WO2014155252A2 - Smoking article filter with bypass channel - Google Patents

Smoking article filter with bypass channel Download PDF

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Publication number
WO2014155252A2
WO2014155252A2 PCT/IB2014/060008 IB2014060008W WO2014155252A2 WO 2014155252 A2 WO2014155252 A2 WO 2014155252A2 IB 2014060008 W IB2014060008 W IB 2014060008W WO 2014155252 A2 WO2014155252 A2 WO 2014155252A2
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WO
WIPO (PCT)
Prior art keywords
channel
pore structure
open pore
filter
smoking article
Prior art date
Application number
PCT/IB2014/060008
Other languages
French (fr)
Other versions
WO2014155252A3 (en
Inventor
Firooz Rasouli
Original Assignee
Philip Morris Products, S.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Philip Morris Products, S.A. filed Critical Philip Morris Products, S.A.
Publication of WO2014155252A2 publication Critical patent/WO2014155252A2/en
Publication of WO2014155252A3 publication Critical patent/WO2014155252A3/en

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Classifications

    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24DCIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/02Manufacture of tobacco smoke filters
    • A24D3/0229Filter rod forming processes
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24DCIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/04Tobacco smoke filters characterised by their shape or structure
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24DCIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06Use of materials for tobacco smoke filters
    • A24D3/062Use of materials for tobacco smoke filters characterised by structural features
    • A24D3/066Use of materials for tobacco smoke filters characterised by structural features in the form of foam or having cellular structure
    • AHUMAN NECESSITIES
    • A24TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24DCIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06Use of materials for tobacco smoke filters
    • A24D3/16Use of materials for tobacco smoke filters of inorganic materials
    • A24D3/163Carbon
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01JCHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J13/00Colloid chemistry, e.g. the production of colloidal materials or their solutions, not otherwise provided for; Making microcapsules or microballoons
    • B01J13/0091Preparation of aerogels, e.g. xerogels

Definitions

  • the present disclosure relates to smoking article filters that include a bypass channel. At least a portion of the filter can be formed having an open pore structure.
  • Combustible smoking articles such as cigarettes, have shredded tobacco (tobacco cut filer) surrounded by a paper wrapper forming a tobacco rod.
  • a cigarette is employed by a smoker by lighting one end thereof and burning the shredded tobacco rod. The smoker then receives mainstream smoke into their mouth by drawing on the opposite end or filter end of the cigarette.
  • the shredded tobacco can be a single type of tobacco or a blend of two or more types of tobacco depending of the brand of cigarette.
  • Filter cigarettes typically include a wrapped rod of tobacco cut filler and a cylindrical filter aligned in end-to-end relationship with the wrapped tobacco rod, with the filter attached to the tobacco rod by tipping paper.
  • the filter may consist of a plug of cellulose acetate tow wrapped in porous plug wrap.
  • a number of smoking articles in which an aerosol generating substrate, such as tobacco, is heated rather than combusted have also been proposed in the art.
  • the aerosol is generated by heating the aerosol generating substrate.
  • Known heated smoking articles include, for example, smoking articles in which an aerosol is generated by electrical heating or by the transfer of heat from a combustible fuel element or heat source to an aerosol generating substrate.
  • volatile compounds are released from the aerosol generating substrate by heat transfer from the heat source and entrained in air drawn through the smoking article. As the released compounds cool they condense to form an aerosol that is inhaled by the consumer.
  • smoking articles in which a nicotine-containing aerosol is generated from a tobacco material, tobacco extract, or other nicotine source, without combustion, and in some cases without heating, for example through a chemical reaction.
  • Some smoking articles include a filter segment including functional materials that capture or convert components of the smoke from the smoking article or release materials into the smoke as smoke is being drawn through the filter.
  • functional materials include, for example, sorbents, catalysts and flavourant materials.
  • additives or treatment processes have been utilized to alter the chemistry or sensory properties of the tobacco or mainstream smoke generated by the tobacco.
  • a smoking article or a filter for a smoking article, including a first filter segment that has an element with a monolithic open pore structure.
  • the open pore structure includes a channel disposed within it.
  • the channel includes a plurality of holes disposed along a length of the channel and functional material is dispersed within the open pore structure.
  • Filters and smoking articles according to the present disclosure provide an effective way to utilize functional material while mitigating taste off-notes produced by the functional material.
  • the filters according to the present disclosure allow initial mainstream smoke to contact less functional material than subsequent mainstream smoke. This can provide a change in the composition of the mainstream smoke over time while the perceived taste of the smoking article remains generally unchanged.
  • Filters and smoking articles according to the present disclosure provide an effective way to retain functional material by incorporation into an open pore structure. Retention of the functional material in the open pore structure may allow for the use of smaller sized functional material, with an accordingly larger surface area and efficiency. This in turn may allow for the use of less functional material (and associated cost and taste alteration) to achieve the desired functional effect.
  • the open pore structure can define the channel opening without the use of additional structural elements (and associated cost).
  • the present disclosure provides a filter for a smoking article including a first filter segment that has a monolithic element with an open pore structure.
  • the open pore structure includes a channel disposed within it.
  • the channel includes a plurality of holes disposed along a length of the channel and functional material is dispersed within the open pore structure.
  • the channel includes a plurality of holes along a length of the channel.
  • the downstream-most holes become plugged so that more mainstream smoke flows through the open pore structure and contacts functional material.
  • more and more of the holes become plugged with mainstream smoke materials and causing more and more mainstream smoke to flow through the open pore structure and contact functional material.
  • the open pore structure is converted from a gel.
