KR20150064199A - Apparatuses, systems, and associated methods for forming porous masses for smoke filters - Google Patents

Abstract

High throughput manufacturing equipment, systems and related methods may include pneumatic compacted phase feed. For example, the method may include feeding a matrix material comprising binder particles and active particles to a mold cavity through a pneumatic compacted feed to form a desired cross-sectional shape; Heating at least a portion of the matrix material (e.g., via microwave irradiation) to bond the matrix at a plurality of contact points to form a porous body elongate; Cooling the porous body elongate; And cutting the porous article elongate in a radial direction to produce a porous article. In some cases, the matrix material may comprise a plurality of active particles, a plurality of binder particles (optionally including a hydrophilic surface modification), and optionally a microwave enhancement additive.

Description

[0001] APPARATUSES, SYSTEMS, AND ASSOCIATED METHODS FOR FORMING POROUS MASSES FOR SMOKE FILTERS [0002]

Exemplary embodiments described herein relate to an apparatus, system, and associated method, including corresponding high throughput manufacturing practices, for producing a porous mass that can be used in a smoke filter.

Centers for Disease Control and Prevention reports that in 2012, more than 300 billion cigarettes and more than 13 billion cigars were sold in the United States alone. In short, tobacco and cigars are constantly being sought around the world.

Increasingly, government regulations can potentially require higher filtration efficiencies in removing harmful components from tobacco smoke. In the case of current cellulose acetate, higher filtration efficiency can be achieved by doping the filter with particles such as increasing concentrations of activated charcoal. However, increasing the particulate concentration changes the smokers' draw characteristics.

One measure of the suction characteristics is the encapsulated pressure drop. The term "encapsulation pressure drop" or "EPD ", as used herein, refers to a condition in which the volume flow rate at the outlet end is 17.5 ml / sec and the specimen is fully encapsulated within the measuring device Refers to the static pressure difference between the two ends of the specimen as the air flow traverses the specimen underneath. EPD was measured here under the recommendation method # 41 of CORESTA ("Cooperation Center for Scientific Research Relative to Tobacco") in June 2007. A higher EPD value translates to a smoker needing to draw in a larger force in the smoking device.

Since increasing the filter efficacy alters the EPD of the filter, the public and thus the manufacturer has been reluctant to adopt significantly different technologies. Thus, despite continued research, there remains interest in developing improved and more effective compositions which, while removing certain constituents at a higher level in mainstream tobacco smoke, have minimal effect on the aspiration characteristics. In addition, the solution should include the mass production method needed to meet the smoking needs of the market.

The following drawings are included to illustrate specific aspects of the invention and are not to be regarded as an exclusive embodiment. The disclosure is not intended to limit the scope of the invention as defined by the appended claims and equivalents thereof, as may occur to those skilled in the art.
Figures 1A-b illustrate non-limiting examples of systems for forming porous bodies according to one or more embodiments described herein (but not necessarily accumulation).
Figures 2a-b illustrate non-limiting examples of systems for forming porous bodies in accordance with one or more embodiments described herein (but not necessarily accumulation).
Figure 3 illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
FIG. 4 illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 5 illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
6A illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 6b illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 7a illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 7b illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 8 illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 9 shows a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 10 illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 11 illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 12 illustrates a non-limiting example (but not necessarily an accumulation) of a system for forming a porous body in accordance with one or more embodiments described herein.
Figure 13 illustrates an exemplary illustration of a combined filter rod manufacturing method according to at least some embodiments described herein.
Figure 14 illustrates an exemplary illustration of at least some of the methods described herein for forming a filter in accordance with at least some embodiments described herein.

Exemplary embodiments described herein relate to an apparatus, system, and related methodology, including a corresponding high throughput manufacturing implementation, for manufacturing a porous article that can be used in a smoke filter.

The exemplary embodiments described herein provide a method and apparatus (and / or system) for high throughput production of porous articles having acceptable smoke stream properties, which can be used in a smoking device filter and have increased smoke stream component filtration efficiency do.

The porous body (described in co-pending PCT application No. PCT / US11 / 56388, filed Oct. 14, 2011, the entire disclosure of which is incorporated herein by reference) generally comprises a plurality of binder Particles (e. G., Polyethylene) and a plurality of active particles (e. G., Carbon particles or zeolites). The contact point may 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 at least partially keeps two particles together. Mechanical bonding is generally the result of sintering. Thus, when described herein, mechanical bonding encompasses embodiments in which a plurality of binder particles and a plurality of active particles are mechanically bonded at a plurality of sintered contact points. Mechanical bonding can be rigid or flexible depending on the bonding material. Mechanical bonding may or may not involve chemical bonding. As used herein, the terms "particle" and "particulate" are used interchangeably and refer to a variety of materials, including spherical and / or ovoid, substantially spherical and / or ovoid, discular and / or plate, flake, Materials of any known shape including polygons (e.g., cubes), random shapes (e.g., crushed rock shapes), marbles (e. G., Crystalline shapes) . PCT / US2011 / 043264, PCT / US2011 / 043268, PCT / US2011 / 043269 and PCT / US2011 / 043271, both filed July 7, 2012, the entire disclosures of which are incorporated herein by reference. Additional non-limiting examples of porous bodies are described in detail herein.

The porous body can be produced by various methods. For example, in some embodiments, the matrix material (e.g., active particles and binder particles) is formed into a desired shape (e.g., using a mold) and the matrix material is heated to mechanically bond the matrix material to each other , And closing the porous body (e.g., cutting the porous body to a desired length). Of the various processes / steps involved in the production of the porous article, forming and heating the matrix material into the desired shape while maintaining homogeneous dispersion can be two steps that limit high throughput manufacturing. Thus, it is contemplated that methods of using a pneumatic compacted phase feed may be used in high throughput manufacturing of the porous bodies described herein (e.g., from about 1 m / min to about 800 m / min, or from about 300 m / min to about 800 m / Flow rate). ≪ / RTI > It is also contemplated that rapid heating (e. G., Microwave, and optionally microwave enhancement additives for matrix materials, including indirect heating with or indirect contact with the heated gas) ) May be included in some preferred methods for high throughput production of the porous bodies described herein. Further, in a further preferred high throughput manufacturing embodiment, if the rapid heating portion of the process is designed to sinter or mechanically bond a portion (e.g., an outer portion) of the matrix material, quality control or complete sintering Secondary sintering or heating may be used.

The term "smoking device " as used herein includes, but is not limited to, tobacco, cigarette holders, cigars, cigar holders, pipes, water pipes, hookahs, electronic smoking devices, self- Including, but not limited to,

It should be noted that the term " about "modifies each number in the list of numbers when" about "is provided herein with respect to the numbers in the list of numbers. In some numerical range lists, it should be noted that some of the lower limits listed may be larger than some of the upper limits enumerated. Those of ordinary skill in the art will appreciate that the selected subset will require the selection of an upper limit that exceeds the selected lower limit.

I. Method and Apparatus for Formation of Porous Body

The process of forming the porous body may include a continuous process, a batch process, or a hybrid continuous-batch process. As used herein, "continuous treatment" refers to the manufacture or production of a material without interruption. The material flow can be continuous, peristaltic, or a combination of both. As used herein, the term " batch processing " refers to the step of advancing the single component or group to the next station after manufacturing or producing the material as a single component or group of components in the individual station. As used herein, the term " continuous-batch processing "refers to two types of hybridization in which some processes or series of processes are performed in a continuous fashion and others are performed in a batch process.

Generally, the porous body can be formed from a matrix material. As used herein, the term "matrix material" refers to a precursor, e. G., Binder particles and active particles, used to form a porous article. In some embodiments, the matrix material comprises, consists of, or is essentially composed of binder particles and active particles. In some embodiments, the matrix material may comprise binder particles, active particles, and additives. Non-limiting examples of suitable binder particles, active particles and additives are provided in the present disclosure.

The formation of the porous body is generally accomplished by forming the matrix material into a desired shape (e.g., suitable for introduction into something such as a smoking device filter, water filter, air filter, etc.), and at least a portion of the matrix material (E. G., Sintering).

Formation of the matrix material into a single shape may involve a mold cavity. In some embodiments, the mold cavity may be a single piece or a collection of single pieces with or without end caps, plates, or caps. In some embodiments, the mold cavity may be a plurality of mold cavity parts that form the mold cavity during assembly. In some embodiments, the mold cavity components can be assembled with aids such as conveyors, belts, and the like. In some embodiments, the mold cavity component may be stationary along a material path and configured to allow a conveyor, belt, etc. to pass therethrough, wherein the mold cavity is positioned radially to provide a desired level of compression to the matrix material Expand and contract.

The mold cavity may include, but is not limited to, any of a variety of shapes including, but not limited to, circular, substantially circular, oval, substantial oval, polygonal (e.g., triangular, square, rectangular, pentagonal etc.), polygonal with rounded edges, toroidal, Sectional shape. In some embodiments, the porous body may have a cross-sectional shape comprising apertures, which may be formed by the use of one or more dies, by machining, by suitably molded mold cavities, or by any other suitable method Lt; / RTI > In some embodiments, the porous article may have a particular shape for a cigarette holder or pipe adapted to fit within a cigarette holder or pipe to enable smoke to pass through the filter to the consumer. When discussing the shape of the porous article herein with respect to a conventional smoking device filter, the shape may be referred to in terms of the diameter or circumference of the cylindrical cross-section (where the circumference is the circumference of the circle). However, in embodiments where the porous article described herein is in a shape other than an intrinsic cylinder, it will be understood that the term "circumference" is used to mean the circumference of a cross-section of any shape, including a circular cross-section.

In general, the mold cavity may have a radial direction perpendicular to the longitudinal and longitudinal directions, e.g., a shape that is substantially cylindrical. Those of ordinary skill in the art will know how to interpret the embodiments presented herein for molded cavities, e.g., spheres and cuboids, where the length and radial orientation are not predetermined, where applicable. In some embodiments, the mold cavity may have a cross-sectional shape that varies along the longitudinal direction, for example, a conical shape, a shape that transitions from square to circular, or a spiral. In some embodiments that use a sheet-shaped mold cavity (e.g., formed by an opening between two plates), the longitudinal direction may be the machine direction or the direction of flow of the matrix material. In some embodiments, the mold cavity can be a paper of a desired cross-sectional shape, for example, a cylindrical wound or molded. In some embodiments, the mold cavity may be a source of paper bonded in a longitudinal seam.

In some embodiments, the mold cavity has a longitudinal axis and may have an opening and a second end as a first end along the longitudinal axis. In some embodiments, the matrix material may be passed along the longitudinal axis of the mold cavity during processing. By way of non-limiting example, FIG. 1 shows a mold cavity 120 having a longitudinal axis along a material path 110.

In some embodiments, the mold cavity has a longitudinal axis and may have a first end and a second end along the longitudinal axis, wherein at least one end is closed. In some embodiments, the closed end may be open.

In some embodiments, the individual mold cavities may be filled with a matrix material prior to mechanical engagement. In some embodiments, a single mold cavity can be used to continuously produce a porous article by continuously passing the matrix material before and / or during mechanical bonding. In some embodiments, a single mold cavity can be used to produce the individual porous article. In some embodiments, the single mold cavity can be reused and / or continuously reused to produce multiple individual porous bodies.

In some embodiments, the mold cavity may be at least partially lined with a wrapper and / or coated with a release agent. In some embodiments, the wrapper may be a separate wrapper, e.g., a piece of paper. In some embodiments, the wrapper may be a spoolable length of wrapper, such as 50 ft. Of roll paper.

In some embodiments, the mold cavity can be lined with more than one wrapping paper. In some embodiments, forming the porous body may include lining the mold cavity (s) with the wrapper (s). In some embodiments, forming the porous article may include wrapping the matrix material in a wrapper so that the wrapper effectively forms a mold cavity. In this embodiment, the wrapper may be preformed as a mold cavity, molded as a mold cavity in the presence of the matrix material, or packaged around the matrix material, which is a preformed shape (e.g., with the aid of a tackifier) . In some embodiments, the wrapper may be fed continuously through the mold cavity. The wrapper can hold the porous article in a uniform shape, can release the porous article from the mold cavity, help pass the matrix material through the mold cavity, protect the porous article during handling or transportation, .

Suitable packaging materials include paper (e.g., wood-based paper, paper containing flax, flax paper, paper made from other natural or synthetic fibers, functionalized paper, special marking paper, But are not limited to, fluorinated polymers such as polytetrafluoroethylene, silicon), films, coated paper, coated plastics, coated films, and the like, and any combinations thereof. In some embodiments, the wrapper may be paper suitable for use in a smoking device filter.

In some embodiments, the wrapper may be self-attached (e. G., Glued) to help maintain the desired shape, e. G., A substantially cylindrical configuration. In some embodiments, the mechanical bonding of the matrix material may also mechanically bond (or sinter) the matrix material to the wrapper, which may alleviate the need to attach the wrapper itself.

Suitable release agents may be chemical or physical release agents. Non-limiting examples of chemical mold release agents can include oils, oil-based solutions and / or suspensions, saponified solutions and / or suspensions, coatings bonded to mold surfaces, etc., and any combination thereof. Non-limiting examples of physical release agents include paper, plastic, and any combination thereof. A physical release agent, which may be referred to as a release wrapper, may be implemented similar to a wrapper as described herein.

Once molded into the desired cross-sectional shape using a mold cavity, the matrix material can be mechanically bonded at multiple contact points. Mechanical bonding may occur during and / or after the matrix material is in the mold cavity. Mechanical bonding can be achieved without the adhesive using heat and / or pressure (i.e., forming sintered contact points). In some cases, an adhesive may optionally be included.

The heat can be radiant heat, convection heat, convection heat and any combination thereof. Heating may include, but is not limited to, heated fluid within the mold cavity, heated fluid outside the mold cavity, secondary radiation from components of the heated inert gas, porous body (e.g., nanoparticles, active particles, etc.) A heating furnace, a flame, a conductive or thermoelectric material, an ultrasonic wave, etc., and any combination thereof. As a non-limiting example, heating may involve a convection oven or a heating block. Another non-limiting example may involve heating using microwave energy (single-mode or multi-mode application devices). In another non-limiting example, heating may involve passing heated air, nitrogen, or other gas through the matrix material while in the mold cavity. In some embodiments, a heated inert gas may be used to alleviate any unwanted oxidation of the active particles and / or additive. Another non-limiting example may involve a mold cavity made of a thermoelectric material to allow the mold cavity to heat. In some embodiments, heating may involve passing the heated gas through the matrix material through a combination of the above, e.g., a matrix material, into a microwave oven.

