U.S. patent application number 13/649735 was filed with the patent office on 2013-02-07 for apparatuses, systems, and associated methods for forming porous masses for smoke filters.
The applicant listed for this patent is Thomas S. Garrett, Zeming Gou, Lawton E. Kizer, Raymond M. Robertson. Invention is credited to Thomas S. Garrett, Zeming Gou, Lawton E. Kizer, Raymond M. Robertson.
Application Number | 20130032158 13/649735 |
Document ID | / |
Family ID | 45939007 |
Filed Date | 2013-02-07 |
United States Patent
Application |
20130032158 |
Kind Code |
A1 |
Garrett; Thomas S. ; et
al. |
February 7, 2013 |
Apparatuses, Systems, and Associated Methods for Forming Porous
Masses for Smoke Filters
Abstract
High-throughput production methods for manufacturing porous
masses suitable for use in conjunction with smoking devices may
include continuously combining a matrix material and a paper
wrapper to form a desired cross-sectional shape where the matrix
material is confined by the paper wrapper, the matrix material
comprising a binder particle and an active particle; heating at
least a portion of the matrix material so as to bind the matrix
material at a plurality of contact points, thereby forming a porous
mass length, wherein heating involves irradiating with microwave
radiation at least a portion of the matrix material; cooling the
porous mass length; and cutting the porous mass length radially
thereby producing a porous mass.
Inventors: |
Garrett; Thomas S.;
(Narrows, VA) ; Robertson; Raymond M.;
(Blacksburg, VA) ; Kizer; Lawton E.; (Blacksburg,
VA) ; Gou; Zeming; (Pearisburg, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Garrett; Thomas S.
Robertson; Raymond M.
Kizer; Lawton E.
Gou; Zeming |
Narrows
Blacksburg
Blacksburg
Pearisburg |
VA
VA
VA
VA |
US
US
US
US |
|
|
Family ID: |
45939007 |
Appl. No.: |
13/649735 |
Filed: |
October 11, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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PCT/US11/56388 |
Oct 14, 2011 |
|
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13649735 |
|
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61393378 |
Oct 15, 2010 |
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Current U.S.
Class: |
131/280 ;
156/242 |
Current CPC
Class: |
A24D 3/062 20130101;
B82Y 30/00 20130101; A24D 3/0241 20130101; A24D 3/0233 20130101;
A24D 3/0237 20130101; A24D 3/066 20130101; B29B 11/16 20130101;
A24D 3/00 20130101; B30B 11/14 20130101; A24D 3/0229 20130101 |
Class at
Publication: |
131/280 ;
156/242 |
International
Class: |
B32B 37/24 20060101
B32B037/24; A24C 5/47 20060101 A24C005/47 |
Claims
1. A method comprising: continuously combining a matrix material
and a paper wrapper to form a desired cross-sectional shape where
the matrix material is confined by the paper wrapper, the matrix
material comprising a binder particle and an active particle;
heating at least a portion of the matrix material so as to bind the
matrix material at a plurality of contact points thereby forming a
porous mass length, wherein heating involves irradiating with
microwave radiation the at least a portion of the matrix material;
cooling the porous mass length; and cutting the porous mass length
radially thereby producing a porous mass.
2. The method of claim 1, wherein the paper wrapper is removable
from the porous mass.
3. The method of claim 1, wherein the matrix material has a
moisture content of about 5% by weight or less.
4. The method of claim 1, wherein the porous mass is produced at a
linear speed of about 800 m/min or less.
5. The method of claim 1, wherein irradiating with microwave
radiation occurs in a residence time of about 10 seconds or
less.
6. The method of claim 1, wherein the matrix material is indexed
and a spacer is disposed between the indexed matrix material.
7. The method of claim 1, wherein heating is to a temperature at or
above a softening temperature of the at least a portion of the
matrix material.
8. The method of claim 1, wherein cooling is passive.
9. The method of claim 1 further comprising: operably connecting
the porous mass with a filter or a filter section not comprising
the porous mass so as to form a segmented filter.
10. The method of claim 9 further comprising: operably connecting
the segmented filter with a tobacco column to form a smoking
device.
11. A method comprising: continuously combining a matrix material
and a paper wrapper to form a desired cross-sectional shape where
the matrix material is confined by the paper wrapper, the matrix
material comprising a binder particle and an active particle that
comprises a plurality of carbon particles; heating at least a
portion of the matrix material so as to bind the matrix material at
a plurality of contact points thereby forming a porous mass length,
wherein heating involves irradiating with microwave radiation the
at least a portion of the matrix material; cooling the porous mass
length; and cutting the porous mass length radially thereby
producing a porous mass.
12. The method of claim 11, wherein the matrix material has a
moisture content of about 5% by weight or less.
13. The method of claim 11, wherein the porous mass is produced at
a linear speed of about 800 m/min or less.
14. The method of claim 11, wherein irradiating with microwave
radiation occurs in a residence time of about 10 seconds or
less.
15. The method of claim 11, wherein the matrix material is indexed
and a spacer is disposed between the indexed matrix material.
16. The method of claim 11, wherein heating is to a temperature at
or above a softening temperature of the at least a portion of the
matrix material.
17. The method of claim 11 further comprising: operably connecting
the porous mass with a filter or a filter section not comprising
the porous mass so as to form a segmented filter.
18. The method of claim 17 further comprising: operably connecting
the segmented filter with a tobacco column to form a smoking
device.
19. A method comprising: continuously combining a matrix material
and a paper wrapper to form a desired cross-sectional shape where
the matrix material is confined by the paper wrapper, the matrix
material comprising a binder particle and an active particle that
comprises a plurality of carbon particles; heating at least a
portion of the matrix material so as to bind the matrix material at
a plurality of contact points, thereby forming a porous mass
length, wherein heating involves irradiating with microwave
radiation the at least a portion of the matrix material, and
wherein irradiating with microwave radiation occurs in a residence
time of about 10 seconds or less; and wherein the porous mass
length is produced at a linear speed of about 800 m/min or
less.
20. The method of claim 19, wherein the matrix material has a
moisture content of about 5% by weight or less.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority as a
continuation-in-part of PCT Application Number PCT/US11/56388 filed
on Oct. 14, 2011 (published as WO 2012/051548) and U.S. Provisional
Patent Application Ser. No. 61/393,378 filed on Oct. 15, 2010.
BACKGROUND
[0002] The present invention relates to high-throughput production
apparatuses, systems, and associated methods for manufacturing
porous masses that may be used in smoke filters.
[0003] The Centers for Disease Control and Prevention reports that
in 2012 over 300 billion cigarettes and over 13 billion cigars were
sold in the United States alone. In view of new international
recommendations related to tobacco product regulation, there is a
need for more efficient tobacco smoke filters and materials used to
make tobacco smoke filters. One such technology includes porous
masses described in co-pending PCT Application Number
PCT/US11/56388 filed on Oct. 14, 2011. Generally porous masses may
comprise a plurality of binder particles (e.g., polyethylene) and a
plurality of active particles (e.g., carbon particles or zeolites)
mechanically bound at a plurality of contact points, typically with
the application of heat.
[0004] While porous masses have been demonstrated to meet, and in
some aspects exceed, international filtration regulations, this
demonstration has been done on a relatively small scale. High
volume production methods are needed to meet the ever-increasing
demand for cigarettes and cigars, as illustrated by the U.S. 2012
sales numbers.
SUMMARY OF THE INVENTION
[0005] The present invention relates to high-throughput production
apparatuses, systems, and associated methods for manufacturing
porous masses that may be used in smoke filters.
[0006] One embodiment of the present invention may involve
continuously combining a matrix material and a paper wrapper to
form a desired cross-sectional shape where the matrix material is
confined by the paper wrapper, the matrix material comprising a
binder particle and an active particle; heating at least a portion
of the matrix material so as to bind the matrix material at a
plurality of contact points thereby forming a porous mass length,
wherein heating involves irradiating with microwave radiation the
at least a portion of the matrix material; cooling the porous mass
length; and cutting the porous mass length radially thereby
producing a porous mass.
[0007] Another embodiment of the present invention may involve
continuously combining a matrix material and a paper wrapper to
form a desired cross-sectional shape where the matrix material is
confined by the paper wrapper, the matrix material comprising a
binder particle and an active particle that comprises a plurality
of carbon particles; heating at least a portion of the matrix
material so as to bind the matrix material at a plurality of
contact points thereby forming a porous mass length, wherein
heating involves irradiating with microwave radiation the at least
a portion of the matrix material; cooling the porous mass length;
and cutting the porous mass length radially thereby producing a
porous mass.
[0008] Yet another embodiment of the present invention may involve
continuously combining a matrix material and a paper wrapper to
form a desired cross-sectional shape where the matrix material is
confined by the paper wrapper, the matrix material comprising a
binder particle and an active particle that comprises a plurality
of carbon particles; heating at least a portion of the matrix
material so as to bind the matrix material at a plurality of
contact points thereby forming a porous mass length, wherein
heating involves irradiating with microwave radiation the at least
a portion of the matrix material, and wherein irradiating with
microwave radiation occurs in a residence time of about 10 seconds
or less; and wherein the porous mass length is produced at a linear
speed of about 800 m/min or less.
[0009] The features and advantages of the present invention will be
readily apparent to those skilled in the art upon a reading of the
description of the preferred embodiments that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The following figures are included to illustrate certain
aspects of the present invention, and should not be viewed as
exclusive embodiments. The subject matter disclosed is capable of
considerable modification, alteration, and equivalents in form and
function, as will occur to those skilled in the art and having the
benefit of this disclosure.
[0011] FIGS. 1A-B illustrate nonlimiting examples of systems for
forming porous masses according to the present invention (not
necessarily to scale).
[0012] FIGS. 2A-B illustrate nonlimiting examples of systems for
forming porous masses according to the present invention (not
necessarily to scale).
[0013] FIG. 3 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0014] FIG. 4 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0015] FIG. 5 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0016] FIG. 6 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0017] FIG. 7 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0018] FIG. 8 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0019] FIG. 9 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0020] FIG. 10 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0021] FIG. 11 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
[0022] FIG. 12 illustrates a nonlimiting example of a system for
forming porous masses according to the present invention (not
necessarily to scale).
DETAILED DESCRIPTION
[0023] The present invention relates to high-throughput production
apparatuses, systems, and associated methods for manufacturing
porous masses that may be used in smoke filters.
[0024] The present invention provides methods and apparatuses
(and/or systems) for high-throughput production of porous masses
that can be used in smoking device filters with increased
filtration efficacy of smoke stream components and with acceptable
draw characteristics. As used herein, the term "smoking device"
refers to articles or devices including, but not limited to,
cigarettes, cigarette holders, cigars, cigar holders, pipes, water
pipes, hookahs, electronic smoking devices, roll-your-own
cigarettes, and/or cigars.
