cooling can be active or passive, i.e. the cooling can be assisted or naturally occurring. Active cooling allows the fluid to pass around and / or into the mold, the porous body; lowering the temperature of the local environment around the mold, for example, passing frozen components; and these Any combination can be included. Active cooling can include elements including, but not limited to, cooling coils, liquid jets, thermoelectric materials, and any combination thereof. The cooling rate may be random or controlled.

  Some embodiments may transfer the porous body to another location. Suitable forms of transfer include, but are not limited to, transport, transport, rolling, pushing, loading, robot motion, etc., and any combination thereof.

  Those of ordinary skill in the art having the benefit of the present disclosure should be able to understand multiple devices and / or systems that can produce a porous body. As a non-limiting example, FIGS. 1-12 illustrate a plurality of devices and / or systems that can produce a porous body.

  It should be noted that if a system is used, the use of a device with system elements and vice versa is within the scope of the disclosed invention.

  For ease of understanding, the term “material path” is used herein to refer to the path along which the matrix material, elongated porous body, and / or porous body travels within the system and / or apparatus. Used to identify. In some embodiments, the material path can be continuous. In some embodiments, the material path can be discontinuous. As a non-limiting example, a system for batch processing using multiple independent molds can be considered to have discontinuous material paths.

  Referring now to FIGS. 1A and 1B, the system 100 includes a hopper 122 that can be operably coupled to the material path 110 to supply matrix material (not shown) to the material path 110. The system 100 also includes a paper feeder 132 that is operably coupled to the material path 110 and feeds paper 130 into the material path 110 to feed the matrix material between the mold 120 and the matrix material. A substantially surrounding wrapper can be formed. The heating element 124 is in thermal communication with the matrix material while the matrix material is in the mold 120. The heating element 124 mechanically bonds the matrix material at a plurality of points (eg, forms sintered contact points), thereby providing an encased elongated porous body (not shown). it can. After the wrapped elongated porous body exits the mold 120 and is properly cooled, the cutter 126 cuts the wrapped elongated porous body radially, i.e. perpendicular to the long axis, thereby Encased porous bodies and / or porous body compartments are provided.

  1A and 1B demonstrate that the system 100 may be tilted at any angle. Those of ordinary skill in the art having the benefit of the present disclosure should understand the configuration considerations when adjusting the tilt angle at which the system 100 or any of its components are placed. As a non-limiting example, FIG. 1B shows that the hopper 122 can be configured such that the outlet of the hopper 122 (and any corresponding matrix feeder) is in the mold 120. In some implementations, the mold can be at a vertical or horizontal angle or inclined at any angle therebetween.

  In some embodiments, the step of feeding the matrix material into the material path comprises any suitable feeder system, such as manual feeding, volumetric feeder, mass flow feeder, weight feeder, pressurized container (eg, pressurized hopper or Pressure tanks), augers or screws, chutes, slides, conveyors, tubes, conduits, channels, and the like, and any combination thereof. In some embodiments, the material path is a mechanical element between the hopper and the mold, such as garniture, compression mold, flowing water compression mold, ram press, piston, stirrer, extruder, twin screw extruder, solid phase extruder, etc. , And any combination thereof, including but not limited to. In some embodiments, the feeding process includes forced feed, controlled speed feed, volumetric feed, mass flow feed, weight feed, vacuum assisted feed, fluidized powder feed, high concentration phase air feed (eg, slag flow, Sliding flow or irregular sliding flow, shear bed flow or ripple flow, and extrusion flow), lean phase air feed, and any combination thereof.

  In some embodiments, feeding the matrix material into the material path by high concentration phase air feed can advantageously allow for high throughput processing. High-concentration phase air supply has been performed at a high flow rate using a large-diameter outlet, but unexpectedly in the present invention, it has been shown that it is effective even at a high speed and a small-diameter. For example, surprisingly, the use of high-concentration phase air feeds is possible with small diameters (eg, about 5 mm to about 25 mm and about 5 mm to about 10 mm) and high throughput (eg, about 6.1 mm tube outlet [ Further explained herein) at about 575 kg / hr or about 500 m / min). By comparison, weight feeding is typically a production with a similar diameter and less than about 10 m / min, and high-concentration phase air feeding can be performed at similar speeds at outlets with dimensions greater than 50 mm. Combining small diameters and high throughput for matrix materials, especially for granular or particulate matrix materials, was unexpected. One of ordinary skill in the art will recognize the appropriate size and shape of the outlet of the high concentration phase air feeder to match the mold. As a non-limiting example, the outlet is similar in shape to the mold, but is smaller in size than the mold and can extend into the mold. In another embodiment, the outlet is shaped to fit a mold for a sheet porous body (eg, a long rectangular outlet) or shaped to fit a mold for a hollow cylindrical porous body (eg, a donut shape). Exit).

  Furthermore, the high concentration phase air feed method advantageously reduces particle migration and separation, which can cause problems, especially when the size and / or shape of the binder particles and active particles are different. Can do. Without being limited by theory, the air pressure applied to the pressure hopper creates a plug flow of the matrix material, which minimizes the separation of particulates, and therefore at the feeder outlet, a more homogeneous and more consistent matrix material A composition is provided. In some embodiments, the pressure hopper can be designed as a mass flow. Mass flow conditions may depend on, among other things, the slope of the inner wall of the pressure hopper, the material of the wall, and the composition of the matrix material.

  In some embodiments, the feed rate of the matrix material to the material path is about 800 m / min, 600 m / min from a lower limit of about 1 m / min, 10 m / min, 25 m / min, 100 m / min, or 150 m / min. Min, 500 m / min, 400 m / min, 300 m / min, 200 m / min, or 150 m / min up to the upper limit, the feed rate being in the range from any lower limit to any upper limit. Any sub-combination in between can be included. In some embodiments, in combination with a mold having a diameter ranging from a lower limit of about 0.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, or 6 mm to an upper limit of about 10 mm, 9 mm, 8 mm, 7 mm, or 6 mm The feed rate of the matrix material to the material path is about 800 m / min, 600 m / min, 500 m / min from the lower limit of about 1 m / min, 10 m / min, 25 m / min, 100 m / min, or 150 m / min. 400 m / min, 300 m / min, 200 m / min, or 150 m / min up to the upper limit, each of the mold diameter and feed rate independently ranging from any lower limit to any upper limit And any sub-combination in between can be included. Those skilled in the art will recognize that the combinations of the diameter (or shape) and feed rate that can be achieved include, among other things, the size and shape of the particles in the matrix material, other components of the matrix material (eg, additives), the matrix material Permeability and deaeration constant, distance traveled (eg, tube length, which is further described herein), placement of transport system, etc., and any combination thereof Must understand.

  In some implementations, the air stream can be characterized by a solid to fluid ratio of about 15 or greater. In some embodiments, the airflow ranges from a lower limit of about 15, 20, 30, 40, or 50 to an upper limit of about 500, 400, 300, 200, 150, 130, 100, or 70. The ratio of solid to fluid can range from any lower limit to any upper limit, and can include any sub-combination therebetween. The ratio of solids to fluid may depend, inter alia, on the type of high concentration phase air feed, and extrusion high concentration phase feed typically occurs at higher values.

  In some embodiments, the high concentration phase air feed is about 1 psig (6.9 kPag), 2 psig (13.8 kPag), 5 psig (34.5 kPag), 10 psig (68.9 kPag), or 25 psig (172 kPag). Applying air pressure from a lower limit to an upper limit of about 150 psig (1034 kPag), 125 psig (862 kPag), 100 psig (689 kPag), 50 psig (345 kPag), or 25 psig (172 kPag), the air pressure can be any lower limit To any upper limit, including any sub-combination in between. The air pressure may be a plurality of gases, such as inert gases (eg, nitrogen, argon, helium, etc.), oxygenated gases, heated gases, dry gases (ie, less than about 6 ppm water), and the like It should be noted that it can be applied in any combination (eg, a heated dry inert gas such as nitrogen or argon). An example of a system that includes a high concentration phase air supply is included herein.

  In some embodiments, the feeding process can be intermittent feeding to allow the spacer material to be inserted at predetermined intervals. Suitable spacer materials include additives, interstitial partition walls (eg, mold parts), porous partition walls (eg, paper and release wrappers), filters, cavities, etc., and any combination thereof. In some embodiments, the feeding step can include agitation and / or vibration. Those of ordinary skill in the art having the benefit of the present disclosure will appreciate that a suitable degree of agitation and / or vibration, for example, an evenly dispersed matrix material comprising large binder particles and small active particles may be adversely affected by vibration. It must be understood that there is a risk that uniformity may be at least partially lost. Furthermore, the influence of the feed operating parameters and / or the feeder on the final properties of the porous body to be produced, for example at least the void volume (further explained below), the encapsulation pressure drop (further explained below), And the effect on composition uniformity should be understood by those skilled in the art.

  In some embodiments, the matrix material or components thereof can be dried before being introduced into the material path and / or while passing through the material path. The drying step can be accomplished in some embodiments using heating the matrix material or components thereof, flowing a dry gas over the matrix material or components thereof, or any combination thereof. In some embodiments, the matrix material is about 10 wt% or less, about 5 wt% or less, or more preferably about 2 wt% or less, and in some embodiments, as low as 0.01 wt%. Can have a moisture content. The moisture content can be analyzed by known methods including lyophilization or weight loss after drying.

  Referring now to FIGS. 2A and 2B, the system 200 includes a hopper 222 that can be operably coupled to the material path 210 to supply matrix material to the material path 210. The system 200 also includes a feed feeder 232 that is operably coupled to the material path 210 and supplies paper 230 to the material path 210 to feed the matrix material between the mold 220 and the matrix material. A substantially surrounding wrapper can be formed. In addition, the system 200 includes a release feeder 236 that is operably coupled to the material path 210 and provides a release wrapper 234 to the material path 210 between the paper 230 and the mold 220. A wrapper can be formed. In some embodiments, the release feeder 236 can be configured as a conveyor 238 to continuously circulate the release wrapper 234. The heating element 224 is in thermal communication with the matrix material while the matrix material is in the mold 220. The heating element 224 can mechanically bond the matrix material at multiple points (eg, form a sintered contact point), thereby providing an encased elongated porous body. After the wrapped long porous body exits from the mold 220 and is properly cooled, the cutter 226 cuts the wrapped long porous body radially, thereby enclosing the porous body And / or a porous body compartment is provided. In embodiments where the release wrapper 234 is not configured as a conveyor 238, the release wrapper 234 may be wrapped from an encased porous body prior to cutting, or after cutting, and / or wrapped from an encased porous body. It may be removed from the porous body compartment.

  Referring now to FIG. 3, the system 300 includes component hoppers 322 a and 322 b that can supply components of matrix material to the hopper 322. The matrix material can be mixed and preheated in hopper 322 by mixer 328 and pre-heater 344. A hopper 322 is operably coupled to the material path 310 to supply matrix material to the material path 310. The system 300 also includes a feed feeder 332 that is operably coupled to the material path 310 to feed paper 330 into the material path 310 between the mold 320 and the matrix material. A wrapper can be formed that substantially surrounds the matrix material. The mold 320 can include a fluid connection 346 through which a heated fluid (liquid or gas) passes through the material path 310 to mechanically couple the matrix material at multiple points (eg, , To form a sintered contact point), thereby providing an encased elongated porous body. It should be noted that the fluid connections 346 can be placed anywhere along the mold 320 and that multiple fluid connections 346 can be placed along the mold 320. After the wrapped elongate porous body exits the mold 320 and is properly cooled, the cutter 326 cuts the encased elongate porous body radially and thereby encased the porous body and An encased porous body compartment is provided.

  Those of ordinary skill in the art having the benefit of the present disclosure should understand that preheating can also be performed before hopper 322 for individual feed ingredients and / or after hopper 322 for mixed ingredients. .

  Suitable mixers include ribbon blenders, paddle blenders, plow blenders, double cone blenders, twin shell blenders, planetary blenders, fluid blenders, high strength blenders, rotating drums, mixing screws, rotating mixers, and any combination thereof. For example, but not limited to.

  In some embodiments, the component hopper holds the individual components of the matrix material, for example a two component hopper, one holding the binder particles and the other holding the active particles. it can. In some embodiments, the component hopper holds a mixture of components of the matrix material, such as a two-component hopper, one holding a mixture of binder particles and active particles, the other such as perfume. It can be one that possesses additives. In some embodiments, the components in the component hopper can be solids, liquids, gases, or combinations thereof. In some embodiments, components of multiple different component hoppers may be added to one hopper in different proportions to achieve the desired blend of matrix materials. As a non-limiting example, a three component hopper may individually hold active particles, binder particles, and liquid active compounds (additives further described below). The binder particles can be added to the hopper at twice the rate of the active particles, and the active compound is sprayed to form at least a partial coating on both the active particles and the binder particles. be able to.

