KR20200057034A - Aerosol generating device with porous mass - Google Patents

Abstract

Disclosed herein is an aerosol-generating device comprising an aerosol-forming substrate, a support element, an aerosol-cooling element, and an aerosol-generating article comprising a mouthpiece. At least one of the aerosol cooling elements and filters comprises a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles.

Description

Aerosol generating device with porous mass

This application claims the priority of United States Provisional Application No. 62 / 562,290, filed on September 22, 2017, the entire contents and invention of which are incorporated herein by reference.

The present invention relates generally to aerosol-generating devices comprising a binder and optionally a porous mass comprising active or inactive particles. In particular, the present invention relates to an aerosol-generating device comprising a porous mass comprising 20 to 100% by weight of a binder and 0 to 80% by weight of active or inactive particles.

Some smoking articles provide smokers with aerosols similar to cigarette smoke. Some smoking articles generate aerosol vapors from the aerosol-generating means by heating the aerosol-generating means to a fuel source such as tobacco, for example. Cigarettes are heated or burned sufficiently to vaporize nicotine and produce aerosol streams containing nicotine. The smoking article may have an outer cylinder of fuel with good soot properties, preferably cut tobacco or recycled tobacco, that surrounds a metal tube containing tobacco, recycled tobacco or other nicotine sources and water vapor.

In other smoking articles, inhalable aerosols are created by transferring heat from a heat source to a physically separated aerosol-forming substrate or material that can be located inside, around, or upstream of the heat source. During consumption of the aerosol-generating article, volatile compounds are released by heat transfer from the heat source and are entrained in the air drawn through the aerosol-generating article. When the released compounds are cooled by passing through cooling elements, they condense to form an aerosol that is inhaled by the user.

Synthetic fibers, such as cellulose esters, are widely used in smoke filters for smoking articles due to the ease with which they can be produced as filter rods in standard tobacco manufacturing equipment. These synthetic fibers generally include cellulose acetate in the form of corrugated continuous fibers or filaments. Filters made of cellulose ester fibers generally function by removing a portion of the particulate material from smoke passing through the fibers. Creasing or other physical location of the fibers in the filter serves to increase the surface area of the filaments that come into contact with smoke. However, these fiber-only filters do not significantly cool the hot aerosol stream and often require additional components to cool the aerosol.

Conventional cigarettes generate temperatures that burn cigarettes and release volatile compounds. The temperature for burning cigarettes can reach over 800 ° C, and this high temperature releases a lot of water contained in the smoke emitted from the cigarette. The mainstream smoke produced by conventional cigarettes tends to be perceived by smokers as having a low temperature since it is relatively dry. Aerosols produced by heating an aerosol-forming substrate with or without combustion may have a higher moisture content due to the lower temperature at which the substrate is heated. Despite the lower aerosol-forming temperature, the aerosol stream produced by this system can have a higher perceived temperature than conventional cigarette smoke. Thus, the overall length of the aerosol-generating article is longer to cool the resulting aerosol to an acceptable temperature before inhalation.

Accordingly, what is needed is an improved aerosol-generating device that improves cooling efficiency while maintaining desirable smoking characteristics.

In some aspects, the present invention relates to an aerosol-generating device comprising an aerosol-generating article. The aerosol-generating article can include an aerosol-forming substrate, a support element, an aerosol cooling element, and a mouthpiece. At least a portion of at least one of the support element, aerosol cooling element and mouthpiece comprises a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles. In some embodiments, each of the support element, aerosol cooling element and mouthpiece comprises a porous mass. In other embodiments, only one or a combination of the support element, aerosol cooling element and mouthpiece comprises a porous mass. Binders can include very high molecular weight polyethylene, ultra high molecular weight polyethylene, or combinations thereof. In some embodiments, the binder may be selected from the group consisting of polyolefin, polyester, polyamide, polyacrylic, polystyrene, polyvinyl, cellulose, and combinations thereof. The binder may further include polyolefin, polyester, polyamide, polyacrylic, polystyrene, polyvinyl, cellulose, or a combination thereof. In some embodiments, the particles may be ion exchanged resin, desiccant, silicate, molecular sieve, silica gel, activated alumina, pearlite, sepiolite, fuller's earth, magnesium silicate, metal oxide, activated carbon, activated carbon, and combinations thereof. It is an active particle that can be selected from the group consisting of. In other embodiments, the porous mass can include inert particles comprising a thermally stable material such as adsorbent carbon. Adsorbable carbon can be selected from the group consisting of porous grade carbon, graphite, low-active carbon and inert carbon. In another embodiment, the inert particles include inorganic solids selected from the group consisting of ceramic, glass, alumina, vermiculite, clay, bentonite and inert materials. Porous mass of 30 to 80% by weight of binder and 20 to 70% by weight of active or inactive particles, 30 to 70% by weight of binder and 30 to 70% by weight of active or inactive particles, or 40 to 70% by weight of binder and 30 to 60% by weight of active or inactive particles. In other embodiments, the porous mass may include 70 to 100% by weight of binder and 0 to 30% by weight of active or inactive particles. In some embodiments, the binder can be a very high molecular weight polyethylene and the active particles can be activated carbon. The porous mass can have an encapsulated pressure drop of less than 3.0 mm water / mm length or less than 1.0 mm water / mm length. The binder can be configured to undergo repetitive thermal cycles without structural modifications. The binder can be configured to undergo a pressure drop change of less than 10%. The binder can be hydrophobic. The porous mass can be configured to provide multi-path airflow. In some examples, the porous mass includes 100% by weight binder. The support element and the aerosol cooling element can be combined into a single unit and the pressure drop can be substantially the same as compared to the support element and aerosol cooling element as individual units.