[0025] Generally porous masses may comprise a plurality of binder
particles and a plurality of active particles mechanically bound at
a plurality of contact points. The contact points may be active
particle-binder contact points, binder-binder contact points,
active particle-active particle contact points, and any combination
thereof. As used herein, the terms "mechanical bond," "mechanically
bonded," "physical bond," and the like refer to a physical
connection that holds two particles at least partially together.
Mechanical bonds may be rigid or flexible depending on the bonding
material. Mechanical bonding may or may not involve chemical
bonding. It should be understood that as used herein, the terms
"particle" and "particulate" may be used interchangeably and
include all known shapes of materials, including spherical and/or
ovular, substantially spherical and/or ovular, discus and/or
platelet, flake, ligamental, acicular, fibrous, polygonal (such as
cubic), randomly shaped (such as the shape of crushed rocks),
faceted (such as the shape of crystals), or any hybrid thereof.
Nonlimiting examples of porous masses are described in detail in
co-pending applications PCT/US2011/043264, PCT/US2011/043268,
PCT/US2011/043269, and PCT/US2011/043270 all filed on Jul. 7, 2012,
the entire disclosures of which are included herein by
reference.
[0026] Porous masses may be produced through a variety of methods.
For example, some embodiments may involve forming the matrix
material (e.g., the active particles and binder particles) into a
desired shape (e.g., with a mold), heating the matrix material to
mechanically bond the matrix material together, and finishing the
porous masses (e.g., cutting the porous masses to a desired
length). Of the various processes/steps involved in the production
of porous masses, heating may be one of the steps that limits
high-throughput manufacturing. Accordingly, methods that employ
rapid heating (e.g., microwave) optionally with a preheating step
(e.g., indirect heating or direct contact with heated gases) may be
preferred methods for enabling high-throughput manufacturing of
porous masses described herein.
[0027] It should be noted that when "about" is provided herein in
reference to a number in a numerical list, the term "about"
modifies each number of the numerical list. It should be noted that
in some numerical listings of ranges, some lower limits listed may
be greater than some upper limits listed. One skilled in the art
will recognize that the selected subset will require the selection
of an upper limit in excess of the selected lower limit.
[0028] The process of forming porous masses may include continuous
processing methods, batch processing methods, or hybrid
continuous-batch processing methods. As used herein, "continuous
processing" refers to manufacturing or producing materials without
interruption. Material flow may be continuous, indexed, or
combinations of both. As used herein, "batch processing" refers to
manufacturing or producing materials as a single component or group
of components at individual stations before the single component or
group proceeds to the next station. As used herein,
"continuous-batch processing" refers to a hybrid of the two where
some processes, or series of processes, occur continuously and
others occur by batch.
[0029] Generally porous masses may be formed from matrix materials.
As used herein, the term "matrix material" refers to the
precursors, e.g., binder particles and active particles, used to
form porous masses. In some embodiments, the matrix material may
comprise, consist of, or consist essentially of binder particles
and active particles. In some embodiments, the matrix material may
comprise binder particles, active particles, and additives.
Nonlimiting examples of suitable binder particles, active
particles, and additives are provided in this disclosure.
[0030] Forming porous masses may generally include forming a matrix
material into a shape and mechanically bonding at least a portion
of the matrix material at a plurality of contact points.
[0031] Forming a matrix material into a shape may involve a mold
cavity. In some embodiments, a mold cavity may be a single piece or
a collection of single pieces, either with or without end caps,
plates, or plugs. In some embodiments, a mold cavity may be
multiple mold cavity parts that when assembled form a mold cavity.
In some embodiments, mold cavity parts may be brought together with
the assistance of conveyors, belts, and the like.
[0032] A mold cavity may have any cross-sectional shape including,
but not limited to, circular, substantially circular, ovular,
substantially ovular, polygonal (like triangular, square,
rectangular, pentagonal, and so on), polygonal with rounded edges,
and the like, or any hybrid thereof. In some embodiments, porous
masses may have a cross-sectional shape comprising holes, which may
be achieved by machining, or any other suitable method (e.g.,
degradation of a degradable material). In some embodiments, the
porous mass may have a specific shape for a cigarette holder or
pipe that is adapted to fit within the cigarette holder or pipe to
allow for smoke passage through the filter to the consumer. When
discussing the shape of a porous mass herein, with respect to a
traditional smoking device filter, the shape may be referred to in
terms of diameter or circumference (wherein the circumference is
the perimeter of a circle) of the cross-section of the cylinder.
But in embodiments where a porous mass of the present invention is
in a shape other than a true cylinder, it should be understood that
the term "circumference" is used to mean the perimeter of any
shaped cross-section, including a circular cross-section.
[0033] Generally, mold cavities may have a longitudinal direction
and a radial direction perpendicular to the longitudinal direction,
e.g., a substantially cylindrical shape. One skilled in the art
should understand how to translate the embodiments presented herein
to mold cavities without defined longitudinal and radial direction,
e.g., spheres and cubes, where applicable. In some embodiments, a
mold cavity may have a cross-sectional shape that changes along the
longitudinal direction, e.g., a conical shape, a shape that
transitions from square to circular, or a spiral. In some
embodiments, a mold cavity may be paper rolled or shaped into a
desired cross-sectional shape, e.g., a cylinder. In some
embodiments, a mold cavity may be a cylinder of paper glued at the
longitudinal seam.
[0034] In some embodiments, mold cavities may have a longitudinal
axis having an opening as a first end and a second end along said
longitudinal axis. In some embodiments, matrix material may pass
along the longitudinal axis of a mold cavity during processing. By
way of nonlimiting example, FIG. 1 shows mold cavity 120 with a
longitudinal axis along material path 110.
[0035] In some embodiments, mold cavities may have a longitudinal
axis having a first end and a second end along said longitudinal
axis wherein at least one end is closed. In some embodiments, said
closed end may be capable of opening.
[0036] In some embodiments, individual mold cavities may be filled
with a matrix material prior to mechanical bonding. In some
embodiments, a single mold cavity may be used to continuously
produce porous masses by continuously passing matrix material
therethrough before and/or during mechanical bonding. In some
embodiments, a single mold cavity may be used to produce an
individual porous mass. In some embodiments, said single mold
cavity may be reused and/or continuously reused to produce a
plurality of individual porous masses.
[0037] In some embodiments, mold cavities may be at least partially
lined with wrappers and/or coated with release agents. In some
embodiments, wrappers may be individual wrappers, e.g., pieces of
paper. In some embodiments, wrappers may be spoolable-length
wrappers, e.g., a 50 ft roll of paper.
[0038] In some embodiments, mold cavities may be lined with more
than one wrapper. In some embodiments, forming porous masses may
include lining a mold cavity(s) with a wrapper(s). In some
embodiments, forming porous masses may include wrapping the matrix
material with wrappers so that the wrapper becomes the mold cavity.
In such embodiments, the wrapper may be preformed as a mold cavity,
formed as a mold cavity in the presence of the matrix material, or
wrapped around matrix material that is in a preformed shape (e.g.,
with the aid of a tackifier). In some embodiments, wrappers may be
continuously fed through a mold cavity. Wrappers may be capable of
holding the porous mass in a shape, capable of releasing the porous
masses from the mold cavities, capable of assisting in passing
matrix material through the mold cavity, capable of protecting the
porous mass during handling or shipment, and any combination
thereof.
[0039] Suitable wrappers may include, but not be limited to, papers
(e.g., wood-based papers, papers containing flax, flax papers,
papers produced from other natural or synthetic fibers,
functionalized papers, special marking papers, colorized papers),
plastics (e.g., fluorinated polymers like polytetrafluoroethylene,
silicone), films, coated papers, coated plastics, coated films, and
the like, and any combination thereof. In some embodiments,
wrappers may be papers suitable for use in smoking device
filters.
[0040] In some embodiments, a wrapper may be adhered (e.g., glued)
to itself to assist in maintaining a desired shape, e.g., in a
substantially cylindrical configuration. In some embodiments,
mechanical bonding of the matrix material may also mechanically
bind the matrix material to the wrapper which may alleviate the
need for adhering the wrapper to itself.
[0041] Suitable release agents may be chemical release agents or
physical release agents. Nonlimiting examples of chemical release
agents may include oils, oil-based solutions and/or suspensions,
soapy solutions and/or suspensions, coatings bonded to the mold
surface, and the like, and any combination thereof. Nonlimiting
examples of physical release agents may include papers, plastics,
and any combination thereof. Physical release agents, which may be
referred to as release wrappers, may be implemented similar to
wrappers as described herein.
[0042] Once formed into a desired cross-sectional shape with the
mold cavity, the matrix material may be mechanically bound at a
plurality of contact points. Mechanical bonding may occur during
and/or after the matrix material is in the mold cavity. Mechanical
bonding may be achieved with heat and/or pressure.
[0043] Heat may be radiant heat, conductive heat, convective heat,
and any combination thereof. Heating may involve thermal sources
including, but not limited to, heated fluids internal to the mold
cavity, heated fluids external to the mold cavity, steam, heated
inert gases, secondary radiation from a component of the porous
mass (e.g., nanoparticles, active particles, and the like), ovens,
furnaces, flames, conductive or thermoelectric materials,
ultrasonics, and the like, and any combination thereof. By way of
nonlimiting example, heating may involve a convection oven or
heating block. Another nonlimiting example may involve heating with
a microwave oven. In another nonlimiting example, heating may
involve passing heated air, nitrogen, or other gas through the
matrix material while in the mold cavity. In some embodiments,
heated inert gases may be used to mitigate any unwanted oxidation
of active particles and/or additives. Another nonlimiting example
may involve mold cavities made of thermoelectric materials so that
the mold cavity heats. In some embodiments, heating may involve a
combination of the foregoing, e.g., passing heated gas through the
matrix material while passing the matrix material through a
microwave oven.
[0044] Secondary radiation from a component of the porous mass
(e.g., nanoparticles, active particles, and the like) may, in some
embodiments, be achieved by irradiating the component with
electromagnetic radiation, e.g., gamma-rays, x-rays, UV light,
visible light, IR light, microwaves, radio waves, and/or long radio
waves. By way of nonlimiting example, the matrix material may
comprise carbon nanotubes that when irradiated with radio frequency
waves emit heat. In another nonlimiting example, the matrix
material may comprise active particles like carbon particles that
are capable of converting microwave irradiation into heat that
mechanically bonds or assists in mechanically bonding the binder
particles together. In some embodiments, the electromagnetic
radiation may be tuned by the frequency and power level so as to
appropriately interact with the component of choice. For example,
activated carbon may be used in conjunction with microwaves at a
frequency ranging from about 900 MHz to about 2500 MHz with a fixed
or adjustable power setting that is selected to match a target rate
of heating.