  In some embodiments, the fluid connection to the mold can be one that allows fluid to enter the mold, one that allows fluid to pass through the mold, and / or one that draws fluid into the mold. As used herein, the term “withdrawal” refers to creating a negative pressure drop, eg, aspiration, around the boundary and / or along the path. Putting the heated fluid into the mold and / or passing through the mold may assist in mechanically bonding (eg, at multiple sintering points) the matrix material therein. it can. Pulling into the mold with the wrapper inside may help to line the mold uniformly, eg, with less wrinkles.

  Referring now to FIG. 4, the system 400 includes a hopper 422 that can be operably coupled to the material path 410 to supply matrix material to the material path 410. The hopper 422 can be configured along the material path 410 such that the outlet of the hopper 422 or an extension from the outlet is in the mold 420. This may advantageously allow the matrix material to be fed into the mold 420 at a rate that can adjust the filling of the matrix material and the resulting void volume of the porous body. In this non-limiting example, the mold 420 includes a thermoelectric material and thus includes a power connection 448. The system 400 also includes a release feeder 436, which is operably coupled to the material path 410 and provides a release wrapper 434 into the material path 410 between the mold 420 and the matrix material. To form a wrapper that substantially surrounds the matrix material. The mold 420 can be made from a thermoelectric material so that the mold 420 provides heat that mechanically couples the matrix material at multiple points (eg, at sintered contact points), thereby enclosing it. Long porous bodies can result. Along the material path 410 after the mold 420, the roller 440 can operatively assist the movement of the elongated porous body wrapped through the mold 420. After the wrapped elongated porous body exits the mold 420 and is properly cooled, the cutter 426 cuts the wrapped elongated porous body radially, thereby enclosing the wrapped porous body. And / or encased porous body compartments are provided. After cutting, the porous body proceeds along the material path 410 and is, for example, packaged or further processed on the porous body conveyor 462. The release wrapper 434 can be removed from the wrapped elongated porous body before cutting or from the wrapped porous body and / or the wrapped porous body compartment after cutting.

  Suitable rollers and / or roller replacements include, but are not limited to, cogs, cogwheels, wheels, belts, gears, etc., and any combination thereof. Furthermore, the roller or the like may be flat, toothed, inclined, and / or uneven.

  Referring now to FIG. 5, the system 500 includes a hopper 522 that can be operably coupled to the material path 510 to supply matrix material to the material path 510. The heating element 524 is in thermal communication with the matrix material while the matrix material is in the mold 520. The heating element 524 can mechanically bond the matrix material at multiple points (eg, at sintered contact points), thereby providing an elongated porous body. After the elongate porous body exits the mold 520, a die 542 can be used to extrude the elongate porous body into the desired cross-sectional shape. The die 542 can include a plurality of dies 542 '(eg, a plurality of dies or a plurality of holes in a single die) through which an elongate porous body can be extruded. After the elongate porous body is extruded through the die 542 and properly cooled, the cutter 526 cuts the elongate porous body radially, thereby providing a porous body and / or a porous body compartment. It is.

  Referring now to FIG. 6A, the system 600 includes a feed feeder 632 that can be operably coupled to a material path 610 to feed paper 630 into the material path 610. A hopper 622 (or other matrix material delivery device, such as an auger) can be operatively coupled to the material path 610 to place the matrix material on the paper 630. The paper 630 can be at least partially wrapped around the matrix material by penetrating the mold 620 (or a compression mold sometimes referred to as a garniture device in the context of a cigarette filter forming device), thereby providing the desired A cross-sectional shape is provided (or optionally, in some embodiments, the matrix material may be combined with paper 630 after the formation of the desired cross-section is initiated or completed). In some embodiments, the paper seam can be glued. The heating element 624 (eg, a microwave source, convection oven, heating block, etc., or a mixture thereof) is in thermal communication with the matrix material while the matrix material is in the mold 620 and / or after exiting the mold 620. ing. The heating element 624 can mechanically bond the matrix material at multiple points (eg, form a sintered contact point), thereby providing an encased elongated porous body. After the wrapped elongate porous body exits the mold 620 and is properly cooled, the cutter 626 cuts the encased elongated porous body radially, thereby enclosing the encased porous body. And / or a porous body compartment is provided. Movement through the system 600 is assisted by the conveyor 658 and the mold 620 can be stationary. Although not shown, a similar embodiment can include paper 630 as part of an annular conveyor, which is peeled away from the elongated porous body prior to cutting, thereby allowing the porous body and / or It should be noted that a porous body compartment is provided.

  Referring now to FIG. 6B, the system 600 ′ includes a feed feeder 632 ′ that is operably coupled to the material path 610 ′ to place the paper 630 ′ into the material path 610 ′. Can be supplied. A hopper 622 '(or other matrix material delivery device, such as an auger) can be operatively connected to the material path 610' to place the matrix material on the paper 630 '. The paper 630 ′ can be at least partially wrapped around the matrix material by penetrating the mold 620 ′ (or a compression mold, sometimes referred to as a garniture device in the context of a cigarette filter forming device), thereby A desired cross-sectional shape is provided (or optionally, in some embodiments, the matrix material may be combined with paper 630 ′ after the formation of the desired cross-section has been initiated or completed). Good). In some embodiments, the paper seam can be glued.

  System 600 'can include a plurality of heating elements 624'. The heating element 624a ′ is in thermal communication with the matrix material while the matrix material is in the mold 620 ′ and / or after exiting the mold 620 ′, and mechanically at least a portion of the matrix material at a plurality of points. Can be bonded (eg, to form a sintered contact point). The elongate porous body can then be shaped to the desired cross-sectional shape or size by compression mold 656 ′ (eg, to change the cross-sectional shape of the wrapped elongate porous body) And then reheated by a second heating element 624b ′ (which can be a heating element similar to the first heating element 624a ′) to provide additional mechanical bonding (eg, sintered) Contact point) can be formed. Optionally, although not shown, the wrapped elongate porous body after exiting the second heating element 624b 'can be reshaped to the desired cross-sectional shape or size. The resulting wrapped elongate porous body is then appropriately cooled and cut radially by a cutter 626 'to form a wrapped porous body and / or a wrapped porous body compartment. The Movement through system 600 'is assisted by conveyor 658' and mold 620 'can be stationary.

  In some embodiments, depending on the degree of the initial sintering or heating step, the elongated porous body can be cooled, cut, and then reheated. One skilled in the art will recognize how to modify other systems and methods described herein to provide more than one sintering (or heating) step.

  In some embodiments, the porous body or the like can be resized and / or reshaped while pressure is applied while the matrix material is at an elevated temperature. Compression molding is a mechanically driven or non-mechanically driven sizing or forming roller, a series of rollers, or a die or series of dies, or any combination thereof, suitable for finalizing or dimensioning the rod. Can consist of A size change and / or a shape change can be performed after each heating step of the method.

  Referring now to FIG. 7A, the system 700 includes a feed feeder 732 that can be operably coupled to a material path 710 to feed paper 730 into the material path 710. As shown in the figure, the mold 720 is a paper that is glued in a cylindrical shape with a long seam glued, and the forming mold 756a (or the forming mold is a garniture device in the context of a cigarette filter forming device). For example, a paper tube folder), whereby paper 730 is wound with glue 752 applied using glue applicator 754 (eg glue spray gun). Optionally, followed by a glue seam heater (not shown). While forming the mold 720, matrix material can be introduced from the hopper 722 along the material path 710. A heating element 724 (eg, a microwave source, convection oven, heating block, etc., or a mixture thereof) in thermal communication with the mold 720 mechanically bonds the matrix material at multiple points (eg, sintering). Contact points), thereby providing an encased porous body. The compression mold 756b can then be used before the matrix material is completely cooled to bring the wrapped elongated porous body to the desired cross-sectional size, which is advantageously It can be used to obtain uniformity of the perimeter and shape (eg, oval) of the porous body. After the wrapped elongate porous body is properly cooled, the cutter 726 cuts the encased elongate porous body radially, thereby enclosing the porous body and / or the porous body compartment. Is brought about. Movement through the system 700 can be assisted by rollers, conveyors, etc. (not shown). Those of ordinary skill in the art having the benefit of the present disclosure should understand that the processes described herein can be implemented in a single device or in multiple devices. For example, the steps of wrapping paper, introducing a matrix material, exposing to heat (eg, applying microwaves or heating in a conventional oven), and changing the size are a single step. The obtained long porous body may be conveyed to a second device for cutting. The system 700 can be arranged in any direction, eg, vertical or horizontal, or any direction in between.

  In some embodiments, the glue or other adhesive used to seal the paper mold (or other flexible mold, such as a plastic mold) is a cold melt adhesive, hot melt adhesive, pressure sensitive It may be an adhesive, a curable adhesive, or the like. Cold melt adhesives may be preferred to mitigate glue breakage during subsequent heating steps (eg, during sintering).

  Referring now to FIG. 7B, the system 700 ′ includes a feed feeder 732 ′ that is operably coupled to the material path 710 ′ to place the paper 730 ′ into the material path 710 ′. Can be supplied. As shown, the mold 720 'is a paper that is glued in a cylindrical shape with a long seam glued together, and the forming mold 756a' (or the forming mold is a garniture device in the context of a cigarette filter forming device). For example, a paper tube folder), so that the paper 730 'is wound with glue 752' applied using a glue applicator 754 '(eg glue spray gun). be able to. While forming the mold 720 ′, the matrix material is hopper 722 ′ (eg, high concentration) operatively connected to the tubing 722a ′ by a fitting 722b ′ (which can be a flexible fitting). Can be introduced along the material path 710 ′ from the pressure hopper of the air feeder. A heating element 724 '(eg, a microwave source, convection oven, heating block, etc., or a mixture thereof) in thermal communication with a mold 720' (shown close to the end of the tubing 722a ') is The matrix material can be mechanically bonded at multiple points (eg, forming sintered contact points), thereby providing an encased porous body. A compression mold 756b '(shown as a roller) then assists in cooling the matrix material while shaping the encased elongate porous body into the desired more uniform perimeter and shape (eg, oval). Can be cooled to do. After the wrapped long porous body is properly cooled, the cutter 726 ′ cuts the wrapped long porous body in the radial direction and thereby the wrapped porous body and / or porous body. A compartment is provided.

  In some embodiments, the mold can be non-porous or variable in porosity, thereby allowing fluid to be removed from the matrix material. Further, the mold and / or material path can be operatively connected to the path to allow fluid to escape from the porous paper in the desired direction. In some embodiments, these fluid passages can be connected to a source below atmospheric pressure. Removal of fluid from the mixture can improve system operability and minimize separation of matrix material particles in some embodiments.

  In some implementations, the feeder can include an extension that is designed to fit within a mold. In some embodiments, the feeder outlet (eg, the outlet of tubing 722a ') can be sized slightly smaller (eg, about 5% smaller) than the inner diameter of the mold. In addition, the feeder or an extension thereof may include a flexible portion that allows the outlet to enter the mold. During high density air feed, such entry may be advantageous by allowing the outlet to move into the mold. Such movement can advantageously allow the outlet to easily find the center of the mold, which increases the operability and provides a fit that minimizes separation of the matrix mixture. Can be provided. In some embodiments, the end of the feeder (eg, the outlet of the pipe 722a ′) is optionally glued before the mold 756a ′, in the mold 756a ′, or after the mold 756a ′. It can be located after the seam heater.

  Furthermore, the outlet can be designed to have various cross-sectional areas in some embodiments, which advantageously allows the packing density of the matrix material mixture to be reduced in the high density air feed. It can assist in minimizing separation and allow pressure and flow in a single system to be varied.

  In some embodiments, the outlet can have an outlet with a mesh that prevents the matrix material from passing therethrough but allows fluid to pass therethrough. Such ventilation allows the pressure to decay in a controlled manner over a longer period of time when the matrix material exits from the outlet, especially when it exits at a high flow rate and high pressure. Significant migration, which can lead to matrix material non-uniformity, can be mitigated.

  Referring now to FIG. 8, the mold 820 of the system 800 is formed from mold parts 820a and 820b, and the mold parts 820a and 820b can be operatively coupled to the mold conveyors 860a and 860b, respectively. Once the mold 820 is formed, matrix material can be introduced from the hopper 822 along the material path 810. The heating element 824 is in thermal communication with the matrix material while the matrix material is in the mold 820. The heating element 824 can mechanically bond the matrix material at multiple points (eg, form a sintered contact point), thereby providing a porous body. After the mold 820 is properly cooled and separated into mold parts 820a and 820b, the porous body is ejected from the mold parts 820a and / or 820b and advanced along the material path 810 by the porous body conveyor 862. Can do. It should be noted that FIG. 8 shows a non-limiting example of a discontinuous material path.

  In some embodiments, the step of discharging the porous body from the mold and / or mold part uses a suction device, an extrusion device, a lifting device, gravity, any combination thereof, and any combination thereof. Can do. The drainage device can be configured to engage the porous body at its end along the side (one side or both sides) and any combination thereof. Suitable suction devices include, but are not limited to, suction cups, vacuum components, tweezers, pliers, forceps, tongs, grippers, claws, clamps, and any combination thereof. Suitable extrusion devices include, but are not limited to, ejectors, perforators, rods, pistons, wedges, spokes, rams, pressurized fluids, etc., and any combination thereof. Suitable lifting devices include, but are not limited to, suction cups, vacuum components, tweezers, pliers, forceps, tongs, grippers, claws, clamps, and any combination thereof. In some implementations, the mold can be configured to work operatively with various removal devices. As a non-limiting example, the push-pull hybrid device can include pushing a longitudinal axis with a rod to eject a portion of the porous body from the other end of the mold, which portion is then forceps And the porous body can be pulled from the mold.