  • the open pore structure can include an aerogel, xerogel, or cryogel.
  • the voids or pores of the open pore structure have an average size of less than 500 micrometres, or less than 250 micrometres, or less than 100 micrometres.
  • the size of the voids or pores can be determined by cutting through a particle or a portion of a monolithic element of the open pore structure and measuring the largest cross-sectional dimension of each of the voids or pores. The average size of the voids or pores is the arithmetic mean of these measurements.
  • This open pore structure allows air or tobacco smoke to flow through the aerogel structure.
  • the open pore structure is an aerogel.
  • the channel is disposed along a length of the open pore structure.
  • the channel can be defined by an open or hollow cylindrical tube that can be coaxially or concentrically positioned within the open pore structure.
  • the channel has an open end at an upstream end of the open pore structure and extends a length downstream along the open pore structure.
  • the channel extends the entire length of the open pore structure.
  • the channel extends only a portion of the length of the open pore structure.
  • the channel can have a diameter in a range from about 1.5 to 2.5 mm, or about 2 mm.
  • the channel can have a length in a range from about 5 to 25 mm or from about 10 to 20 mm.
  • the downstream end of the channel can be sealed with an impermeable material.
  • the downstream end of the channel can be filled with a porous material such as the open pore structure or a fibrous material such as cellulose acetate, for example.
  • the downstream end of the channel is tapered such that the open downstream end of the channel has an open diameter that is less than upstream end of the channel. The diameter of the tapered open end can have a size that is substantially equal to the size or diameter of the holes, described below.
  • the channel includes a plurality or series of holes that provide fluid communication between the channel void or gas space and the open pore structure.
  • the holes are formed in pairs of holes (with two holes on opposing sides of the channel at a same longitudinal location) that are spaced apart along a length of the channel.
  • the hole pairs number from about 2 to about 8, or from about 3 to about 6.
  • the holes have a size or diameter that is configured to allow mainstream smoke to plug the holes and block mainstream smoke from passing thought the blocked or plugged holes.
  • the holes have a diameter of about 0.75 mm or less or from 0.25 mm to about 0.75mm, or about 0.5 mm.
  • the channel can be defined by only the open pore structure.
  • the holes disposed along the length of the channel can be defined by the open pores of the element.
  • the channel is defined by a structural member such as a rigid tubular or cylindrical member.
  • the structural member can be formed of any useful structural material such as cardboard for example.
  • the channel is defined by a nonporous polymeric film that is perforated to form the plurality of holes.
  • the polymeric film can be considered to be non- structural and formed of any useful polymeric material.
  • the functional material can include removing materials, such as catalysts or sorbents, which capture or convert constituents of the mainstream smoke passing though the filter.
  • Functional material can include releasing materials, which release compounds, such as flavourant, into the mainstream smoke passing through the open pore structure or filter.
  • the functional material is a carbon material such as activated carbon or graphene.
  • Functional material that captures smoke constituents can include sorbents such as activated carbon, coated carbon, active aluminium, aluminium oxide, zeolites, sepiolites, molecular sieves, and silica gel, for example.
  • Functional material that captures smoke constituents includes ion exchange materials such as single amino acids, amino functional materials, and polyelectrolytes, for example.
  • activated carbon is dispersed within the open pore structure.
  • the particle size of the material that captures or converts smoke constituents may be measured using a standard mesh test. Alternatively, the particle size can be determined by cutting a cross-sectional slice of the monolithic element of open pore structure and measuring the largest cross-sectional dimension of each of particle shown in that slice. The average particle size is the arithmetic mean of these measurements. For example, at least about 90% by weight of the material may have a particle size between ASTM mesh size 20 and ASTM mesh size 70.
  • Functional material that converts smoke constituents can include catalysts such as manganese, chromium, iron, cobalt, nickel, copper, zirconium, tin, zinc, tungsten, titanium, molybdenum, vanadium materials, and any oxide thereof, titania, ceria and gold or gold on titania and nanostructures such as graphene, graphene oxide, functionalised graphene and carbon nanotubes for example.
  • catalysts such as manganese, chromium, iron, cobalt, nickel, copper, zirconium, tin, zinc, tungsten, titanium, molybdenum, vanadium materials, and any oxide thereof, titania, ceria and gold or gold on titania and nanostructures such as graphene, graphene oxide, functionalised graphene and carbon nanotubes for example.
  • Functional materials that release compounds into the mainstream smoke passing through the open pore structure or filter can include flavourant material.
  • Flavourant material can include particles of a sorbent or cellulosic material impregnated with liquid flavourant or particulate material such as herbaceous material, or any combination thereof.
  • Flavourant materials include, but are not limited to, materials that contain natural or synthetic menthol, peppermint, spearmint, coffee, tea, spices (such as cinnamon, clove and ginger), cocoa, vanilla, fruit flavours, chocolate, eucalyptus, geranium, eugenol, agave, juniper, anethole and linalool.
  • flavourant materials may include essential oils, or a mixture of one or more essential oils.
  • essential oil is an oil having the characteristic odour and flavour of the plant from which it is obtained. Suitable essential oils include, but are not limited to, eugenol, peppermint oil and spearmint oil.
  • the flavourant material comprises menthol, eugenol, or a combination of menthol and eugenol.
  • the term “herbaceous material” is used to denote material from an herbaceous plant.
  • a “herbaceous plant” is an aromatic plant, the leaves or other parts of which are used for medicinal, culinary or aromatic purposes and are capable of releasing flavour into smoke produced by a smoking article.
  • Herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme and carvi.
  • mints such as peppermint and spearmint
  • lemon balm basil
  • cinnamon lemon basil
  • chive coriander
  • lavender sage
  • tea thyme and carvi.