[0045] One skilled in the art, with the benefit of this disclosure,
should understand that different wavelengths of electromagnetic
radiation penetrate materials to different depths. Therefore, when
employing primary or secondary radiation methods one should
consider the mold cavity material, configuration and composition,
the matrix material composition, the component that converts the
electromagnetic radiation to heat, the wavelength of
electromagnetic radiation, the intensity of the electromagnetic
radiation, the irradiation methods, and the desired amount of
secondary radiation, e.g., heat.
[0046] The residence time for heating (including by any method
described herein, e.g., convection oven or exposure to
electromagnetic radiation) and/or applying pressure that causes the
mechanical bonding to occur may be for a length of time ranging
from a lower limit of about a hundredth of a second, a tenth of a
second, 1 second, 5 seconds, 30 seconds, or 1 minute to an upper
limit of about 30 minutes, 15 minutes, 5 minutes, 1 minute, or 1
second, and wherein the residence time may range from any lower
limit to any upper limit and encompasses any subset therebetween.
It should be noted that for continuous processes that utilize
faster heating methods, e.g., exposure to electromagnetic radiation
like microwaves, short residence times may be preferred, e.g.,
about 10 seconds or less, or more preferably about 1 second or
less. Further, processing methods that utilize processes like
convection heating may provide for longer residence times on the
timescale of minutes, which may include residence times of greater
than 30 minutes. One of ordinary skill in the art should understand
that longer times can be applicable, e.g., seconds to minutes to
hours or longer provided that an appropriate temperature and
heating profile may be selected for a given matrix material. It
should be noted that preheating or pretreating methods and/or steps
that are not to a sufficient temperature and/or pressure to allow
for mechanical bonding are not considered part of the residence
time, as used herein.
[0047] In some embodiments, heating to facilitate mechanical
bonding may be to a softening temperature of a component of the
matrix material. As used herein, the term "softening temperature"
refers to the temperature above which a material becomes pliable,
which is typically below the melting point of the material.
[0048] In some embodiments, mechanical bonding may be achieved at
temperatures ranging from a lower limit of about 90.degree. C.,
100.degree. C., 110.degree. C., 120.degree. C., 130.degree. C., or
140.degree. C. or an upper limit of about 300.degree. C.,
275.degree. C., 250.degree. C., 225.degree. C., 200.degree. C.,
175.degree. C., or 150.degree. C., and wherein the temperature may
range from any lower limit to any upper limit and encompass any
subset therebetween. In some embodiments, the heating may be
accomplished by subjecting material to a single temperature. In
another embodiment the temperature profile may vary with time. By
way of nonlimiting example, a convection oven may be used. In some
embodiments, heating may be localized within the matrix material.
By way of nonlimiting example, secondary radiation from
nanoparticles may heat only the matrix material proximal to the
nanoparticle.
[0049] In some embodiments, matrix materials may be preheated
before entering mold cavities. In some embodiments, matrix material
may be preheated to a temperature below the softening temperature
of a component of the matrix material. In some embodiments, matrix
material may be preheated to a temperature about 10%, about 5%, or
about 1% below the softening temperature of a component of the
matrix material. In some embodiments, matrix material may be
preheated to a temperature about 10.degree. C., about 5.degree. C.,
or about 1.degree. C. below the softening temperature of a
component of the matrix material. Preheating may involve heat
sources including, but not limited to, those listed as heat sources
above for achieving mechanical bonding.
[0050] In some embodiments, bonding the matrix material may yield
porous mass or porous mass lengths. As used herein, the term
"porous mass length" refers to a continuous porous mass (i.e., a
porous mass that is not never-ending, but rather long compared to
porous masses, which may be produced continuously). By way of
nonlimiting example, porous mass lengths may be produced by
continuously passing matrix material through a heated mold cavity.
In some embodiments, the binder particles may retain their original
physical shape (or substantially retained their original shape,
e.g., no more that 10% variation (e.g., shrinkage) in shape from
original) during the mechanical bonding process, i.e., the binder
particles may be substantially the same shape in the matrix
material and in the porous mass (or lengths).
[0051] In some embodiments, porous mass lengths may be cut to yield
porous mass. Cutting may be achieved with a cutter. Suitable
cutters may include, but not be limited to, blades, hot blades,
carbide blades, stellite blades, ceramic blades, hardened steel
blades, diamond blades, smooth blades, serrated blades, lasers,
pressurized fluids, liquid lances, gas lances, guillotines, and the
like, and any combination thereof. In some embodiments with
high-speed processing, cutting blades or similar devices may be
positioned at an angle to match the speed of processing so as to
yield porous masses with ends perpendicular to the longitudinal
axis. In some embodiments, the cutter may change position relative
to the porous mass lengths along the longitudinal axis of the
porous mass lengths.
[0052] In some embodiments, porous masses and/or porous mass
lengths may be extruded. In some embodiments, extrusion may involve
a die. In some embodiments, a die may have multiple holes being
capable of extruding porous masses and/or porous mass lengths.
[0053] Some embodiments may involve cutting porous masses and/or
porous mass lengths radially to yield porous mass sections. Cutting
may be achieved by any known method with any known apparatus
including, but not limited to, those described above in relation to
cutting porous mass lengths into porous masses.
[0054] The length of a porous mass, or sections thereof, may range
from a lower limit of about 2 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm,
25 mm, or 30 mm to an upper limit of about 150 mm, 100 mm, 50 mm,
25 mm, 15 mm, or 10 mm, and wherein the length may range from any
lower limit to any upper limit and encompass any subset
therebetween.
[0055] The circumference of a porous mass length, a porous mass, or
sections thereof (wrapped or otherwise) may range from a lower
limit of about 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm,
13 mm, 14 mm, 15 mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22
mm, 23 mm, 24 mm, 25 mm, or 26 mm to an upper limit of about 60 mm,
50 mm, 40 mm, 30 mm, 20 mm, 29 mm, 28 mm, 27 mm, 26 mm, 25 mm, 24
mm, 23 mm, 22 mm, 21 mm, 20 mm, 19 mm, 18 mm, 17 mm, or 16 mm,
wherein the circumference may range from any lower limit to any
upper limit and encompass any subset therebetween.
[0056] Some embodiments may involve wrapping porous mass sections,
porous masses, and/or porous mass lengths with a wrapper after the
matrix material has been mechanically bound, e.g., after removal
from the mold cavity or exiting an extrusion die. Suitable wrappers
include those disclosed above.
[0057] Some embodiments may involve cooling porous mass sections,
porous masses, and/or porous mass lengths (wrapped or otherwise).
Cooling may be active or passive, i.e., cooling may be assisted or
occur naturally. Active cooling may involve passing a fluid over
and/or through the mold cavity, porous mass sections, porous
masses, and/or porous mass lengths (wrapped or otherwise);
decreasing the temperature of the local environment about the mold
cavity, porous mass sections, porous masses, and/or porous mass
lengths (wrapped or otherwise), e.g., passing through a
refrigerated component; and any combination thereof. Active cooling
may involve a component that may include, but not be limited to,
cooling coils, fluid jets, thermoelectric materials, and any
combination thereof. The rate of cooling may be random or it may be
controlled.
[0058] Some embodiments may involve transporting porous mass
sections, porous masses, and/or porous mass lengths (wrapped or
otherwise) to another location. Suitable forms of transportation
may include, but not be limited to, conveying, carrying, rolling,
pushing, shipping, robotic movement, and the like, and any
combination thereof.
[0059] One skilled in the art, with the benefit of this disclosure,
should understand the plurality of apparatuses and/or systems
capable of producing porous mass sections, porous masses, and/or
porous mass lengths. By way of nonlimiting examples, FIGS. 1-11
illustrate a plurality of apparatuses and/or systems capable of
producing porous mass sections, porous masses, and/or porous mass
lengths.
[0060] It should be noted that where a system is used, it is within
the scope of this disclosure to have an apparatus with the
components of a system, and vice versa.
[0061] For ease of understanding, the term "material path" is used
herein to identify the path along which matrix material, porous
mass lengths, and/or porous masses will travel in a system and/or
apparatus. In some embodiments, a material path may be contiguous.
In some embodiments, a material path may be noncontiguous. By way
of nonlimiting example, systems for batch processing with multiple,
independent mold cavities may be considered to have a noncontiguous
material path.
[0062] Referring now to FIGS. 1A-B, system 100 may include hopper
122 operably connected to material path 110 to feed the matrix
material (not shown) to material path 110. System 100 may also
include paper feeder 132 operably connected to material path 110 so
as to feed paper 130 into material path 110 to form a wrapper
substantially surrounding the matrix material between mold cavity
120 and the matrix material. Heating element 124 is in thermal
communication with the matrix material while in mold cavity 120.
Heating element 124 may cause the matrix material to mechanically
bond at a plurality of points thereby yielding a wrapped porous
mass length (not shown). After the wrapped porous mass length exits
mold cavity 120 and is suitably cooled, cutter 126 cuts the wrapped
porous mass length radially, i.e., perpendicular to the
longitudinal axis, thereby yielding wrapped porous masses and/or
wrapped porous mass sections.
[0063] FIGS. 1A-B, demonstrate that system 100 may be at any angle.
One skilled in the art, with the benefit of this disclosure, should
understand the configurational considerations when adjusting the
angle at which system 100, or any component thereof, is placed. By
way of nonlimiting example, FIG. 1B shows hopper 122 may be
configured such that the outlet of hopper 122 (and any
corresponding matrix feed device) is within mold cavity 120. In
some embodiments, a mold cavity may be at an angle at or between
vertical and horizontal.
[0064] In some embodiments, feeding matrix material to a material
path may involve any suitable feeder system including, but not
limited to, hand feeding, volumetric feeders, mass flow feeders,
gravimetric feeders, augers or screws, chutes, slides, conveyors,
tubes, conduits, channels, and the like, and any combination
thereof. In some embodiments, the material path may include a
mechanical component between the hopper and the mold cavity
including, but not limited to, garnitures, compression molds,
flow-through compression molds, ram presses, pistons, shakers,
extruders, twin screw extruders, solid state extruders, and the
like, and any combination thereof. In some embodiments, feeding may
involve, but not be limited to, forced feeding, controlled rate
feeding, volumetric feeding, mass flow feeding, gravimetric
feeding, vacuum-assisted feeding, fluidized powder feeding,
pneumatic dense phase feeding, pneumatic dilute phase feeding, and
any combination thereof. In some embodiments, feeding may be
indexed to enable the insertion of a spacer material at
predetermined intervals. Suitable spacer materials may comprise
additives, solid barriers (e.g., mold cavity parts), porous
barriers (e.g., papers and release wrappers), filters, cavities,
and the like, and any combination thereof. In some embodiments,
feeding may involve shaking and/or vibrating. One skilled in the
art, with the benefit of this disclosure, should understand the
degree of shaking and/or vibrating that is appropriate, e.g., a
homogenously distributed matrix material comprising large binder
particles and small active particles may be adversely effected by
vibrating, i.e., homogeneity may be at least partially lost.