  Referring now to FIG. 9, the mold 920 of the system 900 is formed from mold parts 920a and 920b or 920c and 920d, and the mold parts 920a and 920b or 920c and 920d are mold conveyors 960a, 960b, 960c and 960d, respectively. Can be operatively coupled to each other. Once the mold 920 is formed or while the mold 920 is being formed, a sheet of paper 930 is introduced into the mold 920 by the feed feeder 932. Next, the matrix material from the hopper 922 is introduced along the material path 910 into a paper 930 lined mold 920 and mechanically bonded in the porous body by heat from the heating element 924. (For example, heated to form a plurality of sintered contact points). After being properly cooled, the porous body is discharged by inserting the ejector 964 into the ejector ports 966a and 966b of the mold parts 920a, 920b, 920c, and 920d. The porous body can then be advanced along the material path 910 by the porous body conveyor 962. FIG. 9 shows a non-limiting example of discontinuous material paths.

  The quality control of the production of the porous body can be assisted by cleaning the mold and / or mold parts. Referring again to FIG. 8, a cleaning implement can be incorporated into the system 800. When mold parts 820a and 820b return from the formation process of the porous body, mold parts 820a and 820b pass through a series of cleaning implements including liquid jet 870 and air or gas jet 872. Similarly in FIG. 9, when the mold parts 960a, 960b, 960c, and 960d return from the formation process of the porous body, the mold parts 960a, 960b, 960c, and 960d are subjected to heat and air or gas injection from the heating element 924. Pass through a series of cleaning implements including 972.

  Other suitable cleaning instruments include scrubbers, brushes, solution baths, showers, insertion fluid ejectors (tubes inserted into molds that can eject fluid radially), ultrasonic devices, and these Any combination may be mentioned, but not limited to these.

  In some embodiments, the porous body can include cavities. As a non-limiting example, referring now to FIG. 10, mold parts 1020 a and 1020 b operably coupled to mold conveyors 1060 a and 1060 b are operably coupled to form mold 1020 of system 1000. The hopper 1022 is operatively associated with two metering feeders 1090a and 1090b so that each metering feeder 1090a and metering feeder 1090b partially dies the mold 1020 along the material path 1010. Fill with. An injector 1088 injects a capsule (not shown) into the mold 1020 into the mold 1020, between which the matrix material is added from the dispenser 1090a and from the dispenser 1090b, thereby encapsulating the capsule with the matrix material. Is manufactured. The heating element 1024 is in thermal contact with the mold 1020 to mechanically bond the matrix material at a plurality of points (eg, to form a sintered contact point), thereby creating a porous with the capsule inserted therein. A body is brought about. After the porous body is formed and properly cooled, a rotary grinder 1092 is inserted into the mold 1020 along the long axis direction of the mold 1020. The rotary grinder 1092 is operable to grind the porous body to a desired length in the long axis direction. After the mold 1020 separates into mold parts 1020a and 1020b, the porous body is ejected from the mold parts 1020a and / or 1020b and advanced along the material path 1010 by the porous body conveyor 1062.

  Capsules suitable for use inside a porous body include, but are not limited to, polymer capsules, porous capsules, ceramic capsules, and the like. Capsules can be filled with additives such as granular carbon or perfume (more examples are provided below). The capsule may also include a molecular sieve in some embodiments, the molecular sieve reacting with the selected component in the smoke without adversely affecting the desired scented component of the smoke. Remove components or reduce their concentration. In some embodiments, the capsule may include tobacco as an additional fragrance. If the capsule is not sufficiently filled with the selected material, in some embodiments as a filter, it may cause a lack of interaction between the mainstream smoke component and the material in the capsule. It must be noted that there are.

  Those of ordinary skill in the art having the benefit of the present disclosure should understand that other methods described herein can be modified to produce a porous body containing capsules therein. In some embodiments, more than one type of capsule can be present in a porous body compartment, a porous body, and / or an elongated porous body.

  In some embodiments, the shape of the porous body, eg, length, width, diameter, eg, / or height, can be adjusted by operations other than cutting, including grinding, grinding, Examples include, but are not limited to, grinding, smoothing, polishing, friction, etc., and any combination thereof. These operations are generally referred to herein as grinding. In some embodiments, the side surfaces and / or end surfaces of the porous body are ground to achieve a smooth surface, rough surface, grooved surface, patterned surface, leveling surface, or any combination thereof. Can do. In some embodiments, the sides and / or end faces of the porous body can be ground to achieve the desired dimensions within the specification limits. In some embodiments, the side and / or end face of the porous body is ground while in or out of the mold, after cutting, during further processing, or any combination thereof. can do. One skilled in the art should understand that dust, particulates, and / or small pieces may result from grinding. As such, grinding may involve removing dust, particulates, and / or chips by methods such as evacuation, gas injection, rinsing, vibration, etc., and any combination thereof. .

  Any component and / or tool that can achieve the desired degree of grinding can be used with the systems and methods disclosed herein. Examples of suitable components and / or tools that can achieve the desired degree of grinding include lathes, rotary polishers, brushes, polishers, shock absorbers, etchers, scribers, etc., and any combination thereof However, it is not limited to these.

  In some embodiments, the porous body may be machined as desired, eg, a portion of the porous body may be drilled to reduce weight.

  Those of ordinary skill in the art having the benefit of the present disclosure should understand the components and / or instruments necessary to engage the porous body at various points in the system described herein. As a non-limiting example, a grinding and / or drilling tool used while the porous body is in the mold (or when the elongate porous body exits the mold) can adversely affect the mold. Must be configured not to.

  Referring now to FIG. 11, the hopper 1122 is operably attached to the chute 1182 and supplies matrix material to the material path 1110. Along the material path 1110, the mold 1120 is configured to receive the ram 1180, and the ram 1180 can press the matrix material in the mold 1120. The heating element 1124 is in thermal communication with the matrix material while the matrix material is in the mold 1120 and mechanically couples the matrix material at multiple points (eg, forms a sintered contact point), which Gives a long porous body. Adding a ram 1180 to the system 1100 can advantageously help to ensure that the matrix material is properly filled to form an elongated porous body having a desired void volume. . In addition, the system 1100 includes a cooling region 1194 so that the elongate porous body is cooled while still being contained within the mold 1120. In this non-limiting example, the cooling is passive.

  Referring now to FIG. 12, the hopper 1222 of the system 1200 operably supplies matrix material along the material path 1210 to an extruder 1284 (eg, a screw extruder). Extruder 1284 moves the matrix material to mold 1220. The system 1200 also includes a heating element 1224 that is in thermal communication with the matrix material while the matrix material is in the mold 1220, which mechanically couples the matrix material at multiple points (eg, sintered contact points). Which results in an elongated porous body. Further, system 1200 includes a cooling element 1286 that is in thermal communication with the matrix material while the matrix material is in mold 1220. The movement of the elongate porous body out of the mold 1220 is assisted and / or directed by the roller 1240.

  In some implementations, the control system can interfere with the components and / or apparatus of the inventive system disclosed herein. As used herein, the term “control system” refers to a system that can operate to send and receive electronic or pneumatic signals, which provides for interfacing with a user and for reading data. Including functionality, including collecting data, storing data, changing variable setpoints, maintaining setpoints, providing fault notifications, and any combination thereof it can. Suitable control systems can include variable transformers, resistance meters, programmable logic controllers, digital logic circuits, relays, computers, virtual reality systems, distributed control systems, and any combination thereof. However, it is not limited to these. Suitable system and / or apparatus components that can be operatively coupled to the control system include hoppers, heating elements, cooling elements, cutters, mixers, feed feeders, release feeders, release conveyors, cleaning Equipment, rollers, mold conveyors, conveyors, ejectors, liquid jets, air jets, rams, chutes, extruders, jets, matrix material feeders, glue feeders, grinders, etc., and any combination thereof. However, it is not limited to these. It should be noted that the systems and / or devices disclosed herein may have multiple control systems that can interface with any number of components.

  Those of ordinary skill in the art having the benefit of the present disclosure should understand that the various components of the systems and / or apparatus disclosed herein are interchangeable. As a non-limiting example, if the matrix material includes a component that can convert electromagnetic radiation into heat (eg, nanoparticles, carbon particles, etc.), the heating element can be an electromagnetic radiation source (eg, a microwave source, a convection oven, It can be replaced with a heating block or the like, or a mixture thereof. Further, as a non-limiting example, the paper wrapper may be replaced with a release wrapper.

  In some embodiments, the porous body can be produced by a method that includes a linear velocity of about 800 m / min or less, such as a very slow linear velocity of less than about 1 m / min. As used herein, the term “linear velocity” refers to velocity through a single production line, and may be velocity through individual devices, velocity within a single device, or a combination thereof. Contrast with production rate, which may include several parallel production lines. In some embodiments, the porous body has a lower limit of about 800 m / min, 600 m / min, 500 m / min, 300 m / min, from a lower limit of about 1 m / min, 10 m / min, 50 m / min, or 100 m / min, Or can be produced by the method described herein at a linear velocity in the range up to an upper limit of 100 m / min, the linear velocity being in the range from any lower limit to any upper limit, between Any sub-combination of can be included. One skilled in the art will recognize that increased productivity in equipment may allow linear velocities in excess of 800 m / min (eg, 1000 m / min or higher). Those skilled in the art also have the ability to make a single device parallel lines (eg, two in FIG. 7) so as to increase the overall production rate of porous bodies and the like, for example, to several thousand m / min or more. It should also be understood that the above lines and other lines exemplified herein may be included.

  Some embodiments can include further processing the porous body. Suitable further processing steps include adding perfume or other additives, grinding step, drilling step, further forming step, multi-segment filter forming step, smoking article forming step, packaging step, shipping step, and these Any combination of these can be included, but is not limited to these.

  Some embodiments can include adding an additive to the matrix material, the porous body. Non-limiting examples of additives are provided below. A preferred method of addition is by applying the additive to at least a portion of the matrix material prior to the mechanical bonding step; after the mechanical bonding step, the additive while still in the mold By applying the additive after exiting the mold; by applying the additive after the cutting step; and by any combination thereof; adding the additive into the matrix material It can include, but is not limited to. Applying, soaking, dipping, submerging, soaking, rinsing, washing, painting, coating, pouring, sprinkling, spraying, placing, glazing It should be noted that, including, but not limited to, that, spreading, sticking, and any combination thereof. Further, applying includes, but is not limited to, surface treatments, implantation treatments, and any combination thereof, in which additives are at least partially incorporated into the components of the matrix material. Don't be. Those of ordinary skill in the art having the benefit of the disclosed invention will appreciate that the concentration of the additive depends at least on the composition of the additive, the size of the additive, the purpose of the additive, and the location within the process where the additive is added. Must understand.

  In some embodiments, the step of adding an additive can be performed before, during, and / or after the step of mechanically bonding the matrix material. Those skilled in the art who have the benefit of the disclosed invention will otherwise be affected by the degradation, modification, or mechanical coupling process and associated parameters (eg, elevated temperature and / or pressure). It is to be understood that the additive that is subjected is added after the mechanical coupling step and / or the parameter must be adjusted accordingly (eg, use of inert gas or reduced temperature). Don't be. As a non-limiting example, glass beads may be an additive to the matrix material. In that case, after the mechanical bonding step, the glass beads can be functionalized with other additives such as perfumes and / or active compounds.

  Some embodiments can include grinding after the porous body has been manufactured. The grinding process includes the methods and apparatus / components described above.

II. Methods of Forming Filters and Smokers Including Porous Materials Some embodiments can be to operably connect the porous material to a filter and / or filter compartment. Suitable filters and / or filter compartments include cellulose, cellulose derivatives, cellulose ester tow, cellulose acetate tow, cellulose acetate tow of less than about 10 denier per filament, cellulose acetate tow of greater than 10 denier per filament, randomly oriented cellulose acetate, paper Corrugated paper, polypropylene, polyethylene, polyolefin tow, polypropylene tow, polyethylene terephthalate, polybutylene terephthalate, coarse powder, carbon particles, carbon fiber, fiber, glass beads, zeolite, molecular sieve, second porous body, and these At least one of any combination can be included.

  In some embodiments, the porous body and other filter compartments are features such as concentric filter structures, paper packaging, cavities, vacancies, baffled vacancies, capsules, passageways, etc., and any combination thereof. Can be independently provided.

  In some embodiments, the porous body and other filter compartments can have substantially the same cross-sectional shape and / or outer periphery.