  • Suitable types of mint leaf may be taken from plant varieties including but not limited to Mentha piperita, Mentha arvensis, Mentha niliaca, Mentha citrata, Mentha spicata, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha pulegium, Mentha suaveolens, and Mentha suaveolens variegata.
  • flavourant material can include tobacco material.
  • the functional material can have an average particle size of about 1000 micrometers or less, or about 1000 nanometers or less. Alternatively or additionally, the functional material can have an average particle size of about 5 nanometers or more, or about 1 micrometer or more. In some embodiments, such as those where the functional material includes materials that capture smoke constituents as sorbents such as activated carbon, the functional material can have an average particle size of less than about 200 micrometers, or between about 100 micrometers and 1000 micrometers, more preferably between about 50 micrometers and 750 micrometers.
  • the functional material can have an average particle size between about 5 nanometers and 5000 nanometers, more preferably between about 5 nanometers and 1000 nanometers.
  • the functional material can be present in the open pore structure in an amount from about 1 mg or more, or from about 5 mg or more. Alternatively or additionally, the functional material can be present in the element in an amount from about 180 mg or less, or from about 100 mg or less.
  • the functional material can be present in the open pore structure in an amount from about 50 mg to about 180 mg, or from about 80 mg to about 120 mg.
  • Such loading amounts can be preferable for micro-sized functional material, such as activated carbon, where the average particle size is in a range from about 1 to 1000 micrometers or less than about 200 micrometers.
  • the functional material can be present in the open pore structure in an amount from about 5 mg to about 100 mg, or from about 5 mg to about 50 mg.
  • Such loading amounts can be preferable for nano-sized functional material, such as graphene or carbon nanotubes, where the average particle size is in a range from about 1 to 1000 nanometers.
  • Aerogels are synthetic highly porous material derived from a gel, where the liquid component in the gel has been replaced with a gas. The result is a solid with an open cell structure and low density. Despite their name, aerogels are rigid, dry materials that do not resemble a gel in their physical properties; the name comes from the fact that they are derived from gels. By weight, gels are mostly liquid but behave like solids due to a three-dimensional cross-linked network within the liquid. Gels generally are a dispersion of molecules of a liquid within a solid in which the solid is the continuous phase and the liquid is the dispersed phase
  • Aerogels are often friable but are typically structurally strong. In some cases, their impressive load bearing ability can be traced to a dendritic microstructure, in which spherical particles of average size of about 2-5 nanometers are fused together in clusters. These clusters can form a three dimensional highly porous structure of almost fractal chains, in some cases with pores under about 100 nanometers. The average size and density of the pores can be controlled during the manufacturing process.
  • Aerogels that are useful for mouthpiece filter elements can be formed by creating a gel in solution and then removing the liquid to leave the aerogel structure intact.
  • the gel is formed by combining a gelling agent, and a liquid, for example.
  • the liquid is removed from the gel via supercritical extraction or supercritical drying.
  • Supercritical extraction or drying is performed by increasing the temperature and pressure of the gel to force the liquid into a supercritical fluid (where its liquid and gaseous phases become indistinguishable). By dropping the pressure the liquid is vaporized and removed, forming an aerogel.
  • the gel is placed in a pressure vessel and the pressure vessel is filled with liquid carbon dioxide.
  • the liquid carbon dioxide is essentially a solvent that can displace the liquid (such as water or solvent) in the pores in the gel.
  • the gel is soaked in liquid carbon dioxide.
  • the carbon dioxide replaces the liquid in the pores of the gel.
  • the carbon dioxide is heated past its critical temperature (31 degrees centigrade) and pressure (73 atm).
  • the vessel is then isothermally depressurized, resulting in the aerogel.
  • gelling agent refers to a material that, when mixed with solvent liquid (at appropriate proportions and processing conditions), converts the liquid from a flowable liquid to a moldable solid, semi-solid or gel. Gels include a solid three-dimensional network that spans the volume of liquid medium and entangles it though surface tension effects.
  • the aerogel can be either an organic aerogel or an inorganic aerogel.
  • the gelling agent is synthetic or natural polymer such as cellulose acetate, polystyrene, polylactic acid, and the like.
  • the gelling agent is paper or cellulosic material.
  • the gelling agent is a polysaccharide or protein, or combinations of one or more polysaccharides and one or more proteins. Polysaccharides can include starches, vegetable gums, agar, carrageenan or pectins, for example.
  • Gelling agents can also include alginates or alginate salts such as, alginic acid, sodium alginate, potassium alginate, ammonium alginate or calcium alginate, for example.
  • Gelling agents can include gelatin, for example.
  • carbon can be combined with the gelling agent to form the open pore structure.
  • Liquids can include aqueous solvents, non-aqueous solvents, or any combination thereof.
  • Useful non-aqueous solvents include ethanol, methanol, acetone, methyl ethyl ketone, 2-propanol, carbon dioxide, hexane, and toluene, for example.
  • the filter described herein can be formed by disposing a gel in a mold and removing a component from the gel to form an open pore structure, as described above.
  • the mold can be utilized to from the channel feature.
  • the mold can include a channel protrusion element where the gel is disposed about the channel protrusion element when the mold is filled with the gel material. Then the filter element can be removed from the mold and assembled into a mouthpiece of a smoking article.
  • the open pore structure removed from the mold is a unitary rigid monolithic element.
  • functional material can be blended with the gel to generally disperse the functional material throughout the open pore structure.
  • a nonporous perforated polymeric film is constructed with the open pore structure by applying the polymeric film onto the channel protrusion element of the mold and forming the open pore structure about the polymeric film and channel protrusion element.