Further, one skilled in the art should understand the effects of
feeding parameters and/or feeders on the final properties of the
porous masses produced, e.g., the effects on at least void volume
(discussed further below), encapsulated pressure drop (discussed
further below), and compositional homogeneity.
[0065] In some embodiments, the matrix material or components
thereof may be dried before being introduced into the material path
and/or while along the material path. Drying may be achieved, in
some embodiments, with heating the matrix material or components
thereof, blowing dry gas over the matrix material or components
thereof, and any combination thereof. In some embodiments, the
matrix material may have a moisture content of about 5% by weight
or less, or more preferably about 2% by weight or less, and in some
embodiments as low as 0.01% by weight. Moisture content may be
analyzed by known methods that involve freeze drying or weight loss
after drying.
[0066] Referring now to FIGS. 2A-B, system 200 may include hopper
222 operably connected to material path 210 to feed the matrix
material to material path 210. System 200 may also include paper
feeder 232 operably connected to material path 210 so as to feed
paper 230 into material path 210 to form a wrapper substantially
surrounding the matrix material between mold cavity 220 and the
matrix material. Further, system 200 may include release feeder 236
operably connected to material path 210 so as to feed release
wrapper 234 into material path 210 to form a wrapper between paper
230 and mold cavity 220. In some embodiments, release feeder 236
may be configured as conveyor 238 that continuously cycles release
wrapper 234. Heating element 224 is in thermal communication with
the matrix material while in mold cavity 220. Heating element 224
may cause the matrix material to mechanically bond at a plurality
of points thereby yielding a wrapped porous mass length. After the
wrapped porous mass length exits mold cavity 220 and is suitably
cooled, cutter 226 cuts the wrapped porous mass length radially
thereby yielding wrapped porous masses and/or wrapped porous mass
sections. In embodiments where release wrapper 234 is not
configured as conveyor 238, release wrapper 234 may be removed from
the wrapped porous mass length before cutting or from the wrapped
porous masses and/or wrapped porous mass sections after
cutting.
[0067] Referring now to FIG. 3, system 300 may include component
hoppers 322a and 322b that feed components of the matrix material
into hopper 322. The matrix material may be mixed and preheated in
hopper 322 with mixer 328 and preheater 344. Hopper 322 may be
operably connected to material path 310 to feed the matrix material
to material path 310. System 300 may also include paper feeder 332
operably connected to material path 310 so as to feed paper 330
into material path 310 to form a wrapper substantially surrounding
the matrix material between mold cavity 320 and the matrix
material. Mold cavity 320 may include fluid connection 346 through
which heated fluid (liquid or gas) may pass into material path 310
and mechanically bond the matrix material at a plurality of points
thereby yielding a wrapped porous mass length. It should be noted
that fluid connection 346 can be located at any location along mold
cavity 320 and that more than one fluid connection 346 may be
disposed along mold cavity 320. After the wrapped porous mass
length exits mold cavity 320 and is suitably cooled, cutter 326
cuts the wrapped porous mass length radially thereby yielding
wrapped porous masses and/or wrapped porous mass sections.
[0068] One skilled in the art with the benefit of this disclosure
should understand that preheating can also take place for
individual feed components before hopper 322 and/or with the mixed
components after hopper 322.
[0069] Suitable mixers may include, but not be limited to, ribbon
blenders, paddle blenders, plow blenders, double cone blenders,
twin shell blenders, planetary blenders, fluidized blenders, high
intensity blenders, rotating drums, blending screws, rotary mixers,
and the like, and any combination thereof.
[0070] In some embodiments, component hoppers may hold individual
components of the matrix material, e.g., two component hoppers with
one holding binder particles and the other holding active
particles. In some embodiments, component hoppers may hold mixtures
of components of the matrix material, e.g., two component hoppers
with one holding a mixture of binder particles and active particles
and the other holding an additive like flavorant. In some
embodiments, the components within component hoppers may be solids,
liquids, gases, or combinations thereof. In some embodiments, the
components of different component hoppers may be added to the
hopper at different rates to achieve a desired blend for the matrix
material. By way of nonlimiting example, three component hoppers
may separately hold active particles, binder particles, and active
compounds (an additive described further below) in liquid form.
Binder particles may be added to the hopper at twice the rate of
the active particles, and the active compounds may be sprayed in so
as to form at least a partial coating on both the active particles
and the binder particles.
[0071] In some embodiments, fluid connections to mold cavities may
be to pass a fluid into the mold cavity, pass a fluid through a
mold cavity, and/or drawing on a mold cavity. As used herein, the
term "drawing" refers to creating a negative pressure drop across a
boundary and/or along a path, e.g., sucking. Passing a heated fluid
into and/or through a mold cavity may assist in mechanically
bonding the matrix material therein. Drawing on a mold cavity that
has a wrapper disposed therein may assist in lining the mold cavity
evenly, e.g., with less wrinkles.
[0072] Referring now to FIG. 4, system 400 may include hopper 422
operably connected to material path 410 to feed the matrix material
to material path 410. Hopper 422 may be configured along material
path 410 such that the outlet of hopper 422, or an extension from
its outlet, is within mold cavity 420. This may advantageously
allow for the matrix material to be fed into mold cavity 420 at a
rate to control the packing of the matrix material and consequently
the void volume of resultant porous masses. In this nonlimiting
example, mold cavity 420 comprises a thermoelectric material and
therefore includes power connection 448. System 400 may also
include release feeder 436 operably connected to material path 410
so as to feed release wrapper 434 into material path 410 to form a
wrapper substantially surrounding the matrix material between mold
cavity 420 and the matrix material. Mold cavity 420 may be made of
a thermoelectric material so that mold cavity 420 may provide the
heat to mechanically bond the matrix material at a plurality of
points thereby yielding a wrapped porous mass length. Along
material path 410 after mold cavity 420, roller 440 may be operably
capable of assisting the movement of the wrapped porous mass length
through mold cavity 420. After the wrapped porous mass length exits
mold cavity 420 and is suitably cooled, cutter 426 cuts the wrapped
porous mass length radially thereby yielding wrapped porous masses
and/or wrapped porous mass sections. After cutting, the porous
masses continue along material path 410 on porous mass conveyor
462, e.g., for packaging or further processing. Release wrapper 434
may be removed from the wrapped porous mass length before cutting
or from the wrapped porous masses and/or wrapped porous mass
sections after cutting.
[0073] Suitable rollers and/or substitutes for rollers may include,
but not be limited to, cogs, cogwheels, wheels, belts, gears, and
the like, and any combination thereof. Further rollers and the like
may be flat, toothed, beveled, and/or indented.
[0074] Referring now to FIG. 5, system 500 may include hopper 522
operably connected to material path 510 to feed the matrix material
to material path 510. Heating element 524 is in thermal
communication with the matrix material while in mold cavity 520.
Heating element 524 may cause the matrix material to mechanically
bond at a plurality of points, thereby yielding a porous mass
length. After the porous mass length exits mold cavity 520, die 542
may be used for extruding the porous mass length into a desired
cross-sectional shape. Die 542 may include a plurality of dies 542'
(e.g., multiple dies or multiple holes within a single die) through
which the porous mass length may be extruded. After the porous mass
length is extruded through die 542 and suitably cooled, cutter 526
cuts the porous mass length radially, thereby yielding porous
masses and/or porous mass sections.
[0075] Referring now to FIG. 6, system 600 may include paper feeder
632 operably connected to material path 610 so as to feed paper 630
into material path 610. Hopper 622 (or other matrix material
delivery apparatus, e.g., an auger) may be operably connected to
material path 610 so as to place matrix material on paper 630.
Paper 630 may wrap around the matrix material, at least in part,
because of passing-through mold cavity 620 (or compression mold
sometimes referred to a garniture device in relation to cigarette
filter forming apparatuses), which provide the desired
cross-sectional shape (or optional, in some embodiments, the matrix
material may be combined with paper 630 after formation of the
desired cross-section has begun or is complete). In some
embodiments, the paper seam may be glued. Heating element 624 (or
alternatively an electromagnetic radiation source, e.g., a
microwave source) is in thermal communication with the matrix
material while and/or after being in mold cavity 620. Heating
element 624 may cause the matrix material to mechanically bond at a
plurality of points, thereby yielding a wrapped porous mass length.
After the wrapped porous mass length exits mold cavity 620 and is
suitably cooled, cutter 626 cuts the wrapped porous mass length
radially, thereby yielding wrapped porous masses and/or wrapped
porous mass sections. Movement through system 600 may be aided by
conveyor 658 with mold cavity 620 being stationary. It should be
noted that while not shown, a similar embodiment may include paper
630 as part of a looped conveyor that unwraps from the porous mass
length before cutting, which would yield porous masses and/or
porous mass sections.
[0076] Referring now to FIG. 7, system 700 may include paper feeder
732 operably connected to material path 710 so as to feed paper 730
into material path 710. As shown, mold cavity 720, a
cylindrically-rolled paper glued at the longitudinal seam, may be
formed on-the-fly with compression mold 756a (or compression mold
sometimes referred to a garniture device in relation to cigarette
filter forming apparatuses) causing paper 730 to roll with glue 752
applied with glue-application device 754 (e.g., a glue gun). During
the formation of mold cavity 720, matrix material may be introduced
along material path 710 from hopper 722. Heating element 724 (e.g.,
a microwave element) in thermal communication with mold cavity 720
may cause the matrix material to mechanically bond at a plurality
of points thereby yielding a wrapped porous mass length. Then,
compression mold 756b may be used before complete cooling of the
matrix material to size the wrapped porous mass length into a
desired cross-sectional size, which may advantageously be used for
diameter uniformity. After the wrapped porous mass length is
suitably cooled, cutter 726 cuts the wrapped porous mass length
radially, thereby yielding wrapped porous masses and/or wrapped
porous mass sections. Movement through system 700 may be aided by
rollers, conveyors, or the like, not shown. One skilled in the art
with the benefit of this disclosure should understand that the
processes described may occur in a single apparatus or in multiple
apparatus. For example, rolling the paper, introducing the matrix
material, exposing to heat (e.g., applying microwaves), and
resizing may be performed in a single apparatus and the resultant
porous mass length may be conveyed to a second apparatus for
cutting.