  In some implementations, the filter compartment can include a space that defines a cavity between the two filter compartments. The cavity can be filled with an additive, such as granular carbon, in some embodiments. The cavities, in some embodiments, can include capsules, such as polymer capsules, which themselves contain a catalyst. The cavity also includes, in some embodiments, a molecular sieve that reacts with a selected component in the smoke to remove the selected component without adversely affecting the desired scent component of the smoke. Alternatively, the concentration can be reduced. In one embodiment, the cavity may include tobacco as an additional fragrance. Insufficient filling of the selected material into the cavity, in some embodiments, this may be an interaction between the mainstream smoke component and the material in the cavity and other filter compartment (s). It should be noted that this may cause shortages.

  In some embodiments, the filter compartments can be combined or coupled to form a filter or filter rod. As used herein, the term “filter rod” refers to a long filter suitable for being cut into two or more filters. By way of non-limiting example, a filter rod comprising a porous body as described herein can have a length in the range of about 80 mm to about 150 mm in some embodiments, and can be used to tip a smoking device. Can be cut into filters having a length of about 5 to about 35 mm during (addition of tobacco column to the filter).

  The tipping operation can include combining or connecting a filter or filter rod described herein with a tobacco column. During the tipping operation, the filter rod comprising the porous body described herein may in some embodiments be first cut into a filter or cut into a filter during the tipping process. Can do. Further, in some embodiments, the tipping method can further comprise combining or connecting an additional compartment comprising paper and / or charcoal with a filter, filter rod or tobacco column.

  In the manufacture of filters, filter rods, and / or smoking devices, some embodiments wrap around these various components with paper to maintain these components in the desired arrangement and / or contact. The process of carrying out can be included. For example, manufacturing a filter and / or filter rod can include wrapping paper around a series of adjacent filter compartments. In some embodiments, the porous body wrapped with wrapping paper has an additional wrap disposed around it to maintain contact between the porous body and another compartment of the filter. be able to. Paper suitable for making filters, filter rods and / or smoking devices can include any of the papers described herein in connection with the process of wrapping the porous body. In some embodiments, the paper can include additives, sizing materials, and / or printing agents.

  In the manufacture of filters, filter rods, and / or smoking devices, some embodiments may include these adjacent components (eg, porous bodies, adjacent filter compartments, tobacco columns, etc., or any combination thereof) A) a bonding step. Preferred adhesives can include those that do not impart flavor or aroma under ambient and / or burning conditions. In some embodiments, the wrapping and adhering steps can be used in the manufacture of filters, filter rods, and / or smoking devices.

  Some embodiments described herein are porous rods comprising a plurality of organic particles and binder particles, wherein the plurality of organic particles and binder particles are bonded together at a plurality of contact points. A prepared porous body rod; a filter rod not having the same composition as the porous body rod; a porous body compartment and a filter compartment, respectively; A desired adjacent arrangement comprising a plurality of compartments, the plurality of compartments comprising at least some of the porous body compartments and at least some of the filter compartments. Forming an arrangement; fixing the desired adjacent arrangement with a paper wrapper and / or adhesive to provide a segmented elongated filter rod; Cutting the segmented elongate filter rod into segmented filter rods, the method so as to produce the segmented filter rod at a speed of about 800 m / min or less. To be implemented. Some embodiments can further include forming a smoking device using the segmented filter rod.

  As used herein, the term “adjacent arrangement” means that two filter compartments (or the like) are axially aligned so that one end of the first compartment is one end of the second compartment. Refers to the contact arrangement. Those skilled in the art will recognize that this adjacent arrangement is continuous (ie, not limitless, very long) with multiple compartments, or a length with at least two to more compartments. You will understand that it can be short.

  In some method embodiments described herein, the term “segmented” is used to clarify that various articles are modified, and an article comprising a porous body (eg, It should be noted that it should be considered as covered by the various embodiments described herein in relation to the filter and filter rod).

  Some embodiments described herein are a plurality of porous body compartments comprising a plurality of organic particles and binder particles, wherein the plurality of organic particles and binder particles are brought together at a plurality of contact points. Providing a plurality of filter compartments that do not have the same composition as the porous body compartment; a desired adjacent arrangement comprising a plurality of compartments, comprising: Forming a desired adjacent arrangement wherein the plurality of compartments include at least one of the porous body compartments and at least one of the filter compartments; And / or securing with an adhesive to produce a segmented filter and a segmented elongate filter rod, the method comprising: About 800 m / min bets of by filter rod is implemented to manufacture at a rate. Some embodiments can further include forming a smoking device using at least a portion of the segmented filter or the segmented filter rod.

  Referring now to FIG. 13, a schematic diagram of the process for manufacturing a segmented filter in this embodiment, the cellulose acetate filter rod 1310 is cut into 8 compartments (about 15 mm each) and the porous body filter rod 1312 is cut. Is cut into 10 compartments (about 12 mm each), resulting in segments 1314 and 1316, respectively. The segments 1314 and 1316 are then aligned in an alternating arrangement with the ends in contact, pressed together, wrapped with paper, and seam glued to provide a segmented long filter 1318. It is. In some embodiments, the segmented long filter 1318 is then cut approximately midway between every fourth cellulose acetate segment 1314 to place a portion of the cellulose acetate segment 1314 at each end. A segmented filter rod 1320 can be provided. Those skilled in the art who have the benefit of the present disclosure can use other sizes and arrangements of cellulose acetate segments and porous body segments to provide segmented long filters, which in turn It can be cut at any point to provide the desired segmented filter rod, eg, segmented filter rod 1320 ′, which includes five segments, with the porous body segment at the end. You will understand that. One skilled in the art should recognize that these embodiments are two of the many potential arrangements of segmented filter rods.

  In some embodiments, the above method can be adapted to accommodate more than two filter compartments. For example, the desired arrangement of elongate filter rods may include a first porous body compartment, a first filter compartment, and a second filter compartment in series; a first porous body compartment, a first second filter A compartment, a first first filter compartment, a second second filter compartment, a second porous body compartment, a third second filter compartment, a second first filter compartment, and a fourth The second filter compartment can be in series; Such an arrangement can be at least one embodiment useful for producing a filter comprising three compartments, as illustrated in FIG. 14, where FIG. 14 shows the long filter rod to the filter rod. And the filter rod is further cut twice resulting in a filter compartment comprising three compartments.

  In some embodiments, the capsule can be added so as to be wrapped between two adjacent compartments. As used herein, the terms “wrapped” or “wrapped” refer to being on the inside of the manufactured article and not directly exposed to the outside. Thus, wrapping between two adjacent compartments means that adjacent compartments are in contact, i.e. make them adjacent. In some embodiments, the capsule can be subdivided.

  In some embodiments, the filters described herein are manufactured using known instruments, for example, greater than about 25 m / min with automated instruments and slower with manual instruments. be able to. Although the production rate may be limited only by the capabilities of the instrument, in some embodiments, the filter compartment described herein may be from a lower limit of about 25 m / min, 50 m / min, or 100 m / min. , Approximately 800 m / min, 600 m / min, 400 m / min, 300 m / min, or 250 m / min can be combined to form filter rods at speeds up to the upper limit, the combined speed being at any lower limit To any upper limit, including any sub-combination in between.

  In some embodiments, the porous body used in the manufacture of the filters and / or filter rods described herein can be wrapped with paper. The paper, in some embodiments, can reduce damage and particulate generation due to mechanical manipulation of the porous body. Suitable papers for use in connection with protecting the porous body during operation include wood based paper, flax-containing paper, flax paper, functional paper (eg tar and / or carbon monoxide). Functionalized to reduce), special marking paper, colored paper, and any combination thereof. In some embodiments, the paper can be highly porous, corrugated, and / or have high surface strength. In some embodiments, the paper can be substantially non-porous, for example, less than about 10 CORESTA units.

  In some embodiments, a filter and / or filter rod comprising a porous body as described herein can be transported directly to a production line where it can be combined with a tobacco column to form a smoking device. . One embodiment of such a method comprises providing a filter rod comprising at least one filter compartment comprising a porous body as described herein comprising organic particles and binder particles; providing a tobacco column Cutting the filter rod through the center of the rod and across its longitudinal direction to form at least two filters having at least one filter compartment, each filter compartment comprising: Including a porous body comprising organic particles and binder particles; and at least one of the filters coupled to the tobacco column along the long axis of the filter and the long axis of the tobacco column; Forming a single smoking device.

  In other embodiments, the device filter and / or filter rod containing the porous body can be placed in a suitable container for storage until further use. Suitable storage containers include, but are not limited to, those commonly used in smoking filter technology such as crate, box, drum, bag, carton and the like.

  Some embodiments can include operably coupling a smokable material to a porous body (or a segmented filter comprising at least one of the above). In some embodiments, the porous body (or segmented filter comprising at least one of the above) can be in fluid communication with a smokable substance. In some embodiments, the smoking device can include a porous body (or a segmented filter that includes at least one of the above) in fluid communication with the smokable substance. In some embodiments, the smoking device comprises a housing capable of operably maintaining a porous body (or a segmented filter comprising at least one of the above) in fluid communication with the smokable substance. It may be. In some embodiments, the filter rod, filter, filter compartment, compartmentalized filter, and / or compartmentalized filter rod may be removable, replaceable, and / or disposable from the housing.

  As used herein, the term “smokable substance” refers to a substance that is capable of producing smoke when burned or heated. Suitable smokeable substances include tobacco such as yellow tobacco, oriental tobacco, turkish tobacco, cavendish tobacco, coloho tobacco, criollo tobacco, peric tobacco, shade tobacco, white burley tobacco, hot air dried tobacco, burley tobacco , Maryland tobacco, Virginia tobacco; tea leaves; medicinal herbs; carbonized or pyrolyzed components; inorganic filler components; and any combination thereof. Tobacco can have the form of tobacco leaf in the form of cut filler, treated tobacco stem, reconstituted tobacco filler, expanded capacity tobacco filler, and the like. Tobacco and other cultivated smokable materials may be cultivated in the United States or in jurisdictions other than the United States.

  In some embodiments, the smokable material can be in a column format, such as a tobacco column. As used herein, the term “tobacco column” refers to tobacco blends and optionally other ingredients that can be combined to produce tobacco-based smokable articles such as cigarettes or cigars. And perfume. In some embodiments, the tobacco column comprises tobacco, sugar (eg, sucrose, brown sugar, invert sugar, or high fructose corn syrup), propylene glycol, glycerin, cocoa, cocoa products, locust bean gum, locust bean extract, and Ingredients selected from the group consisting of any combination thereof may be included. In yet other embodiments, the tobacco column can further comprise a flavor, fragrance, menthol, licorice extract, diammonium phosphate, ammonium hydroxide, and any combination thereof. In some embodiments, the tobacco column may include additives. In some embodiments, the tobacco column can include at least one foldable element.

  Suitable housings can include cigarettes, cigarette holders, cigars, cigar holders, pipes, water pipes, hookers, electronic smokers, hand-rolled cigarettes, hand-rolled cigars, paper, and any combination thereof, but these It is not limited to.

  The step of packaging the porous body can include, but is not limited to, placing a tray or box or protective container, eg, a cigarette filter rod, into a tray typically used for packaging and shipping.

  In some embodiments, the filter and / or pack of smoking devices comprising the filter can include a porous body. The pack can be a hinge lid pack, a slide shell pack, a hard cup pack, a soft cup pack, a plastic bag, or any other suitable pack container. In some embodiments, the pack may have an exterior, such as a polypropylene wrapper, and optionally a tear tab. In some embodiments, the filter and / or smoking device may be enclosed as a bundle inside the pack. The bundle can contain multiple filters and / or smoking devices, eg, 20 or more. However, the bundle can also include a single filter and / or smoking device, and in some embodiments, a dedicated filter and / or smoking device embodiment, such as for individual sale, or vanilla, clove Or a filter and / or smoking device containing a special flavor such as cinnamon.

  In some embodiments, the carton of the smoking device pack comprises at least one smoking device comprising a filter (multiple segmented or not) comprising a porous body. Can contain a pack. In some embodiments, the carton (eg, container) has physical integrity that supports the weight of the pack of smoking devices. This can be accomplished by using a relatively thick card stock to form the carton, or using a relatively strong adhesive to bond the carton elements.

  Some embodiments can include shipping the porous body. The porous body can be individual, as at least part of a filter, as at least part of a smoking article, in a pack, in a carton, in a tray, or any combination thereof. Shipments can be trains, trucks, aircraft, ships / ships, or any combination thereof.

III. Porous body In some embodiments, the matrix material is from a lower limit of about 1 wt%, 5 wt%, 10 wt%, 25 wt%, 40 wt%, 50 wt%, 60 wt%, or 75 wt% of the matrix material. Active particles in an amount ranging up to an upper limit of about 99 wt%, 95 wt%, 90 wt%, or 75 wt%, wherein the amount of active particles ranges from any lower limit to any upper limit, , Any sub-combination in between can be included. In some embodiments, the matrix material has a lower limit of about 1 wt%, 5 wt%, 10 wt%, or 25 wt% of the matrix material to about 99 wt%, 95 wt%, 90 wt%, 75 wt%, 60 wt% of the matrix material, An amount of binder particles in the range up to an upper limit of 50 wt%, 40 wt%, or 25 wt% can be included, the amount of binder particles ranging from any lower limit to any upper limit, between Any sub-combination can be included.