The invention will be better understood in terms of the accompanying non-limiting drawings:
1 shows a cross-sectional view of an aerosol-generating device according to some embodiments of the invention;
2 shows a cross-sectional view of an aerosol-generating article according to some embodiments of the invention;
3 shows a cross-sectional view of an aerosol-generating device comprising the heating element of FIG. 2 and an aerosol-generating article, according to some embodiments of the invention;
4 shows a cross-sectional view of a mouthpiece of the aerosol-generating device of FIG. 2, in accordance with some embodiments of the invention;
5 illustrates another cross-sectional view of the mouthpiece of the aerosol-generating device of FIG. 2, in accordance with some embodiments of the present invention;
6 shows another cross-sectional view of the mouthpiece of the aerosol-generating device of FIG. 2, in accordance with some embodiments of the present invention;
7 shows another cross-sectional view of the mouthpiece of the aerosol-generating device of FIG. 2, in accordance with some embodiments of the present invention;
8 shows another cross-sectional view of the mouthpiece of the aerosol-generating device of FIG. 2, in accordance with some embodiments of the present invention;
9 shows a micrograph of a piece of porous mass in accordance with some embodiments of the present invention.

Ⅰ. Introduce

The present invention relates to an aerosol-generating device comprising an aerosol-forming substrate, a support element, an aerosol cooling element and a mouthpiece. At least a portion of at least one of the support element, aerosol cooling element and mouthpiece may comprise a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles. In some embodiments, the support element, aerosol cooling element, and a portion of the mouthpiece comprise a porous mass each comprising 20 to 100% by weight of a binder and 0 to 80% by weight of active or inactive particles. The porous mass provides a multi-path airflow that increases the temperature decrease of the aerosol cooling element, which allows for a reduction in the overall length of the aerosol generating device.

In some embodiments, the structure of the porous mass provides minimal encapsulated pressure drop (ie, loss of pressure during movement through the porous mass) while maximizing the interaction of the aerosol with the binder and active or inactive particles. The binder promotes rapid cooling of the aerosol by undergoing a phase change, but without apparent deformation, which allows fusion heat to be utilized for heat removal without degrading the filter's performance or structure. The binder softens and quickly removes heat, then gradually releases heat as it solidifies in the period between puffs. This design can be improved, modified or supplemented with active or inert materials included in the binder to promote selected filtration or modify heat absorption and release profiles.

Advantageously, rapid cooling of the aerosol using a support element, aerosol cooling element, and / or mouthpiece comprising a porous mass comprising 20 to 100% by weight of a binder and 0 to 80% by weight of active or inactive particles. Promote. In addition, the pressure drop value of the mouthpiece or aerosol cooling element is also reduced, which, while repeated use, maintains the desired hardness of the mouthpiece and the cooling characteristics by the support element, aerosol cooling element and / or mouthpiece while simultaneously drawing Leads to improvement. Specifically, the structural properties of the porous mass are very suitable for undergoing fusion heat changes without significantly altering or deforming the structure. Porous masses perform well at reduced heat, but can also provide positive sensory properties at the same time if desired.

Ⅱ. Aerosol generating device

1 to 3, some embodiments of aerosol-generating devices are shown (these are representative and not limited to the devices considered below). In some embodiments, an aerosol-generating device may include, but is not limited to, an electronic smoking device, an aerosol-generating device having a flammable source, a smokeless smoking device, and the like. Below, reference will be made to the aerosol-generating device (unless otherwise stated).

1 shows an aerosol-generating device 1 according to some embodiments of the invention. The aerosol-generating device 1 comprises a rod 2 of smoking material and a mouthpiece 3. The mouthpiece 3 may include a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles. The mouthpiece 3 is attached to the smoking material rod 2 by means of a tipping wrapper 4. The smoking material rod 2 comprises an outer wrapper 5, a combustible fuel source 6 coaxially located and a cut smoking material 7 disposed between the fuel source 6 and the wrapper 5.

In operation, the aerosol-generating device 1 is ignited and burned along the length of the fuel source, producing very little visible live tobacco smoke. The resulting visible tobacco smoke is derived from the organic component of the smoking article and is best seen at the end of the puff. The substantially non-flammable wrapping paper is burned to produce a fragile white ash similar to conventional tobacco ash, which the smoker can tap as needed. The non-combustible outer wrapper 5 upon carbonization also creates a dark combustion line that runs along the smoking article as combustion proceeds. The smoking article is burned again along the fuel supply 6. As combustion occurs, an aerosol is produced from the aerosol-generated cutting smoking material 7 in which the aerosol is sucked into the smoker's mouth. Due to the rapid cooling properties of the porous mass, the aerosol is cooled before inhalation.

2 shows an exemplary aerosol-generating article 10. The aerosol-generating article 10 can include four elements arranged in a coaxial alignment: an aerosol-forming substrate 20, a support element 30, an aerosol cooling element 40 and a mouthpiece 50. These four elements can be arranged sequentially and surrounded by an outer wrapper 60 to form an aerosol-generating article 10. Support element 30, aerosol cooling element 40, and mouthpiece 50 may be collectively referred to as a “filter”. The aerosol-generating article 10 has a proximal or distal end 80 positioned at the opposite end of the aerosol-generating article 10 relative to the mouth end 70 and the mouth end 70 that the user inserts into their mouth during use. Have However, it should be understood that the components in the aerosol-generating article need not be arranged in this way and that there are other possible configurations. In fact, the components of the aerosol-generating article can be arranged in alternative configurations that are not coaxial with other components, such as offset arrangements, overlapping arrangements, combinations thereof, and the like. In addition, due to the rapid cooling properties of the porous mass, some of these components can be shortened or completely removed from the aerosol-generating article 10.