In some embodiments, secondary radiation from components of the porous article (e.g., nanoparticles, active particles, etc.) may be irradiated by electromagnetic radiation, such as gamma radiation, X-rays, UV light, visible light, IR light, Radio wave and / or long wave radio wave. As a non-limiting example, the matrix material may include carbon nanotubes that emit heat upon irradiation with a radio frequency wave. In yet another non-limiting example, the matrix material can be an active particle that can convert microwave irradiation to heat (which can help mechanically bond or mechanically bond (e.g., sinter) the binder particles together) , Such as carbon particles. In some embodiments, the electromagnetic radiation can be tuned by frequency and power levels to properly interact with the selected component. For example, activated carbon may be used with microwaves at frequencies in the range of about 900 MHz to about 2500 MHz with a fixed or adjustable power setting selected to meet the target heating rate.

Those of ordinary skill in the art will appreciate that electromagnetic radiation of different wavelengths penetrate the material to different depths. Thus, when using primary or secondary radiation, the material, composition and composition of the mold cavity, the matrix material composition, the components that convert electromagnetic radiation into heat, the wavelength of the electromagnetic radiation, the intensity of the electromagnetic radiation, , For example, the amount of heat.

The residence time of the pressure application (including by any of the methods described herein, including by exposure to convection ovens or electromagnetic radiation) and / or inducing mechanical bonding (e. G., Sintered contact points) It can be from 1 minute, 1 minute, 1 second, 5 seconds, 30 seconds, or 1 minute to 1 minute, 15 minutes, 5 minutes, 1 minute, or 1 second. Where the residence time can range from any lower limit to any upper limit and encompasses any subset therebetween. In the case of a faster process, such as a continuous process using exposure to electromagnetic radiation such as microwaves, a short residence time of, for example, about 10 seconds or less, or more preferably about 1 second or less, may be desirable It should be noted that. In addition, treatment methods using a process such as convective heating can provide a longer residence time on a time scale of minutes, which can include residence times in excess of 30 minutes. It will be appreciated by those of ordinary skill in the art that a longer period of time, such as a few seconds to a few minutes or more, may be applicable, but that a suitable temperature and heating profile for a given matrix material may be selected. It should be noted that, as used herein, preheating and / or pre-treatment methods and / or steps, not to a temperature and / or pressure sufficient to enable mechanical bonding, are not considered part of the residence time.

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 a temperature above which the material is softened and typically below the melting point of the material.

In some embodiments, the mechanical bond may be from about 300 占 폚, 275 占 폚, 250 占 폚, 225 占 폚, 200 占 폚, 175 占 폚, or 150 占 폚 from a lower limit of about 90 占 폚, 100 占 폚, 110 占 폚, 120 占 폚, 130 占 폚, , Wherein the temperature ranges from any lower limit to any upper limit and can encompass any subset therebetween. In one embodiment, heating may be achieved by applying the material to a single temperature. In another embodiment, the temperature profile may vary over time. As a non-limiting example, a convection oven may be used. In some embodiments, the heating may be localized into the matrix material. As a non-limiting example, the secondary radiation from the nanoparticles can only heat the matrix material proximate the nanoparticles.

In some embodiments, the matrix material may be preheated before entering the mold cavity. In some embodiments, the matrix material may be preheated to a temperature below the softening temperature of the components of the matrix material. In some embodiments, the matrix material may be preheated to a temperature about 10%, about 5%, or about 1% lower than the softening temperature of the components of the matrix material. In some embodiments, the matrix material may be preheated to a temperature about 10 [deg.] C, about 5 [deg.] C, or about 1 [deg.] C below the softening temperature of the components of the matrix material. Preheating may involve a heat source including those listed as the heat source for achieving non-limiting mechanical engagement.

In some embodiments, bonding the matrix material can yield a porous body or a porous mass length. As used herein, the term "porous body extender " refers to a continuous porous body (i.e., a porous body that can be made in a continuous fashion and is not absolutely finished but longer than a porous body). As a non-limiting example, the porous body extensions may be made by continuously passing a matrix material through a heated mold cavity. In some embodiments, the binder particle retains its original physical shape during the mechanical bonding process (or maintains its original shape substantially, e.g., less than 10% in shape change (e.g., shrinkage) from the beginning) In other words, the binder particles may be substantially the same shape in the matrix material, and in the porous body (or extensions). For simplicity and readability, unless otherwise specified, the term "porous article" encompasses a porous compartment, a porous article, and a porous article extension (such as a packaged article).

In some embodiments, the porous body extensions may be cut to produce the porous body. Cutting can be accomplished using a cutter. Suitable cutters include, but are not limited to, blades, hot blades, carbide blades, stellite blades, ceramic blades, hardened steel blades, diamond blades, smoothing blades, serrated blades, lasers, pressurized fluids, liquid lances, gas lances, guillotines, Combinations thereof, but are not limited thereto. In some embodiments with high speed processing, the cutting blade or similar device may be positioned at an angle that yields a porous article having an end perpendicular to the longitudinal axis in accordance with the processing speed. In some embodiments, the cutter may change the position relative to the porous article elongate along the longitudinal axis of the porous article elongate.

In some embodiments, the porous article and / or the porous article elongate may be extruded. In some embodiments, the extrusion may involve a die. In some embodiments, the die may have a plurality of apertures capable of extruding a porous article and / or a porous article elongate.

Some embodiments may involve radially cutting the porous and / or porous body extensions to yield a porous and / or porous body compartment. Those of ordinary skill in the art will know how radial cuts are interpreted and encompassed by sheet-like cuts. The cutting can be accomplished by any known method using any known apparatus, including those described above in connection with cutting the porous body elongate body into a non-limiting porous body.

The length of the porous article or compartments thereof may be from about 150 mm, 100 mm, 50 mm, 25 mm, 15 mm, or about 100 mm from a lower limit of about 2 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25 mm, Up to an upper limit of 10 mm, where the length ranges from any lower limit to any upper limit and may encompass any subset therebetween.

The circumference of the porous body extension, the porous body or its compartments (packaged, etc.) is about 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, 60 mm, 50 mm, 40 mm, 30 mm, 20 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 , 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 , Where the circumference ranges from any lower limit to any upper limit and can encompass any subset therebetween.

One of ordinary skill in the art will know the dimensional requirements for a porous article configured for a filtration device other than a smoking article. As a non-limiting example, a porous body configured for use in a concentric fluid filter may be a hollow source having an outer diameter of at least about 250 mm. As another non-limiting example, a porous body configured for use as a sheet in an air filter may have a relatively thin thickness (e.g., from about 5 mm to about 50 mm) with a length and width of a few tens of centimeters.

Some embodiments may involve wrapping the porous article in a wrapping paper after the matrix material is mechanically bonded, for example after being removed from the mold cavity or outflowed from the extrusion die. Suitable packaging materials include those disclosed above.

Some embodiments may involve cooling the porous body. Cooling can be active or passive, in other words cooling can be assisted or it can be done naturally. Active cooling may include passing the fluid onto and / or through the porous body of the mold cavity; Reducing the temperature of the local environment around the mold cavity, the porous body, and passing it through, for example, a cooled component; And any combination thereof. Active cooling may involve, without limitation, components that may include cooling coils, fluid jets, thermoelectric materials, and any combination thereof. The cooling rate can be random or controlled.

Some embodiments may involve transporting the porous article to another location. Suitable transport forms may include, but are not limited to, transport, transport, coiling, pushing, transport, robot movement, and the like, and any combination thereof.

Those of ordinary skill in the art will be aware of a number of devices and / or systems capable of manufacturing porous articles. By way of non-limiting example, Figures 1-12 illustrate a number of devices and / or systems from which porous articles can be made.

It should be noted that, where a system is used, it is within the scope of the present disclosure to have a device that uses the components of the system and vice versa.

For ease of understanding, the term "material path" is used herein to identify the path through which a matrix material, a porous body elongate, and / or a porous body migrate in a system and / or device. In some embodiments, the material pathway may be continuous. In some embodiments, the material path can be discontinuous. As a non-limiting example, a system for batch processing using a plurality of independent mold cavities can be considered to have a discontinuous material path.

1a-b, system 100 may include a hopper 122 operatively connected to material path 110 to supply a matrix material (not shown) to material path 110. [ The system 100 is also operatively connected to the material path 110 to supply the paper 130 to the material path 110 to form a wrapper substantially surrounding the matrix material between the mold cavity 120 and the matrix material. And a connected paper feeder 132. The heating element 124 is in thermal communication with the matrix material while in the mold cavity 120. The heating element 124 may cause the matrix material to mechanically bond at multiple points (e.g., by forming sintered contact points) to yield a packaged porous body elongate (not shown). After the packaged porous article extrudate has flowed out of the mold cavity 120 and has cooled appropriately, the cutter 126 is cut into the packaged porous article and / Thereby yielding a porous article compartment.

1a-b show that the system 100 may be at any angle. Those of ordinary skill in the art will appreciate the configuration considerations when adjusting the angle at which the system 100, or any part thereof, is located. By way of 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 within the mold cavity 120. In some embodiments, the mold cavities may be vertical and horizontal or at an angle between them.

In some embodiments, feeding the matrix material to the material path may be accomplished by any suitable means, including, but not limited to, a manual feed, a positive feed, a mass flow feed, a gravity feed, a pressurized vessel (e.g., a pressurized hopper or pressurized tank), an auger May include any suitable feeder system, including, but not limited to, a screw, a chute, a slide, a conveyor, a tube, a conduit, a channel, and the like and any combination thereof. In some embodiments, the material path includes, but is not limited to, garniture, compression mold, flow compression mold, ram press, piston, shaker, extruder, double screw extruder, solid state extruder, And a mechanical part between the hopper and the mold cavity, including the combination. In some embodiments, the feed is selected from the group consisting of a forced feed, a controlled feed, a volumetric feed, a mass flow feed, a gravity feed, a vacuum-assisted feed, a fluidized powder feed, a pneumatic dense phase feed (e.g., a slug flow, a dune, Or through an irregular Dune flow, shear layer or ripple flow and extrusion flow), pneumatic dilution phase feed, and any combination thereof.

In some embodiments, feeding the matrix material with the pneumatic compacted phase feed to the material path can advantageously enable high throughput processing. Pneumatic compacted feeds have been performed at high flow rates using large diameter outlets, but unexpectedly at this point, even small diameters have been found to be effective at high speeds. For example, it has been surprisingly found that the use of a pneumatic coarse phase feed provides a high throughput (e. G., About 6.1 mm tubing outlets (e. G., About 5 mm to about 25 mm and about 5 mm to about 10 mm) Lt; RTI ID = 0.0 > kg / hr < / RTI > or about 500 m / min. By comparison, the gravity feed typically yields less than about 10 m / min at similar diameters, and the pneumatic compacted feed can be performed at similar rates using an outlet that is greater than 50 mm in size. The combination of small diameters and high throughputs in matrix materials, particularly granular or particulate matrix materials, has not been expected. Those of ordinary skill in the art will appreciate the appropriate size and shape of the outlet of the pneumatic compact phase feeder for receiving the mold cavity. By way of non-limiting example, the outlet may be similar in shape to the mold cavity, but smaller than the mold cavity and extend into the mold cavity. In another example, the outlet may be configured to receive a mold cavity for a sheet porous article (e.g., a long rectangular-shaped outlet) or a hollow cylindrical porous article (e.g., a donut-shaped outlet).

In addition, the pneumatic compacted phase feed process can advantageously mitigate particle migration and separation, which can be particularly problematic when the size and / or shape of the binder and active particles are different. While not wishing to be bound by theory, it is believed that the air pressure applied in the pressurized hopper creates plug flow of the matrix material, which minimizes particulate separation and consequently provides a more uniform and consistent matrix material composition at the outlet of the feeder . In some embodiments, the pressurized hopper may be designed for mass flow. The mass flow conditions may vary, in particular, depending on the inclination of the pressure hopper inner wall, 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 from a lower limit of about 1 m / min, 10 m / min, 25 m / min, 100 m / min, or 150 m / min, up to an upper limit of 500 m / min, 500 m / min, 400 m / min, 300 m / min, 200 m / min, or 150 m / min, wherein the feed rate ranges from any lower limit to any upper limit Range, and can encompass any subset between them. In some embodiments, 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 relative to the material path in combination with the mold cavity having a width of from about 1 m / min, 10 m / min, 25 m / min, 100 m / min or 150 m / min to about 800 m / min Min, 600 m / min, 500 m / min, 400 m / min, 300 m / min, 200 m / min or up to an upper limit of 150 m / min, wherein the feed rate and mold cavity diameter Range from any lower limit to any upper limit and may encompass any subset therebetween. It will be appreciated by those of ordinary skill in the art that the combination of the achievable diameter (or shape) and the feed rate is dependent on the size and shape of the particles in the matrix material in particular, other components (e.g., additives), matrix material permeability and degassing constants in the matrix material, (E.g., the length of the piping, as further described herein), the delivery system configuration, and the like, and any combination thereof.

In some embodiments, the pneumatic flow may be characterized by a solid-to-fluid ratio of about 15 or greater. In some embodiments, the pneumatic flow is characterized by a solid-to-fluid ratio ranging from a lower limit of about 15, 20, 30, 40 or 50 to an upper limit of about 500, 400, 300, 200, 150, 130, Where the solid to fluid ratio ranges from any lower limit to any upper limit and can encompass any subset therebetween. The solid-to-fluid ratio may vary depending on the type of pneumatic compacted feed, in particular where the extruded dense phase feed is typically made at a higher value.

In some embodiments, the pneumatic coarse phase feed comprises applying an air pressure from a lower limit of about 1 psig, 2 psig, 5 psig, 10 psig, or 25 psig to about 150 psig, 125 psig, 100 psig, 50 psig, or 25 psig Where the air pressure ranges from any lower limit to any upper limit and can encompass any subset therebetween. The air pressure can be any of a number of gases, such as inert gases (e.g., nitrogen, argon, helium, etc.), oxygenated gases, heated gases, dry gases (E. G., Heated and dried inert gas such as nitrogen or argon). ≪ / RTI > Examples of systems that include pneumatic compacted phase feed are included herein.

In some embodiments, the feed can be interlocked to enable insertion of the spacer material at predetermined intervals. Suitable spacer materials can include additives, solid barriers (e.g., mold cavity parts), porous barriers (e.g., paper and release wrappers), filters, cavities, and the like, and any combination thereof. In some embodiments, the feed may involve shaking and / or vibration. Those of ordinary skill in the art will appreciate the extent of the appropriate agitation and / or vibration, for example homogeneously distributed matrix material comprising large binder particles and small active particles may be negatively influenced by vibration That is, homogeneity may be at least partially lost. It will also be appreciated by those of ordinary skill in the art that the supply parameters and / or the effects of the feeder on the final properties of the resulting porous article, such as at least the void volume (discussed further below), the encapsulation pressure drop And the effect on composition homogeneity.

In some embodiments, the matrix material or components thereof may be dried before being introduced into the material path and / or along the material path. In some embodiments, drying may be accomplished by heating the matrix material or components thereof, blowing dry gas onto the matrix material or components thereof, and any combination thereof. In some embodiments, the matrix material may have a water content of less than or equal to about 10 wt%, less than or equal to about 5 wt%, or more preferably less than or equal to about 2 wt%, and in some embodiments, less than or equal to 0.01 wt%. The moisture content can be analyzed by known methods involving lyophilization or weight loss after drying.