  The active particles can be any material adapted to improve the performance of smoke flowing over it. A material adapted to improve the performance of smoke flowing thereon refers to any material that can remove, reduce or add components of the smoke stream. Removal or reduction (or addition) can be selective. By way of example, compounds such as those shown in the following list can be selectively removed or reduced from a smoke stream from a cigarette. This table is available from the US FDA (Food and Drug Administration) as a draft proposal for the first list of harmful / hazardous ingredients in tobacco products, including tobacco smoke, and some abbreviations in the list below Are well known chemicals in the art. In some embodiments, the active particles can reduce or eliminate at least one component selected from the following list of components in the smoke, or any combination thereof. Smoke flow components include, but are not limited to: acetaldehyde, acetamide, acetone, acrolein, acrylamide, acrylonitrile, aflatoxin B-1, 4-aminobiphenyl, 1-aminonaphthalene, 2-aminonaphthalene, ammonia, Ammonium salt, anabasine, anatabine, 0-anisidine, arsenic, A-α-C, benz [a] anthracene, benz [b] fluoroanthene, benz [j] aceanthrylene, benz [k] fluoroanthene, benzene, benzo (b) Furan, benzo [a] pyrene, benzo [c] phenanthrene, beryllium, 1,3-butadiene, butyraldehyde, cadmium, caffeic acid, carbon monoxide, catechol, chlorinated dioxin / furan, chromium, chrysene, cobalt , Coumarin, cresol, Crotonaldehyde, cyclopenta [c, d] pyrene, dibenz (a, h) acridine, dibenz (a, j) acridine, dibenz [a, h] anthracene, dibenzo (c, g) carbazole, dibenzo [a, e] pyrene , Dibenzo [a, h] pyrene, dibenzo [a, i] pyrene, dibenzo [a, l] pyrene, 2,6-dimethylaniline, ethyl carbamate (urethane), ethylbenzene, ethylene oxide, eugenol, formaldehyde, furan, Glu-P-1, glu-P-2, hydrazine, hydrogen cyanide, hydroquinone, indeno [l, 2,3-cd] pyrene, IQ, isoprene, lead, MeA-α-C, mercury, methyl ethyl ketone, 5-methylchrysene 4- (methylnitrosamino) -1- (3-pyridyl) -1-butanone (NNK), 4- (methyl Trosoamino) -1- (3-pyridyl) -1-butanol (NNAL), naphthalene, nickel, nicotine, nitrate, nitric oxide, nitrogen oxide, nitrite, nitrobenzene, nitromethane, 2-nitropropane, N-nitrosoana Basin (NAB), N-nitrosodiethanolamine (NDELA), N-nitrosodiethylamine, N-nitrosodimethylamine (NDMA), N-nitrosoethylmethylamine, N-nitrosomorpholine (NMOR), N-nitrosonornicotine (NNN) N-nitrosopiperidine (NPIP), N-nitrosopyrrolidine (NPYR), N-nitrososarcosine (NSAR), phenol, PhlP, polonium-210 (radioisotope), propionaldehyde, propylene oxide, pyridine, quinoline, Resorcinol, selenium, styrene, tar, 2-toluidine, toluene, Trp-P-1, Trp-P-2, uranium-235 (radioisotope), uranium-238 (radioisotope), vinyl acetate, vinyl chloride, And any combination thereof.

An example of the active particles is activated carbon (or activated charcoal or activated coal). The activated carbon can be low activity (about 50% to about 75% CCl ₄ adsorption) or high activity (about 75% to about 99% CCl ₄ adsorption) or a combination of both. In some embodiments, the activated carbon can include those derived from (eg, pyrolyzed from) coconut shell, coal, synthetic resin, and the like. Examples of commercially available carbon can include, but are not limited to, product grades provided by Calgon, Jacobi, Norit and other similar suppliers. As a non-limiting example, one of Norit's granular activated carbon products is NORIT ™ GCN 3070. In another example, Jacobi provides activated carbon in grades including CZ, CS, CR, CT, CX and GA-Plus with various particle sizes.

In some embodiments, the activated carbon comprises nanoscale carbon particles, such as any number of wall carbon nanotubes, carbon nanohorns, bamboo-like carbon nanostructures, fullerenes and fullerene aggregates, and several layers of graphene and graphene oxide Can be graphene. Other examples of active particles include ion exchange resin, desiccant, silicate, molecular sieve, silica gel, activated alumina, zeolite, perlite, sepiolite, acid clay, magnesium silicate, metal oxide (eg, iron oxide, about 12 nm) Iron oxide nanoparticles such as Fe ₃ O ₄ , manganese oxide, copper oxide, and aluminum oxide), gold, platinum, iodine pentoxide, nanoparticles (eg, metal nanoparticles such as gold and silver; such as alumina Metal oxide nanoparticles; various crystal structures of iron oxides such as gadolinium oxide, hematite and magnetite, gad nanotubes, and magnetic, paramagnetic, and superparamagnetic nanoparticles such as endofullerenes such as Gd @ C ₆₀ And onion-like nanoparticles such as gold and silver nanoshells, onion-like iron oxide, and any such material Other nanoparticles or microparticles), as well as any combination of the above (including activated carbon). The functional group may improve the removal of the smoke component and / or improve the incorporation of the nanoparticles into the porous body. The ion exchange resin is, for example, a polymer having a main chain, such as a styrene-divinylbenzene (DVB) copolymer, an acrylic polymer, a methacrylic polymer, a phenol formaldehyde condensate, and an epichlorohydrin amine condensate; Contains charged functional groups. In some embodiments, the active particles are a combination of various active particles. In some embodiments, the porous body can include a plurality of active particles. In some embodiments, the active particles can include at least one element selected from the group of active particles disclosed herein. It should be noted that “element” is used as a generic term to describe the items in the list. In some embodiments, the active particles are combined with at least one perfume.

  Suitable active particles can have at least one dimension of less than about 1 nanometer (eg, graphene) to a size on the order of particles having a diameter of about 5000 microns. The active particles have a lower limit size in at least one dimension of about 0.1 nanometer, 0.5 nanometer, 1 nanometer, 10 nanometer, 100 nanometer, 500 nanometer, 1 micron, 5 micron It can range from 10 microns, 50 microns, 100 microns, 150 microns, 200 microns, or 250 microns. The active particles have an upper limit size in at least one dimension of about 5000 microns, 2000 microns, 1000 microns, 900 microns, 700 microns, 500 microns, 400 microns, 300 microns, 250 microns, 200 microns, 150 microns, It can range from 100 microns, 50 microns, 10 microns, or 500 nanometers. Any combination of the above lower and upper limits may be suitable for use in the embodiments described herein, with the maximum size selected being greater than the minimum size selected . In some embodiments, the active particles can be a mixture of particle sizes ranging from the above lower limit to the upper limit. In some embodiments, the size of the active particles can be multimode.

  The binder particles can be any suitable thermoplastic binder particles. In some embodiments, the binder particles do not substantially flow at their melting temperature. This means a material that shows little or no polymer flow when heated to its melting temperature. Materials that meet these criteria include, but are not limited to, ultra high molecular weight polyethylene, very high molecular weight polyethylene, high molecular weight polyethylene, and combinations thereof. In one embodiment, the binder particles have a melt flow index (MFI, ASTM D1238 at 190 ° C. and 15 kg of about 3.5 g / 10 min or less (or about 0-3.5 g / 10 min at 190 ° C. and 15 kg). ). In another embodiment, the binder particles have a melt flow index (MFI) of about 2.0 g / 10 min or less at 190 ° C. and 15 kg (or about 0-2.0 g / 10 min at 190 ° C. and 15 kg). . An example of such a material is ultra high molecular weight polyethylene, UHMWPE (which has no polymer flow and has an MFI of about 0 at 190 ° C. and 15 kg, or an MFI of about 0 at 190 ° C. and 15 kg. -1.0) and another material is very high molecular weight polyethylene (VHMWPE), which has an MFI of about 1.0-2.0 g / at 190 ° C and 15 kg, for example. Can have a MFI in the range of 10 minutes), or high molecular weight polyethylene, HMWPE (which can have a MFI of about 2.0-3.5 g / 10 minutes at 190 ° C. and 15 kg, for example). Can be. In some embodiments, it may be preferable to use a mixture of binder particles having different molecular weights and / or different melt flow indexes.

With respect to molecular weight, “ultrahigh molecular weight polyethylene” as used herein refers to a polyethylene composition having a weight average molecular weight of at least about 3 × 10 ⁶ g / mol. In some embodiments, the molecular weight of the ultrahigh molecular weight polyethylene (ultrahigh molecular weight polyethylene) composition comprises about 3x10 ⁶ g / mol to about 30 × 10 ⁶ g / mol, or about 3x10 ⁶ g / mol to about 20x10 ⁶ g / mole, or about 3x10 ⁶ g / mol to about 10x10 ⁶ g / mol, or from about 3x10 ⁶ g / mol to about 6x10 ⁶ g / mol. “Very high molecular weight polyethylene” refers to a polyethylene composition having a weight average molecular weight of less than about 3 × 10 ⁶ g / mole and greater than about 1 × 10 ⁶ g / mole. In some embodiments, the molecular weight of a very high molecular weight polyethylene composition is from about 2 × 10 ⁶ g / mol to less than about 3 × 10 ⁶ g / mol. “High molecular weight polyethylene” refers to a polyethylene composition having a weight average molecular weight of at least about 3 × 10 ⁵ g / mole to 1 × 10 ⁶ g / mole. For the purposes of this specification, the molecular weights referred to herein are determined according to the Margolies equation ("Margolies molecular weight").

  Suitable polyethylene materials include several sources such as a division of Celanese, Dallas, Texas, USA, GUR ™ UHMWPE from Ticona Polymers, and DSM (Netherlands), Braskem (Brazil), It is commercially available from BASF Beijing second factory (China), Shanghai Chemical and Qilu (China), Mitsui Chemicals and Asahi Kasei (Japan). In particular, GUR ™ polymers are 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), GUR ™ X series (X143, X184, X168, X172, X192).

An example of a suitable polyethylene material is one having an intrinsic viscosity in the range of about 5 dl / g to about 30 dl / g and a crystallinity of about 80% or more, as described in US Patent Application Publication No. 2008/0090081. is there. Another example of a suitable polyethylene material is from about 300,000 g / mol to about 2, as measured by ASTM-D4020, described in International Application No. PCT / US2011 / 034947 filed May 3, 2011. It has a molecular weight in the range of 1,000,000 g / mol, an average particle size D ₅₀ of about 300 μm to about 1500 μm, and a bulk density of about 0.25 g / ml to about 0.5 g / ml.

  The binder particles can take any shape. Such shapes include spherical, hyperion-like, starfish-like, crondura, ie interplanetary dust-like, granular, potato-like, irregular, or combinations thereof. In preferred embodiments, binder particles suitable for being described herein are non-fibrous. In some embodiments, the binder particles are in the form of powder, pellets, or particulates. In some embodiments, the binder particles are a combination of various binder particles.

  In some embodiments, the binder particles have a lower size limit in a dimension in at least one direction of about 0.1 nanometer, 0.5 nanometer, 1 nanometer, 10 nanometer, 100 nanometer, 500 nanometer. It can range from 1 micron, 5 microns, 10 microns, 50 microns, 100 microns, 150 microns, 200 microns, and 250 microns. The binder particles have an upper size limit in a dimension in at least one direction of about 5000 microns, 2000 microns, 1000 microns, 900 microns, 700 microns, 500 microns, 400 microns, 300 microns, 250 microns, 200 microns, 150 microns, 100 It can range from microns, 50 microns, 10 microns, and 500 nanometers. Any combination of the above lower and upper limits may be suitable for use in the embodiments described herein, with the maximum size selected being greater than the minimum size selected . In some embodiments, the binder particles can be a mixture of particle sizes ranging from the above lower limit to the upper limit. In some embodiments, smaller diameter particles may be advantageous in that the heating to bind the binder particles together is faster, which may be due to the porosity described herein. It may be particularly useful in high productivity processes for manufacturing the body.

  Although the ratio of binder particle size to active particle size can include any repetition of what is defined by the size ranges described herein, a particular size ratio can be used for a particular application and / or May be advantageous for the product. As a non-limiting example, in a smoking device filter, the size of the active particles and binder particles must be such that the EPD can aspirate fluid through the porous body. In some embodiments, the ratio of binder particle size to active particle size is in the range of about 10: 1 to about 1:10, or more preferably in the range of about 1: 1.5 to about 1: 4. Can be.

In addition, the binder particles can have a bulk density in the range of about 0.10 g / cm ³ to about 0.55 g / cm ³ . In another embodiment, the bulk density may range from about 0.17 g / cm ³ to about 0.50 g / cm ³ . In yet another embodiment, the bulk density may range from about 0.20 g / cm ³ to about 0.47 g / cm ³ .