  • the polymeric film can be fixed to the open pore structure and define the channel once the open pore structure is removed from the mold. This can provide a number of manufacturing advantages.
  • a segment of filtration material is fixed downstream of the open pore structure.
  • This segment of filtration material can be in axial alignment with the open pore structure and in direct contact with the open pore structure.
  • this segment of filtration material is a cylindrical element having a length in a range from about 5 to 15 mm.
  • the overall length of the smoking article is between about 70 mm and about 130 mm. In some embodiments the overall length of the smoking article is about 85 mm.
  • the external diameter of smoking article can be between about 5.0 mm and about 8.5 mm, or between about 5.0 mm and about 7.1 mm for slim sized smoking articles or between about 7.1 mm and about 8.5 mm for regular sized smoking articles.
  • the overall length of the filter of the smoking article can be between about 18 mm and about 36 mm. In some embodiments the overall length of the filter is about 27 mm.
  • the smoking article may include an aerosol generating substrate, such as a tobacco rod, in axial alignment with the filter.
  • the resistance to draw (RTD) of the smoking articles and the filters of the present disclosure can vary.
  • the RTD of the smoking article with the filter is between about 50 to 130 mm H 2 0.
  • the RTD of a smoking article with the filter refers to the static pressure difference between the two ends of the specimen when it is traversed by an air flow under steady conditions in which the volumetric flow is 17.5 millilitres per second at the output end.
  • the RTD of a specimen can be measured using the method set out in ISO Standard 6565:2002.
  • smoking articles according to the present disclosure may be packaged in containers, for example in soft packs or hinge-lid packs, with an inner liner coated with one or more flavourants.
  • smoking article is used herein to indicate cigarettes, cigars, cigarillos and other articles in which a smokable material, such as a tobacco, is lit and combusted to produce smoke.
  • a smokable material such as a tobacco
  • smoking article also includes articles in which smokable material is not combusted such as but not limited to smoking articles that heat the smoking composition directly or indirectly, or smoking articles that neither combust nor heat the smoking composition, but rather use air flow or a chemical reaction to deliver nicotine or other materials from the smokable material.
  • open pore structure is used herein to indicate a structure that includes a network or matrix defining interconnected voids or pores.
  • An aerosol, gas, or vapour can pass through the open pore structure via the interconnected voids or pores of the open pore structure.
  • the term "mouthpiece” is used herein to indicate the portion of the smoking article that is designed to be contacted with the mouth of the consumer.
  • the mouthpiece can be the portion of the smoking article that includes the filter, or in some cases the mouthpiece can be defined by the extent of the tipping paper. In other cases, the mouthpiece can be defined a portion of the smoking article extending about 40 mm from the mouth end of the smoking article, or extending about 30 mm from the mouth end of the smoking article.
  • upstream and “downstream” refer to relative positions of elements of the smoking article described in relation to the direction of mainstream smoke as it is drawn from a tobacco rod and through the filter and mouthpiece.
  • combustible smoking articles such as cigarettes
  • aerosols produced by non-combustible smoking articles as described above.
  • Figure 1 shows a schematic side view of a partially unrolled smoking article according to the present disclosure
  • FIG 2 shows a schematic side view of a filter according to the present disclosure
  • a smoking article 10 in this case a cigarette
  • the smoking article 10 includes a rod 20, such as a tobacco rod, and a mouth end filter 30.
  • the depicted smoking article 10 includes a plug wrap 60 that circumscribes at least a portion of the filter 30, and cigarette paper 40 that circumscribes at least a portion of the rod 20.
  • Tipping paper 50 or other suitable wrapper circumscribes the plug wrap 60 and cigarette paper 40 as is generally known in the art.
  • FIG. 2 shows a filter 30 for a smoking article.
  • the filter includes an element 46 having a monolithic open pore structure. Although not shown in Figure 2, functional material is dispersed within the element.
  • a channel 42 is disposed within the element.
  • the channel includes a plurality of holes 44 disposed along its length, with the downstream end of the channel being sealed 48.
  • the filter includes a second filter segment 36 disposed downstream of the element 46.

Abstract

A filter (30) for a smoking article (10) includes a first filter segment having an element (46) having monolithic open pore structure and a channel (42) disposed within the element. The channel has a plurality of holes (44) disposed along a length of the channel. Functional material is dispersed within the element.

Description

SMOKING ARTICLE FILTER WITH BYPASS CHANNEL
The present disclosure relates to smoking article filters that include a bypass channel. At least a portion of the filter can be formed having an open pore structure.
Combustible smoking articles, such as cigarettes, have shredded tobacco (tobacco cut filer) surrounded by a paper wrapper forming a tobacco rod. A cigarette is employed by a smoker by lighting one end thereof and burning the shredded tobacco rod. The smoker then receives mainstream smoke into their mouth by drawing on the opposite end or filter end of the cigarette. The shredded tobacco can be a single type of tobacco or a blend of two or more types of tobacco depending of the brand of cigarette.
Filter cigarettes typically include a wrapped rod of tobacco cut filler and a cylindrical filter aligned in end-to-end relationship with the wrapped tobacco rod, with the filter attached to the tobacco rod by tipping paper. In conventional filter cigarettes, the filter may consist of a plug of cellulose acetate tow wrapped in porous plug wrap.