2a-b, system 200 may include a hopper 222 operatively connected to material path 210 to supply a matrix material to material path 210. [ The system 200 is also operatively connected to the material path 210 to supply the paper 230 to the material path 210 to form a wrapper substantially surrounding the matrix material between the mold cavity 220 and the matrix material. And a connected paper feeder 232. The system 200 also includes a dispensing feeder 234 operatively connected to the material path 210 to feed the dispensed wrapper 234 to the material path 210 to form a wrapper between the paper 230 and the mold cavity 220. [ Lt; RTI ID = 0.0 > 236 < / RTI > In some embodiments, the release feeder 236 may be configured as a conveyor 238 that continuously circulates the release wrapper 234. The heating element 224 is in thermal communication with the matrix material while in the mold cavity 220. The heating element 224 can cause the matrix material to mechanically bond at multiple points (e.g., by forming sintered contact points) to yield a packaged porous body elongate. After the packed porous article extrudate is discharged from the mold cavity 220 and properly cooled, the cutter 226 cuts the packaged porous article extrudate radially to produce a packaged porous article and / or a packaged porous article compartment. In embodiments in which the deformed wrapping paper 234 is not configured as a conveyor 238, the deformed wrapping paper 234 may be removed from the wrapped porous article extensions before being cut or from the wrapped porous article and / or wrapped porous article compartment after cutting .

Referring now to FIG. 3, the system 300 may include component hoppers 322a and 322b that supply the components of the matrix material to the hopper 322. [ The matrix material may be mixed and preheated in hopper 322 using mixer 328 and preheater 344. The hopper 322 may be operably connected to the material path 310 to supply the matrix material to the material path 310. The system 300 also includes a paper path 330 that is operatively coupled to the material path 310 to supply the paper 330 to the material path 310 to form a wrapper substantially surrounding the matrix material between the mold cavity 320 and the matrix material. And a connected paper feeder 332. The mold cavity 320 may include a fluid connection 346 through which heated fluid (liquid or gas) passes into the material path 310 and mechanically couples the matrix material at multiple points To form a sintered contact point) to produce a packaged porous body elongate. It should be noted that the fluid connection 346 may be disposed at any location along the mold cavity 320 and more than one fluid connection 346 may be disposed along the mold cavity 320. After the packed porous article extrudate has flowed out of the mold cavity 320 and has cooled appropriately, the cutter 326 cuts the packed porous article extrudate radially to yield a packaged porous article and / or a packaged porous article compartment.

It will be appreciated by those of ordinary skill in the art that the preheating may be performed on the individual feed components prior to the hopper 322 and / or on the mixed components after the hopper 322.

Suitable mixers can include any combination of ribbon blender, paddle blender, plow blender, dual cone blender, dual shell blender, planetary blender, fluidized blender, high intensity blender, rotary drum, blending screw, But is not limited thereto.

In some embodiments, the component hopper accommodates discrete components of the matrix material, for example one in two component hoppers receives binder particles and the other receives active particles. In some embodiments, the component hopper accommodates a mixture of components of the matrix material, for example one in two component hoppers receives a mixture of binder particles and active particles, and the other one contains an additive such as a flavoring agent Accept. In some embodiments, the components in the component hopper can be solid, liquid, gas, or a combination thereof. In some embodiments, the components of the different component hoppers may be added to the hopper at different rates to achieve the desired blend for the matrix material. As a non-limiting example, three component hoppers may individually accommodate active particles, binder particles, and active compounds in liquid form (additives described further below). The binder particles may be added to the hopper at a rate of two times the active particles and the active compound may be injected to form at least a partial coating on both the active particles and the binder particles.

In some embodiments, the fluid connection to the mold cavity may be to transfer the fluid to the mold cavity and / or to allow the fluid to pass through the mold cavity and / or onto the mold cavity. As used herein, the term "aspiration " refers to creating a negative pressure drop across the boundary and / or along the path, e.g., suction. Transferring and / or passing the heated fluid to the mold cavity may help mechanically couple the matrix material therein (e.g., at multiple sintered contact points). Sucking the mold cavity in which the wrapper is disposed can help uniformly lining the mold cavity with fewer wrinkles, for example.

4, the system 400 may include a hopper 422 operatively connected to a material path 410 to supply a matrix material to a material path 410. The hopper 422 may be configured along the material path 410 such that the outlet of the hopper 422 or an extension from that outlet is within the mold cavity 420. This may advantageously make it possible to supply the matrix material to the mold cavity 420 at a rate that controls the filling of the matrix material and thus the void volume of the resulting porous body. In this non-limiting example, the mold cavity 420 includes a thermoelectric material and accordingly includes a power connection 448. [ The system 400 may also be operable in the material path 410 to supply a mold release wrapper 434 to the material path 410 to form a wrapper substantially surrounding the mold material 420 between the mold cavity 420 and the matrix material. Shaped feeder 436 coupled thereto. The mold cavity 420 may be formed of a thermoelectric material such that the mold cavity 420 provides heat to mechanically bond the matrix material at multiple points (e.g., by forming sintered contact points) ≪ / RTI > Along material path 410 after mold cavity 420, roller 440 may operatively assist in movement of the packaged porous body extensions through mold cavity 420. After the packaged porous article extrudate has flowed out of the mold cavity 420 and cooled appropriately, the cutter 426 cuts the packaged porous article extrudate radially to yield a packaged porous article and / or a packaged porous article compartment. After cutting, the porous article continues to follow the material path 410 on the porous body conveyor 462, for example, for packaging or further processing. The deformed wrapper 434 can be removed from the porous body extensions packaged before cutting, or from the packed and / or packaged porous body compartments after cutting.

Suitable roller and / or roller substitutes may include, but are not limited to, cogs, nose wheels, wheels, belts, gears, and the like, and any combination thereof. In addition, the rollers may be flat, serrated, slanted and / or saw-edged.

Referring now to FIG. 5, the system 500 may include a hopper 522 operatively connected to a material path 510 to supply a matrix material to a material path 510. The heating element 524 is in thermal communication with the matrix material while in the mold cavity 520. The heating element 524 may cause the matrix material to mechanically bond at multiple points (e.g., by forming sintered contact points) to yield a porous body elongate. After the porous article extensions are discharged from the mold cavity 520, a die 542 may be used to extrude the porous article extensions into a desired cross-sectional shape. The die 542 may include a plurality of die 542 '(e.g., multiple die or multiple holes in a single die) through which the porous body extensions may be extruded. After the porous article extrudate is extruded through the die 542 and properly cooled, the cutter 526 cuts the porous article extrudate radially to produce a porous article and / or a porous article compartment.

6A, system 600 may include a paper feeder 632 operatively connected to material path 610 to feed paper 630 to material path 610. The hopper 622 (or other matrix material delivery device, e.g., auger) may be operatively connected to the material path 610 to position the matrix material on the paper 630. The paper 630 can be wound at least partially around the matrix material due to the through-mold cavity 620 (or sometimes a compression mold, sometimes referred to as a garniture device in conjunction with the cigarette filter forming device) (Or, optionally, in some embodiments, the matrix material can be combined with the paper 630 after molding of the desired cross section is initiated or completed). In some embodiments, the paper seam can be glued. The heating element 624 (e.g., microwave source, convection oven, heating block, or the like, or hybrid thereof) is in thermal communication with the matrix material during and / or after the mold cavity 620. The heating element 624 can cause the matrix material to mechanically bond at multiple points (e.g., by forming sintered contact points) to yield a packaged porous body elongate. After the packaged porous article extrudate has flowed out of the mold cavity 620 and has cooled appropriately, the cutter 626 cuts the packaged porous article extrudate radially to yield a packaged porous article and / or a packaged porous article compartment. Movement through the system 600 may be assisted by the conveyor 658 and the mold cavity 620 may be stationary. Although not shown, it should be noted that a similar embodiment may include paper 630 as part of a circulating conveyor that is unpackaged from the porous body extension before cutting to yield a porous article and / or a porous article compartment.

Referring now to FIG. 6B, the system 600 'may include a paper feeder 632' operatively connected to the material path 610 'to feed the paper path 630' to the material path 610 ' . The hopper 622 '(or other matrix material delivery device, e.g., auger) may be operatively connected to the material path 610' to position the matrix material on the paper 630 '. The paper 630 'is at least partly permeable to the matrix 620' due to its passage through a mold cavity 620 'providing a desired cross-sectional shape (e.g., a compression mold, sometimes referred to as a garniture device in conjunction with a cigarette filter- (Or, optionally, in some embodiments, the matrix material may be combined with the paper 630 'after molding of the desired cross section is initiated or completed). In some embodiments, the paper seam can be glued.

The system 600 'may include more than one heating element 624'. The first heating element 624a 'is in thermal communication with the matrix material during and / or after it is in the mold cavity 620', such that at least a portion of the matrix material is mechanically coupled at multiple points (e.g., So that a sintered contact point is formed). The porous body extensions are then cut to a desired cross-sectional shape or size using a compression mold 656 '(e.g., to re-shape the cross-sectional shape of the packaged porous body extensions), and then the second heating element 624b' (Which may be a heating element similar to that of the first heating element 624a ', for example both microwaves, or alternatively, for example, the first heating element is microwave and the second heating element is May be reheated to form additional mechanical bonding (e. G., Sintered contact points). Optionally, although not shown, the packaged porous body extensions may be cut again to the desired cross-sectional shape or size after the second heating element 624b '. The resulting packaged porous body extensions are then suitably cooled and can be radially cut into packaged porous bodies and / or packaged porous body compartments using cutters 626. Movement through the system 600 'may be assisted by a conveyor 658', and the mold cavity 620 'may be stationary.

In some cases, depending on the degree of the first sintering or heating step, the porous body extensions may be cooled, cut, and then reheated. One of ordinary skill in the art will know how to modify other systems and methods described herein to provide two or more sintering (or heating) steps.

In some embodiments, while the matrix material is at an elevated temperature, the porous body or the like can be re-cut and / or reformed by application of pressure. Compression molding may be configured as a driven or non-driven cutting or forming roller, a series of rollers, or a die or series of dies, and any combination thereof, suitable for making the bar into its final shape or dimension. The re-cutting and / or re-forming may be performed after each heating step of the method.

7A, system 700 may include a paper feeder 732 operatively connected to material path 710 to feed paper 730 to material path 710. In this embodiment, As shown, the mold cavity 720, which is a cylindrically wound paper adhered to the longitudinal seam, can be used to bond the paper 730 to the adhesive 752 applied using an adhesive-applying device 754 (e.g., glue gun) (Or a molding die, sometimes referred to as a garniture device including a paper tube folder in connection with a cigarette filter forming device), optionally followed by an adhesive seam heater (not shown) . During formation of the mold cavity 720, the matrix material may be introduced along the material path 710 from the hopper 722. A heating element 724 (e.g., a microwave source, convection oven, heating block, or the like, or a hybrid thereof) in thermal communication with the mold cavity 720 may mechanically couple the matrix material at multiple points For example, to form a sintered contact point) to yield a packaged porous body elongate. The packed porous article extensions can then be cut to the desired cross-sectional size using a compression mold 756b prior to complete cooling of the matrix material, which may result in uniformity of the circumference and shape of the packaged porous article (e.g., ovality )). ≪ / RTI > After the packed porous body extensions are suitably cooled, the cutter 726 cuts the packed porous body extensions radially to produce packaged porous bodies and / or packaged porous body compartments. Movement through system 700 may be assisted by rollers, conveyors, etc., not shown. Those of ordinary skill in the art will appreciate that the processes described may be performed on a single device or on multiple devices. For example, rewinding the paper may be performed in a single device, by winding the paper, introducing the matrix material, exposing it to heat (e.g., by applying a microwave or by heating in a convection oven) , The resulting porous body elongate can be delivered to a second device for cutting. The system 700 can be oriented in any direction, e.g., vertical or horizontal, or in any direction therebetween.

In some embodiments, adhesives or other adhesives used to seal the paper mold cavity (or other flexible mold cavity material such as plastic) may be cold melt adhesives, hot melt adhesives, pressure sensitive adhesives, curable adhesives, and the like. In order to alleviate adhesion failure during subsequent heating processes (e.g. during sintering), cold melt adhesives may be preferred.

Referring now to FIG. 7B, a system 700 'may include a paper feeder 732' operatively connected to material path 710 'to feed paper 730' to material path 710 ' . As shown, the mold cavity 720 ', which is a cylindrically wound paper adhered at the longitudinal seam, allows the paper 730' to adhere to the applied adhesive (e. G., Using a glue gun) (Or a forming mold, sometimes referred to as a garniture device, including a paper tube folder in connection with a cigarette filter forming device), which causes the forming mold 756a 'to be wound together with the forming mold 752'. During formation of the mold cavity 720 ', the matrix material may be transferred to a hopper 722' operatively connected to the tubing 722a 'by a joint 722b', which may be a flexible joint (e.g., Lt; / RTI > through the material path 710 '). (E.g., a microwave source, a convection oven, a heating block, or the like) that is in thermal communication with the mold cavity 720 '(as shown in close proximity to the end of the pipe 722a' ) Can cause the matrix material to mechanically bond at multiple points (e.g., by forming sintered contact points) to yield a packaged porous body elongate. The compression mold 756b '(denoted by the roller) may then be cooled to assist in cooling the matrix material while shaping the packaged porous body extensions into the desired more uniform circumference and shape (e.g., ovality). After the packed porous body extensions are suitably cooled, the cutter 726 'cuts the packed porous body extensions radially to yield packaged porous bodies and / or packaged porous body compartments.

In some embodiments, the mold cavity may be non-porous or the degree of porosity may be altered to enable removal of the fluid from the matrix material. In addition, the forming mold and / or material path may be operably connected to a passageway that allows passage of fluid from the porous paper in the desired orientation. In some cases, these fluid passages may be connected to a source below atmospheric pressure. In some embodiments, removal of the fluid from the mixture may improve system performance and minimize matrix material particle separation.

In some embodiments, the feeder may include an extension designed to fit within the mold cavity. In some embodiments, the outlet of the feeder (e.g., the outlet of line 722a ') may be cut to be slightly smaller (e.g., about 5% smaller) than the inner diameter of the mold cavity. The feeder or its extension may also include a flexible portion that allows the outlet to move into the mold cavity. During pneumatic compacted phase supply, this movement may be advantageous by making it possible for the outlet to move into the mold cavity. Such movement can advantageously enable the outlet to freely locate the center of the mold cavity, which can provide an appropriate value to improve performance and minimize matrix mixture separation. In some embodiments, the feeder (e.g., the outlet of the pipe 722a ') is located before the forming mold 756a', within the forming mold 756a ', or after the forming mold 756a' Can be terminated after the adhesive seam heater.

Further, in some embodiments, the outlet can be designed to have a variable cross-sectional area, which can increase the filling density of the matrix mixture in pneumatic compacted bed feed, minimize particle separation, and change the pressure and flow rate in a single system It can be advantageous to make it.