  In addition to the binder particles described above, other conventional thermoplastics can also be used as binder particles. Such thermoplastics include polyolefins, polyesters, polyamides (or nylon ™), acrylic polymers, polystyrene, polyvinyl, polytetrafluoroethylene (PTFE), polyetheretherketone (PEEK), any copolymer thereof, Including, but not limited to, any of these derivatives, and any combination thereof. Non-fibrous plasticized cellulose derivatives may also be suitable for use as the binder particles described herein. Examples of suitable polyolefins include, but are not limited to, polyethylene, polypropylene, polybutylene, polymethylpentene, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polyethylene further include, but are not limited to, low density polyethylene, linear low density polyethylene, high density polyethylene, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polyesters include polyethylene terephthalate, polybutylene terephthalate, polycyclohexylene dimethylene terephthalate, polytrimethylene terephthalate, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable acrylic polymers include, but are not limited to, polymethyl methacrylate, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable polystyrenes include polystyrene, acrylonitrile-butadiene-styrene, styrene-acrylonitrile, styrene-butadiene, styrene-maleic anhydride, any copolymer thereof, any derivative thereof, and any combination thereof. However, it is not limited to these. Examples of suitable polyvinyls include, but are not limited to, ethylene vinyl acetate, ethylene vinyl alcohol, polyvinyl chloride, any copolymer thereof, any derivative thereof, and any combination thereof. Examples of suitable cellulose derivatives include cellulose acetate, cellulose acetate butyrate, plasticized cellulose derivatives, cellulose propionate, ethyl cellulose, any copolymer thereof, any derivative thereof, and any combination thereof. It is not limited to. In some embodiments, the binder particles can be any copolymer, any derivative, and any combination of the binder particles listed above.

  In some embodiments, the binder particles described herein can be hydrophilic surface treated. Hydrophilic surface treatments (eg, oxygenated functional groups such as carboxy, hydroxy, and epoxy) are chemically oxidants, flames, ions, plasma, corona discharge, ultraviolet light, ozone, and combinations thereof (eg, ozonation and Can be achieved by exposure to at least one of (UV treatment). Since many of the active particles described herein are hydrophilic either as a function of their composition or as adsorbed water, hydrophilic surface treatment on the binder particles can be achieved by combining the binder particles with the active particles. The attractive force (for example, van der Waals force, static electricity, hydrogen bond, etc.) can be increased. This increased attractive force reduces segregation of active and binder particles in the matrix material, thereby varying the EPD, integrity, perimeter, cross-sectional shape and other properties of the resulting porous body. Can be minimized. Furthermore, this increased attractive force provides a more homogeneous matrix material, which increases the flexibility of the filter design (e.g. lowering the overall EPD, reducing the concentration of binder particles, Or both).

  In some embodiments, the matrix material and / or porous body can include active particles, binder particles, and additives. In some embodiments, the matrix material or porous body is from a lower limit of about 0.01 wt%, 0.05 wt%, 0.1 wt%, 1 wt%, 5 wt%, or 10 wt% of the matrix material or porous body. An additive in an amount ranging up to an upper limit of about 25 wt%, 15 wt%, 10 wt%, 5 wt%, or 1 wt% of the matrix material or porous body, wherein the amount of additive can be any lower limit To any upper limit, including any sub-combination in between.

  In some embodiments, the porous body can have a void volume ranging from about 40% to about 90%. In some embodiments, the porous body may have a void volume ranging from about 60% to about 90%. In some embodiments, the porous body may have a void volume in the range of about 60% to about 85%. The void volume is the free space left after taking into account the space occupied by the active particles.

Although not wishing to be bound by any particular theory to determine the void volume, it has been tested that the final density of the mixture appears to be determined almost exclusively by the active particles, and thus the binder The space occupied by the particles was not taken into account in this calculation. Thus, void volume is calculated in this context based on the space remaining after being occupied by active particles. To determine the void volume, the upper and lower diameters based on the mesh size are first averaged for the active particles, and then the density of the active particles is used (assuming a spherical shape based on the average diameter). The capacity was calculated. The void volume percentage is then calculated as follows:

  In some embodiments, the porous body can have an encapsulation pressure drop (EPD) in the range of about 0.10 to about 25 mm water column per mm length of the porous body. In some embodiments, the porous body may have an EPD in the range of about 0.10 to about 10 mm water column per mm length of the porous body. In some embodiments, the porous may have an EPD in the range of about 2 to about 7 mm water column per mm length of the porous body (or 7 mm water column or less per mm length of the porous body).

  In some embodiments, the porous body is about 20 mm water column or less per mm length, 19 mm water column or less per mm length, 18 mm water column or less per mm length, 17 mm water column or less per mm length, 16 mm per mm length. Water column or less, 15 mm water column or less per mm length, 14 mm water column or less per mm length, 13 mm water column or less per mm length, 12 mm water column or less per mm length, 11 mm water column or less per mm length, 10 mm water column or less per mm length , 9 mm water column or less per mm length, 8 mm water column or less per mm length, 7 mm water column or less per mm length, 6 mm water column or less per mm length, 5 mm water column or less per mm length, 4 mm water column or less per mm length, mm E of 3 mm or less water column per length, 2 mm or less water column per mm length, or 1 mm water column or less per mm length In combination with D, at least about 1 mg / mm, 2 mg / mm, 3 mg / mm, 4 mg / mm, 5 mg / mm, 6 mg / mm, 7 mg / mm, 8 mg / mm, 9 mg / mm, 10 mg / mm, 11 mg / mm, 12 mg / mm, 13 mg / mm, 14 mg / mm, 15 mg / mm, 16 mg / mm, 17 mg / mm, 18 mg / mm, 19 mg / mm, 20 mg / mm, 21 mg / mm, 22 mg / mm, 23 mg / mm, It can have an active particle loading of 24 mg / mm, or 25 mg / mm.

  By way of example, in some embodiments, the porous body can have an active particle loading of at least about 1 mg / mm and an EPD of about 20 mm water column or less per mm length. In other embodiments, the porous body may have an active particle loading of at least about 1 mg / mm and an EPD of about 20 mm water column or less per mm length, and the active particles are not carbon. In other embodiments, the porous body may have active particles comprising carbon at a loading of at least about 6 mg / mm in combination with EPD of 10 mm water column or less per mm length.

  In some embodiments, the porous body may be effective in removing components from tobacco smoke, such as those listed herein. Porous bodies can be used to reduce the release of certain tobacco smoke components targeted by the World Health Organization Framework Convention on the Regulation of Tobacco (“WHO FCTC”). As a non-limiting example, a porous body in which activated carbon is used as the active particles can be used to reduce the release of certain tobacco smoke components to a level below the recommended value for WHO FCTC. The components may include, but are not limited to, acetaldehyde, acrolein, benzene, benzo [a] pyrene, 1,3-butadiene, and formaldehyde in some embodiments. The porous body with activated carbon has acetaldehyde in the smoke stream of about 3.0% to about 6.5% per mm length of the porous body; acrolein in the smoke stream about 7% per mm length of the porous body. 0.5% to about 12%; benzene in the smoke stream from about 5.5% to about 8.0% per mm length of the porous body; benzo [a] pyrene in the smoke stream in mm length of the porous body About 9.0% to about 21.0% per thickness; 1,3-butadiene in the smoke stream from about 1.5% to about 3.5% per mm length of the porous body; and formaldehyde in the smoke stream May be reduced by about 9.0% to about 11.0% per mm length of the porous body. In another embodiment, porous bodies in which ion exchange resins are used as active particles can be used to reduce the release of certain tobacco smoke components below the recommended value for WHO. In some embodiments, the porous body having an ion exchange resin comprises acetaldehyde in the smoke stream from about 5.0% to about 7.0% per mm length of the porous body; Reducing the formaldehyde in the smoke stream by about 9.0% to about 11.0% per mm length of the porous body; and about 4.0% to about 6.5% per mm length of the mass; is there. Those skilled in the art should understand that the numerical values reported herein for the concentration of a particular smoke stream component may vary depending on the test procedure and tobacco blend. The amount of reduction quoted in this specification is the CORESTA recommended method No. 74 refers to a carbonyl value test by the same method as 74, ie, a method for measuring selected carbonyl groups in cigarette mainstream smoke by high performance liquid chromatography using the smoking procedure proposed by Health Canada. Sample cigarettes were prepared from a commercial US brand by manually replacing a standard cellulose acetate filter with a double segmented filter consisting of a porous body segment and a cellulose acetate segment. The length of the porous body segment varied between 5 and 15 mm.

IV. Additives Suitable additives are active compounds, ionic resins, zeolites, nanoparticles, microwave enhancing additives, ceramic particles, glass beads, softeners, plasticizers, pigments, dyes, perfumes, fragrances, controlled release vesicles , Adhesives, tackifiers, surface modifiers, vitamins, peroxides, biocides, antifungal agents, antibacterial agents, antistatic agents, flame retardants, decomposition agents, and any combination thereof Although it can, it is not limited to these.

  Suitable active ingredients are compounds and / or molecules suitable for removing ingredients from the smoke stream, such as malic acid, potassium carbonate, citric acid, tartaric acid, lactic acid, ascorbic acid, polyethyleneimine, cyclodextrin, sodium hydroxide, It can include, but is not limited to, sulfamic acid, sodium sulfamate, polyvinyl acetate, carboxylated acrylic esters, and any combination thereof. It should be noted that the active particles can be considered as active compounds and vice versa. As a non-limiting example, fullerenes and some carbon nanotubes can be considered fine particles and molecules.

  Suitable ionic resins include polymers having a backbone, such as styrene-divinylbenzene (DVB) copolymer, acrylic polymer, methacrylic polymer, phenol formaldehyde condensate, and epichlorohydrin amine condensate; a plurality attached to the polymer backbone Of charged functional groups, and any combination thereof, but is not limited thereto.

Zeolites can include crystalline aluminosilicates having pores, eg, channels, or cavities of uniform molecular size dimensions. Zeolites can include natural and synthetic materials. Suitable zeolites are zeolite beta (Na ₇ (Al ₇ Si ₅₇ O ₁₂₈ ) tetragonal), zeolite ZSM-5 (Na _n (Al _n Si _96-n O ₁₉₂ ) 16 H ₂ O, n <27), zeolite A, zeolite X, zeolite Y, zeolite KG, zeolite ZK-5, zeolite ZK-4, mesoporous silicate, SBA-15, MCM-41, MCM48 modified with 3-aminopropylsilyl group, It can include, but is not limited to, aluminophosphates, mesoporous aluminosilicates, other related porous materials (such as, for example, mixed oxide gels), and any combination thereof.

Suitable nanoparticles are nanoscale carbon particles such as carbon nanotubes of any number of walls, carbon nanohorns, bamboo-like carbon nanostructures, fullerenes and fullerene aggregates, and graphene including several layers of graphene and graphene oxide; Metal nanoparticles such as gold and silver; metal oxide nanoparticles such as alumina, silica, and titania; various crystal structures of iron oxides such as gadolinium oxide, hematite and magnetite, about 12 nm Fe ₃ O ₄ Magnetic, paramagnetic, and superparamagnetic nanoparticles such as gad nanotubes, and endofullerenes such as Gd @ C ₆₀ ; and gold and silver nanoshells, onion-like iron oxide, and the outer shell of any such material Other nanoparticles and microparticles, including core-shell and onion-like nanoparticles; and It can include serial (including activated carbon) any combination without limitation. Nanoparticles are nanorods, nanospheres, nanoliths, nanowires, nanostars (such as nanotripods and nanotetrapods), hollow nanostructures, hybrid nanostructures that are two or more nanoparticles bonded together, It should be noted that non-nanoparticles having nanocoating or nanothickness walls may also be included. Nanoparticles are functionalized derivatives of nanoparticles, such as, but not limited to, covalent and / or non-covalent bonds such as pie stacking, physisorption, ionic association, van der Waals association, etc. It should be further noted that functionalized nanoparticles can be included. Suitable functional groups are amines (primary, secondary or tertiary), amides, carboxylic acids, aldehydes, ketones, ethers, esters, peroxides, silyls, organosilanes, hydrocarbons, aromatic hydrocarbons, and A molecular moiety comprising any combination of these; a polymer; a chelating agent such as a structure comprising ethylenediaminetetraacetic acid, diethylenetriaminepentaacetic acid, triglycolamic acid, and a pyrrole ring; and any combination thereof However, it is not limited to these. The functional group may improve the removal of smoke components and / or improve the incorporation of nanoparticles into the porous body.

  Suitable microwave enhancing additives can include, but are not limited to, microwave responsive polymers, carbon particles, fullerenes, carbon nanotubes, metal nanoparticles, water, and the like, and any combination thereof.

  Suitable ceramic particles include oxides (eg, silica, titania, alumina, beryllia, ceria, and zirconia), non-oxides (eg, carbides, borides, nitrides, and silicides), composites thereof, and Any combination of these may be included, but is not limited to these. The ceramic particles can be crystalline, non-crystalline, or semi-crystalline.

  As used herein, “pigment” refers to compounds and / or particles that are incorporated into the matrix material and / or its components throughout that impart color. Suitable pigments are titanium dioxide, silicon dioxide, tartrazine, E102, phthalocyanine blue, phthalocyanine green, quinacridone, perylenetetracarboxylic acid diimide, dioxazine, perinone disazo pigment, anthraquinone dye, carbon black, titanium dioxide, metal powder, iron oxide , Ultramarine, and any combination thereof.