A number of smoking articles in which an aerosol generating substrate, such as tobacco, is heated rather than combusted have also been proposed in the art. In heated smoking articles, the aerosol is generated by heating the aerosol generating substrate. Known heated smoking articles include, for example, smoking articles in which an aerosol is generated by electrical heating or by the transfer of heat from a combustible fuel element or heat source to an aerosol generating substrate. During smoking, volatile compounds are released from the aerosol generating substrate by heat transfer from the heat source and entrained in air drawn through the smoking article. As the released compounds cool they condense to form an aerosol that is inhaled by the consumer. Also known are smoking articles in which a nicotine-containing aerosol is generated from a tobacco material, tobacco extract, or other nicotine source, without combustion, and in some cases without heating, for example through a chemical reaction.
Some smoking articles include a filter segment including functional materials that capture or convert components of the smoke from the smoking article or release materials into the smoke as smoke is being drawn through the filter. Such functional materials are known and include, for example, sorbents, catalysts and flavourant materials.
Various treatment methods and additives have been proposed for altering the overall character or taste of the tobacco utilized in smoking articles. For example, additives or treatment processes have been utilized to alter the chemistry or sensory properties of the tobacco or mainstream smoke generated by the tobacco.
It would be desirable to provide a filter for a smoking article that includes functional material while mitigating taste off-notes produced by the functional material. It is desirable to provide a smoking article that can alter the amount of functional material that contacts mainstream smoke as the smoking article is consumed.
According to the current disclosure, there is provided a smoking article, or a filter for a smoking article, including a first filter segment that has an element with a monolithic open pore structure. The open pore structure includes a channel disposed within it. The channel includes a plurality of holes disposed along a length of the channel and functional material is dispersed within the open pore structure.
Filters and smoking articles according to the present disclosure provide an effective way to utilize functional material while mitigating taste off-notes produced by the functional material. The filters according to the present disclosure allow initial mainstream smoke to contact less functional material than subsequent mainstream smoke. This can provide a change in the composition of the mainstream smoke over time while the perceived taste of the smoking article remains generally unchanged.
Filters and smoking articles according to the present disclosure provide an effective way to retain functional material by incorporation into an open pore structure. Retention of the functional material in the open pore structure may allow for the use of smaller sized functional material, with an accordingly larger surface area and efficiency. This in turn may allow for the use of less functional material (and associated cost and taste alteration) to achieve the desired functional effect. In addition, the open pore structure can define the channel opening without the use of additional structural elements (and associated cost).
The present disclosure provides a filter for a smoking article including a first filter segment that has a monolithic element with an open pore structure. The open pore structure includes a channel disposed within it. The channel includes a plurality of holes disposed along a length of the channel and functional material is dispersed within the open pore structure.
The channel includes a plurality of holes along a length of the channel. As the smoking article is utilized, the downstream-most holes become plugged so that more mainstream smoke flows through the open pore structure and contacts functional material. Thus, as smoking progresses, more and more of the holes become plugged with mainstream smoke materials and causing more and more mainstream smoke to flow through the open pore structure and contact functional material.
Preferably the open pore structure is converted from a gel. For example, the open pore structure can include an aerogel, xerogel, or cryogel. In many embodiments, the voids or pores of the open pore structure have an average size of less than 500 micrometres, or less than 250 micrometres, or less than 100 micrometres. The size of the voids or pores can be determined by cutting through a particle or a portion of a monolithic element of the open pore structure and measuring the largest cross-sectional dimension of each of the voids or pores. The average size of the voids or pores is the arithmetic mean of these measurements. This open pore structure allows air or tobacco smoke to flow through the aerogel structure. Preferably the open pore structure is an aerogel.
The channel is disposed along a length of the open pore structure. The channel can be defined by an open or hollow cylindrical tube that can be coaxially or concentrically positioned within the open pore structure. Preferably the channel has an open end at an upstream end of the open pore structure and extends a length downstream along the open pore structure. In some embodiments, the channel extends the entire length of the open pore structure. In other embodiments, the channel extends only a portion of the length of the open pore structure. The channel can have a diameter in a range from about 1.5 to 2.5 mm, or about 2 mm. The channel can have a length in a range from about 5 to 25 mm or from about 10 to 20 mm.
In some preferred embodiments, the downstream end of the channel can be sealed with an impermeable material. In other preferred embodiments, the downstream end of the channel can be filled with a porous material such as the open pore structure or a fibrous material such as cellulose acetate, for example. In some preferred embodiments, the downstream end of the channel is tapered such that the open downstream end of the channel has an open diameter that is less than upstream end of the channel. The diameter of the tapered open end can have a size that is substantially equal to the size or diameter of the holes, described below.
The channel includes a plurality or series of holes that provide fluid communication between the channel void or gas space and the open pore structure. Preferably the holes are formed in pairs of holes (with two holes on opposing sides of the channel at a same longitudinal location) that are spaced apart along a length of the channel. In some preferred embodiments, the hole pairs number from about 2 to about 8, or from about 3 to about 6. The holes have a size or diameter that is configured to allow mainstream smoke to plug the holes and block mainstream smoke from passing thought the blocked or plugged holes. In some preferred embodiments, the holes have a diameter of about 0.75 mm or less or from 0.25 mm to about 0.75mm, or about 0.5 mm.
In some embodiments, the channel can be defined by only the open pore structure. In such embodiments, the holes disposed along the length of the channel can be defined by the open pores of the element. In some other preferred embodiments, the channel is defined by a structural member such as a rigid tubular or cylindrical member. The structural member can be formed of any useful structural material such as cardboard for example. In some preferred embodiments the channel is defined by a nonporous polymeric film that is perforated to form the plurality of holes. In these embodiments, the polymeric film can be considered to be non- structural and formed of any useful polymeric material. The functional material can include removing materials, such as catalysts or sorbents, which capture or convert constituents of the mainstream smoke passing though the filter. Functional material can include releasing materials, which release compounds, such as flavourant, into the mainstream smoke passing through the open pore structure or filter. Preferably the functional material is a carbon material such as activated carbon or graphene.