In some embodiments, the outlet may be vented using a mesh that does not allow the matrix material to flow, but allows the fluid to pass. Such an exhaust enables pressure to be dissipated in a controlled manner over a longer length, especially when the matrix material flows out of the outlet at high flow rates and high pressures, which can lead to significant particle movements (which can lead to matrix material heterogeneity) Can be mitigated.

8, a mold cavity 820 of system 800 may be formed from mold cavity components 820a and 820b operably connected to mold cavity conveyors 860a and 860b, respectively. Once the mold cavity 820 is formed, a matrix material may be introduced along the material path 810 from the hopper 822. [ The heating element 824 is in thermal communication with the matrix material while in the mold cavity 820. The heating element 824 may cause the matrix material to mechanically bond at multiple points (e.g., by forming sintered contact points) to yield a porous article. After the mold cavity 820 is properly cooled and separated into the mold cavity parts 820a and 820b, the porous body is removed from the mold cavity part 820a and / or 820b and is conveyed through the porous body conveyor 862 Material path 810 may continue to follow. It should be noted that Figure 8 shows a non-limiting example of a discontinuous material path.

In some embodiments, removing the porous body from the mold cavity and / or mold cavity part may include a pulling mechanism, a pushing mechanism, a lifting mechanism, gravity, any combination thereof and any combination thereof. The removal mechanism can be configured to trap the porous article at the end, along the side (s), and any combination thereof. Suitable pulling mechanisms may include, but are not limited to, suction cups, vacuum components, tweezers, pliers, clamps, clamps, grippers, hooks, clamps, and the like, and any combination thereof. Suitable pushing mechanisms may include, but are not limited to, ejectors, punches, rods, pistons, wedges, spokes, rams, pressurized fluids, and the like, and any combination thereof. Suitable lifting mechanisms include, but are not limited to, suction cups, vacuum components, tweezers, pliers, clamps, clamps, grippers, hooks, clamps, and the like, and any combination thereof. In some embodiments, the mold cavity can be configured to operably act with various removal mechanisms. As a non-limiting example, a hybrid pushing-pulling mechanism may include pushing in a longitudinal direction using a rod to move the porous body partially outwardly of the other end of the mold cavity, which in turn may be used to pull the porous body from the mold cavity Can be caught by forceps.

9, the mold cavity 920 of the system 900 includes mold cavity components 920a and 920b operably connected to mold cavity conveyors 960a, 960b, 960c, and 960d, respectively. 920b, or 920c and 920d. Once the mold cavity 920 is formed, or during the formation, a sheet of paper 930 is introduced into the mold cavity 920 through the paper feeder 932. A matrix material is then introduced into the paper 930 along the material path 910 from the hopper 922 to lining the mold cavity 920 and mechanically coupled to the porous body by heat from the heating element 924 For example, to form a plurality of sintered contact points. After proper cooling, removal of the porous body can be achieved by inserting the ejector 964 into the ejector ports 966a and 966b of the mold cavity components 920a, 920b, 920c, and 920d . The porous body can then continue to follow the material path 910 through the porous body conveyor 962. [ Figure 9 also shows a non-limiting example of a discontinuous material path.

Quality control of the porous article manufacturing can be assisted by cleaning of the mold cavity and / or mold cavity parts. Referring again to FIG. 8, a cleaning mechanism may be introduced into system 800. As the mold cavity components 820a and 820b return from forming the porous body, the mold cavity components 820a and 820b are connected to a series of cleaners 820a and 820b, including liquid jets 870 and air or gas jets 872, . Similarly, in FIG. 9, as the mold cavity parts 960a, 960b, 960c, and 960d return from forming the porous body, the mold cavity parts 960a, 960b, 960c, 960d pass through a series of washers including heat from heating element 924 and air or gas jets 972. [

Other suitable dishwashers may include, but are not limited to, scrubbers, brushes, baths, showers, injected fluid jets (tubes injected with radial fluid, mold cavity inserted tubes), ultrasonic devices, and any combination thereof .

In some embodiments, the porous body may comprise a cavity. 10, the mold cavity components 1020a and 1020b operably connected to the mold cavity conveyors 1060a and 1060b are configured to form a mold cavity 1020 of the system 1000 Is operatively connected. The hopper 1022 includes two volumetric feeders 1090a and 1090b so that each volumetric feeder 1090a and 1090b can partially fill the mold cavity 1020 along the material path 1010 with a matrix material. Respectively. Between the addition of the matrix material from the volumetric feeder 1090a and the volumetric feeder 1090b the injector 1088 places the capsule (not shown) in the mold cavity 1020 to yield a capsule surrounded by the matrix material do. The heating element 1024 in thermal contact with the mold cavity 1020 is configured to mechanically couple the matrix material at multiple points (e.g., by forming a sintered contact point) to yield a porous article having the capsule disposed therein cause. After the porous body is formed and appropriately cooled, a rotary grinder 1092 is inserted into the mold cavity 1020 along the longitudinal direction of the mold cavity 1020. The rotary grinder 1092 is capable of operatively grinding the porous body to a desired length in the longitudinal direction. After the mold cavity 1020 is separated into the mold cavity parts 1020a and 1020b, the porous body is removed from the mold cavity part 1020a and / or 1020b and is passed through the porous body conveyor 1062 to the material path 1010a ).

Capsules suitable for use in porous bodies and the like may include, but are not limited to, polymer capsules, porous capsules, ceramic capsules, and the like. The capsules may be filled with additives, such as granulated carbon or flavoring agents (more examples are provided below). In some embodiments, the capsule may also contain molecular sieves that react with, remove, or reduce the concentration of the selected component in the smoke, without adversely affecting the desired flavor component in the smoke. In some embodiments, the capsule may contain tobacco as an additional flavoring agent. It should be noted that, if the capsule is poorly filled with the selected material, in some filter embodiments, this may result in a lack of interaction between the components of the mainstream smoke and the substances in the capsule.

Those of ordinary skill in the art will appreciate that other methods described herein can be modified to yield a porous article having a capsule therein. In some embodiments, more than one capsule may be present in the porous compartment, the porous article and / or the porous article elongate.

In some embodiments, the shape, e.g., length, width, diameter, and / or height, of the porous body can be increased by any operation other than cutting, including but not limited to sanding, milling, polishing, smoothing, polishing, rubbing, Lt; / RTI > In general, these operations will be referred to herein as polishing. Some embodiments may involve polishing the sides and / or ends of the porous article to achieve a smooth surface, a matched surface, a grooved surface, a patterned surface, a leveled surface, and any combination thereof. Some embodiments may involve polishing the sides and / or ends of the porous body to achieve the desired dimensions within the specification limits. Some embodiments may involve polishing the sides and / or ends of the porous body during, after, during, and during any further processing, during or after being in or out of the mold cavity. Those of ordinary skill in the art will appreciate that dust, particles and / or debris may be generated from polishing. Thus, polishing may involve removing dust, particles, and / or debris by methods such as vacuum, gas blowing, cleaning, shaking, etc., and any combination thereof.

Any component and / or device capable of achieving a desired level of polishing may be used with the systems and methods disclosed herein. Examples of suitable components and / or devices that can achieve the desired level of abrasion include, but are not limited to, a lathe, a rotary sander, a brush, a polisher, a buffer, an etchant, a scribe, .

In some embodiments, the porous article can be machined to be lighter in weight, for example, by removing a part of the porous article, if desired.

Those of ordinary skill in the art will be familiar with the components and / or instrumentation necessary to associate the porous article with the system described herein at various points. By way of non-limiting example, the abrasive and / or punching apparatus used during the time when the porous body is in the mold cavity (or where the porous body extension is released from the mold cavity) should be constructed so as not to have a deleterious effect on the mold cavity.

Referring now to FIG. 11, a hopper 1122 is operatively attached to chute 1182 and feeds a matrix material to material path 1110. Along the material path 1110, the mold cavity 1120 is configured to receive a ram 1180 that can press the matrix material within the mold cavity 1120. The heating element 1124 in thermal communication with the matrix material while in the mold cavity 1120 may be configured to mechanically couple the matrix material at multiple points (e.g., by forming a sintered contact point) cause. The inclusion of the ram 1180 in the system 1100 can advantageously help ensure that the matrix material is properly filled to form a porous body elongate with the desired void volume. In addition, the system 1100 includes a cooling zone 1194 while the porous body extension is still contained within the mold cavity 1120. In this non-limiting example, cooling is accomplished passively.

Referring now to FIG. 12, a hopper 1222 of system 1200 operatively feeds a matrix material to an extruder 1284 (e.g., a screw) along material path 1210. The extruder 1284 moves the matrix material to the mold cavity 1220. The system 1200 also communicates thermally with the matrix material while in the mold cavity 1220 and mechanically couples the matrix material at multiple points (e.g., by forming sintered contact points) to yield a porous article elongate And a heating element 1224 that generates heat. The system 1200 also includes a cooling element 1286 in thermal communication with the porous body extension while in the mold cavity 1220. Movement of the porous body extensions out of the mold cavity 1220 is assisted and / or induced by the rollers 1240.

In some embodiments, the control system may be connected to components of the system and / or apparatus described herein. As used herein, the term "control system " refers to a system that is capable of working to receive and transmit electronic or pneumatic signals, including connecting with a user, providing data decryption, collecting data, Storing changes, changing variable setpoints, maintaining setpoints, providing failure notifications, and any combination thereof. Suitable control systems may include, but are not limited to, variable converters, ohmmeters, programmable logic controllers, digital logic circuits, electrical relays, computers, virtual reality systems, distributed control systems, and any combination thereof. Suitable systems and / or device parts operable to be connected to the control system include, but are not limited to, a hopper, a heating element, a cooling element, a cutter, a mixer, a paper feeder, a dispensing feeder, a release conveyor, a cleaning element, a roller, a mold cavity conveyor, , A liquid jet, an air jet, a ram, a chute, an extruder, an injector, a matrix material feeder, an adhesive feeder, a grinder, and the like, and any combination thereof. It should be noted that the system and / or apparatus described herein may have more than one control system that can be connected to any number of components.

Those of ordinary skill in the art will appreciate the compatibility of the various systems and / or device components disclosed herein. As a non-limiting example, when the matrix material comprises a component capable of converting electromagnetic radiation into heat (e.g., nanoparticles, carbon particles, etc.), the heating element may be an electromagnetic radiation source Oven, heating block, etc., or hybridization thereof). Further, as a non-limiting example, the paper wrapper may be compatible with the release wrapper.

In some embodiments, the porous body can be produced at a linear velocity of about 800 m / min or less, including by a method involving a very slow linear velocity of less than about 1 m / min. As used herein, the term "linear speed" is intended to encompass a single manufacturing process, as opposed to a manufacturing speed which may encompass several parallel manufacturing lines, which may be individual devices, within a single device, Refers to the speed along the line. In some embodiments, the porous body is formed from the lower limit of about 1 m / min, 10 m / min, 50 m / min or 100 m / min to about 800 m / min, 600 m / min, 500 m Min, up to an upper limit of 300 m / min or 100 m / min, where the linear velocity ranges from any lower limit to any upper limit and any subset therebetween It can be encompassed. It will be appreciated by a person of ordinary skill in the art that the productivity improvement of a machine may enable a linear speed (for example, 1000 m / min or more) exceeding 800 m / min. It will be appreciated by those of ordinary skill in the art that, in order to increase the overall manufacturing speed of the porous body, etc., for example, up to several thousand meters per minute or more, a single device may be connected to multiple parallel lines (e.g., two or more lines of FIG. 7, Line). ≪ / RTI >

Some embodiments may involve further processing of the porous body. Suitable further treatments may include, but are not limited to, doping using a flavoring agent or other additives, polishing, punching out, further shaping, formation of a multisplit filter, formation of a smoking device, packaging, no.

Some embodiments may involve doping the matrix material, the porous article, with an additive. Non-limiting examples of additives are provided below. Suitable doping methods include incorporating an additive into the matrix material; Applying an additive to at least a portion of the matrix material prior to mechanical bonding; Applying the additive while in the mold cavity after mechanical bonding; Applying the additive after leaving the mold cavity; Applying additives after cutting; And any combination thereof, but are not limited thereto. It should be noted that applications include, but are not limited to, immersion, impregnation, sedimentation, absorption, cleaning, washing, painting, coating, showering, spraying, spraying, batching, spraying, sprinkling, It should also be noted that the application includes, but is not limited to, surface treatment, an injection treatment in which the additive is at least partially introduced into the components of the matrix material, and any combination thereof. It will be appreciated by those of ordinary skill in the art that the concentration of the additive will depend at least on the composition of the additive, the size of the additive, the purpose of the additive, and the point in the process in which the additive is included.

In some embodiments, doping using an additive can be done before, during, and / or after mechanically bonding the matrix material. Those skilled in the art who are familiar with the disclosure should add additives that are degraded, changed, or otherwise affected by the mechanical bonding process and related parameters (e.g., temperature rise and / or pressure) , So that the parameters should be adjusted (e.g., the use of an inert gas or reduced temperature). As a non-limiting example, the glass beads can be additives in the matrix material. At this time, the glass beads may be functionalized by other additives such as flavorings and / or active compounds after mechanical bonding.

Some embodiments may include polishing the porous body after it is manufactured. Polishing involves the methods and apparatus / parts described above.

II. Filter comprising porous article and method of forming smoking device

Some embodiments may include operably connecting the porous body to the filter and / or filter compartment. Suitable filter and / or filter compartments include, but are not limited to, cellulose, cellulose derivatives, cellulose ester tow, cellulose acetate tow, cellulose acetate tow less than about 10 denier per filament, cellulose acetate tow of about 10 denier per filament, randomly oriented acetate, The present invention relates to a method for producing a porous article, which comprises the steps of forming a porous body, a corrugated board, polypropylene, polyethylene, polyolefin tow, polypropylene tow, polyethylene terephthalate, polybutylene terephthalate, granulated powder, carbon particles, And combinations thereof.

In some embodiments, the porous body and other filter compartments may independently have features such as concentric filter designs, paper packages, cavities, cavity chambers, baffled void chambers, capsules, channels, and the like, and any combination thereof.

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

In some embodiments, the filter compartment may include a space defining a cavity between the two filter compartments. In some embodiments, the cavity can be filled with an additive, such as granulated carbon. In some embodiments, the cavity may contain a capsule, such as a polymer capsule containing itself a catalyst. In some embodiments, the cavity may also contain molecular sieves that react with a selected component of the smoke to remove the component or reduce its concentration, without adversely affecting the desired flavor component in the smoke. In one embodiment, the cavity may include a cigarette as an additional flavor agent. It should be noted that, in some embodiments, when the cavity is insufficiently filled with the selected material, it may cause a lack of interaction between the ingredient in the mainstream smoke and the material in the cavity and other filter compartment (s).