[0077] In some embodiments, while the matrix material is at an
elevated temperature, the porous mass or the like may be resized
and/or reshaped with the application of pressure.
[0078] Referring now to FIG. 8, mold cavity 820 of system 800 may
be formed from mold cavity parts 820a and 820b operably connected
to mold cavity conveyors 860a and 860b, respectively. Once mold
cavity 820 is formed, matrix material may be introduced along
material path 810 from hopper 822. Heating element 824 is in
thermal communication with the matrix material while in mold cavity
820. Heating element 824 may cause the matrix material to
mechanically bond at a plurality of points, thereby yielding a
porous mass. After mold cavity 820 is suitably cooled and separated
into mold cavity parts 820a and 820b, the porous mass may be
removed from mold cavity parts 820a and/or 820b and continue along
material path 810 via porous mass conveyor 862. It should be noted
that FIG. 8 illustrates a nonlimiting example of a noncontiguous
material path.
[0079] In some embodiments, removing porous masses from mold
cavities and/or mold cavity parts may involve pulling mechanisms,
pushing mechanisms, lifting mechanisms, gravity, any hybrid
thereof, and any combination thereof. Removing mechanisms may be
configured to engage porous masses at the ends, along the side(s),
and any combination thereof. Suitable pulling mechanisms may
include, but not be limited to, suction cups, vacuum components,
tweezers, pincers, forceps, tongs, grippers, claws, clamps, and the
like, and any combination thereof. Suitable pushing mechanisms may
include, but not be limited to, ejectors, punches, rods, pistons,
wedges, spokes, rams, pressurized fluids, and the like, and any
combination thereof. Suitable lifting mechanisms may include, but
not be limited to, suction cups, vacuum components, tweezers,
pincers, forceps, tongs, grippers, claws, clamps, and the like, and
any combination thereof. In some embodiments, mold cavities may be
configured to operably work with various removal mechanisms. By way
of nonlimiting example, a hybrid push-pull mechanism may include
pushing longitudinally with a rod, so as to move the porous mass
partially out the other end of the mold cavity, which can then be
engaged by forceps to pull the porous mass from the mold
cavity.
[0080] Referring now to FIG. 9, mold cavity 920 of system 900 is
formed from mold cavity parts 920a and 920b or 920c and 920d
operably connected to mold cavity conveyors 960a, 960b, 960c, and
960d, respectively. Once mold cavity 920 is formed, or during
forming, sheets of paper 930 are introduced into mold cavity 920
via paper feeder 932. Then matrix material is introduced into paper
930 from hopper 922 along material path 910 lined mold cavity 920
and mechanically bound into porous masses with heat from heating
element 924. After suitable cooling, removal of the porous masses
may be achieved by insertion of ejector 964 into ejector ports 966a
and 966b of mold cavity parts 920a, 920b, 920c, and 920d. The
porous masses may then continue along material path 910 via porous
mass conveyor 962. Again, FIG. 9 illustrates a nonlimiting example
of a noncontiguous material path.
[0081] Quality control of porous mass production may be assisted
with cleaning of mold cavities and/or mold cavity parts. Referring
again to FIG. 8, cleaning instruments may be incorporated into
system 800. As mold cavity parts 820a and 820b return from forming
porous masses, mold cavity parts 820a and 820b pass a series of
cleaners including liquid jet 870 and air or gas jet 872. Similarly
in FIG. 9, as mold cavity parts 960a, 960b, 960c, and 960d return
from forming porous masses, mold cavity parts 960a, 960b, 960c, and
960d pass a series of cleaners that include heat from heating
element 924 and air or gas jet 972.
[0082] Other suitable cleaners may include, but not be limited to,
scrubbers, brushes, baths, showers, insert fluid jets (tubes that
insert into mold cavities capable of jetting fluids radially),
ultrasonic apparatuses, and any combination thereof.
[0083] In some embodiments, porous mass sections, porous masses,
and/or porous mass lengths may comprise cavities. By way of
nonlimiting example, referring now to FIG. 10, mold cavity parts
1020a and 1020b operably connected to mold cavity conveyors 1060a
and 1060b operably connect to form mold cavity 1020 of system 1000.
Hopper 1022 is operably attached to two volumetric feeders 1090a
and 1090b such that each volumetric feeder 1090a and 1090b fills
mold cavity 1020 partially with the matrix material along material
path 1010. Between the addition of matrix material from volumetric
feeder 1090a and volumetric feeder 1090b, injector 1088 places a
capsule (not shown) into mold cavity 1020, thereby yielding a
capsule surrounded by matrix material. Heating element 1024, in
thermal contact with mold cavity 1020, causes the matrix material
to mechanically bond at a plurality of points, thereby yielding a
porous mass with a capsule disposed therein. After the porous mass
is formed and suitably cooled, rotary grinder 1092 is inserted into
mold cavity 1020 along the longitudinal direction of mold cavity
1020. Rotary grinder 1092 is operably capable of grinding the
porous mass to a desired length in the longitudinal direction.
After mold cavity 1020 separates into mold cavity parts 1020a and
1020b, the porous mass is removed from mold cavity parts 1020a
and/or 1020b and continues along material path 1010 via porous mass
conveyor 1062.
[0084] Suitable capsules for use within porous masses and the like
may include, but not be limited to, polymeric capsules, porous
capsules, ceramic capsules, and the like. Capsules may be filled
with an additive, e.g., granulated carbon or a flavorant (more
examples provided below). The capsules, in some embodiments, may
also contain a molecular sieve that reacts with selected components
in the smoke to remove or reduce the concentration of the
components without adversely affecting desirable flavor
constituents of the smoke. In some embodiments, the capsules may
include tobacco as an additional flavorant. One should note that if
the capsule is insufficiently filled with a chosen substance, in
some filter embodiments, this may create a lack of interaction
between the components of the mainstream smoke and the substance in
the capsules.
[0085] One skilled in the art, with the benefit of this disclosure,
should understand that other methods described herein may be
altered to produce porous mass sections, porous masses, and/or
porous mass lengths with capsules therein. In some embodiments,
more than one capsule may be within a porous mass section, porous
mass, and/or porous mass length.
[0086] In some embodiments, the shape, e.g., length, width,
diameter, and/or height, of porous mass sections, porous masses,
and/or porous mass lengths may be adjusted by operations other than
cutting including, but not limited to, sanding, milling, grinding,
smoothing, polishing, rubbing, and the like, and any combination
thereof. Generally, these operations will be referred to herein as
grinding. Some embodiments may involve grinding the sides and/or
ends of porous mass sections, porous masses, and/or porous mass
lengths to achieve smooth surfaces, roughened surfaces, grooved
surfaces, patterned surfaces, leveled surfaces, and any combination
thereof. Some embodiments may involve grinding the sides and/or
ends of porous mass sections, porous masses, and/or porous mass
lengths to achieve desired dimensions within specification
limitations. Some embodiments may involve grinding the sides and/or
ends of porous mass sections, porous masses, and/or porous mass
lengths while in or exiting mold cavities, after cutting, during
further processing, and any combination thereof. One skilled in the
art should understand that dust, particles, and/or pieces may be
produced from grinding. As such, grinding may involve removing the
dust, particles, and/or pieces by methods like vacuuming, blowing
gases, rinsing, shaking, and the like, and any combination
thereof.
[0087] Any component and/or instrument capable of achieving the
desired level of grinding may be used in conjunction with systems
and methods disclosed herein. Examples of suitable components
and/or instruments capable of achieving the desired level of
grinding may include, but not be limited to, lathes, rotary
sanders, brushes, polishers, buffers, etchers, scribes, and the
like, and any combination thereof.
[0088] In some embodiments, the porous mass may be machined to be
lighter in weight, if desired, for example, by drilling out a
portion of the porous mass.
[0089] One skilled in the art, with the benefit of this disclosure,
should understand the component and/or instrument configurations
necessary to engage porous mass sections, porous masses, and/or
porous mass lengths at various points with the systems described
herein. By way of nonlimiting example, grinding instruments and/or
drilling instruments used while porous masses are in mold cavities
(or porous mass lengths are leaving mold cavities) should be
configured so as not to deleteriously affect the mold cavity.
[0090] Referring now to FIG. 11, hopper 1122 is operably attached
to chute 1182 and feeds the matrix material to material path 1110.
Along material path 1110, mold cavity 1120 is configured to accept
ram 1180, which is capable of pressing the matrix material in mold
cavity 1120. Heating element 1124, in thermal communication with
the matrix material while in mold cavity 1120, causes the matrix
material to mechanically bond at a plurality of points, thereby
yielding a porous mass length. Inclusion of ram 1180 in system 1100
may advantageously assist in ensuring the matrix material is
properly packed so as to form a porous mass length with a desired
void volume. Further, system 1100 comprises cooling area 1194,
while the porous mass length is still contained within mold cavity
1120. In this nonlimiting example, cooling is achieved
passively.
[0091] Referring now to FIG. 12, hopper 1222 of system 1200
operably feeds the matrix material to extruder 1284 (e.g., screw)
along material path 1210. Extruder 1284 moves matrix material to
mold cavity 1220. System 1200 also includes heating element 1224 in
thermal communication with the matrix material while in mold cavity
1220 that causes the matrix material to mechanically bond at a
plurality of points, thereby yielding a porous mass length.
Further, system 1200 includes cooling element 1286 in thermal
communication porous mass length while in mold cavity 1220.
Movement of the porous mass length out of mold cavity 1220 is
assisted and/or directed by roller 1240.
[0092] In some embodiments, a control system may interface with
components of the systems and/or apparatuses disclosed herein. As
used herein, the term "control system" refers to a system that can
operate to receive and send electronic or pneumatic signals and may
include functions of interfacing with a user, providing data
readouts, collecting data, storing data, changing variable
setpoints, maintaining setpoints, providing notifications of
failures, and any combination thereof. Suitable control systems may
include, but are not limited to, variable transformers, ohmmeters,
programmable logic controllers, digital logic circuits, electrical
relays, computers, virtual reality systems, and any combination
thereof. Suitable system and/or apparatus components that may be
operably connected to a control system may include, but not be
limited to, hoppers, heating elements, cooling elements, cutters,
mixers, paper feeders, release feeders, release conveyors, rollers,
mold cavity conveyors, conveyors, ejectors, liquid jets, air jets,
rams, chutes, extruders, injectors, matrix material feeders,
grinders, and the like, and any combination thereof. It should be
noted that systems and/or apparatuses disclosed herein may have
more than one control system that can interface with any number of
components.