Functional material that captures smoke constituents can include sorbents such as activated carbon, coated carbon, active aluminium, aluminium oxide, zeolites, sepiolites, molecular sieves, and silica gel, for example. Functional material that captures smoke constituents includes ion exchange materials such as single amino acids, amino functional materials, and polyelectrolytes, for example. In many embodiments activated carbon is dispersed within the open pore structure. In some embodiments, the particle size of the material that captures or converts smoke constituents may be measured using a standard mesh test. Alternatively, the particle size can be determined by cutting a cross-sectional slice of the monolithic element of open pore structure and measuring the largest cross-sectional dimension of each of particle shown in that slice. The average particle size is the arithmetic mean of these measurements. For example, at least about 90% by weight of the material may have a particle size between ASTM mesh size 20 and ASTM mesh size 70.
Functional material that converts smoke constituents can include catalysts such as manganese, chromium, iron, cobalt, nickel, copper, zirconium, tin, zinc, tungsten, titanium, molybdenum, vanadium materials, and any oxide thereof, titania, ceria and gold or gold on titania and nanostructures such as graphene, graphene oxide, functionalised graphene and carbon nanotubes for example.
Functional materials that release compounds into the mainstream smoke passing through the open pore structure or filter can include flavourant material. Flavourant material can include particles of a sorbent or cellulosic material impregnated with liquid flavourant or particulate material such as herbaceous material, or any combination thereof. Flavourant materials include, but are not limited to, materials that contain natural or synthetic menthol, peppermint, spearmint, coffee, tea, spices (such as cinnamon, clove and ginger), cocoa, vanilla, fruit flavours, chocolate, eucalyptus, geranium, eugenol, agave, juniper, anethole and linalool. In addition, flavourant materials may include essential oils, or a mixture of one or more essential oils. An "essential oil" is an oil having the characteristic odour and flavour of the plant from which it is obtained. Suitable essential oils include, but are not limited to, eugenol, peppermint oil and spearmint oil. In many embodiments the flavourant material comprises menthol, eugenol, or a combination of menthol and eugenol. The term "herbaceous material" is used to denote material from an herbaceous plant. A "herbaceous plant" is an aromatic plant, the leaves or other parts of which are used for medicinal, culinary or aromatic purposes and are capable of releasing flavour into smoke produced by a smoking article. Herbaceous material includes herb leaf or other herbaceous material from herbaceous plants including, but not limited to, mints, such as peppermint and spearmint, lemon balm, basil, cinnamon, lemon basil, chive, coriander, lavender, sage, tea, thyme and carvi. The term "mints" is used to refer to plants of the genus Mentha. Suitable types of mint leaf may be taken from plant varieties including but not limited to Mentha piperita, Mentha arvensis, Mentha niliaca, Mentha citrata, Mentha spicata, Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha pulegium, Mentha suaveolens, and Mentha suaveolens variegata. In some embodiments, flavourant material can include tobacco material.
The functional material can have an average particle size of about 1000 micrometers or less, or about 1000 nanometers or less. Alternatively or additionally, the functional material can have an average particle size of about 5 nanometers or more, or about 1 micrometer or more. In some embodiments, such as those where the functional material includes materials that capture smoke constituents as sorbents such as activated carbon, the functional material can have an average particle size of less than about 200 micrometers, or between about 100 micrometers and 1000 micrometers, more preferably between about 50 micrometers and 750 micrometers.
In other embodiments, such as those where functional material includes materials that convert smoke constituents such as catalysts, graphene or carbon nanotubes, the functional material can have an average particle size between about 5 nanometers and 5000 nanometers, more preferably between about 5 nanometers and 1000 nanometers.
The functional material can be present in the open pore structure in an amount from about 1 mg or more, or from about 5 mg or more. Alternatively or additionally, the functional material can be present in the element in an amount from about 180 mg or less, or from about 100 mg or less.
In some embodiments, such as those where the functional material includes materials that capture smoke constituents as sorbents or releasing materials such as flavourants, the functional material can be present in the open pore structure in an amount from about 50 mg to about 180 mg, or from about 80 mg to about 120 mg. Such loading amounts can be preferable for micro-sized functional material, such as activated carbon, where the average particle size is in a range from about 1 to 1000 micrometers or less than about 200 micrometers.
In some other embodiments, such as those where functional material includes materials that convert smoke constituents such as catalysts, graphene or carbon nanotubes, the functional material can be present in the open pore structure in an amount from about 5 mg to about 100 mg, or from about 5 mg to about 50 mg. Such loading amounts can be preferable for nano-sized functional material, such as graphene or carbon nanotubes, where the average particle size is in a range from about 1 to 1000 nanometers.
A preferred open pore structure is aerogel. Aerogels are synthetic highly porous material derived from a gel, where the liquid component in the gel has been replaced with a gas. The result is a solid with an open cell structure and low density. Despite their name, aerogels are rigid, dry materials that do not resemble a gel in their physical properties; the name comes from the fact that they are derived from gels. By weight, gels are mostly liquid but behave like solids due to a three-dimensional cross-linked network within the liquid. Gels generally are a dispersion of molecules of a liquid within a solid in which the solid is the continuous phase and the liquid is the dispersed phase
Aerogels are often friable but are typically structurally strong. In some cases, their impressive load bearing ability can be traced to a dendritic microstructure, in which spherical particles of average size of about 2-5 nanometers are fused together in clusters. These clusters can form a three dimensional highly porous structure of almost fractal chains, in some cases with pores under about 100 nanometers. The average size and density of the pores can be controlled during the manufacturing process.