In some embodiments, the filter compartments may be combined or connected to form a filter or filter rod. As used herein, the term "filter rod" refers to a filter of a length suitable for being cut into two or more filters. By way of non-limiting example, in some embodiments, the filter rod comprising the porous article described herein may have a length in the range of about 80 mm to about 150 mm, and may be a smoking device tipping operation Addition) may be cut with a filter comprising a stretch of about 5 to about 35 mm in length.

The tipping operation may involve combining or connecting the filter or filter rod described herein with the tobacco column. During the tipping operation, the filter rod comprising the porous article described herein may first be cut with a filter in some embodiments, or cut with a filter during the tipping process. In addition, in some embodiments, the tipping method may further comprise combining or connecting additional compartments, including paper and / or charcoal, to the filter, filter rod or tobacco column.

In the manufacture of filters, filter bars, and / or smoking devices, some embodiments may involve packaging the paper around the various components thereof to maintain the components in the desired configuration and / or contact. For example, fabricating the filter and / or the filter rod may involve packaging the paper around a series of adjacent filter compartments. In some embodiments, the porous article packaged in a paper package may have additional packaging disposed about it to maintain contact between the porous article and another filter compartment. Paper suitable for making filters, filter bars, and / or smoking devices may include any of the papers described herein in connection with packaging the porous article. In some embodiments, the paper may comprise additives, sizing agents, and / or printing agents.

In the manufacture of filters, filter bars and / or smoking devices, some embodiments may involve adhering adjacent components thereof (e.g., to a porous filter compartment, tobacco column, etc., or any combination thereof) . Preferred adhesives may include those that do not provide flavor or aroma under ambient conditions and / or under combustion conditions. In some embodiments, packaging and gluing may be used in the manufacture of filters, filter bars, and / or smoking devices.

Some embodiments described herein provide a porous bar comprising a plurality of organic particles and binder particles bound together at a plurality of points of contact; Providing a filter rod that does not have the same composition as the porous bar; Cutting the porous body rod and the filter rod into a porous body compartment and a filter compartment, respectively; Forming a desired contiguous configuration comprising a plurality of compartments, wherein the plurality of compartments include at least a portion of the porous compartment and at least a portion of the compartment; Fixing the desired adjacent configuration using paper wrappers and / or adhesives to yield segmented filter rod extensions; The segmented filter rod entanglement may involve cutting the segmented filter rod, wherein the method is performed to produce a segmented filter rod at a speed of about 800 m / min or less. Some embodiments may further involve forming a smoking device using at least a portion of the segmented filter rod.

As used herein, the term "adjacent configuration " refers to a configuration in which two filter compartments (or the like) are axially aligned such that one end of the first compartment is in contact with one end of the second compartment. As will be appreciated by those of ordinary skill in the art, such contiguous configurations may be contiguous with multiple compartments (i.e., they are not strictly terminated, but rather very long), or they may be shorter in length with more than two compartments.

In some method embodiments described herein, the term "segmented" is used to modify various articles for clarity, and is used herein to refer to articles (e.g., filters and filter rods) But should be viewed as being encompassed by the various embodiments described.

Some embodiments described herein provide a plurality of porous compartments comprising a plurality of organic particles and binder particles bound together at a plurality of points of contact; Providing a plurality of filter compartments that do not have the same composition as the porous compartment; Forming a desired contiguous configuration comprising a plurality of compartments, wherein the plurality of compartments include at least one of the porous compartments and at least one of the compartment compartments; Fixing the desired adjacent configuration using paper wrappers and / or adhesives to produce a segmented filter or segmented filter rod extensions, wherein the method comprises filtering the segmented filter at a rate of about 800 m / Or to produce segmented filter bars. Some embodiments may further comprise forming a smoking device using at least a portion of the segmented or segmented filter rods.

Referring now to Fig. 13, which is a schematic diagram of a method for manufacturing a segmented filter in this example, a cellulose acetate filter rod 1310 is cut into eight compartments (each about 15 mm) and a porous filter rod 1312 is cut into 10 (About 12 mm each), resulting in segments 1314 and 1316, respectively. The segments 1314,1316 are then aligned with the end-to-end of the alternating configuration, are tightly sealed together, packaged using paper, bonded at the seam line, and produce a segmented filter extension 1318 do. In some cases, the segmented filter extensions 1318 are then cut around the center per every fourth cellulose acetate segment 1314 such that a portion of the cellulose acetate segment 1314 is separated from the segmented filter rod 1320, Can be calculated. Those of ordinary skill in the art will recognize that cellulose acetate segments and porous segments of different sizes and configurations can be used to produce segmented filter extensions and then cut at any point to form desired segmented filter bars, Quot ;, it will be appreciated that the segmented filter rod 1320 ', including the five segments where the porous segment is at the end, can be calculated. Those of ordinary skill in the art will recognize that these examples are two of the many potential configurations of segmented filter rods.

In some embodiments, the method may be adapted to accommodate three or more filter compartments. For example, a desired configuration of the filter rod extensions may include a first porous compartment, a first second filter compartment, a first first filter compartment, a second second compartment compartment, a second compartment compartment, a third second compartment compartment, a second first compartment compartment, A first filter compartment and a second filter compartment, of a first filter compartment order and a fourth filter compartment order. This configuration is followed by a filter comprising three compartments, as shown in Fig. 14, which shows the filter rod extensions cut into filter rods that are then cut twice to produce a filter compartment containing three compartments. ≪ RTI ID = 0.0 > and / or < / RTI >

In some embodiments, a capsule may be included to be enclosed between two adjacent compartments. As used herein, the term "nested" or "nesting" refers to being present in the interior and not being directly exposed to the outside of the article being manufactured. Thus, nesting between two adjacent sections allows adjacent sections to be in contact, i. In some embodiments, the capsule may be a part.

In some embodiments, the filters described herein can be fabricated using known equipment, for example in excess of about 25 m / min for automated equipment and lower for manual manufacturing equipment. Although the speed of fabrication may be limited only by the instrument capacity, in some embodiments, the filter compartments described herein may be combined to provide a flow rate of about 800 m / min from a lower limit of about 25 m / min, 50 m / min, or 100 m / min Min, 600 m / min, 400 m / min, 300 m / min, or 250 m / min, where the combined speed ranges from any lower limit to any upper limit , And can encompass any subset between them.

In some embodiments, the porous bodies used in the fabrication of the filters and / or filter rods described herein may be packaged in paper. In some embodiments, the paper can reduce damage and particulate generation due to mechanical manipulation of the porous article. Paper suitable for use in connection with protecting the porous body during operation includes wood-based paper, paper containing flax, flax paper, cotton paper, functionalized paper (e.g., functionalized to reduce tar and / or carbon monoxide (S)), special marking paper, colored paper, and any combination thereof. In some embodiments, the paper is highly porous and / or wrinkled and / or may have a high surface strength. In some embodiments, the paper may be substantially non-porous, e.g., less than about 10 CORESTA units.

In some embodiments, the filter and / or filter rod comprising the porous article described herein may be transported to a manufacturing line and combined with a tobacco column to form a smoking device. Examples of such methods include providing a filter rod comprising at least one filter compartment comprising a porous article as described herein comprising organic particles and binder particles; Tobacco column; Cutting the filter rod across a longitudinal axis passing through the center of the rod to form two or more filters having one or more filter compartments, each filter compartment comprising a porous body comprising organic particles and binder particles; And connecting at least one filter to the tobacco column along the longitudinal axis of the filter and the longitudinal axis of the tobacco column to form one or more smoking devices.

In another embodiment, the device filter and / or filter rod comprising the porous article may be placed in a suitable vessel for storage up to further use. Suitable storage containers include those conventionally used in the field of smoking device filters, including, but not limited to, crate, box, drum, bag, paper box and the like.

Some embodiments may include operably connecting the smoking article to a porous article (or a segmented filter comprising at least one of the foregoing). In some embodiments, the porous body (or a segmented filter comprising at least one of the foregoing) may be in fluid communication with the smokable material. In some embodiments, the smoking device may comprise a porous article (or a segmented filter comprising at least one of the above) through which the smokable material and the fluid flow. In some embodiments, the smoking device may include a housing capable of operably holding a porous article (or a segmented filter comprising at least one of the above) through which the smokable material and the fluid pass. In some embodiments, the filter rod, filter, filter compartment, compartmentalized filter and / or compartmentalized filter rod may be removable and / or replaceable and / or disposable from the housing.

As used herein, the term "smokable material" refers to a material capable of generating smoke upon combustion or heating. Suitable smoking substances include, but are not limited to, cigarettes such as Bright Leaf Cigarettes, Oriental Cigarettes, Turkey Cigarettes, Cavendish Cigarettes, CoroHo Cigarettes, Creol Tobacco, Ferric Cigarettes, Shade Cigarettes, Tobacco, Maryland tobacco, Virginia tobacco; car; Herb; Carbonization or pyrolysis components; Inorganic filler component; And any combination thereof, but are not limited thereto. Cigarettes may have the form of tobacco leaves, such as cut filler forms, processed tobacco stalks, reconstituted tobacco fillers, and bulky expanded tobacco fillers. Tobacco and other cultivated smokable materials may be grown in the United States, or may be grown in jurisdictions outside the United States.

In some embodiments, the smokable material may be in the form of a column, e.g., a tobacco column. As used herein, the term "tobacco column " refers to a blend of tobacco, and optionally other ingredients and flavoring agents, which in combination can produce a tobacco-based smoking article, such as tobacco or cigar. In some embodiments, the tobacco column is selected from tobacco, sugar (e.g., sucrose, sulfur sugar, phosgene or high fructose corn syrup), propylene glycol, glycerol, cocoa, cocoa products, carob bean gum, ≪ / RTI > and combinations thereof. In another embodiment, the tobacco column may further comprise flavors, fragrances, menthol, licorice extract, diammonium phosphate, ammonium hydroxide, and any combination thereof. In some embodiments, the tobacco column may comprise an additive. In some embodiments, the tobacco column may include one or more bendable elements.

Suitable housings include, but are not limited to, cigarettes, cigarette holders, cigars, cigar holders, pipes, water pipes, hookers, electronic smoking devices, self-winding cigarettes, self-winding cigars, paper and any combination thereof.

Packaging of the porous article may include, but is not limited to, placing it in a tray that is typically used to package and transport a tray or box or protective container, e.g., a cigarette filter rod.

In some embodiments, a pack of smoking devices having filters and / or filters may comprise a porous article. The pack may be a hinge-lid pack, a slide-and-shell pack, a hard-cup pack, a soft-cup pack, a plastic bag or any other suitable packed container. In some embodiments, the pack may include an outer package, such as a polypropylene package, and optionally a tear tab. In some embodiments, the filter and / or smoking device may be sealed in a bundle within the pack. The bundle may contain, for example, 20 or more filters and / or smoking devices. In some embodiments, however, the bundle may be a single filter and / or a filter comprising a smoking device, such as an exclusion filter and / or a smoking device embodiment, such as for individual sale, or a specific spice such as vanilla, clove or cinnamon, / RTI > and / or a smoking device.

In some embodiments, the paper box of the smoking device pack may comprise one or more smoking device packs comprising one or more smoking devices together with a filter (multi-segmented, etc.) comprising a porous article. In some embodiments, the paper box (e.g., the container) has physical integrity to contain the weight from the smoking device pack. This can be accomplished by using a thicker card stock to form the paper box, or by using stronger adhesives to bond the elements of the paper box.

Some embodiments may involve transporting the porous body. The porous bodies may be individually, at least as part of the filter, as at least part of the smoking apparatus, in a pack, in a paper box, in a tray, and any combination thereof. Transportation may be by train, truck, plane, boat / ship, and any combination thereof.

III. Porous article

The matrix material may have any weight ratio of active to binder particles. In some embodiments, the matrix material is formed 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 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, Lt; RTI ID = 0.0 > a < / RTI > In some embodiments, the matrix material comprises at least about 99 wt%, 95 wt%, 90 wt%, 75 wt% of the matrix material from a lower limit of about 1 wt%, 5 wt%, 10 wt%, or 25 wt% , 60 wt%, 50 wt%, 40 wt%, or 25 wt%, wherein the amount of binder particles ranges from any lower limit to any upper limit, Lt; RTI ID = 0.0 > a < / RTI >

The active particles may be any material adapted to enhance the smoke flowing thereon. What is adapted to enhance smoke flowing thereover refers to any material that can remove, reduce, or add ingredients to the smoke stream. The removal or reduction (or addition) may be optional. As an example, in the smoke stream from tobacco, compounds such as those shown below in the following list can be selectively removed or reduced. These tables are available from the US Food and Drug Administration (FDA) from the Tobacco Smoke, an initial proposed list of harmful / potentially harmful constituents in tobacco products, including tobacco smoke; All abbreviations in the following list are chemicals that are well known in the relevant art. In some embodiments, the active particles can reduce or eliminate one or more components (including any combination thereof) selected from the list of components in the following fumes. The smoke stream components include but are not limited to acetaldehyde, acetamide, acetone, acrolein, acrylamide, acrylonitrile, aflatoxin B-1, 4-aminobiphenyl, 1-aminonaphthalene, 2-aminonaphthalene, Benzene [a] anthracene, benz [b] fluoroanthan, benz [j] asanthrylene, benz [k] fluoroanthane, benzene, benzo (a) anthaben, 0-anisidine, arsenic, b) furan, benzo [a] pyrene, benzo [c] phenanthrene, beryllium, 1,3-butadiene, butyraldehyde, cadmium, caffeic acid, carbon monoxide, catechol, chlorinated dioxin / furan, chromium, (A, j) acridine, dibenz [a, h] anthracene, di (a, j) acridine, Benzo [a, h] pyrene, dibenzo [a, i] pyrene, dibenzo [a, l] pyrene, 2,6-dimethyl Aniline, ethyl carbamate (urethane), Pyridine, glu-P-2, hydrazine, hydrogen cyanide, hydroquinone, indeno [1,2,3-cd] pyrene, IQ, (3-pyridyl) -1-butanone (NNK), 4- (methylpyrrolidone) (NNAL), naphthalene, nickel, nicotine, nitrate, nitric oxide, nitrogen oxide, nitrite, nitrobenzene, nitromethane, N-nitrosodecanolamine (NDELA), N-nitrosodiethylamine, N-nitroso dimethylamine (NDMA), N-nitrosoethylmethylamine, N-nitrosopyrrolidine (NPYR), N-nitroso sarcosine (NSAR), N-nitrosopyrrolidine Phenol, PhlP, polonium-210 (radioisotope), propionaldehyde, propylene Trp-P-1, Trp-P-2, uranium-235 (radioisotope), uranium-238 (radioisotope) ), Vinyl acetate, vinyl chloride, and any combination thereof.

An example of an active particle is activated carbon (or activated charcoal or activated coal). Activated carbon may be a combination of the (CCl ₄ adsorption of about 50% to about 75%) of the low active or high active (CCl ₄ adsorption of about 75% to about 95%), or both. Activated carbon may include those derived from coconut shells, coal, synthetic resins, etc. (e.g. pyrolyzed therefrom). Examples of commercially available carbon include, but are not limited to, product classes provided by Calgon, Jacobi, Norit and other like suppliers. As a non-limiting example, Norit® GCN 3070 is one of Norit's granular activated carbon products. In another example, Jacoby offers grades of activated carbon in various particle sizes including CZ, CS, CR, CT, CX and GA-plus.