In use, air is drawn from the distal end 80 to the mouth end 70 or proximal end by the user through the aerosol-generating article 10. The distal end 80 of the aerosol-generating article 10 may also be described as a downstream end of the aerosol-generating article 10 and the mouth end 70 of the aerosol-generating article 10 is also upstream of the aerosol-generating article 10. It can also be described as an end. The element of the aerosol-generating article 10 positioned between the mouth end 70 and the distal end 80 may be described as downstream of the mouth end 70 or, alternatively, as appropriate, upstream of the distal end 80.

The aerosol-forming substrate 20 is located at the distal or downstream end of the aerosol-generating article 10. In the embodiment shown in Figure 2, the aerosol-forming substrate 20 may include a corrugated sheet of corrugated homogenized tobacco material surrounded by wrapping paper. The corrugated sheet of homogenized tobacco material may include an aerosol former, such as glycerin.

The support element 30 can be located immediately upstream of the aerosol-forming substrate 20 and can be adjacent to the aerosol-forming substrate 20. In some aspects, the aerosol-forming substrate 20 is proximal to, but not in contact with, the support element 30. In the embodiment shown in Figure 2, the support element 30 may be a hollow cellulose acetate tube. The support element 30 positions the aerosol-forming substrate 20 at the distal end 80 of the aerosol-generating article 10 so that it can be penetrated by the heating element of the aerosol-generating device. As described further below, the support element 30 is aerosol-generating article 20 toward the aerosol-cooling element 40 when the aerosol-forming substrate 20 is inserted into the aerosol-forming substrate 20 when the heating element of the aerosol-generating device is inserted. It serves to prevent the upstream of the (10) from being driven, otherwise heat may be applied to the aerosol-forming substrate (20). In some embodiments, the support element 30 also acts as a spacer to space the aerosol-cooling element 40 of the aerosol-generating article 10 from the aerosol-forming substrate 20. In some embodiments,

The support element 30 and the aerosol cooling element 40 can form a single unit of the aerosol-generating article 10, which may be the mouthpiece extended and / or the support element 30, the aerosol cooling element 40 And the total total length of the mouthpiece 50 can be reduced. For example, such a single unit can be formed when the mouthpiece comprises a filter rod comprising a porous mass. In some embodiments, when a single unit is formed, the pressure drop is substantially the same as when compared to the aerosol cooling element and the support element as individual units, respectively, for example within 0.5%.

As shown in FIG. 2, the aerosol cooling element 40 is located immediately upstream of the support element 30 and is adjacent to the proximal end of the support element 30. In other embodiments, the aerosol cooling element 40 is not adjacent the proximal end of the support element 30. In use, volatiles released from the aerosol-forming substrate 20 travel upstream along the aerosol-cooling element 40 towards the mouth end 70 of the aerosol-generating article 10. Volatile materials can be cooled within aerosol cooling element 40 to form an aerosol that is inhaled by the user. The aerosol-cooling element may include a porous mass comprising 20 to 100% by weight of binder and 0 to 80% by weight of active or inactive particles wrapped in wrapping paper 90. The porous mass can define a plurality of channels for airflow extending along the length of the aerosol cooling element 40.

The mouthpiece 50 is located immediately upstream of the aerosol cooling element 40 and is adjacent to the proximal end of the aerosol cooling element 40. In some embodiments, the mouthpiece may not be adjacent the proximal end of the aerosol cooling element 40. In some aspects, the aerosol-generating device may further include another support element between the aerosol-cooling element 40 and the mouthpiece 50. As shown in Figure 2, the mouthpiece 50 comprises a porous mass comprising 20 to 100% by weight binder and 0 to 80% by weight active or inactive particles.

To assemble the aerosol-generating article 10, the four elements described above are aligned within the outer wrapper 60 and tightly packed. As shown in Fig. 2, the outer wrapping paper is a conventional cigarette paper.

In some embodiments, the distal end of the outer wrapper 60 of the aerosol-generating article 10 is surrounded by a band of tipping paper (not shown).

The aerosol-generating article 10 shown in FIG. 2 is designed to engage an aerosol-generating device comprising a heating element to form an aerosol consumed by a user. In use, the heating element of the aerosol-generating device causes the aerosol-forming substrate 20 of the aerosol-generating article 10 to be pulled downstream through the aerosol-generating article 10 and volatilize a compound capable of forming an aerosol inhaled by the user. Heat to a sufficient temperature.

FIG. 3 shows a portion of an exemplary aerosol-generating system 100 comprising an aerosol-generating device 110 and an aerosol-generating article 10 according to the embodiment described above and shown in FIG. 2.

In one embodiment, the aerosol-generating device 110 includes a heating element 120. As shown in FIG. 3, the heating element 120 is mounted within the aerosol-generating article receiving chamber of the aerosol-generating device 110. In use, the user inserts the aerosol-generating article 10 into the aerosol-generating article accommodating chamber of the aerosol-generating device 110 such that the heating element 120 aerosol-forming substrate 10 of the aerosol-generating article 10 as shown in FIG. 20) It should be inserted directly into. In the embodiment shown in FIG. 3, the heating element 120 of the aerosol-generating device 110 is a heater blade. Of course, other aerosol-generating device configurations can be used without departing from the scope of the present disclosure.