Aerogels that are useful for mouthpiece filter elements can be formed by creating a gel in solution and then removing the liquid to leave the aerogel structure intact. The gel is formed by combining a gelling agent, and a liquid, for example. In many embodiments, the liquid is removed from the gel via supercritical extraction or supercritical drying. Supercritical extraction or drying is performed by increasing the temperature and pressure of the gel to force the liquid into a supercritical fluid (where its liquid and gaseous phases become indistinguishable). By dropping the pressure the liquid is vaporized and removed, forming an aerogel.
In some embodiments, the gel is placed in a pressure vessel and the pressure vessel is filled with liquid carbon dioxide. The liquid carbon dioxide is essentially a solvent that can displace the liquid (such as water or solvent) in the pores in the gel. The gel is soaked in liquid carbon dioxide. The carbon dioxide replaces the liquid in the pores of the gel. Then the carbon dioxide is heated past its critical temperature (31 degrees centigrade) and pressure (73 atm). The vessel is then isothermally depressurized, resulting in the aerogel.
The term "gelling agent" refers to a material that, when mixed with solvent liquid (at appropriate proportions and processing conditions), converts the liquid from a flowable liquid to a moldable solid, semi-solid or gel. Gels include a solid three-dimensional network that spans the volume of liquid medium and entangles it though surface tension effects.
The aerogel can be either an organic aerogel or an inorganic aerogel. In many embodiments the gelling agent is synthetic or natural polymer such as cellulose acetate, polystyrene, polylactic acid, and the like. In some embodiments the gelling agent is paper or cellulosic material. In some embodiments the gelling agent is a polysaccharide or protein, or combinations of one or more polysaccharides and one or more proteins. Polysaccharides can include starches, vegetable gums, agar, carrageenan or pectins, for example. Gelling agents can also include alginates or alginate salts such as, alginic acid, sodium alginate, potassium alginate, ammonium alginate or calcium alginate, for example. Gelling agents can include gelatin, for example. In some embodiments carbon can be combined with the gelling agent to form the open pore structure.
A liquid can be combined with the gelling agent to form the gel and resulting aerogel. Liquids can include aqueous solvents, non-aqueous solvents, or any combination thereof. Useful non-aqueous solvents include ethanol, methanol, acetone, methyl ethyl ketone, 2-propanol, carbon dioxide, hexane, and toluene, for example.
The filter described herein can be formed by disposing a gel in a mold and removing a component from the gel to form an open pore structure, as described above. The mold can be utilized to from the channel feature. For example, the mold can include a channel protrusion element where the gel is disposed about the channel protrusion element when the mold is filled with the gel material. Then the filter element can be removed from the mold and assembled into a mouthpiece of a smoking article. In many embodiments, the open pore structure removed from the mold is a unitary rigid monolithic element. In some preferred embodiments functional material can be blended with the gel to generally disperse the functional material throughout the open pore structure.
In some embodiments, a nonporous perforated polymeric film is constructed with the open pore structure by applying the polymeric film onto the channel protrusion element of the mold and forming the open pore structure about the polymeric film and channel protrusion element. The polymeric film can be fixed to the open pore structure and define the channel once the open pore structure is removed from the mold. This can provide a number of manufacturing advantages.
In preferred embodiments, a segment of filtration material is fixed downstream of the open pore structure. This segment of filtration material can be in axial alignment with the open pore structure and in direct contact with the open pore structure. In many embodiments, this segment of filtration material is a cylindrical element having a length in a range from about 5 to 15 mm.
In many embodiments the overall length of the smoking article is between about 70 mm and about 130 mm. In some embodiments the overall length of the smoking article is about 85 mm. The external diameter of smoking article can be between about 5.0 mm and about 8.5 mm, or between about 5.0 mm and about 7.1 mm for slim sized smoking articles or between about 7.1 mm and about 8.5 mm for regular sized smoking articles. The overall length of the filter of the smoking article can be between about 18 mm and about 36 mm. In some embodiments the overall length of the filter is about 27 mm. The smoking article may include an aerosol generating substrate, such as a tobacco rod, in axial alignment with the filter.
The resistance to draw (RTD) of the smoking articles and the filters of the present disclosure can vary. In many embodiments the RTD of the smoking article with the filter is between about 50 to 130 mm H20. The RTD of a smoking article with the filter refers to the static pressure difference between the two ends of the specimen when it is traversed by an air flow under steady conditions in which the volumetric flow is 17.5 millilitres per second at the output end. The RTD of a specimen can be measured using the method set out in ISO Standard 6565:2002.
In one or more embodiments, smoking articles according to the present disclosure may be packaged in containers, for example in soft packs or hinge-lid packs, with an inner liner coated with one or more flavourants.
It will be understood that any of the features described above are equally applicable to a smoking article or a filter for a smoking article according to this disclosure.
All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein.
The term "smoking article" is used herein to indicate cigarettes, cigars, cigarillos and other articles in which a smokable material, such as a tobacco, is lit and combusted to produce smoke. The term "smoking article" also includes articles in which smokable material is not combusted such as but not limited to smoking articles that heat the smoking composition directly or indirectly, or smoking articles that neither combust nor heat the smoking composition, but rather use air flow or a chemical reaction to deliver nicotine or other materials from the smokable material.
The term "open pore structure" is used herein to indicate a structure that includes a network or matrix defining interconnected voids or pores. An aerosol, gas, or vapour can pass through the open pore structure via the interconnected voids or pores of the open pore structure.