[0093] One skilled in the art, with the benefit of this disclosure,
should understand the interchangeability of the various components
of the systems and/or apparatuses disclosed herein. By way of
nonlimiting example, heating elements may be interchanged with
electromagnetic radiation sources (e.g., a microwave source) when
the matrix material comprises a component capable of converting
electromagnetic radiation to heat (e.g., nanoparticles, carbon
particles, and the like). Further, by way of nonlimiting example,
paper wrappers may be interchanged with release wrappers.
[0094] In some embodiments, porous mass sections, porous masses,
and/or porous mass lengths may be produced at linear speeds of
about 800 m/min or less, including by methods that involve very
slow linear speeds of less than about 1 m/min. As used herein, the
term "linear speed" refers to the speed along a single production
line in contrast to a production speed that may encompass several
production lines in parallel, which may be along individual
apparatuses, within a single apparatus, or a combination thereof.
In some embodiments, porous mass sections, porous masses, and/or
porous mass lengths may be produced by methods described herein at
linear speeds that range from a lower limit of about 1 m/min, 10
m/min, 50 m/min, or 100 m/min to an upper limit of about 800 m/min,
600 m/min, 500 m/min, 300 m/min, or 100 m/min, and wherein the
linear speed may range from any lower limit to any upper limit and
encompass any subset therebetween. One skilled in the art would
recognized that productivity advancements in machinery may enable
linear speeds of greater than 800 m/min (e.g., 1000 m/min or
greater). One of ordinary skill in the art should also understand
that a single apparatus may include multiple lines (e.g., two or
more lines of FIG. 7 or other lines illustrated herein) in parallel
so as to increase the overall production rate of porous masses and
the like, e.g., to several thousand m/min or greater.
[0095] Some embodiments may involve further processing of porous
mass sections, porous masses, and/or porous mass lengths (wrapped
or otherwise). Suitable further processing may include, but not be
limited to, doping with a flavorant or other additive, grinding,
drilling out, further shaping, forming multi-segmented filters,
forming smoking devices, packaging, shipping, and any combination
thereof.
[0096] Some embodiments may involve doping matrix materials, porous
mass sections, porous masses, and/or porous mass lengths (wrapped
or otherwise) with an additive. Nonlimiting examples of additives
are provided below. Suitable doping methods may include, but not be
limited to, including the additives in the matrix material; by
applying the additives to at least a portion of the matrix material
before mechanical bonding; by applying the additives after
mechanical bonding while in the mold cavity; by applying the
additives after leaving the mold cavity; by applying the additives
after cutting; and any combination thereof. It should be noted that
applying includes, but is not limited to, dipping, immersing,
submerging, soaking, rinsing, washing, painting, coating,
showering, drizzling, spraying, placing, dusting, sprinkling,
affixing, and any combination thereof. Further, it should be noted
that applying includes, but is not limited to, surface treatments,
infusion treatments where the additive incorporates at least
partially into a component of the matrix material, and any
combination thereof. One skilled in the art with the benefit of
this disclosure should understand the concentration of the additive
will depend at least on the composition of the additive, the size
of the additive, the purpose of the additive, and the point in the
process in which the additive is included.
[0097] In some embodiments, doping with an additive may occur
before, during, and/or after mechanically bonding the matrix
materials. One skilled in the art with the benefit of this
disclosure should understand that additives which degrade, change,
or are otherwise affected by the mechanical bonding process and
associated parameter (e.g., elevated temperatures and/or pressures)
should be added after mechanical bonding and/or the parameters
should be adjusted accordingly (e.g., use of inert gases or reduced
temperatures). By way of nonlimiting example, glass beads may be an
additive in the matrix material. Then, after mechanical bonding,
the glass beads may be functionalized with other additives like
flavorants and/or active compounds.
[0098] Some embodiments may involve grinding porous mass sections,
porous masses, and/or porous mass lengths (wrapped or otherwise)
after being produced. Grinding includes those methods and
apparatuses/components described above.
[0099] Some embodiments may involve operably connecting porous mass
sections, porous masses, and/or porous mass lengths (wrapped or
otherwise) to filters and/or filter sections. Suitable filters
and/or filter sections may include, but not be limited to, those
that comprise a section that comprises cavities, other porous
masses, polypropylenes, polyethylenes, polyolefin tows,
polypropylene tows, polyethylene terephthalates, polybutylene
terephthalates, random oriented acetates, papers, corrugated
papers, concentric filters, carbon-on-tow, silica, magnesium
silicate, zeolites, molecular sieves, salts, catalysts, sodium
chloride, nylon, flavorants, tobacco, capsules, cellulose,
cellulosic derivatives, cellulose acetate, catalytic converters,
iodine pentoxide, coarse powders, carbon particles, carbon fibers,
fibers, glass beads, nanoparticles, void chambers, baffled void
chambers, cellulose acetate tow with less than about 10 denier per
filament, cellulose acetate tow with about 10 denier per filament
or greater, and any combination thereof.
[0100] In some embodiments, a filter section may comprise a space
that defines a cavity between two filter sections (one section
including porous mass sections, porous masses, and/or porous mass
lengths (wrapped or otherwise)). The cavity may, in some
embodiments, be filled with an additive, e.g., granulated carbon or
a flavorant. The cavity may, in some embodiments, contain a
capsule, e.g., a polymeric capsule, that itself contains a
flavorant or catalyst. The cavity, in some embodiments, may also
contain a molecular sieve that reacts with selected components in
the smoke to remove or reduce the concentration of the components
without adversely affecting desirable flavor constituents of the
smoke. In an embodiment, the cavity may include tobacco as an
additional flavorant. One should note that if the cavity is
insufficiently filled with a chosen substance, in some embodiments,
this may create a lack of interaction between the components of the
mainstream smoke and the substance in the cavity and in the other
filter section(s).
[0101] Some embodiments may involve operably connecting smokeable
substances to porous mass sections, porous masses, and/or porous
mass lengths (wrapped or otherwise) (or segmented filters
comprising at least one of the foregoing). In some embodiments,
porous mass sections, porous masses, and/or porous mass lengths
(wrapped or otherwise) (or segmented filters comprising at least
one of the foregoing) may be in fluid communication with a
smokeable substance. In some embodiments, a smoking device may
comprise porous mass sections, porous masses, and/or porous mass
lengths (wrapped or otherwise) (or segmented filters comprising at
least one of the foregoing) in fluid communication with a smokeable
substance. In some embodiments, a smoking device may comprise a
housing operably capable of maintaining porous mass sections,
porous masses, and/or porous mass lengths (wrapped or otherwise)
(or segmented filters comprising at least one of the foregoing) in
fluid communication with a smokeable substance. In some
embodiments, filter rods, filters, filter sections, sectioned
filters, and/or sectioned filter rods may be removable,
replaceable, and/or disposable from the housing.
[0102] As used herein, the term "smokeable substance" refers to a
material capable of producing smoke when burned or heated. Suitable
smokeable substances may include, but not be limited to, tobaccos,
e.g., bright leaf tobacco, Oriental tobacco, Turkish tobacco,
Cavendish tobacco, corojo tobacco, criollo tobacco, Perique
tobacco, shade tobacco, white burley tobacco, flue-cured tobacco,
Burley tobacco, Maryland tobacco, Virginia tobacco; teas; herbs;
carbonized or pyrolyzed components; inorganic filler components;
and any combination thereof. Tobacco may have the form of tobacco
lamina in cut filler form, processed tobacco stems, reconstituted
tobacco filler, volume expanded tobacco filler, or the like.
Tobacco, and other grown smokeable substances, may be grown in the
United States, or may be grown in a jurisdiction outside the United
States.
[0103] In some embodiments, a smokeable substance may be in a
column format, e.g., a tobacco column. As used herein, the term
"tobacco column" refers to the blend of tobacco, and optionally
other ingredients and flavorants that may be combined to produce a
tobacco-based smokeable article, such as a cigarette or cigar. In
some embodiments, the tobacco column may comprise ingredients
selected from the group consisting of: tobacco, sugar (such as
sucrose, brown sugar, invert sugar, or high fructose corn syrup),
propylene glycol, glycerol, cocoa, cocoa products, carob bean gums,
carob bean extracts, and any combination thereof. In still other
embodiments, the tobacco column may further comprise flavorants,
aromas, menthol, licorice extract, diammonium phosphate, ammonium
hydroxide, and any combination thereof. In some embodiments,
tobacco columns may comprise additives. In some embodiments,
tobacco columns may comprise at least one bendable element.
[0104] Suitable housings may include, but not be limited to,
cigarettes, cigarette holders, cigars, cigar holders, pipes, water
pipes, hookahs, electronic smoking devices, roll-your-own
cigarettes, roll-your-own cigars, papers, and any combination
thereof.
[0105] Packaging porous mass sections, porous masses, and/or porous
mass lengths (wrapped or otherwise) may include, but not be limited
to, placing in trays or boxes or protective containers, e.g., trays
typically used for packaging and transporting cigarette filter
rods.
[0106] In some embodiments, the present invention provides a pack
of filters and/or smoking devices with filters that comprises
porous mass sections, porous masses, and/or porous mass lengths
(wrapped or otherwise). The pack may be a hinge-lid pack, a
slide-and-shell pack, a hard-cup pack, a soft-cup pack, a plastic
bag, or any other suitable pack container. In some embodiments, the
packs may have an outer wrapping, such as a polypropylene wrapper,
and optionally a tear tab. In some embodiments, the filters and/or
smoking devices may be sealed as a bundle inside a pack. A bundle
may contain a number of filters and/or smoking devices, for
example, 20 or more. However, a bundle may include a single filter
and/or smoking device, in some embodiments, such as exclusive
filter and/or smoking device embodiments like those for individual
sale, or a filter and/or smoking device comprising a specific
spice, like vanilla, clove, or cinnamon.
[0107] In some embodiments, the present invention provides a carton
of smoking device packs that includes at least one pack of smoking
devices that includes at least one smoking device with a filter
(multi-segmented or otherwise) that comprises porous mass sections,
porous masses, and/or porous mass lengths (wrapped or otherwise).
In some embodiments, the carton (e.g., a container) has the
physical integrity to contain the weight from the packs of smoking
devices. This may be accomplished through thicker cardstock being
used to form the carton or stronger adhesives being used to bind
elements of the carton.
[0108] Some embodiments may involve shipping porous mass sections,
porous masses, and/or porous mass lengths (wrapped or otherwise).
Said porous mass sections, porous masses, and/or porous mass
lengths (wrapped or otherwise) may be as individuals, as at least a
portion of filters, as at least a portion of smoking devices, in
packs, in carton, in trays, and any combination thereof. Shipping
may be by train, truck, airplane, boat/ship, and any combination
thereof.