The aerosol-generating device 110 includes a power supply and electronics (not shown) that enable the heating element 120 to operate. Such an operation may be operated manually or automatically as the user draws on the aerosol-generating article 10 inserted into the aerosol-generating article receiving chamber of the aerosol-generating device 110. A plurality of openings are optionally provided in the aerosol-generating device to allow air to flow to the aerosol-generating article 10. 3 provides an exemplary airflow direction as illustrated by the arrows. In another aspect, a porous mass in an aerosol cooling element, support, mouthpiece, or any combination thereof can provide multipath airflow. The structure of the porous mass can include one or more channels for multi-directional airflow. In a conventional aerosol-generating device, air must first pass through a supporting element with little or no cooling effect. The air then passes through the aerosol cooling element and finally through the mouthpiece. Without being bound by theory, it is believed that, unlike corrugated fibers oriented only parallel to the airflow, since the pores of the porous mass are arbitrary, the porous mass allows this multidirectional airflow. Thus, the porous mass does not limit the direction of air flow and instead provides a tortuous path to improve cooling. In this way, the porous mass improves the temperature reduction of the aerosol cooling element, support element and / or mouthpiece. This improved temperature reduction also allows the length of the aerosol cooling element, support and / or mouthpiece to be shorter when a porous mass is used in one of these elements compared to corrugated fibers. These effects are further amplified by the efficiency of the binder and selective active or inactive material particles. In addition, the stability of the binder at high temperatures allows the filter to function when placed directly in the aerosol-generating segment. The support element 40 of the aerosol-generating article 10 resists the penetration forces experienced by the aerosol-generating article 10 while inserting the heating element 120 of the aerosol-generating device 110 into the aerosol-forming substrate 20. . As a result, the support element 40 of the aerosol-generating article 10 resists the downstream motion of the aerosol-forming substrate within the aerosol-generating article 10 while inserting the heating element of the aerosol-generating device into the aerosol-forming substrate.

When the inner heating element 120 is inserted and operated into the aerosol-forming substrate 10 of the aerosol-generating article 10, the aerosol-forming substrate 20 of the aerosol-generating article 10 is the heating element of the aerosol-generating device 110 ( 120) to a temperature below 400 ° C (or other temperature as discussed herein). At this temperature, volatile compounds are released from the aerosol-forming substrate 20 of the aerosol-generating article 10. When the user inhales at the mouth end 70 of the aerosol-generating article 10, volatile compounds released from the aerosol-forming substrate 20 are drawn downstream through the aerosol-generating article 10 and aerosol-generating into the user's mouth It is condensed to form an aerosol drawn through the mouthpiece 50 of the article 10.

When the aerosol passes downstream through the aerosol cooling element 40, the temperature of the aerosol can be reduced due to the transfer of heat energy from the aerosol to the aerosol cooling element 40. When the aerosol enters the aerosol cooling element 40, its temperature may be on the order of about 60 ° C. Due to cooling in the aerosol cooling element 40, the temperature of the aerosol upon exiting the aerosol cooling element may be on the order of 40 ° C. Thus, a temperature reduction of at least 10 ° C or more, for example at least 20 ° C or at least 30 ° C, can be achieved.

Ⅲ. Porous mass

As described herein, the present invention relates to a porous mass used in smoking devices, particularly aerosol-generating devices. Specifically, the porous mass mass can form at least a portion of a support element of an aerosol-generating device, an aerosol cooling element, a mouthpiece, or some combination of any or all of these.

In the embodiments shown in Figures 4-8, various arrangements of mouthpieces having a porous mass are shown and described. These examples illustrate any combination of conventional materials such as cellulose acetate and porous mass in the mouthpiece. Although not shown in Figures 4-8, the support element and aerosol element are also designed to include porous masses in various arrangements.

4-8 illustrate various embodiments of the mouthpiece of the aerosol-generating device of FIG. 2, according to an embodiment of the invention. As described with reference to the mouthpiece, "filter 51" is different from the combination "filter" of the mouthpiece, support element and aerosol cooling element mentioned herein. The mouthpiece 50 includes a filter 51 that can include a porous mass comprising 20 to 100 weight percent binder and 0 to 80 weight percent active or inactive particles. For example, in FIG. 4, the entire filter 51 of the mouthpiece 50 may include a substantially uniform porous mass.

As shown in Fig. 5, the mouthpiece 50 has a filter 51 comprising two segments. In this embodiment, the porous mass 53 is positioned adjacent the mouth end 70 of the mouthpiece 50. The conventional filter material 52 can be located downstream adjacent the aerosol cooling element. It is also contemplated that the porous mass 53 can be positioned downstream adjacent the aerosol cooling element 40. For example, FIG. 6 shows the mouthpiece 50 of a conventional filter material 53 upstream adjacent the mouth end 70 and a porous mass 52 downstream of the aerosol cooling element 40. An example is shown.

In FIG. 7, the mouthpiece 50 includes a multi-segment filter 51 comprising three segments. In this embodiment, the conventional filter material 53 can be disposed on the side of the porous mass 52. For example, one conventional filter material 53 may be provided at the proximal end adjacent the mouth end 70 and another conventional filter material may be provided downstream near the aerosol cooling element 40 and porosity. The mass 52 is sandwiched between them. Similarly, as shown in FIG. 8, one or more porous masses 52 are disposed on the side of a conventional filter material 53 in an arrangement similar to one porous mass 52 at the proximal end adjacent the mouth end 70. Other porous masses 52 may be provided downstream close to the aerosol cooling element 40, and a conventional filter 53 sandwiched between them. In the embodiment shown in Figures 7 and 8, the filter segment can be any combination of conventional materials and porous masses (as long as at least one of these sections is a porous mass). In some embodiments, the support element and aerosol cooling element include a porous mass and the mouthpiece can include cellulose acetate.