  As used herein, “dye” refers to a compound and / or particle that is a surface treatment that imparts color. Suitable dyes are CARTASOL ™ dyes (cationic dyes available from Clariant Services), liquid and / or particulate (eg, CARTASOL ™ Brilliant Yellow K-6G liquid, CARTASOL ™ Yellow K). -4GL liquid, CARTASOL (TM) Yellow K-GL liquid, CARTASOL (TM) Orange K-3GL liquid, CARTASOL (TM) Scarlet K-2GL liquid, CARTASOL (TM) Red K-3BN liquid, CARTASOL (R) Blue K-5R liquid, CARTASOL (TM) Blue K-RL liquid, CARTASOL (TM) Turquoise K-RL liquid / granular, CARTASOL (TM) B row K-BL liquid), FASTUSOL ™ dye (auxiliary color group available from BASF) (eg, Yellow 3GL, Fastusol C Blue 74L), but is not limited thereto.

  Suitable perfumes are any perfume suitable for use in a smoking device filter and may include those that impart a taste and / or flavor to the smoke stream. Suitable perfumes can include, but are not limited to, organic materials (or naturally flavored particles), natural perfume carriers, artificial perfume carriers, and any combination thereof. Organic materials (or naturally flavored particles) include, but are not limited to, tobacco, cloves (eg, clove powder and clove flour), cocoa, coffee, tea, and the like. Natural and artificial fragrances can include, but are not limited to, menthol, cloves, cherries, chocolate, orange, mint, mango, vanilla, cinnamon, tobacco, and the like. Such flavors can be provided by, but not limited to, menthol, anethole (licorice), anisole, limonene (citrus), eugenol (clove), and any combination thereof. In some embodiments, multiple fragrances may be used, including any combination of fragrances provided herein. These perfumes may be placed in the tobacco column, filter compartment, or porous body described herein. The amount of fragrance depends on the desired level of flavor in the smoke, but takes into account all filter compartments, smoking tool length, smoking tool type, smoking tool diameter, and other factors known to those skilled in the art. Be put in.

  Suitable fragrances are methyl formate, methyl acetate, methyl butyrate, ethyl acetate, ethyl butyrate, isoamyl acetate, pentyl butyrate, pentyl pentanoate, octyl acetate, myrcene, geraniol, nerol, citral, citronellal, citronellol, linalool, nerolidol , Limonene, camphor, terpineol, alpha-ionone, tujon, benzaldehyde, eugenol, cinnamic aldehyde, ethyl maltol, vanilla, anisole, anethole, estragole, thymol, furaneol, methanol, spice, spice extract, herbal extract, essential oil, Care products, volatile organic compounds, volatile small molecules, methyl formate, methyl acetate, methyl butyrate, ethyl acetate, ethyl butyrate, isoamyl acetate, pentyl butyrate, pentyl pentanoate, octyl acetate Myrcene, geraniol, nerol, citral, citronellal, citronellol, linalool, nerolidol, limonene, camphor, terpineol, alpha-ionone, tujon, benzaldehyde, eugenol, cinnamic aldehyde, ethyl maltol, vanilla, anisole, anethole, estragole, thymol, Furaneol, methanol, rosemary, lavender, citrus, freesia, apricot blossom, leaf vegetable, peach, jasmine, rosewood, pine, thyme, oak moss, musk, vetiver, myrrh, black currant, bergamot, grapefruit, acacia, passiflora, sandalwood, Tonka beans, mandarin, neroli, violet leaf, gardenia, red fruit, ylang-ylang, snapper, mimosa, tonka beans, wood, Burgundy, daffodil, hyacinth, daffodil, black currant bud, iris, raspberry, lily of the valley, sandalwood, vetiver, cedarwood, neroli, bergamot, strawberry, carnation, oregano, honey, civet, hiriotrope, caramel, coumarin, patchouli, dewberry, heroial , Bergamot, hyacinth, coriander, pimento berry, lovedanum, goldfish, bergamot, aldehyde, orchid, strawberry, benzoin, oris, gecko, palmarosa, cinnamon, nutmeg, moss, egonoki, pineapple, bergamot, foxglove, tulip, wisteria, clematis, Ambergris, Gum, Resin, Civet, Peach, Plum, Kaiyuka, Myrrh, Geranium, Rose Violet, Scratch , Spicy carnation, galvanum, hyacinth, petit glen, iris, hyacinth, honeysuckle, pepper, raspberry, benzoin, mango, coconut, hesperides, marine incense, moss, mousse de chine, nectarine, mint, anise, cinnamon, oris, apricot , Plumeria, marigold, rose oil, narcissus, trubal sam, frankincense, strawberry, orange flower, bourbon vetiver, opopanax, white musk, papaya, rock sugar, jackfruit, honey, lotus flower, muguet, mulberry, sagebrush, ginger , Juniper berries, odorant penzoin, buttons, violets, lemon, lime, hibiscus, white rum, basil, lavender, balsam, camellia, spider, carocalonde, white orchid, Larily, White Rose, Labrum Lily, Manjugiku, Ambergris, Atlantic Ivy, Lawn, Seringa, Spearmint, Clary Sage, Boxwood, Grape, Blueberry, Lotus, Cyclamen, Orchid, Glycine, Tiare Flower, Ginger Lily, Green Oxanthus, Passiflora, Blue Rose, balam, snapper, african sunflower, anatolian rose, auberge daffodil, british cod, brim chocolate, bulgaria rose, chinese patchouli, chinese gardenia, calabria mandarin, comoros gekkakou, ceylon cardamom, caribbean passion fruit, damask rose, georgia Peach, White Madonna Lily, Egyptian Jasmine, Egyptian Marigold, Ethiopian Civet Farnesia kingfisher, Florence iris, French jasmine, French geissen, French hyacinth, Guinea orange, Guyana wakapua, Grass petit glen, Grass rose, Grass geese, Haitian vetiver, Hawaii pineapple, Israel basil, Indian sandalwood, Indian ocean Vanilla, Italian Bergamot, Italian Iris, Jamaican Pepper, Mayborough, Madagascar Ylang Ylang, Madagascar Carbanilla, Moroccan Jasmine, Moroccan Rose, Moroccan Oak Moss, Moroccan Orange Flower, Mysore Sandalwood, Oriental Rose, Russian Leather, Russian Coriander, Sicily Mandarin, South African Mary Gold, South African Tonka Bean, Singapore Patchouli, Spanish Orange Flower, Sicilian Lime, Reuni On Island vetiver, Turkish rose, Thai benzoin, Tunisian orange flower, Yugoslav oak moss, Virginia cedarwood, Utah, Western Indian rosewood, etc., and any combination thereof may be included.

  Suitable tackifiers are methylcellulose, ethylcellulose, hydroxyethylcellulose, carboxymethylcellulose, carboxyethylcellulose, water soluble cellulose acetate, amide, diamine, polyester, polycarbonate, silyl modified polyamide compound, polycarbamate, urethane, natural resin, shellac, acrylic acid Polymer, 2-ethylhexyl acrylate, acrylic ester polymer, acrylic acid derivative polymer, acrylic acid homopolymer, acrylic ester homopolymer, poly (methyl acrylate), poly (butyl acrylate), poly (2-ethylhexyl acrylate) ), Acrylate copolymer, methacrylic acid derivative polymer, methacrylic acid homopolymer, methacrylic acid ester homopolymer, poly ( Methyl tacrylate), poly (butyl methacrylate), poly (2-ethylhexyl methacrylate), acrylamide-methyl-propane sulfonate polymer, acrylamide-methyl-propane sulfonate derivative polymer, acrylamide-methyl-propane sulfonate copolymer, acrylic acid / acrylamide -Methyl-propanesulfonate copolymer, benzylcocodi- (hydroxyethyl) quaternary amine, formaldehyde condensed p-T-amino-phenol, (meth) acrylate dialkylaminoalkyl, acrylamide, N- (dialkylaminoalkyl) acrylamide, methacrylamide , Any derivative thereof such as hydroxyalkyl (meth) acrylate, methacrylic acid, acrylic acid, hydroxyethyl acrylate, etc. And it can include any combination of these, but not limited to.

  Suitable vitamins can include, but are not limited to, vitamin A, vitamin B1, vitamin B2, vitamin C, vitamin D, vitamin E, or any combination thereof.

  Suitable antibacterial agents include antibacterial metal ions, chlorhexidine, chlorhexidine salts, triclosan, polymoxine, tetracycline, aminoglycosides (eg gentamicin), rifampicin, bacitracin, erythromycin, neomycin, chloramconifer, miconazole, quinolone, penicillin, nonoxynol 9 , Fusidic acid, cephalosporin, mupirocin, metronidazole cecropin, protegrin, bacteriocin, defensin, nitrofurazone, maphenide, acyclovir, vancomycin, clindamycin, lincomycin, sulfonamide, norfloxacin, pefloxacin, nalidixic acid, oxalic acid, enoxacin Acid, ciprofloxacin, polyhexamethylene biguanide (PHMB), PHM Derivatives (eg biodegradable biguanides such as polyethylene hexamethylene biguanide (PEHMB)), chlorhexidine gluconate, chlorhexidine hydrochloride, ethylenediaminetetraacetic acid (EDTA), EDTA derivatives (eg EDTA disodium or EDTA tetrasodium) and the like, and Any combination of these may be included, but is not limited to these.

  The antistatic agent, in some embodiments, can include any suitable anionic, cationic, amphoteric, or nonionic antistatic agent. Antistatic agents can generally include, but are not limited to, alkaline sulfates, alkaline phosphates, phosphate esters of alcohols, phosphate esters of ethoxylated alcohols, and any combination thereof. Some examples may include alkali neutralized phosphate esters (eg, TRYFAC ™ 5559 or TRYFAC ™ 5576 available from Henkel, Inc., Mulldin, South Carolina, USA) However, it is not limited to these. Cationic antistatic agents can generally include, but are not limited to, quaternary ammonium salts and positively charged imidazolines. Examples of nonionic antistatic agents include poly (oxyalkylene) derivatives, such as ethoxylated fatty acids such as EMERSEST ™ 2650 (ethoxylated fatty acids available from Henkel, Mulldin, South Carolina, USA) Ethoxylated fatty alcohols such as TRYCOL ™ 5964 (ethoxylated lauryl alcohol available from Henkel, Mulldin, South Carolina, USA), TRYMEEN ™ 6606 (Henkel, Mulldin, South Carolina, USA) Ethoxylated fatty amines such as ethoxylated tallow amine, available from the company, EMID ™ 6545 (diethanolamine oleate available from Henkel, Mulldin, South Carolina, USA) Alkanolamides such as), and any combination thereof. Anionic and cationic materials tend to be more effective antistatic agents.

  Although porous bodies and the like are mainly discussed herein for smoking article filters, porous bodies and the like are not limited to fluid filters (or parts thereof) in other applications, such as: It should be noted that it can be used as liquid filtration, water purification, electric vehicle air filter, medical equipment air purifier, household air purifier etc. Those skilled in the art who have the benefit of the present disclosure can make modifications and / or restrictions necessary to adapt the present disclosure to other filtration applications, such as the size, shape, size ratio, and matrix material of the matrix material components. You must understand the composition of the ingredients. As a non-limiting example, the matrix material can be molded into other shapes, such as a hollow cylinder for a concentric water filter composition or a pleated sheet for an air filter.

  In some embodiments, the system includes a material path with a mold disposed along its material path, at least one hopper in front of at least a portion of the mold that supplies matrix material to the material path, A heat source in thermal communication with at least the first portion and a cutter disposed along the material path after the first portion of the material path may be provided.

  Some embodiments may include continuously introducing matrix material into the mold and placing a release wrapper as the mold lining. Furthermore, the embodiment heats at least a portion of the matrix material to bond the matrix material at a plurality of contact points, thereby forming an elongated porous body, and radially extending the elongated porous body. Cutting to thereby yield a porous body.

  Some embodiments include the step of continuously introducing the matrix material into the mold, combining at least one of the matrix materials at a plurality of contact points, thereby forming an elongated porous body. Heating the part, thereby forming a long porous body, and extruding the long porous body through a die.

  In some embodiments, the system can include a mold, the mold comprising at least two mold parts, wherein the first conveyor includes the first mold part and the second conveyor is the second. Includes mold parts. The first conveyor and the second conveyor combine the first mold part and the second mold part together to form a mold, and then the first mold part in a continuous manner to the second mold part. It can have the ability to be separated from the part. The system may further include a hopper capable of filling the mold with the matrix material and a heat source in thermal communication with at least the first portion of the mold for converting the matrix material into a porous body.

  Some embodiments include introducing the matrix material into a plurality of molds, and heating the matrix material within the molds to bond the matrix material at a plurality of contact points, thereby forming a porous body. Steps may be included.