[0109] In some embodiments, porous mass sections, porous masses,
and/or porous mass lengths (wrapped or otherwise) may have a void
volume in the range of about 40% to about 90%. In some embodiments,
porous mass sections, porous masses, and/or porous mass lengths
(wrapped or otherwise) may have a void volume of about 60% to about
90%. In some embodiments, porous mass sections, porous masses,
and/or porous mass lengths (wrapped or otherwise) may have a void
volume of about 60% to about 85%. Void volume is the free space
left after accounting for the space taken by the active
particles.
[0110] To determine void volume, although not wishing to be limited
by any particular theory, it is believed that testing indicates
that the final density of the mixture was driven almost entirely by
the active particle; thus the space occupied by the binder
particles was not considered for this calculation. Thus, void
volume, in this context, is calculated based on the space remaining
after accounting for the active particles. To determine void
volume, first the upper and lower diameters based on the mesh size
were averaged for the active particles, and then the volume was
calculated (assuming a spherical shape based on that averaged
diameter) using the density of the active material. Then, the
percentage void volume is calculated as follows:
Void Volume ( % ) = 1 - [ ( porus mass volume , cm 3 ) - ( Weight
of active particles , gm ) ( density of the active particles , gm /
cm 3 ) ] * 100 porus mass volume , cm 3 ##EQU00001##
[0111] In some embodiments, porous mass sections, porous masses,
and/or porous mass lengths (wrapped or otherwise) may have an
encapsulated pressure drop (EPD) in the range of about 0.10 to
about 25 mm of water per mm length of porous mass. In some
embodiments, porous mass sections, porous masses, and/or porous
mass lengths (wrapped or otherwise) may have an EPD in the range of
about 0.10 to about 10 mm of water per mm length of porous mass. In
some embodiments, porous mass sections, porous masses, and/or
porous mass lengths (wrapped or otherwise) may have an EPD of about
2 to about 7 mm of water per mm length of porous mass (or no
greater than 7 mm of water per mm length of porous mass).
[0112] In some embodiments, porous mass sections, porous masses,
and/or porous mass lengths (wrapped or otherwise) may have an
active particle loading of at least about 1 mg/mm, 2 mg/mm, 3
mg/mm, 4 mg/mm, 5 mg/mm, 6 mg/mm, 7 mg/mm, 8 mg/mm, 9 mg/mm, 10
mg/mm, 11 mg/mm, 12 mg/mm, 13 mg/mm, 14 mg/mm, 15 mg/mm, 16 mg/mm,
17 mg/mm, 18 mg/mm, 19 mg/mm, 20 mg/mm, 21 mg/mm, 22 mg/mm, 23
mg/mm, 24 mg/mm, or 25 mg/mm in combination with an EPD of less
than about 20 mm of water or less per mm of length, 19 mm of water
or less per mm of length, 18 mm of water or less per mm of length,
17 mm of water or less per mm of length, 16 mm of water or less per
mm of length, 15 mm of water or less per mm of length, 14 mm of
water or less per mm of length, 13 mm of water or less per mm of
length, 12 mm of water or less per mm of length, 11 mm of water or
less per mm of length, 10 mm of water or less per mm of length, 9
mm of water or less per mm of length, 8 mm of water or less per mm
of length, 7 mm of water or less per mm of length, 6 mm of water or
less per mm of length, 5 mm of water or less per mm of length, 4 mm
of water or less per mm of length, 3 mm of water or less per mm of
length, 2 mm of water or less per mm of length, or 1 mm of water or
less per mm of length.
[0113] By way of example, in some embodiments, porous mass
sections, porous masses, and/or porous mass lengths (wrapped or
otherwise) may have an active particle loading of at least about 1
mg/mm and an EPD of about 20 mm of water or less per mm of length.
In other embodiments, the porous mass may have an active particle
loading of at least about 1 mg/mm and an EPD of about 20 mm of
water or less per mm of length, wherein the active particle is not
carbon. In other embodiments, the porous mass may have an active
particle comprising carbon with a loading of at least 6 mg/mm in
combination with an EPD of 10 mm of water or less per mm of
length.
[0114] In some embodiments, porous mass sections, porous masses,
and/or porous mass lengths (wrapped or otherwise) may be effective
at the removal of components from tobacco smoke, for example, those
in the listing herein. Porous mass sections, porous masses, and/or
porous mass lengths (wrapped or otherwise) may be used to reduce
the delivery of certain tobacco smoke components targeted by the
World Health Organization Framework Convention on Tobacco Control
("WHO FCTC"). By way of nonlimiting example, a porous mass where
activated carbon is used as the active particles can be used to
reduce the delivery of certain tobacco smoke components to levels
below the WHO FCTC recommendations. The components may, in some
embodiments, include, but not be limited to, acetaldehyde,
acrolein, benzene, benzo[a]pyrene, 1,3-butadiene, and formaldehyde.
Porous mass sections, porous masses, and/or porous mass lengths
(wrapped or otherwise) with activated carbon may reduce
acetaldehydes in a smoke stream by about 3.0% to about 6.5%/mm
length of porous mass; acrolein in a smoke stream by about 7.5% to
about 12%/mm length of porous mass; benzene in a smoke stream by
about 5.5% to about 8.0%/mm length of porous mass; benzo[a]pyrene
in a smoke stream by about 9.0% to about 21.0%/mm length of porous
mass; 1,3-butadiene in a smoke stream by about 1.5% to about
3.5%/mm length of porous mass; and formaldehyde in a smoke stream
by about 9.0% to about 11.0%/mm length of porous mass. In another
example, porous mass sections, porous masses, and/or porous mass
lengths (wrapped or otherwise) where an ion exchange resin is used
as the active particles can be used to reduce the delivery of
certain tobacco smoke components to below the WHO recommendations.
In some embodiments, porous mass sections, porous masses, and/or
porous mass lengths (wrapped or otherwise) having an ion exchange
resin may reduce: acetaldehydes in a smoke stream by about 5.0% to
about 7.0%/mm length of porous mass; acrolein in a smoke stream by
about 4.0% to about 6.5%/mm length of porous mass; and formaldehyde
in a smoke stream by about 9.0% to about 11.0%/mm length of porous
mass. One of ordinary skill in the art should understand that the
values reported here relative to the concentration of specific
smoke stream components may vary by test protocol and tobacco
blend. The reductions cited herein refer to carbonyl testing by a
method similar to the CORESTA Recommended Method No. 74,
Determination of Selected Carbonyls in Mainstream Cigarette Smoke
by High Performance Liquid Chromatography, using the Health Canada
Intense Smoking Protocol. The sample cigarettes were prepared from
a US commercial brand by manually replacing the standard cellulose
acetate filter with a dual segmented filter consisting of porous
mass segments and cellulose acetate segments. The length of the
porous mass segment varied between 5 and 15 mm.
[0115] There may be any weight ratio of active particles to binder
particles in the matrix material. In some embodiments, the matrix
material may comprise active particles in an amount ranging from a
lower limit of about 1 wt %, 5 wt %, 10 wt %, 25 wt %, 40 wt %, 50
wt %, 60 wt %, or 75 wt % of the matrix material to an upper limit
of about 99 wt %, 95 wt %, 90 wt %, or 75 wt % of the matrix
material, and wherein the amount of active particles can range from
any lower limit to any upper limit and encompass any subset
therebetween. In some embodiments, the matrix material may comprise
binder particles in an amount ranging from a lower limit of about 1
wt %, 5 wt %, 10 wt %, or 25 wt % of the matrix material to an
upper limit of about 99 wt %, 95 wt %, 90 wt %, 75 wt %, 60 wt %,
50 wt %, 40 wt %, or 25 wt % of the matrix material, and wherein
the amount of binder particles can range from any lower limit to
any upper limit and encompass any subset therebetween.
[0116] The active particles may be any material adapted to enhance
smoke flowing thereover. Adapted to enhance smoke flowing thereover
refers to any material that can remove, reduce, or add components
to a smoke stream. The removal or reduction (or addition) may be
selective. By way of example, in the smoke stream from a cigarette,
compounds such as those shown below in the following listing may be
selectively removed or reduced. This table is available from the
U.S. FDA as a Draft Proposed Initial List of Harmful/Potentially
Harmful Constituents in Tobacco Products, including Tobacco Smoke;
any abbreviations in the below listing are well-known chemicals in
the art. In some embodiments, the active particle may reduce or
remove at least one component selected from the listing of
components in smoke below, including any combination thereof. Smoke
stream components may include, but not be limited to, acetaldehyde,
acetamide, acetone, acrolein, acrylamide, acrylonitrile, aflatoxin
B-1, 4-aminobiphenyl, 1-aminonaphthalene, 2-aminonaphthalene,
ammonia, ammonium salts, anabasine, anatabine, 0-anisidine,
arsenic, A-.alpha.-C, benz[a]anthracene, benz[b]fluoroanthene,
benz[j]aceanthrylene, benz[k]fluoroanthene, benzene, benzo(b)furan,
benzo[a]pyrene, benzo[c]phenanthrene, beryllium, 1,3-butadiene,
butyraldehyde, cadmium, caffeic acid, carbon monoxide, catechol,
chlorinated dioxins/furans, chromium, chrysene, cobalt, coumarin, a
cresol, crotonaldehyde, cyclopenta[c,d]pyrene, dibenz(a,h)acridine,
dibenz(a,j)acridine, dibenz[a,h]anthracene, dibenzo(c,g)carbazole,
dibenzo[a,e]pyrene, dibenzo[a,h]pyrene, dibenzo[a,i]pyrene,
dibenzo[a,l]pyrene, 2,6-dimethylaniline, ethyl carbamate
(urethane), ethylbenzene, ethylene oxide, eugenol, formaldehyde,
furan, glu-P-1, glu-P-2, hydrazine, hydrogen cyanide, hydroquinone,
indeno[1,2,3-cd]pyrene, IQ, isoprene, lead, MeA-a-C, mercury,
methyl ethyl ketone, 5-methylchrysene,
4-(methylnitrosamino)-1-(3-pyridyI)-1-butanone (NNK),
4-(methylnitrosamino)-1-(3-pyridyI)-1-butanol (NNAL), naphthalene,
nickel, nicotine, nitrate, nitric oxide, a nitrogen oxide, nitrite,
nitrobenzene, nitromethane, 2-nitropropane, N-nitrosoanabasine
(NAB), N-nitrosodiethanolamine (NDELA), N-nitrosodiethylamine,
N-nitrosodimethylamine (NDMA), N-nitrosoethylmethylamine,
N-nitrosomorpholine (NMOR), N-nitrosonornicotine (NNN),
N-nitrosopiperidine (NPIP), N-nitrosopyrrolidine (NPYR),
N-nitrososarcosine (NSAR), phenol, PhIP, polonium-210
(radio-isotope), propionaldehyde, propylene oxide, pyridine,
quinoline, resorcinol, selenium, styrene, tar, 2-toluidine,
toluene, Trp-P-1, Trp-P-2, uranium-235 (radio-isotope), uranium-238
(radio-isotope), vinyl acetate, vinyl chloride, and any combination
thereof.