The above-described examples are representative and not restrictive. Of course, the filter of the present invention may have any number of sections, for example 2, 3, 4, 5, 6, or more sections. Moreover, the sections can be the same or different from each other. For example, the sections can have a stacked arrangement of filter materials. The filter can have a diameter ranging from 5 to 10 mm and a length from 5 to 100 mm.

In some embodiments, the support element can include a porous mass. In another embodiment, the aerosol cooling element comprises a porous mass. In some embodiments, the mouthpiece comprises a porous mass. In other embodiments, the support element and aerosol cooling element include a porous mass. In another embodiment, the support element and mouthpiece include a porous mass. In another embodiment, the aerosol cooling element and mouthpiece comprise a porous mass. In other embodiments, the support element, aerosol cooling element, and mouthpiece include a porous mass.

The porous mass described herein can be prepared as a filter rod to be used as a filter in an aerosol-generating device. In some embodiments, creating filters and / or filter sections may include cutting filter rod lengths or filter rods. In some embodiments, creating a filter section can include cutting the filter rod length, filter rod, or filter. The filter rod length, filter rod and / or filter section can be any cross section including, but not limited to, circular, substantially circular, ovoid, substantially ovoid, polygonal (including having rounded edges) or any hybrid thereof. It can take the form.

In the above-described embodiment, a porous mass is combined with a conventional material. As used herein, bonding means that the porous mass is in line (or in series) with the tobacco column; Thus, when a user sucks in a heated cigarette, it means that the smoke from the tobacco column must pass through the porous mass (eg in series), most of which must pass through both the porous mass and the conventional filter material. . 5-8, the porous mass and conventional filter material are coaxial, juxtaposed (next to but not in contact), adjacent, and have an equivalent cross-sectional area (or substantially equivalent cross-sectional area). However, it is understood that the porous mass and conventional materials need not be combined in this way, and other possible configurations may exist. Moreover, the porous mass is most likely expected to be used in a combined or multi-segment filter configuration as shown in Figures 5-8; The present invention is not limited to this, and as discussed above in connection with FIG. 4, the filter may include only a porous mass. It is also expected that the porous mass will be juxtaposed on the tobacco column as shown in Figure 2, but is not so limited. For example, the porous mass can be separated from the cigarette by hollow cavities (eg, tubes or channels).

Conventional filter materials used are fibrous tow (e.g., cellulose acetate tow, polyolefin tow and combinations thereof), paper, void chambers (e.g. formed by rigid elements such as paper or plastic) , Baffled void chambers and combinations thereof. Also included are fibrous tows and paper with active ingredients (attached, impregnated or otherwise incorporated). Such active materials include activated carbon (or activated carbon), ion exchange resins, desiccants or other materials adapted to affect tobacco smoke. The void chamber can be filled (or partially filled) with the active ingredient or a material containing the active ingredient. Such active ingredients include activated carbon (or activated carbon), ion exchange resins, desiccants or other materials adapted to affect tobacco smoke. Further, the conventional material may be a porous mass of the binder (ie, only the binder without any active particles). For example, these porous masses without active particles can be made of thermoplastic particles (such as polyolefin powders containing binders described below) that are bonded or molded together in a porous cylindrical shape.

In some embodiments, the porous mass can include inert particles that are thermally stable materials. The inert particles can include adsorbent carbon, including but not limited to porous grade carbon, graphite, low activated carbon and inert carbon. In other embodiments, the inert particles include inorganic solids including, but not limited to, ceramic, glass, alumina, vermiculite, clay, bentonite and inert materials.

The porous mass includes active or inactive particles bound together with a binder. For example, FIG. 9 shows a micrograph of an embodiment of a porous mass in which the active particles (eg, activated carbon particles) 57 are bound to the porous mass by the binder 58 (active particles and binder are below Discussed in more detail). These porous masses are configured to maximize the active particle surface area (i.e., the functionality of the active particles is increased by exposing the surface area of these particles) and have a minimal encapsulated pressure drop (i.e., pressure loss during movement through the porous mass). do.

Note: In this example (FIG. 9), the binder and active particles are bound at the contact point, the contact points are randomly distributed throughout the porous mass, and the binder retains its original physical shape (or its original shape is In practice, for example, deformation (eg shrinkage) from the original form is maintained at 10% or less).

In terms of range, the porous mass is 0 to 80% by weight of active or inactive particles, for example, 0.01 to 80% by weight, 5 to 75% by weight, 10 to 75% by weight, 20 to 70% by weight, 0 to 30% by weight %, 30 to 70% by weight, 30 to 60% by weight, or 40 to 50% by weight of active or inactive particles. In some embodiments, particles may be present, but the porous mass is less than 80% by weight of active or inactive particles, such as less than 70% by weight, less than 60% by weight, less than 50% by weight, less than 40% by weight, less than 30% by weight , Less than 20% by weight, less than 10% by weight, or less than 5% by weight of active or inactive particles. Porous mass of 20 to 100% by weight of binder, for example 70 to 100% by weight, 20 to 99.9% by weight, 25 to 95% by weight, 25 to 90% by weight, 30 to 70% by weight, 30 to 80% by weight, 40 to 70% by weight, or 50 to 60% by weight of binder. In some embodiments, the porous mass can include 100% by weight binder.

In some embodiments, the porous mass has a void volume in the range of 40-90%. In other embodiments, it has a pore volume of 60 to 90%. In another embodiment, it has a pore volume of 60 to 85%. Pore volume refers to the free space between the active particles and the binder after the porous mass is formed.