In some embodiments, the activated carbon may be nano-scale carbon particles, such as carbon nanotubes having any number of walls, carbon nanofines, bamboo-type carbon nanostructures, fullerene and fullerene aggregates, Lt; / RTI > Other examples of the active particles include ion exchange resins, desiccants, silicates, molecular sieves, silica gel, activated alumina, zeolites, perlite, sepiolite, fuller's earth, magnesium silicates, metal oxides ₃ O ₄ iron oxide nanoparticles, manganese, copper oxide and aluminum oxide), gold, platinum, iodine pentoxide, phosphorus pentoxide, nano-particles, such as (e. g., gold and silver metal nanoparticles, such as; the alumina and Paramagnetic and paramagnetic nanoparticles such as iron oxides of various crystal structures such as gadolinium oxide, hematite and magnetite, goethite-nanotubes and endofullenes such as Gd @ C ₆₀ , and gold and silver nanoshells Core-shell and onion-type nanoparticles such as onionated iron oxide, and other nanoparticles or microparticles having an outer shell of any of the above materials, But it can include any combination including Christmas), without being limited thereto. Ion exchange resins include, for example, styrene-divinyl benzene (DVB) copolymers, backbones such as acrylate, methacrylate, phenol formaldehyde condensates and epichlorohydrin amine condensates; And polymers having a plurality of electrically charged functional groups attached to the polymer backbone. In some embodiments, the active particles are combinations of various active particles. In some embodiments, the porous body may comprise a plurality of active particles. In some embodiments, the active particles may comprise one or more elements selected from the group of active particles disclosed herein. It should be noted that "element" is used as a generic term to describe an item in a list. In some embodiments, the active particles are combined with one or more flavoring agents.

Suitable active particles may have dimensions of at least one of the following: particles having diameters of less than about 1 nanometer, such as graphene, and up to about 5000 micrometers. The active particles can be about 0.1 nanometers, 0.5 nanometers, 1 nanometer, 10 nanometers, 100 nanometers, 500 nanometers, 1 micrometer, 5 micrometers, 10 micrometers, 50 micrometers, Meter, 200 micrometer, or 250 micrometer. The active particles may be present in an amount ranging from about 5000 micrometers, 2000 micrometers, 1000 micrometers, 900 micrometers, 700 micrometers, 500 micrometers, 400 micrometers, 300 micrometers, 250 micrometers, 200 micrometers, Meter, 50 micrometer, 10 micrometer, or 500 nanometer. If the selected maximum size is greater than the selected minimum size, any combination of the lower and upper limits may be suitable for use in the embodiments described herein. In some embodiments, the active particles can be a mixture of particle sizes in the upper and lower limits range. In some embodiments, the size of the active particles can be multimodal.

The binder particles can be any suitable thermoplastic binder particles. In one embodiment, the binder particles exhibit substantially no flow at their melting temperature. Means a material which shows little or no polymer flow when heated to its melting temperature. Substances meeting these criteria include, but are not limited to, high molecular weight polyethylene, ultra 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 占 폚 and 15 kg at less than about 3.5 g / 10 min (or at about 0-3.5 g / 10 min at 190 占 폚 and 15 kg) . In another embodiment, the binder particles have a melt flow index (MFI) at 190 占 폚 and 15 kg to less than about 2.0 g / 10 min (or about 0-2.0 g / 10 min at 190 占 폚 and 15 kg). An example of such a material is UHMWPE, which is an ultrahigh molecular weight polyethylene (having no polymer flow, MFI of about 0 at 190 占 폚 and 15 kg or MFI of about 0-1.0 at 190 占 폚 and 15 kg); Another material is VHMWPE, which is ultra high molecular weight polyethylene (e.g., may have an MFI ranging from about 1.0-2.0 g / 10 min at 190 [deg.] C and 15 kg); Or HMWPE, which is a high molecular weight polyethylene (which may have an MFI of, for example, about 2.0-3.5 g / 10 min at 190 캜 and 15 kg). In some embodiments, it may be desirable to use a mixture of binder particles having different molecular weights and / or different melt flow exposures.

With respect to molecular weight, "polar high molecular weight polyethylene" as used herein refers to a polyethylene composition having a weight-average molecular weight of at least about 3 x 10 ⁶ g / mol. In some embodiments, the molecular weight of the geukgo molecular weight polyethylene composition comprises from about 3 × 10 ⁶ g / mol to about 30 × 10 ⁶ g / mol, or between about 3 × 10 between ⁶ g / mol to about 20 × 10 ⁶ g / mol , Or between about 3 × 10 ⁶ g / mol and about 10 × 10 ⁶ g / mol, or between about 3 × 10 ⁶ g / mol and about 6 × 10 ⁶ g / mol. "Ultra high molecular weight polyethylene" refers to a polyethylene composition having a weight average molecular weight of less than about 3 x 10 ⁶ g / mol and greater than about 1 x 10 ⁶ g / mol. In some embodiments, the molecular weight of the ultra high molecular weight polyethylene composition is between about 2 × 10 ⁶ g / mol to about 3 × 10 ⁶ g / mol or less. "High molecular weight polyethylene" is about 3 × 10 ⁵ g / mol or more to 1 × 10 ⁶ g / mol weight-refers to a polyethylene composition having a number average molecular weight. For purposes of this specification, the molecular weight referred to herein is determined according to the Margolies equation ("Margolies molecular weight").

Suitable polyethylene materials include GUR UHMWPE from Ticona Polymers LLC, a subsidiary of Celanese Corporation of Dallas, Texas, and Braskem (Brazil), DSM (Netherlands), Braskem Including commercial products from various sources, including Beijing Factory No. 2 (BAAF), Shanghai Chemical and Qilu (China), Mitsui and Asahi (Japan) ≪ / RTI > In particular, GUR® polymers may include: GUR® 2000 series (2105, 2122, 2122-5, 2126), GUR® 4000 series (4120, 4130, 4150, 4170, 4012, 4122-5, , 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 ranging from about 5 dl / g to about 30 dl / g and a crystallinity of greater than about 80%, as described in U.S. Patent Application Publication No. 2008/0090081. Another example of a suitable polyethylene material is a polyacetal material having a molecular weight of about 300,000 g / mol to about 2,000,000 g / mol, as determined by ASTM-D 4020, as described in International Application No. PCT / US2011 / 034947, A mean particle size D ₅₀ between about 300 μm and about 1500 μm, and a bulk density between about 0.25 g / ml and about 0.5 g / mL.

The binder particles may take any shape. Such shapes include spherical, hyperion, wrought, crowroned or interplanetary dust, granular, potato, irregular, or combinations thereof. In a preferred embodiment, suitable binder particles described herein are non-fibrous. In some embodiments, the binder particles are in the form of a powder, pellet, or particulate. In some embodiments, the binder particles are a combination of various binder particles.

In some embodiments, the binder particles may be about 0.1 nanometers, 0.5 nanometers, 1 nanometer, 10 nanometers, 100 nanometers, 500 nanometers, 1 micrometer, 5 micrometers, 10 micrometers, 50 micrometers, 100 Micrometers, 150 micrometers, 200 micrometers, and 250 micrometers. The binder particles may be present in an amount ranging from about 5000 micrometers, 2000 micrometers, 1000 micrometers, 900 micrometers, 700 micrometers, 500 micrometers, 400 micrometers, 300 micrometers, 250 micrometers, 200 micrometers, Meter, 50 micrometers, 10 micrometers, and 500 nanometers. Any combination of the lower and upper limits, where the selected maximum size is greater than the selected minimum size, may be suitable for use in the embodiments described herein. In some embodiments, the binder particles may be a mixture of particle sizes in the range from above the lower limit to below the lower limit. In some embodiments, smaller diameter particles may be advantageous for faster heating to bond the binder particles together, which may be particularly useful in high throughput processes for making the porous article described herein.

The ratio of binder particle size to active particle size may include any repetition as revealed in each size range described herein, and certain size ranges may be advantageous for certain applications and / or products. As a non-limiting example, in a smoking device filter, the size of the active particles and binder particles should be such as to enable the EPD to draw fluid through the porous body. In some embodiments, the ratio of binder particle size to active particle size may range from about 10: 1 to about 1: 10, or more preferably from about 1: 1.5 to about 1: 4.

Additionally, the binder particles may have a bulk density ranging from 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 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 electrically conductive binder particles, other conventional thermoplastic materials may be used as binder particles. Such thermoplastic materials include but are not limited to polyolefins, polyesters, polyamides (or nylons), polyacrylics, polystyrenes, polyvinyls, polytetrafluoroethylenes (PTFE), polyetheretherketones Derivatives thereof, and any combinations thereof. Non-fibrous plasticized cellulosic 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, any combination thereof, and the like. Examples of suitable polyethylenes also include low-density polyethylene, linear low-density polyethylene, high-density polyethylene, any of its copolymers, any derivatives thereof, any combination thereof, and the like. Examples of suitable polyesters include polyethylene terephthalate, polybutylene terephthalate, polycyclohexylenedimethylene terephthalate, polytrimethylene terephthalate, any of its copolymers, any derivatives thereof, any combination thereof, and the like . Examples of suitable polyacrylics include, but are not limited to, polymethylmethacrylate, any copolymer thereof, any derivative thereof, any combination thereof, and the like. Examples of suitable polystyrenes include polystyrene, acrylonitrile-butadiene-styrene, styrene-acrylonitrile, styrene-butadiene, styrene-maleic anhydride, any copolymer thereof, any derivative thereof, any combination thereof, , But is not limited thereto. Examples of suitable polyvinyls include, but are not limited to, ethylene vinyl acetate, ethylene vinyl alcohol, polyvinyl chloride, any copolymer thereof, any derivative thereof, any combination thereof, and the like. Examples of suitable celluloses include, but are not limited to, cellulose acetate, cellulose acetate butyrate, plasticized cellulose, cellulose propionate, ethyl cellulose, any of its copolymers, any derivatives thereof, any combination thereof, and the like . In some embodiments, the binder particles can be any copolymer, any derivative, and any combination of the binders listed above.

In some embodiments, the binder particles described herein may comprise a hydrophilic surface treatment. Hydrophilic surface treatment (e.g., oxygenating functional groups such as carboxy, hydroxyl and epoxy) can be carried out in the presence of a chemical oxidant, a flame, an ion, a plasma, a corona discharge, ultraviolet radiation, ozone and combinations thereof (e.g. ozone and ultraviolet radiation treatment) It can be achieved by exposure to more than one. Since many of the active particles described herein are hydrophilic depending on the function of either the composition or the adsorbed water, the hydrophilic surface treatment for the binder particles may be advantageous because the attraction between the binder particles and the active particles (e.g., Valence, electrostatic, hydrogen bonding, etc.). This enhanced attraction can minimize the variability in the EPD, integrity, circumference, cross-sectional shape, and other properties of the resulting porous body by alleviating the separation of the active and binder particles in the matrix material. In addition, it has been observed that the augmented attraction provides more homogeneous matrix material, which can provide flexibility in 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 the porous body may comprise active particles, binder particles and additives. In some embodiments, the matrix material or porous article is formed from a lower limit of about 0.01 wt%, 0.05 wt%, 0.1 wt%, 1 wt%, 5 wt%, or 10 wt% in the matrix material or the porous article to about 25 wt% %, 15 wt.%, 10 wt.%, 5 wt.% Or 1 wt.%, Wherein the amount of additive ranges from any lower limit to any upper limit, Lt; RTI ID = 0.0 > a < / RTI >

In some embodiments, the porous body may have a void volume in the range of about 40% to about 90%. In some embodiments, the porous article may have a void volume of about 60% to about 90%. In some embodiments, the porous article may have a pore volume from about 60% to about 85%. The void volume is the free space remaining after taking into account the space taken up by the active particles.

In determining pore volume, it is not intended to be bound by any particular theory, but it has been found that the final density of the mixture under test is almost exclusively exerted by the active particles; So that the space occupied by the binder particles should therefore not be taken into account in the calculation. Thus, in this context, the void volume is calculated on the basis of the space remaining after considering the active particles. To determine the pore volume, the upper and lower diameters based on the mesh size were first averaged over the active particles and then the volume was calculated using the density of the active material (assuming a spherical shape based on the average diameter) box). The pore volume percentage is then calculated as follows:

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

In some embodiments, the porous article is less than about 20 mm water per mm length, less than or equal to 19 mm water per mm length, less than or equal to 18 mm water per mm length, less than or equal to 17 mm water per mm length, Water less than 15 mm, water per mm length less than 14 mm, mm less than 13 mm water per mm, water less than 12 mm water per mm, water less than 11 mm water per mm, water less than 10 mm, Less than 9 mm, less than 8 mm water per mm, less than 7 mm water per mm, less than 6 mm water per mm, less than 5 mm water per mm, less than 4 mm water per mm, At least about 1 mg / mm, 2 mg / mm, 3 mg / mm, 4 mg / mm, 5 mg / mm, in combination with EPD of less than 2 mm water per mm length or less than 1 mm water per mm length, 8 mg / mm, 9 mg / mm, 10 mg / mm, 11 mg / mm, 12 mg / mm, 13 mg / mm, 14 mg / mm, 15 mg / 20 mg / mm, 21 mg / mm, 22 mg / mm, 23 mg / mm, 24 mg / mm or 25 mg / mm Can have an active particle loading.

By way of example, in some embodiments, the porous article may have an EPD of about 20 mm or less water per mm length and an active particle loading of about 1 mg / mm or greater. In another embodiment, the porous article has an EPD of less than about 20 mm water per mm length and an active particle loading of at least about 1 mg / mm, wherein the active particles may not be carbon. In another embodiment, the porous body may have active particles comprising carbon with a loading of at least 6 mg / mm in combination with an EPD of no more than 10 mm water per mm length.