Embodiments disclosed herein include the following:
A. Supplying a matrix material into a mold by high concentration phase air supply to form a desired cross-sectional shape, wherein the matrix material includes a plurality of binder particles and a plurality of active particles; Heating at least a portion of the matrix material to bond at least a portion of the matrix material at a plurality of sintered contact points thereby forming an elongated porous body; cooling the elongated porous body And cutting the elongated porous body, thereby producing the porous body;
B. Supplying a matrix material into a mold by high concentration phase air supply to form a desired cross-sectional shape, the matrix material comprising a plurality of active particles and a plurality of binder particles having hydrophilic surface modification Heating at least a portion of the matrix material to bond at least a portion of the matrix material at a plurality of sintered contact points, thereby forming an elongated porous body; A step of re-forming a cross-sectional shape of the long porous body; a step of cooling the long porous body; and a step of cutting the long porous body and thereby producing the porous body. , And C.I. Supplying a matrix material into a mold by high-concentration phase air supply to form a desired cross-sectional shape, the matrix material comprising a plurality of active particles and a plurality of binder particles having hydrophilic surface modification And including a microwave enhancing additive; heating at least a portion of the matrix material by irradiating the matrix material with microwave radiation to sinter at least a portion of the matrix material Bonding at the contact point, thereby forming a long porous body; re-forming the cross-sectional shape of the long porous body after heating; cooling the long porous body; and the long Cutting the porous body, thereby producing the porous body.

  Each of Embodiments A, B, and C can have one or more of the following additional elements in any combination. That is, in Element 1, the high concentration phase air supply is performed at a supply speed of about 1 m / min to about 800 m / min; in Element 2, the high concentration phase air supply is about 1 m / min to about 800 m / min. Performed at the feed rate and the mold has a diameter of about 3 mm to about 10 mm; in Element 3, heating comprises irradiating at least a portion of the matrix material using microwave radiation; In matrix 5, the matrix material further comprises a microwave enhancing additive; in element 5, the mold is at least partially formed by a paper wrapper; in element 6, the binder particles have a hydrophilic surface treatment; The method further comprises reshaping the cross-sectional shape of the elongate porous body after heating; in element 8, the method reheats the elongate porous body before cutting, thereby Shape the second plurality of sintered contact points In element 9, the method further comprises reheating the porous body, thereby forming a second plurality of sintered contact points; in element 10, the porous body Is a sheet suitable for use in an air filter; in element 11, the porous body is a sheet with a thickness of about 5 mm to about 50 mm; in element 12, the porous body is used for a smoking article filter In element 13, the porous body is suitable for use in a water filter; and in element 14, the porous body is a hollow cylinder.

  By way of non-limiting example, typical combinations applicable to A, B, C include: That is, element 1 combined with element 3; element 2 combined with element 3; element 4 combined with any previous element; element 3 combined with element 4; elements 7-9 Any combination of any previous elements; element 7 combined with element 8; element 7 combined with element 9; element 7 combined with element 3; element 5 Any one of elements 10-14 combined with any previous element; element 6 combined with any previous element; and element 6 And one of elements 1 to 4 combined.

In order to facilitate a better understanding of the embodiments described herein, the following examples of representative embodiments are presented. The following examples should in no way be read as limiting or defining the scope of the invention.
Example

  To measure integrity, the sample is placed in a French square glass bottle and stirred vigorously for 5 minutes using a wrist action shaker. After completion, the weight of the sample before and after stirring is compared. The difference is converted into a percent loss amount. This test simulates degradation under extreme conditions. Less than 2% weight loss is considered acceptable quality.

Porous body samples were made with GUR 2105 with carbon additive, and GUR X192 with carbon additive was made both with and without paper packaging. The sample was a cylinder having a size of 8 mm × 20 mm. The results of the integrity test are shown in Table 1 below.

  This example demonstrates that increasing the proportion of binder (GUR) in the porous body and using a wrapper (paper) increases the integrity of the porous body. Furthermore, the porous body can be configured to have the same integrity as a Dalmatian filter (plasticized carbon-on-toe filter), since this porous body increases the removal of smoke components. Used for.

  To measure the amount of particles released when gas is aspirated through the filter (or porous body), the sample is sucked without a liquid flavor and the released particles are collected on a Cambridge pad .

The particle release characteristics of the porous body were compared with a Dalmatian filter (plasticized carbon-on-toe filter). The sample is an 8 mm × 20 mm cylinder (1) a porous body containing 333 mg of carbon, (2) a porous body containing 338 mg of pre-washed carbon, and (3) 74 mg of carbon. It was a Dalmatian filter. Table 2 below shows the results of the particle release test.

  In this example, the porous body of the present invention is a particle that is released upon suction even though it has a carbon loading of many times, in this example 4.5 times that of a Dalmatian filter. Demonstrate that the quantities are equivalent. Furthermore, when the porous body is treated such as washing, the release of particles can be reduced. Other mitigation measures include increasing the binder concentration in the porous body, increasing the degree of mechanical bonding in the porous body (eg, by increasing the time spent at the bonding temperature), There may be optimization of the size and shape of the additive (eg, carbon).

  Matrix material consisting of 80% by weight carbon (PICCATIF, ie 60% activated carbon available from Jacobi) and 20% by weight GUR ™ 2105 is mixed and put into a paper tube closed at one end. It was. The filled tube was placed in a microwave oven (about 300 W and about 2.45 GHz) and irradiated for 75 seconds. A significant portion of the matrix material joined and was cut into two compartments, 17 mm and 21 mm. These compartments of the porous body were analyzed and showed EPDs of 8.4 mm water column / mm length and 2.7 mm water column / mm length, respectively.

  This example demonstrates that microwave irradiation can be applied to the production of porous bodies and the like. As discussed above, microwave irradiation, in some embodiments, can be used in addition to other techniques in the formation of the porous bodies and the like described herein.

A first matrix material consisting of 80 wt% carbon (PICCATIF, ie 60% activated carbon available from Jacobi) and 20 wt% GUR ™ 2105, and 80 wt% carbon (PICCATIF, Jacobi) For each of the second matrix materials consisting of 20% by weight plasma treated GUR ™ 2105 (ie an example of a hydrophilic surface-modified binder) Two porous materials were prepared. The properties of the obtained porous material were measured (Table 3). The ellipticity of the porous body is measured using a method similar to that used to measure the ellipticity of a conventional cigarette filter, in which a perimeter / ellipticity tester optically samples the sample. To measure the outer circumference, the maximum diameter (a), and the minimum diameter (b). The ellipticity is calculated as ab, and indicates the degree of deformation of the cross-sectional shape from a circle to an ellipse.

  For each of these measurements, especially for EPD, the standard deviation of the porous body containing the plasma treated GUR ™ 2105 is less than that of the untreated GUR ™ 2105. Furthermore, when comparing EPD values between samples, plasma treated GUR ™ 2105 yields a lower EPD than untreated GUR ™ 2105 for the same binder particle concentration. This example shows that binder particles with a hydrophilic surface minimize the variation in properties of the porous body (as indicated by the reported coefficient of variation) and reduce the total EPD of the porous body. To demonstrate.

Two samples of matrix material were used to prepare the porous body. (1) Control: 10% by weight GUR ™ 2105, 10% by weight GUR ™ 2122, 80% by weight activated carbon, and (2) Graphite: 10% by weight GUR ™ 2105, 10 % By weight GUR ™ 2122, 79% by weight activated carbon, 1% by weight powdered graphite (available from McMaster-Carr) (ie an example of a microwave enhancing additive). This matrix material was fed into a mold formed by paper wound into a tube / cylindrical shape by high concentration phase air feeding at 60 psi (414 kPa). The mold containing the matrix material in it was passed through the single mode, 2.45 GHz microwave chamber at 2 m / min. The microwave input energy was changed in various ways. The resulting porous body was analyzed for EPD, perimeter, and rod integrity (as measured above) (Table 4).

  This example improves the microwave sintering process as evidenced by a decrease in EPD, including the microwave enhancement additive, and with the same degree of microwave power, comparable to improved rod integrity. To demonstrate.

  In view of the foregoing, the present invention is well suited to accomplish the unique features of the present invention along with the objects and advantages thereof described. The present invention may be modified and implemented in a different manner, but in an equivalent manner that will be apparent to one of ordinary skill in the art having the benefit of the teachings herein, so that the particulars disclosed above This embodiment is for illustration only. Furthermore, no limitation to the details of construction or design shown herein is intended except as set forth in the claims below. Accordingly, the specific exemplary embodiments disclosed above may be altered, combined or modified, and all such variations are within the scope and spirit of the invention. It is clear that it is considered. The invention appropriately disclosed in the present specification is practiced without any elements not specifically disclosed in the specification and / or any optional elements disclosed in the present specification. Can do. Although compositions and methods are described in terms of “comprising”, “containing”, or “including” various components or steps, these compositions and methods The method can “consist essentially of” or “consist of” various components or steps. All numbers and ranges disclosed above may vary by some amount. Whenever a range of numbers having a lower limit and an upper limit is disclosed, any number contained in the range and any included range is also specifically disclosed. In particular, as disclosed herein (in the form of “about a to about b”, or equivalently “approximately a to b”, or equivalently “approximately ab”). All numerical ranges are to be understood as describing all numbers and ranges encompassed within that wider numerical range. Also, the terms of the claims have their plain and ordinary meanings unless expressly and explicitly defined otherwise by the patentee. Moreover, the indefinite article “a” or “an” as used in the claims is defined herein to mean one or more of the elements it introduces. Any conflict in the usage of a word or term in this specification and any conflict between one or more patents or other documents that may be incorporated herein by reference is consistent with this specification. Definition must be adopted.

Claims (18)

Supplying a matrix material into a mold by high-concentration phase air supply to form a desired cross-sectional shape, wherein the matrix material includes a plurality of binder particles and a plurality of active particles;
Heating at least a portion of the matrix material to bond at least a portion of the matrix material at a plurality of sintered contact points, thereby forming an elongated porous body;
Cooling the elongate porous body; and cutting the elongate porous body, thereby producing a porous body;
The high concentration phase air supply is performed at a supply speed of about 1 m / min to about 800 m / min, and the mold has a diameter of about 5 mm to about 25 mm .
Method.   The method of claim 1, wherein the high concentration phase air feed is performed at a feed rate of about 1 m / min to about 800 m / min, and the mold has a diameter of about 3 mm to about 10 mm.   The method of claim 1, wherein heating comprises irradiating the at least a portion of the matrix material using microwave radiation. The method of claim 3 , wherein the matrix material further comprises a microwave enhancing additive.   The method of claim 1, wherein the mold is at least partially formed by a paper wrapper.   The method according to claim 1, wherein the binder particles are subjected to a hydrophilic surface treatment.   The method according to claim 1, further comprising the step of re-forming the cross-sectional shape of the elongated porous body after heating.   The method of claim 1, further comprising reheating the elongate porous body prior to cutting, thereby forming a second plurality of sintered contact points.   The method of claim 1, further comprising reheating the porous body, thereby forming a second plurality of sintered contact points. Supplying a matrix material into a mold by high concentration phase air supply to form a desired cross-sectional shape, wherein the matrix material has a plurality of active particles and a plurality of binder particles having hydrophilic surface modification A process comprising:
Heating at least a portion of the matrix material to bond at least a portion of the matrix material at a plurality of sintered contact points, thereby forming an elongated porous body;
Re-forming the cross-sectional shape of the elongated porous body after heating;
Cooling the elongate porous body; and cutting the elongate porous body, thereby producing a porous body;
And wherein the high concentration phase air feed is performed at a feed rate of about 1 m / min to about 800 m / min and the mold has a diameter of about 5 mm to about 25 mm . 11. The method of claim 10 , wherein the high concentration phase air feed is performed at a feed rate of about 1 m / min to about 800 m / min and the mold has a diameter of about 3 mm to about 10 mm. The method of claim 10 , wherein heating comprises irradiating the at least a portion of the matrix material using microwave radiation. The method of claim 12 , wherein the matrix material further comprises a microwave enhancing additive. The method of claim 10 , wherein the mold is at least partially formed by a paper wrapper. The method of claim 10 , further comprising reheating the elongated porous body prior to cutting, thereby forming a second plurality of sintered contact points. The method of claim 10 , further comprising reheating the porous body, thereby forming a second plurality of sintered contact points. Supplying a matrix material into a mold by high-concentration phase air supply to form a desired cross-sectional shape, wherein the matrix material includes a plurality of active particles and a plurality of binder particles having hydrophilic surface modification And including a microwave enhancing additive;
At least a portion of the matrix material is heated by irradiating the matrix material using microwave radiation to bond at least a portion of the matrix material at a plurality of sintered contact points, thereby creating a long porous Forming a material;
Re-forming the cross-sectional shape of the elongated porous body after heating;
Cooling the elongate porous body; and cutting the elongate porous body, thereby producing a porous body;
And wherein the high concentration phase air feed is performed at a feed rate of about 1 m / min to about 800 m / min and the mold has a diameter of about 5 mm to about 25 mm . 18. The method of claim 17 , further comprising the step of reheating the elongated porous body prior to cutting, thereby forming a second plurality of sintered contact points.

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