The term "encapsulated pressure drop" or "EPD" as used herein refers to a volumetric flow at the output end of 17.5 ml / when the sample is completely encapsulated within the measuring device so that air does not pass through the package. It refers to the static pressure difference between both ends of the specimen when the standard is moved by airflow under a stable state at seconds. EPD was published in June 2007 by CORESTA ("Cooperation Center for Scientific Research Relative to Tobacco") Recommended Method No. It was measured herein under 41. The porous mass optionally has an encapsulated pressure drop (EPD) of less than 3.0 mm of water per mm length of the porous mass. In another embodiment, the porous mass has an EPD of less than 1.0 mm water per mm length of the porous mass. And in another embodiment, the porous mass has an EPD of 0.6 mm or less of water per mm length of the porous mass (or water not greater than 0.6 mm per mm length of the porous mass) or 0.5 mm per mm length of the porous mass Have an EPD of the following water (or water not greater than 0.5 mm per mm length of the porous mass). In some examples, to obtain the desired EPD, the active particles must have a larger particle size than the binder. In one embodiment, the ratio of binder particle size to active particle size is in the range of 1: 1.5 to 4.0.

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

The porous mass can have any physical shape; In one embodiment, it has the form of a cylinder.

The active or inactive particles can be materials employed to enhance smoke flow thereon and facilitate heat removal or heat dissipation, for example high heat capacity materials. “Adopted to enhance the smoke flow over it” means any material that can remove or add components to the smoke. Removal can be optional. In tobacco smoke from tobacco, carbonyls (e.g. formaldehyde, acetaldehyde, acetone, propionaldehyde, crotonaldehyde, butylaldehyde, methyl ethyl ketone, acrolein) and other compounds (e.g. benzene, 1,3 Butadiene and benzo [a] pyrene (or BaPyrene) can be selectively removed, for example. An example of such a material is activated carbon (or activated carbon). Activated carbon can be low activity (50-75% CCl ₄ adsorption) or high activity (75-95% CCl ₄ adsorption) or a combination of both. Other examples of such materials are ion exchange resins, desiccants, silicates, molecular sieves, silica gels, activated alumina, pearlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxides (e.g. iron oxides) and the foregoing. Combinations (including activated carbon). Ion exchange resins include, for example, polymers having a backbone such as styrene-divinyl venene (DVB) copolymers, acrylates, methacrylates, phenol formaldehyde condensates and epichlorohydrin amine condensates; And a plurality of electrically charged functional groups attached to the polymer backbone. In one embodiment, the active particles are a combination of various active particles.

In some embodiments, the active particles have an average particle size of 0.5 to 5000 microns, such as 10 to 1000 microns, or 200 to 900 microns, or a mixture of these particle sizes. In other embodiments, the active particles may be a mixture of various particle sizes having an average particle size of 0.5 to 5000 microns, for example 10 to 1000 microns, or 200 to 900 microns.

The binder can be any binder that withstands thermal cycles that occur during use of the aerosol-generating device, for example, repeated heating at temperatures up to 300 ° C. As used herein, a “thermal cycle” in an aerosol-generating device may be 14 “puffs” or inhalations on the device, or the use of the device for 6 minutes (whichever occurs first). Can be. In one embodiment, the binder is substantially free of flow at its melting temperature. This means a material with little or no polymer flow when heated to its melting temperature. It is advantageous to have little or no polymer flow, since even at temperatures above the melting point of the binder, the binder will not be clearly relocated or migrated within the aerosol-generating device. Materials meeting these criteria include, but are not limited to, ultra high molecular weight polyethylene, very high molecular weight polyethylene, high molecular weight polyethylene, and combinations thereof. The binder is configured to undergo repeated thermal cycles without structural modification below 350 ° C. For example, the structure of the binder undergoes a pressure change of less than 10% during repeated thermal cycles. The binder can also be hydrophobic, which condenses water vapor to facilitate heat removal and advantageously facilitates some selective filtration of phenols.

In some examples, the binder has a melt flow index (MFI, ASTM D1238 2013) of less than 3.5 g / 10 min at 190 ° C. and 15 Kg (or 0-3.5 g / 10 min at 15 ° C. at 190 ° C.). In some examples, the binder has a melt flow index (MFI) of less than or equal to 2.0 g / 10 min at 190 ° C. and 15 Kg (or 0-2.0 g / 10 min at 190 ° C. and 15 Kg). One example of such a material is UHMWPE, ultra high molecular weight polyethylene without polymer flow, which is about 0 g / 10 min MFI at 190 ° C and 15 Kg, or MFI from 0 to 1.0 g / 10 min at 190 ° C and 15 Kg. Other materials can be, for example, very high molecular weight polyethylene VHMWPE, which can have an MFI in the range of 1.0 to 2.0 g / 10 min at 190 ° C. and 15 Kg. Another material is high molecular weight polyethylene, HMWPE, which can have an MFI of 2.0 to 3.5 g / 10 min at 190 ° C. and 15 Kg, for example. For example, the porous mass can include a binder and active particles, where the binder is a very high molecular weight polyethylene and the active particles are activated carbon. The binder is configured to undergo repetitive heat cycles without structural modifications.