In some embodiments, the porous article may be effective in removing ingredients from the cigarette smoke, such as those listed herein. Porous bodies can be used to reduce the delivery of certain tobacco smoke components targeted by the World Health Organization Framework Convention on Tobacco Control ("WHO FCTC") on tobacco control. As a non-limiting example, a porous body in which activated carbon is used as active particles can be used to reduce the delivery of certain tobacco smoke components to levels below the WHO FCTC spooler. In some embodiments, the components may include, but are not limited to, acetaldehyde, acrolein, benzene, benzo [a] pyrene, 1,3-butadiene and formaldehyde. The porous article having activated carbon has acetaldehyde in the smoke stream from about 3.0% to about 6.5% / mm of porous body length; Acrolein in the smoke stream from about 7.5% to about 12% / mm porous body length; From about 5.5% to about 8.0% / mm of porous body length of benzene in the smoke stream; The benzo [a] pyrene in the smoke stream from about 9.0% to about 21.0% / mm of porous body length; Butadiene in the smoke stream by about 1.5% to about 3.5% / mm porous body length; And reduce formaldehyde in the smoke stream by about 9.0% to about 11.0% / mm porous body length. In another example, a porous article in which an ion exchange resin is used as active particles can be used to reduce the delivery of certain tobacco smoke components to below the WHO rating. In some embodiments, the porous article comprising an ion exchange resin has acetaldehyde in the stream of smoke from about 5.0% to about 7.0% / mm of porous body length; Acrolein in the smoke stream from about 4.0% to about 6.5% / mm porous body length; And reduce formaldehyde in the smoke stream by about 9.0% to about 11.0% / mm porous body length. It will be appreciated by those of ordinary skill in the art that the values reported herein with respect to the concentration of a particular smoke stream component may vary depending on the test protocol and the tobacco blend. The reduction referred to herein is the determination of selected carbonyls in mainstream tobacco smoke by high performance liquid chromatography using the Health Canada Intense Smoking Protocol of the CORESTA recommendation method No. 74, Smoke by High Performance Liquid Chromatography). Sample cigarettes were prepared from US commercial brands by manually replacing a standard cellulose acetate filter with a double-segmented filter consisting of a porous segment and a cellulose acetate segment. The length of the porous segment varied between 5 and 15 mm.

IV. additive

Suitable additives include, but are not limited to, active compounds, ionic resins, zeolites, nanoparticles, microwave enhancing additives, ceramic particles, glass beads, softeners, plasticizers, pigments, dyes, flavors, fragrances, controlled release vesicles, But are not limited to, vitamins, peroxides, biocides, antifungal agents, antimicrobial agents, antistatic agents, flame retardants, disintegrating agents, and any combination thereof.

Suitable active compounds include, but are not limited to, malic acid, potassium carbonate, citric acid, tartaric acid, lactic acid, ascorbic acid, polyethyleneimine, cyclodextrin, sodium hydroxide, sulfamic acid, sodium sulfamate, polyvinylacetate, Including combinations thereof, suitable for removing components from the smoke stream. It should be noted that the active particles may be regarded as active compounds and vice versa. By way of non-limiting example, fullerenes and some carbon nanotubes can be considered to be particulates and molecules.

Suitable ionic resins include backbones such as styrene-divinyl benzene (DVB) copolymers, acrylates, methacrylates, phenol formaldehyde condensates and epichlorohydrin amine condensates; A plurality of electrically charged functional groups attached to the polymer backbone; And polymers having any combination thereof, but are not limited thereto.

Zeolites may include pores having uniform molecular-sized dimensions, such as crystalline aluminosilicates with channels or cavities. Zeolites may include natural and synthetic materials. Suitable zeolites include zeolite beta (Na ₇ (Al ₇ Si ₅₇ O ₁₂₈ ) tetragonal), zeolite ZSM-5 (Na _n (Al _n Si _{96 - n} O ₁₉₂ ) 16H ₂ O, n <27) Zeolite X, Zeolite Y, Zeolite KG, Zeolite ZK-5, Zeolite ZK-4, Mesoporous Silicate, SBA-15, MCM-41, MCM48 Modified by 3-Aminopropylsilyl Groups, Alumino-Phosphate, Mesoporous Aluminum (For example, mixed oxide gels), and any combination thereof, but are not limited thereto.

Suitable nanoparticles include nano-scale carbon such as carbon nanotubes having any number of walls, carbon nanofines, bamboo-type carbon nanostructures, fullerene and fullerene aggregates, and graphene including thin layer graphene and oxidized graphene particle; Metal nanoparticles such as gold and silver; Metal oxide nanoparticles such as alumina, silica and titania; Paramagnetic and paramagnetic nanoparticles such as iron oxide of various crystal structures such as gadolinium oxide, hematite and magnetite, about 12 nm Fe ₃ O ₄ , goethite-nanotubes and endofullans such as Gd @ C ₆₀ ; And core-shell and onion-type nanoparticles such as gold and silver nanoshells, onion-type iron oxides, and other nanoparticles or microparticles having an outer shell of either of these materials, and any combination of the above (including activated carbon) But is not limited thereto. Nanoparticles include nanorods, nanospheres, nanorays, nanowires, nanostars (e.g., nanotripods and nanotetrafluorides), hollow nanostructures, hybrid nanostructures in which two or more nanoparticles are linked together, It should be noted that non-nanoparticles having a coating or nano-back wall may be included. Nanoparticles can also include nanoparticles that are functionalized by non-limiting covalent and / or non-covalent, e.g., pi-lamination, physical adsorption, ionic bonding, van der Waals bonding, It is to be noted that the compound of the present invention may contain a derivatized derivative. Suitable functional groups include, but are not limited to, amines (1 DEG, 2 DEG or 3 DEG), amide, carboxylic acid, aldehyde, ketone, ether, ester, peroxide, silyl, organosilane, hydrocarbon, aromatic hydrocarbon, tea; polymer; Chelating agents such as those comprising ethylene diamine tetraacetate, diethylenetriamine pentaacetic acid, triglycolic acid, and pyrrole rings; And any combination thereof, but are not limited thereto. The functional groups can enhance the removal of the smoke component and / or enhance the introduction of the nanoparticles into the porous body.

Suitable microwave enhancement additives may include, but are not limited to, microwave reactive polymers, carbon particles, fullerenes, carbon nanotubes, metal nanoparticles, water, and the like, and any combinations thereof.

Suitable ceramic particles include, but are not limited to, oxides (e.g., silica, titania, alumina, beryllium, ceria and zirconia), non-oxides (e.g. carbides, borides, nitrides and silicides), composites thereof, But is not limited thereto. The ceramic particles can be crystalline, non-crystalline or semi-crystalline.

As used herein, the pigment refers to compounds and / or particles that impart color and are introduced throughout the matrix material and / or its components. Suitable pigments include titanium dioxide, silicon dioxide, tartrazine, E102, phthalocyanine blue, phthalocyanine green, quinacridone, perylenetetracarboxylic acid di-imide, dioxazine, perinone disazo pigment, anthraquinone pigment, carbon black , Titanium dioxide, metal powder, iron oxide, ultramarine, and any combination thereof.

As used herein, a dye refers to a compound and / or particle that imparts hue and is a surface treatment. Suitable dyes include CARTASOL® dyes (cationic dyes available from Clariant Services) in liquid and / or granular form (eg, Cartastol® Brilliant Yellow K-6G Liquid, ® Yellow K-4GL Liquid, Cartathol® Yellow K-GL Liquid, Cartascol® Orange K-3L Liquid, Cartascol® Scarlet K-2GL Liquid, Cartascol® Red K-3BN Liquid, Cartascol® Blue K-5R Liquid, Cartathol® Blue K-RL Liquid, Cartascol® Turquoise K-RL Liquid / Granule, Cartascol® Brown K-BL Liquid, FASTUSOL® Dyes (colorant available from BASF) (E.g., Yellow 3GL, Part Sole C Blue 74L), but is not limited thereto.

Suitable flavors may be any flavor suitable for use in a smoking device filter, including those that impart flavor and / or flavor to the smoke stream. Suitable flavoring agents include, but are not limited to, organic materials (or natural flavor particles), carriers for natural flavors, carriers for artificial flavors, and any combination thereof. Organic materials (or natural flavor particles) include, but are not limited to, tobacco, cloves (e.g., ground cloves and clove flowers), cocoa, coffee, tea and the like. Natural and artificial flavors may include, but are not limited to, menthol, clove, cherry, chocolate, orange, mint, mango, vanilla, cinnamon, tobacco and the like. Such flavoring agents may be provided by menthol, anethole (licorice), anisole, limonene (citrus), eugenol (clove), and the like, and any combination thereof. In some embodiments, more than one flavor may be used, including any combination of flavors provided herein. These flavors can be placed in the tobacco column, filter compartment or porous article described herein. The amount of flavor will vary depending on the desired flavor level in the smoke stream considering all filter compartments, the length of the smoking device, the type of smoking device, the diameter of the smoking device, as well as other factors known to those of ordinary skill in the art.

Suitable fragrances include but are not limited to methyl formate, methyl acetate, methyl butyrate, ethyl acetate, ethyl butyrate, isoamyl acetate, pentyl butyrate, pentyl pentanoate, octyl acetate, myrcene, geraniol, Anthol, anthol, estragol, thymol, laurylol, laurylol, nerolidol, limonene, camphor, terpineol, alpha-ionone, tubon, benzaldehyde, eugenol, cinnamaldehyde, ethyl maltol, vanilla, Volatile organic compounds, volatile small molecules, methyl formate, methyl acetate, methyl butyrate, ethyl acetate, ethyl butyrate, isoamyl acetate, pentyl butyrate, isopropyl alcohol, Pentylpentanoate, octyl acetate, myrcene, geraniol, nerol, citral, citronellal, citronellol, Anthol, anthol, estragol, thymol, furanone, laurylol, nanolitol, limonene, camphor, terpineol, alpha-ionone, Rosemary, lavender, citrus, freesia, apricot flower, greens, peach, jasmine, rosewood, pine, thyme, oak moss, musk, betibeer, myrrh, black currant, bergamot, grape, acacia, clock flower, sandalwood, Iris, raspberries, lily of the valley, sandalwood, red beans, mandarin, neroli, violet leaves, gardenia, red fruity, ylang-ylang, acacia parnassiana, mimosa, tonka bean, wood, yangyanghyang, narcissus, hyacinth, , Bergamot, cedarwood, neroli, bergamot, strawberry, carnation, oregano, honey, musk, liquid heliotrope, caramel, coumarin, parsley, dewberry, heloni, bergamot, hyacinth, coriander, pimento berry, lavada , Cassis, bergamot, aldehyde, orchid, pumpkin, benzoin, white iris, tuberose, palmarosa, cinnamon, nutmeg, moss, quince tree, pineapple, bergamot, digittalis, tulip, wisteria, clematis, Myrrh, coconut, hyssop, ginseng, hyacinth, petit grain, iris, hyacinth, indigo, pepper, raspberry, benzoin, mangoes, rose violet, yellow daffodil, incense deity carnation Aromatic flowers, Bourbon Betisberger, Firides, Harry incense, Osmanthus, Oak moss, Judo, Mint, Anise, Cinnamon, White iris, Apricot, Plumeria, Marigold, Rose oto, Narcissus sauce, Lemon, Hibiscus, White Rum, White Rum, Pumpkin, Sugar Candy, Jack Fruit, Honey Dew, Lotus Flower, Muguet, Audi, Absinthe, Ginger, Juniper Berry, Basil, la Ivy, grass, Para rubber tree, Spearmint, Salvia, Face, Grape, Brim, Bamboo, Balsamic, Poet-Thieng, Osmanthus, Carrocarunde, White orchid, Collar, White, Rubeum lily, Tagetes Bell, lotus, cyclamen, orchid, glycine, thiare flower, ginger lily, green osmantus, clock flower, blue rose, beerum, kashie, African tagetes, anatolian rose, auburn new narcissus, Egyptian jasmine, Egyptian marigold, Ethiopian musk, Lycoris sylvestris, Lycoris rose, Chinese rose, Chinese rose, Chinese pizza, Chinese gardenia, Calabria Mandarin, Comoros Islands tuberose, Parisian Iris, French Jasmine, French Yellow Daffodil, French Hyacinth, Guinea Orange, Guyana Wakapua, Grass Petit Grain, Morocco Jasmine, Morocco Rose, Morocco Rose, Morocco Rose, Morocco Rose, Moroccan Rose, Moroccan Rose, Moroccan Rose, Moroccan Rose, Moroccan Rose, Moroccan Rose, Moroccan Rose, Orchid Moss, Moroccan Orange Flower, Miyors Sandalwood, Oriental Rose, Russian Leather, Russian Coriander, Sicilian Mandarin, South African Marigold, South America Tongca Bean, Singapore Pawlli, Spain Orange Flowers, Sicilian Lime, Reunion Islands Betisbury, Turkey Rose, Thailand But are not limited to, benzoin, Tunisian orange flowers, Yugoslavian oak moss, Virginia cedar wood, Utah Western pickles, West Indies, etc., and any combination thereof.

Suitable pressure sensitive adhesives include, but are not limited to, methylcellulose, ethylcellulose, hydroxyethylcellulose, carboxymethylcellulose, carboxyethylcellulose, water soluble cellulose acetate, amides, diamines, polyesters, polycarbonates, silyl-modified polyamide compounds, polycarbamates, Poly (methyl acrylate), poly (butylacrylate), polyacrylic acid, polyacrylic acid, polyacrylic acid, polyacrylic acid, (Meth) acrylic acid ester copolymer, poly (methyl methacrylate), poly (butyl methacrylate), poly (methyl methacrylate), poly Poly (2-ethylhexyl methacrylate), acrylamido-methyl-pro Acrylamido-methyl-propanesulfonate copolymer, an acrylamido-methyl-propanesulfonate copolymer, an acrylamido-methyl-propanesulfonate copolymer, a benzyl coco di- (hydroxy Ethyl) quaternary amine, pT-amyl-phenol condensed with formaldehyde, dialkylaminoalkyl (meth) acrylate, acrylamide, N- (dialkylaminoalkyl) acrylamide, methacrylamide, hydroxyalkyl ) Acrylate, methacrylic acid, acrylic acid, hydroxyethyl acrylate, and the like, any derivative thereof, and any combination thereof, but is not limited thereto.

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

Suitable antimicrobial agents include, but are not limited to, antimicrobial metal ions, chlorhexidine, chlorhexidine salts, triclosan, polyoxine, tetracycline, aminoglycosides (such as gentamicin), rifampicin, But are not limited to, Cole, myconeazole, quinolone, penicillin, nonoxynol 9, fusidic acid, cephalosporin, mucyrosine, metronidazole reacerpin, proteoglycans, (PHMB), PHMB derivatives (examples: acyclovir, vanoximine, clindamycin, ricomycin, sulfonamide, norfloxacin, phefloxacin, nalidizic acid, oxalic acid, enoxacinic acid, ciprofloxacin, polyhexamethylenebiguanide For example, biodegradable biguanides such as polyethylene hexamethylene beguinide (PEHMB)), chlorexidine gluconate, chlorohexidine hydrochloride, ethylenediamine LA acid (EDTA), EDTA derivatives (e.g., disodium EDTA or sodium EDTA Inc.) and the like, but may contain any combination thereof, without being limited thereto.