The term "mouthpiece" is used herein to indicate the portion of the smoking article that is designed to be contacted with the mouth of the consumer. The mouthpiece can be the portion of the smoking article that includes the filter, or in some cases the mouthpiece can be defined by the extent of the tipping paper. In other cases, the mouthpiece can be defined a portion of the smoking article extending about 40 mm from the mouth end of the smoking article, or extending about 30 mm from the mouth end of the smoking article. The terms "upstream" and "downstream" refer to relative positions of elements of the smoking article described in relation to the direction of mainstream smoke as it is drawn from a tobacco rod and through the filter and mouthpiece.
The term "smoke" is used herein to indicate smoke produced by combustible smoking articles, such as cigarettes, and aerosols produced by non-combustible smoking articles as described above.
As used in this specification and the appended claims, the singular forms "a", "an", and "the" encompass embodiments having plural referents, unless the content clearly dictates otherwise.
As used in this specification and the appended claims, the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.
As used herein, "have", "having", "include", "including", "comprise", "comprising" or the like are used in their open ended sense, and generally mean "including, but not limited to". It will be understood that "consisting essentially of, "consisting of, and the like are subsumed in "comprising," and the like.
The words "preferred" and "preferably" refer to embodiments of the invention that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.
In many of the depicted figures, various aspects of smoking articles or components of smoking articles described above are illustrated. The schematic drawings are not necessarily to scale and are presented for purposes of illustration and not limitation. Various drawings depict various aspects described in this disclosure. However, it will be understood that other aspects not depicted in the drawings fall within the scope and spirit of this disclosure. Like numbers used in the figures refer to like components, steps and the like. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labelled with the same number. In addition, the use of different numbers to refer to components is not intended to indicate that the different numbered components cannot be the same or similar.
The disclosure will be further described, by way of example only, with reference to the accompanying drawings, in which:
Figure 1 shows a schematic side view of a partially unrolled smoking article according to the present disclosure;
Figure 2 shows a schematic side view of a filter according to the present disclosure; Referring now to Figure 1 , a smoking article 10, in this case a cigarette, is depicted. The smoking article 10 includes a rod 20, such as a tobacco rod, and a mouth end filter 30. The depicted smoking article 10 includes a plug wrap 60 that circumscribes at least a portion of the filter 30, and cigarette paper 40 that circumscribes at least a portion of the rod 20. Tipping paper 50 or other suitable wrapper circumscribes the plug wrap 60 and cigarette paper 40 as is generally known in the art.
Figure 2 shows a filter 30 for a smoking article. The filter includes an element 46 having a monolithic open pore structure. Although not shown in Figure 2, functional material is dispersed within the element. A channel 42 is disposed within the element. The channel includes a plurality of holes 44 disposed along its length, with the downstream end of the channel being sealed 48. The filter includes a second filter segment 36 disposed downstream of the element 46.

Claims

CLAIMS:
1. A filter for a smoking article comprising:
a first filter segment comprising:
an element having a monolithic open pore structure;
a channel disposed within the element, the channel comprises a plurality of holes disposed along a length of the channel; and
functional material dispersed within the element.
2. A filter according to claim 1 , wherein the element comprises a monolithic open pore structure converted from a gel, such as an aerogel.
3. A filter according to claim 1 , wherein the functional material is activated carbon having an average size of less than 200 micrometers.
4. A filter according to claim 1 , wherein the functional material is activated carbon having an average size in a range from about 100 to 1000 micrometres.
5. A filter according to claim 1 , wherein the functional material is graphene or carbon nanotubes having an average size in a range from about 5 to 5000 nanometers.
6. A filter according to any of the preceding claims, wherein the channel is defined by a nonporous perforated polymeric film.
7. A filter according to any of the preceding claims, wherein a downstream end of the channel is sealed.
8. A filter according to any of claims 1 to 7, wherein a downstream end of the channel is tapered down to an open diameter that is less than an upstream end of the channel.
9. A filter according to any of claims 1 to 7, wherein a downstream end of the channel is filled with a porous material, such as cellulose acetate.
10. A smoking article comprising:
a filter comprising a first filter segment comprising:
an element having a monolithic open pore structure;
a channel disposed within the element, the channel comprises a plurality of holes disposed along a length of the channel; and
functional material dispersed within the element.
11. A smoking article according to claim 10, wherein the element comprises a monolithic open pore structure converted from a gel, such as an aerogel.
12. A smoking article according to claim 10 or claim 11 , wherein the channel is defined by a nonporous perforated polymeric film.
13. A smoking article according to any of claims 10 to 12, wherein a downstream end of the channel is filled with a porous material, such as cellulose acetate.
14. A method of forming a filter for a smoking article comprising:
disposing a gel in a mold, the mold including a channel protrusion element and the gel being disposed about the channel protrusion element;
removing a component from the gel to form an open pore structure, the channel protrusion element defining a channel within the open pore structure;
removing the open pore structure from the mold;
assembling the open pore structure in a mouthpiece of a smoking article.
15. A method according to claim 14, further comprising combining a functional material with the gel.
PCT/IB2014/060008 2013-03-28 2014-03-20 Smoking article filter with bypass channel WO2014155252A2 (en)

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CN110326815A (en) * 2019-07-18 2019-10-15 深圳市华远新材料有限公司 A kind of cigarette filter tip materials and preparation method thereof of low resistance to suction and high filtration
WO2021105721A1 (en) * 2019-11-29 2021-06-03 Nicoventures Trading Limited An article for use in a non-combustible aerosol provision system

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