In the context of molecular weight, “ultra high molecular weight polyethylene” as used herein refers to a polyethylene composition having a weight average molecular weight of at least about 3 × 10 ⁶ g / mol. In some embodiments, the molecular weight of the ultrahigh molecular weight polyethylene composition is from about 3 × 10 ⁶ g / mol to about 30 × 10 ⁶ g / mol, or from about 3 × 10 ⁶ g / mol to about 20 × 10 ⁶ g / mol, or About 3 × 10 ⁶ g / mol to about 10 × 10 ⁶ g / mol, or about 3 × 10 ⁶ g / mol to about 6 × 10 ⁶ g / mol. “Very high molecular weight polyethylene” refers to a polyethylene composition having a weight average molecular weight of less than 3 × 10 ⁶ g / mol and greater than 1 × 10 ⁶ g / mol. In some examples, the molecular weight of the very high molecular weight polyethylene composition is between 2 × 10 ⁶ g / mol and 3 × 10 ⁶ g / mol. “High molecular weight polyethylene” refers to a polyethylene composition that has a weight average molecular weight of at least 3 × 10 ⁵ g / mol and can range from 3 × 10 ⁵ g / mol to 1 × 10 ⁶ g / mol. For purposes of this specification, the molecular weight referenced herein is determined according to the Margolies equation ("Margolies molecular weight").

Suitable polyethylene materials include GUR® UHMWPE from Ticona Polymers LLC, a division of Celanese Corporation of Dallas, Texas, and DSM (Netherlands), Braskem (Brazil), Beijing Factory No. 2 (BAAF), Shanghai Chemical and Qilu (China), Mitsui and Asahi (Japan). Specifically, GUR polymers are: GUR 2000 series (2105, 2122, 2122-5, 2126), GUR 4000 series (4120, 4130, 4150, 4170, 4012, 4122-5, 4022-6, 4050-3 / 4150- 3), GUR 8000 series (8110, 8020) and GUR X series (X127, X143, X184, X168, X172, X192).

One example of a suitable polyethylene material is one having an intrinsic viscosity ranging from 5 dl / g to 30 dl / g and a crystallinity of 80% or more, as described in US Patent Application Publication No. 2008/0090081. Other examples of suitable polyethylene materials are molecular weights within the range of 300,000 g / mol to 2,000,000 g / mol, as determined by ASTM-D 4020 (2011), as described in WO 2011/140053, average particle size D ₅₀ of 300 to 1500 μm, And a bulk density of 0.25 to 0.5 g / ml.

In one embodiment, the binder is a combination of various binders. In one embodiment, the binder is 0.5 to 5000 microns, for example 10 to 1000 microns, 20 to 600 microns, 125 to 5000 microns, 125 to 1000 microns, 150 to 600 microns, 200 to 600 microns, 250 to 600 microns, Or from 300 to 600 microns. In other embodiments, the binder may be a mixture of various particle sizes. In other embodiments, the binder may be a mixture of various particle sizes having an average particle size ranging from 125 to 5000 microns, for example 125 to 1000 microns or 125 to 600 microns.

In addition, the binder can have a bulk density of 0.10 to 0.55 g / cm ³ , for example 0.17 to 0.50 g / cm ³ or 0.20 to 0.47 g / cm ³ .

In addition to the binders described above, other conventional thermoplastics can be used as the binder. Such thermoplastic materials can include, for example: polyolefins, polyesters, polyamides (or nylons), polyacrylics, polystyrenes, polyvinyls and celluloses. Polyolefins include, but are not limited to, polyethylene, polypropylene, polybutylene, polymethylpentene, copolymers thereof and mixtures thereof.

Polyethylene further includes low density polyethylene, linear low density polyethylene, high density polyethylene, copolymers thereof and mixtures thereof and the like. Polyesters include polyethylene terephthalate, polybutylene terphthalate, polycyclohexylene dimethylene terphthalate, polytrimethylene terephthalate, copolymers thereof, mixtures thereof, and the like. Polyacrylics include, but are not limited to, polymethyl methacrylate, copolymers thereof, and variants thereof. Polystyrene includes, but is not limited to, polystyrene, acrylonitrile-butadiene-styrene, styrene-acrylonitrile, styrene-butadiene, styrene-maleic anhydride, copolymers thereof, mixtures thereof, and the like. Polyvinyl includes, but is not limited to, ethylene vinyl acetate, ethylene vinyl alcohol, polyvinyl chloride, copolymers thereof and mixtures thereof. Cellulose compounds include, but are not limited to, cellulose acetate, cellulose acetate butyrate, cellulose propionate, ethyl cellulose, copolymers thereof, mixtures thereof, and the like.

The binder can take any form. These morphologies include spherical, hyperion, asteroid, control or interplanetary dust, granular, potato, irregular, or combinations thereof.

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

The porous mass can be produced by any means. In one embodiment, the active particles and binder are blended together and introduced into the mold. The mold is heated to a temperature above the melting point of the binder, for example to about 200 ° C. in one embodiment and held at that temperature for a period of time (40 ± 10 minutes in one embodiment). Thereafter, the mass is removed from the mold and cooled to room temperature. In one embodiment, this process is characterized by a free sintering process because the binder does not flow (or rarely flow) at its melting temperature and no pressure is applied to the blended material in the mold. In this embodiment, a point bond is formed between the active particle and the binder. This enables good bonding and maximizes the clearance space, while minimizing blinding of the active particle surface by free flowing melt binder. See also US Patent Nos. 6,770,736, 7,049,382, 7,160,453, which are incorporated herein by reference.

Alternatively, a porous mass can be prepared using a process of sintering under pressure. As the mixture of active particles and binder is heated (or at a temperature that may be below, at or above the melting temperature of the binder), pressure is applied to the mixture to promote adhesion of the porous mass.

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

The invention will be better understood in terms of the following non-limiting examples.