In some embodiments, the antistatic agent may comprise any suitable anionic, cationic, amphoteric or nonionic antistatic agent. Anionic antistatic agents generally include, but are not limited to, alkaline sulphates, alkaline phosphates, phosphate esters of alcohols, phosphate esters of ethoxylated alcohols, and any combination thereof. Examples include, but are not limited to, alkali neutralized phosphate esters (e.g., TRYFAC® 5559 or TRYFRAC® 5576 available from Henkel Corporation, Molden, South Carolina) It is not. Cationic antistatic agents may include, but are not limited to, quaternary ammonium salts and imidazolines, which generally have a positive charge. Examples of nonionic materials include poly (oxyalkylene) derivatives such as ethoxylated fatty acids such as EMEREST® 2650 (ethoxylated fatty acid available from Henkel Corporation of Molden, South Carolina), TUNCOL (TM) 5964 (ethoxylated lauryl alcohol available from Henkel Corporation of Moldin, South Carolina), TRYMEEN® 6606 (ethoxylated tallow amine available from Henkel Corporation of Molden, South Carolina) , And alkanolamides such as EMID® 6545 (oleic diethanolamine available from Henkel Corporation of Molden, South Carolina), and any combinations thereof. Anionic and cationic materials tend to be more effective antistatic agents.

Porous bodies, etc., are discussed herein primarily for smoking device filters, but porous materials and the like are not limited in their application to other applications, including but not limited to liquid filtration, water purification, automotive air filters, air filters for medical equipment, It should be noted that it may also be used as a fluid filter (or a portion thereof). Those of ordinary skill in the art will appreciate that variations and / or limitations necessary to adapt this disclosure for other filtration applications, such as size, shape, size ratio of matrix material components, and matrix material composition Will know about the composition of. As a non-limiting example, the matrix material may be molded into a concentric water filter configuration or other shape, such as a hollow cylinder, for a pleated sheet for an air filter.

In some embodiments, the system includes a mold cavity disposed along the material path, at least one hopper prior to at least a portion of the mold cavity for supplying the matrix material to the material path, A heat source, and a material path including a cutter disposed along a material path after a first portion of the material path.

Some embodiments may include continuously introducing the matrix material into the mold cavity and placing the release wrapper as a liner of the mold cavity. The embodiment may also include heating at least a portion of the matrix material to bond the matrix material at a plurality of contact points to form a porous body elongate and radially cutting the porous body elongate to yield a porous body.

Some embodiments include continuously introducing the matrix material into the mold cavity, heating at least a portion of the matrix material to bond the matrix material at multiple points of contact, thereby forming a porous body elongate, and extruding the porous body elongate through the die .

In some embodiments, the system includes two or more mold cavity components, wherein the first conveyor comprises a first mold cavity component and the second conveyor comprises a second mold cavity component . The first conveyor and the second conveyor may be configured to combine the first mold cavity component and the second mold cavity component to form a mold cavity and then to detach the first mold cavity component from the second mold cavity component in a continuous manner can do. The system may also include a hopper to enable filling the mold cavity with the matrix material, and a heat source in thermal communication with at least a first portion of the mold cavity to convert the matrix material to a porous body.

Some embodiments may include introducing a matrix material into a plurality of mold cavities, heating the matrix material within the mold cavity to bond the matrix material at a plurality of points of contact, and forming a porous article.

Embodiments disclosed herein include:

A. feeding a matrix material comprising a plurality of binder particles and a plurality of active particles to a mold cavity through a pneumatic compacted feed to form a desired cross-sectional shape; 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 to form a porous article elongate; Cooling the porous body elongate; A method comprising cutting the porous article elongate to produce a porous article;

B. feeding a matrix material comprising a plurality of active particles and a plurality of binder particles comprising a hydrophilic surface modification to a mold cavity through a pneumatic dense phase feed to form a desired cross-sectional shape; 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 to form a porous article elongate; Reforming the cross-sectional shape of the porous body extender after heating; Cooling the porous body elongate; A method comprising cutting the porous article elongate to produce a porous article; And

C. feeding a matrix material comprising a plurality of active particles, a plurality of binder particles comprising a hydrophilic surface modification and a microwave enhancement additive to a mold cavity through a pneumatic dense phase feed to form a desired cross-sectional shape; Heating at least a portion of the matrix material by irradiating the matrix material using microwave irradiation to couple at least a portion of the matrix material at a plurality of sintered contact points to form a porous article elongate; Reforming the cross-sectional shape of the porous body extender after heating; Cooling the porous body elongate; And cutting the porous article elongate to produce a porous article.

Each embodiment A, B, and C may include any combination of one or more of the following additional elements: Element 1: a pneumatic compact phase feed has a feed rate of from about 1 m / min to about 800 m / min &Lt; / RTI &gt; Element 2: the pneumatic compacted feed is made at a feed rate of about 1 m / min to about 800 m / min, and the mold cavity has a diameter of about 3 mm to about 10 mm; Element 3: heating involves irradiating at least a portion of the matrix material with microwave radiation; Element 4: The matrix material further comprises a microwave enhancement additive; Element 5: the mold cavity is at least partially defined by a paper wrapper; Element 6: the binder particle comprises a hydrophilic surface treatment; Element 7: The method further comprises reforming the cross-sectional shape of the porous body elongate after heating; Element 8: The method further comprises reheating the porous body elongate before cutting to form a second plurality of sintered contact points; Element 9: The method further comprises reheating the porous body to form a second plurality of sintered contact points; Element 10: The porous body is a sheet suitable for use in an air filter; Element 11: The porous article is a sheet having a thickness of about 5 mm to about 50 mm; Element 12: The porous article is suitable for use in a smoking article filter; Element 13: The porous body is suitable for use in a water filter; And Element 14: Porous body is a hollow cylinder.

As a non-limiting example, representative combinations applicable to A, B, C include: Element 1 in combination with Element 3; Element 2 in combination with element 3; Element 4 in combination with any of the foregoing; Element 3 in combination with element 4; At least one of elements 7-9 in combination with any of the foregoing; Element 7 combined with element 8; Element 7 combined with element 9; Element 7 combined with element 3; Element 5 in combination with any of the foregoing; One of elements 10-14 in combination with any of the foregoing; Element 6 in combination with any of the foregoing; And element 6 combined with one of elements 1-4.

In order to better understand the embodiments described herein, the following examples of exemplary embodiments are provided. The following examples should not be construed as limiting or limiting the scope of the invention in any way.

[ Example ]

Example 1. To measure completeness, the sample is placed in a French square vial and shaken vigorously for 5 minutes using a wrist action shaker. At completion, weigh the samples before and after shaking. Converts the difference to a percentage loss value. These tests mimic the deterioration under extreme circumstances. It is assumed that a weight loss of less than 2% is acceptable quality.

A porous sample was prepared using GUR 2105 containing carbon additive and GUR X192 containing carbon additive, both using paper packaging and without paper packaging. The sample was cylindrical with a size of 8 mm x 20 mm. The results of the completeness test are shown in Table 1 below.

<Table 1>

This example demonstrates that increasing the percentage of binder (GUR) in the porous article and including wrapping paper (paper) improve the integrity of the porous article. In addition, the porous body can be designed to have completeness comparable to Dalmatian filters (plasticized tow-phase-carbon filters) that are used to increase the removal of smoke components.

Example 2. To measure the amount of particles that are released when a fluid is drawn through a filter (or a porous body), the sample is dry-pumped and the released particles are collected on a Cambridge pad.

The particle emission characteristics of the porous body were compared with a Dalmatian filter (plasticized tow-phase-carbon filter). The sample contained (1) a porous body containing 333 mg of carbon, (2) a porous body containing 338 mg of carbon washed, and (3) a Dalmatian filter having 74 mg of carbon. . The results of the particle emission test are shown in Table 2 below.

<Table 2>

This embodiment proves that even when compared with Dalmatian filters having several times more carbon load, which is 4.5 times more in the case of this embodiment, the porous body has an emissive particle quantity at the time of attraction comparable to that of the porous body. In addition, particle emission can be mitigated using a porous body containing treatments such as cleaning. Other mitigation steps include increasing the concentration of binder in the porous body, increasing the degree of mechanical bonding in the porous body (e.g., by increasing the time at the bonding temperature), adding (e. G., Carbon) And optimizing the size and shape of the substrate.

Example 3 80 wt% carbon (PICATIF, 60% activated carbon available from Jacoby) and 20 wt% GUR 2105 matrix material were mixed and poured into paper tubes with one end clogged. The filled tube was placed in a microwave oven and irradiated for 75 seconds (about 300 W and about 2.45 GHz). Many of the matrix materials were bonded together and then cut into two compartments of 17 mm and 21 mm. The porous compartments were analyzed to demonstrate an EPD of 8.4 mm / mm in water and 2.7 mm / mm in water, respectively.

The present embodiment demonstrates the applicability of microwave irradiation in the production of porous articles and the like. As discussed above, in some embodiments, in addition to other heating techniques, microwave irradiation may be used to form the porous bodies, etc. described herein.

Example 4 80% by weight of carbon (60% activated carbon available from Picatif, Jacoby) and 20% of GUR 2105 as the first matrix material and 80% by weight of carbon (60% activated carbon available from Pikatty, Jacoby) % And plasma treated GUR® 2105 (ie, an example of a binder containing hydrophilic surface modification) Five porous bodies were prepared for each 20 wt% of the second matrix material. The properties of the resulting porous body were measured (Table 3). The ovality of the porous body is similar to that used to measure the ovality of a conventional tobacco filter by measuring the circumference, maximum diameter (a) and minimum diameter (b) by optically scanning the sample with a circumference / Method. The ovality is calculated as ab, and the degree of deformation from the circular shape of the cross-sectional shape to the oval shape is displayed.

<Table 3>

For each of these measurements, particularly EPD, the standard deviation in the porous article containing plasma treated GUR 2105 is equal to or less than that of non-treated GUR 2105. Also, when comparing EPD values between samples at the same binder particle concentration, plasma treated GUR 2105 yields a lower EPD compared to non-treated GUR 2105. This example demonstrates that binder particles having a hydrophilic surface minimizes the variability (indicated by the reported coefficient of variation) of the properties of the porous body and reduces the overall EPD of the porous body.

Example 5 A porous article was prepared using the following two matrix material samples: (1) Control - 10% by weight of GUR® 2105, 10% by weight of GUR® 2122, 80% by weight of activated carbon, and 2) 1 wt.% Of GUR® 2122®, 10 wt.% Of GUR® 2122, 79 wt.% Of activated carbon, powdered graphite (available from McMaster-Carr) (ie, examples of microwave enhancement additives) . The matrix material was fed to the mold cavity formed by the tubular / cylindrical shaped dried paper through a pneumatic compacted feed at 60 psi. The mold cavity containing the matrix material was passed through a single mode 2.45 GHz microwave chamber at 2 m / min. Microwave input energy. The resulting porous body was analyzed for EPD, circumferential and rod integrity (as measured above) (Table 4).

<Table 4>

This example demonstrates that the inclusion of microwave enhancement additives improves the microwave sintering process as evidenced by the reduction of EPD and similarly improved bar integrity for similar microwave power.

Accordingly, the present invention is fully suited to accomplish those of ordinary skill in the art, as well as the results and advantages mentioned. The specific embodiments disclosed above are merely illustrative, since the present invention may be modified and practiced in different, but equivalent manners apparent to those of ordinary skill in the art. In addition, there is no limitation on the details of the construction or design shown herein, unless it is different from what is described in the claims below. It is therefore evident that the specific exemplary embodiments disclosed above may be altered, combined or modified, and all such variations may be regarded as falling within the spirit and scope of the invention. The invention illustratively disclosed herein may suitably be embodied in the absence of any elements not specifically disclosed herein and / or any optional elements described herein. Although compositions and methods have been described in terms of "including", "containing", or "including" various components or steps, it should be understood that the compositions and methods may be "essentially composed" "It is possible. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range having a lower limit and an upper limit is started, all the numbers and all the enclosing ranges falling within the range are specifically disclosed. Specifically, all ranges of values disclosed herein ("about a to about b", or equivalently, "about a to b", or equivalently, "about ab" It should be understood that the scope is presented. Also, unless expressly and otherwise clearly defined by a patentee, the terms of the claims have their ordinary meanings. Also, as used in the claims, the indefinite article "a" or "an" is defined herein to mean one or more than one element that it introduces. Where there is any conflict in the use of words or terms in one or more patents or other documents that may be interfered with in this specification and herein, the definitions consistent with this specification should be adopted.

Claims (20)

Supplying a matrix material comprising a plurality of binder particles and a plurality of active particles to a mold cavity through a pneumatic compacted feed to form a desired cross-sectional shape;
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 to form a porous body length;
Cooling the porous body elongate;
The porous article is cut to produce a porous article
&Lt; / RTI &gt; The method of claim 1, wherein the pneumatic compacted feed comprises a feed rate of about 1 m / min to about 800 m / min. The method of claim 1, wherein the pneumatic compacted feed is made at a feed rate of from about 1 m / min to about 800 m / min and the mold cavity has a diameter of from about 3 mm to about 10 mm. 2. The method of claim 1, wherein heating comprises irradiating at least a portion of the matrix material with microwave radiation. 5. The method of claim 4, wherein the matrix material further comprises a microwave enhancement additive. The method of claim 1, wherein the mold cavity is formed at least partially by a paper wrapper. The method of claim 1 wherein the binder particles are hydrophilic surface treated. The method of claim 1, further comprising reforming the cross-sectional shape of the porous body extender after heating. The method of claim 1, further comprising reheating the porous body extensions prior to cutting to form a second plurality of sintered contact points. The method of claim 1, further comprising reheating the porous body to form a second plurality of sintered contact points. Feeding a matrix material comprising a plurality of active particles and a plurality of hydrophilic surface-modified binder particles to a mold cavity through a pneumatic dense phase feed to form a desired cross-sectional shape;
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 to form a porous article elongate;
Reforming the cross-sectional shape of the porous body extender after heating;
Cooling the porous body elongate;
The porous article is cut to produce a porous article
&Lt; / RTI &gt; 12. The method of claim 11, wherein the pneumatic compacted feed comprises a feed rate of from about 1 m / min to about 800 m / min. 12. The method of claim 11, wherein the pneumatic compacted feed is at a feed rate of from about 1 m / min to about 800 m / min and the mold cavity has a diameter of from about 3 mm to about 10 mm. 12. The method of claim 11, wherein the heating comprises irradiating at least a portion of the matrix material with microwave radiation. 15. The method of claim 14, wherein the matrix material further comprises a microwave enhancement additive. 12. The method of claim 11, wherein the mold cavity is formed at least partially by a paper wrapper. 12. The method of claim 11, further comprising reheating the porous body extensions prior to cutting to form a second plurality of sintered contact points. 12. The method of claim 11, further comprising reheating the porous body to form a second plurality of sintered contact points. Feeding a matrix material comprising a plurality of active particles, a plurality of hydrophilic surface-modified binder particles and a microwave enhancement additive to the mold cavity through a pneumatic dense phase feed to form a desired cross-sectional shape;
Heating at least a portion of the matrix material by irradiating the matrix material using microwave irradiation to couple at least a portion of the matrix material at a plurality of sintered contact points to form a porous article elongate;
Reforming the cross-sectional shape of the porous body extender after heating;
Cooling the porous body elongate;
The porous article is cut to produce a porous article
&Lt; / RTI &gt; 20. The method of claim 19, further comprising reheating the porous body extensions prior to cutting to form a second plurality of sintered contact points.

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