Example 1

The aerosol-generating device was constructed using a porous material for the aerosol-cooling element and / or support element as compared to the aerosol-generating device without the aerosol-cooling element. The aerosol-generating device was tested with the Cerulean SM450 smoking machine using the Health Canada protocol "Determination of Tar, Nicotine and Carbon Monoxide in Mainstream Tobacco Smoke" in December 1999 using a measurement of tar, nicotine and carbon monoxide in mainstream tobacco smoke. The maximum puff temperature was measured over 11 puffs using a thermocouple thermometer inserted into the mouthpiece. The porous mass in Sample A-C consisted of ultra high molecular weight polyethylene and adsorbent carbon. The porous mass was attached to the aerosol-generating substrate with support elements in Samples A and B and no support elements in Sample C. In Samples B and C, the porous mass was placed immediately after the substrate, and in Sample A, the porous mass was placed behind the support element. Samples with a porous mass (A-C) were compared to a device without a cooling element (Sample D). The maximum puff temperature for each configuration is shown in Table 1 below.

Table 1 Sample Configuration Maximum temperature (℃) A Support element, porous mass, mouthpiece 57.8 B Porous mass, support element, mouthpiece 59.0 C Porous mass, mouthpiece 57.7 D Support element mouthpiece 63.0

As shown in Table 1, Sample D, which did not contain a porous mass, contained the same components as Sample D, but had a higher maximum puff temperature than Samples A and B, to which the porous mass was added. Sample D also had a higher maximum puff temperature than Sample C, which included a porous mass and a mouthpiece but no support element. Thus, the inclusion of the porous mass reduced the maximum puff temperature and even allowed the support element to be omitted in Sample D.

Example 2

Porous mass was prepared using the ingredients shown in Table 2 below. The encapsulated pressure drop of the porous mass was measured using a Cerulean Quantum Solo V benchtop pressure drop tester. The results are shown in Table 2 below.

Table 2 Sample Porous mass Encapsulated pressure drop
(mm water / mm length) 4 60% ultra high molecular weight polyethylene, 40% carbon 0.82 5 100% ultra high molecular weight polyethylene 1.27 6 100% plasticized cellulose acetate plastic 0.18

As shown in Table 2, the encapsulated pressure drop was reduced from Sample 5 to 4 by adding 40% carbon. The encapsulated pressure drop of the porous mass containing plasticized cellulose acetate plastic was much less than that of Samples 4 and 5.

Although the invention has been described in detail, modifications within the spirit and scope of the invention will be apparent to those skilled in the art. It should be understood that portions of the various embodiments and features and aspects of the invention disclosed in the above-described and / or appended claims may be wholly or partially combined or interchanged. In the description of the various embodiments described above, embodiments referring to other embodiments may be appropriately combined with other embodiments understood by those skilled in the art. In addition, those skilled in the art will understand that the foregoing description is merely illustrative and is not intended to limit the present invention. All U.S. patents and publications cited herein are incorporated by reference in their entirety.

Claims (20)

As an aerosol generating device,
An aerosol-generating article,
The aerosol-generating article is:
An aerosol-forming substrate;
Support elements;
Aerosol cooling elements; And
Including a mouthpiece,
At least one of the support element, the aerosol cooling element and the mouthpiece comprises a porous mass comprising 20 to 100% by weight of a binder and 0 to 80% by weight of active or inactive particles. According to claim 1,
And the support element comprises the porous mass. According to claim 1,
And wherein the aerosol-cooling element comprises the porous mass. According to claim 1,
And wherein the mouthpiece comprises the porous mass. According to claim 1,
And wherein the support element and the aerosol cooling element comprise the porous mass. According to claim 1,
And the support element and the mouthpiece comprise the porous mass. According to claim 1,
And wherein the aerosol cooling element and the mouthpiece comprise the porous mass. According to claim 1,
Wherein the support element, the aerosol cooling element and the mouthpiece comprise the porous mass. The method according to any one of claims 1 to 8,
Wherein the binder comprises very high molecular weight polyethylene, ultra high molecular weight polyethylene, or combinations thereof. The method according to any one of claims 1 to 8,
The binder is selected from the group consisting of polyolefin, polyester, polyamide, polyacrylic, polystyrene, polyvinyl, cellulose and combinations thereof. The method of claim 9,
The binder further comprises polyolefin, polyester, polyamide, polyacrylic, polystyrene, polyvinyl, cellulose or a combination thereof. The method according to any one of claims 1 to 11,
The active particles are in the group consisting of ion exchange resin, desiccant, silicate, molecular sieve, silica gel, activated alumina, pearlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxide, activated carbon, activated carbon and combinations thereof. Device selected. The method according to any one of claims 1 to 11,
And wherein the inactive particles comprise a thermally stable material. The method according to any one of claims 1 to 11,
And wherein the inert particles comprise adsorbent carbon selected from the group consisting of porous grade carbon, graphite, low activated carbon and inert carbon. The method according to any one of claims 1 to 11,
Wherein the inert particles comprise inorganic solids selected from the group consisting of ceramic, glass, alumina, vermiculite, clay, bentonite and inert materials. The method according to any one of claims 1 to 15,
Wherein the porous mass has an encapsulated pressure drop of less than 3.0 mm water / mm length. The method according to any one of claims 1 to 16,
The device, wherein the binder is configured to undergo a repetitive heat cycle without structural modification. The method of claim 17,
And the binder is configured to undergo a pressure drop change of less than 10%. The method according to any one of claims 1 to 18,
Wherein the porous mass is configured to provide multi-path airflow. The method according to any one of claims 1 to 19,
The device, wherein the support element and the aerosol cooling element are combined into a single unit, and the pressure drop is substantially the same as the support element and aerosol cooling element as individual units.

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