[0117] One example of an active material is activated carbon (or
activated charcoal or active coal). The activated carbon may be of
any activity that is available (e.g., carbon capable of 60%
CCl.sub.4 adsorption). In some embodiments, the active carbon may
be nano-scaled carbon particle, such as carbon nanotubes of any
number of walls, carbon nanohorns, bamboo-like carbon
nanostructures, fullerenes and fullerene aggregates, and graphene
including few layer graphene and oxidized graphene. Other examples
of such materials include ion exchange resins, desiccants,
silicates, molecular sieves, silica gels, activated alumina,
zeolites, perlite, sepiolite, Fuller's Earth, magnesium silicate,
metal oxides (e.g., iron oxide and iron oxide nanoparticles like
about 12 nm Fe.sub.3O.sub.4), nanoparticles (e.g., metal
nanoparticles like gold and silver; metal oxide nanoparticles like
alumina; magnetic, paramagnetic, and superparamagnetic
nanoparticles like gadolinium oxide, various crystal structures of
iron oxide like hematite and magnetite, gado-nanotubes, and
endofullerenes like Gd@C.sub.60; and core-shell and onionated
nanoparticles like gold and silver nanoshells, onionated iron
oxide, and other nanoparticles or microparticles with an outer
shell of any of said materials) and any combination of the
foregoing (including activated carbon). It should be noted that
nanoparticles include nanorods, nanospheres, nanorices, nanowires,
nanostars (like nanotripods and nanotetrapods), hollow
nanostructures, hybrid nanostructures that are two or more
nanoparticles connected as one, and non-nano particles with
nano-coatings or nano-thick walls. It should be further noted that
nanoparticles include the functionalized derivatives of
nanoparticles including, but not limited to, nanoparticles that
have been functionalized covalently and/or non-covalently, e.g.,
pi-stacking, physisorption, ionic association, van der Waals
association, and the like. Suitable functional groups may include,
but not be limited to, moieties comprising amines (1.degree.,
2.degree., or 3.degree.), amides, carboxylic acids, aldehydes,
ketones, ethers, esters, peroxides, silyls, organosilanes,
hydrocarbons, aromatic hydrocarbons, and any combination thereof;
polymers; chelating agents like ethylenediamine tetraacetate,
diethylenetriaminepentaacetic acid, triglycollamic acid, and a
structure comprising a pyrrole ring; and any combination thereof.
Functional groups may enhance removal of smoke components and/or
enhance incorporation of nanoparticles into a porous mass. Ion
exchange resins include, for example, a polymer with a backbone,
such as styrene-divinyl benzene (DVB) copolymer, acrylates,
methacrylates, phenol formaldehyde condensates, and epichlorohydrin
amine condensates; and a plurality of electrically-charged
functional groups attached to the polymer backbone. In some
embodiments, the active particles are a combination of various
active particles. In some embodiments, the porous mass may comprise
multiple active particles. In some embodiments, an active particle
may comprise at least one element selected from the group of active
particles disclosed herein. It should be noted that "element" is
being used as a general term to describe items in a list. In some
embodiments, the active particles are combined with at least one
flavorant.
[0118] Suitable active particles may have at least one dimension of
about less than one nanometer, such as graphene, to as large as a
particle having a diameter of about 5000 microns. Active particles
may range from a lower size limit in at least one dimension of
about: 0.1 nanometers, 0.5 nanometers, 1 nanometer, 10 nanometers,
100 nanometers, 500 nanometers, 1 micron, 5 microns, 10 microns, 50
microns, 100 microns, 150 microns, 200 microns, or 250 microns. The
active particles may range from an upper size limit in at least one
dimension of about: 5000 microns, 2000 microns, 1000 microns, 900
microns, 700 microns, 500 microns, 400 microns, 300 microns, 250
microns, 200 microns, 150 microns, 100 microns, 50 microns, 10
microns, or 500 nanometers. Any combination of lower limits and
upper limits above may be suitable for use in the present
invention, wherein the selected maximum size is greater than the
selected minimum size. In some embodiments, the active particles
may be a mixture of particle sizes ranging from the above lower and
upper limits. In some embodiments, the size of the active particles
may be polymodal.
[0119] The binder particles may be any suitable thermoplastic
binder particles. In one embodiment, the binder particles exhibit
virtually no flow at its melting temperature. This means a material
that when heated to its melting temperature exhibits little to no
polymer flow. Materials meeting these criteria include, but are not
limited to, ultrahigh molecular weight polyethylene, very high
molecular weight polyethylene, high molecular weight polyethylene,
and combinations thereof. In one embodiment, the binder particles
have a melt flow index (MFI, ASTM D1238) of less than or equal to
about 3.5 g/10 min at 190.degree. C. and 15 kg (or about 0-3.5 g/10
min at 190.degree. C. and 15 kg). In another embodiment, the binder
particles have a melt flow index (MFI) of less than or equal to
about 2.0 g/10min at 190.degree. C. and 15 Kg (or about 0-2.0 g/10
min at 190.degree. C. and 15 kg). One example of such a material is
ultra high molecular weight polyethylene, UHMWPE (which has no
polymer flow, MFI of about 0, at 190.degree. C. and 15 kg, or an
MFI of about 0-1.0 at 190.degree. C. and 15 kg); another material
may be very high molecular weight polyethylene, VHMWPE (which may
have MFIs in the range of, for example, about 1.0-2.0 g/10 min at
190.degree. C. and 15 kg); or high molecular weight polyethylene,
HMWPE (which may have MFIs of, for example, about 2.0-3.5 g/10min
at 190.degree. C. and 15 kg). In some embodiments, it may be
preferable to use a mixture of binder particles having different
molecular weights and/or different melt flow indexes.
[0120] In terms of molecular weight, "ultra-high molecular weight
polyethylene" as used herein refers to polyethylene compositions
with weight-average molecular weight of at least about
3.times.10.sup.6 g/mol. In some embodiments, the molecular weight
of the ultra-high molecular weight polyethylene composition is
between about 3.times.10.sup.6 g/mol and about 30.times.10.sup.6
g/mol, or between about 3.times.10.sup.6 g/mol and about
20.times.10.sup.6 g/mol, or between about 3.times.10.sup.6 g/mol
and about 10.times.10.sup.6 g/mol, or between about
3.times.10.sup.6 g/mol and about 6.times.10.sup.6 g/mol. "Very-high
molecular weight polyethylene" refers to polyethylene compositions
with a weight average molecular weight of less than about
3.times.10.sup.6 g/mol and more than about 1.times.10.sup.6 g/mol.
In some embodiments, the molecular weight of the very-high
molecular weight polyethylene composition is between about
2.times.10.sup.6 g/mol and less than about 3.times.10.sup.6 g/mol.
"High molecular weight polyethylene" refers to polyethylene
compositions with weight-average molecular weight of at least about
3.times.10.sup.5 g/mol to 1.times.10.sup.6 g/mol. For purposes of
the present specification, the molecular weights referenced herein
are determined in accordance with the Margolies equation
("Margolies molecular weight").
[0121] Suitable polyethylene materials are commercially available
from several sources including GUR.RTM. UHMWPE from Ticona Polymers
LLC, a division of Celanese Corporation of Dallas, Tex., and DSM
(Netherland), Braskem (Brazil), Beijing Factory No. 2 (BAAF),
Shanghai Chemical, and Qilu (People's Republic of China), Mitsui
and Asahi (Japan). Specifically, GUR.RTM. polymers may include:
GUR.RTM. 2000 series (2105, 2122, 2122-5, 2126), GUR.RTM. 4000
series (4120, 4130, 4150, 4170, 4012, 4122-5, 4022-6,
4050-3/4150-3), GUR.RTM. 8000 series (8110, 8020), GUR.RTM. X
series (X143, X184, X168, X172, X192).
[0122] One example of a suitable polyethylene material is that
having an intrinsic viscosity in the range of about 5 dl/g to about
30 dl/g and a degree of crystallinity of about 80% or more as
described in U.S. Patent Application Publication No. 2008/0090081.
Another example of a suitable polyethylene material is that having
a molecular weight in the range of about 300,000 g/mol to about
2,000,000 g/mol as determined by ASTM-D 4020, an average particle
size, D.sub.50, between about 300 .mu.m and about 1500 .mu.m, and a
bulk density between about 0.25 g/ml and about 0.5 g/ml as
described in U.S. Provisional Application No. 61/330,535 filed May
3, 2010.
[0123] The binder particles may assume any shape. Such shapes
include spherical, hyperion, asteroidal, chrondular or
interplanetary dust-like, granulated, potato, irregular, or
combinations thereof. In preferred embodiments, the binder
particles suitable for use in the present invention are
non-fibrous. In some embodiments the binder particles are in the
form of a powder, pellet, or particulate. In some embodiments, the
binder particles are a combination of various binder particles.
[0124] In some embodiments, the binder particles may range from a
lower size limit in at least one dimension of about: 0.1
nanometers, 0.5 nanometers, 1 nanometer, 10 nanometers, 100
nanometers, 500 nanometers, 1 micron, 5 microns, 10 microns, 50
microns, 100 microns, 150 microns, 200 microns, and 250 microns.
The binder particles may range from an upper size limit in at least
one dimension of about: 5000 microns, 2000 microns, 1000 microns,
900 microns, 700 microns, 500 microns, 400 microns, 300 microns,
250 microns, 200 microns, 150 microns, 100 microns, 50 microns, 10
microns, and 500 nanometers. Any combination of lower limits and
upper limits above may be suitable for use in the present
invention, wherein the selected maximum size is greater than the
selected minimum size. In some embodiments, the binder particles
may be a mixture of particle sizes ranging from the above lower and
upper limits. In some embodiments, smaller diameter particles may
be advantageous in faster heating for binding of the binder
particles together, which may be especially useful in
high-throughput processes for producing porous masses described
herein.
[0125] While the ratio of binder particle size to active particle
size can include any iteration as dictated by the size ranges for
each described herein, specific size ratios may be advantageous for
specific applications and/or products. By way of nonlimiting
example, in smoking device filters the sizes of the active
particles and binder particles should be such that the EPD allows
for drawing fluids through the porous mass. In some embodiments,
the ratio of binder particle size to active particle size may range
from about 10:1 to about 1:10, or more preferably range from about
1:1.5 to about 1:4.
[0126] Additionally, the binder particles may have a bulk density
in the range of about 0.10 g/cm.sup.3 to about 0.55 g/cm.sup.3. In
another embodiment, the bulk density may be in the range of about
0.17 g/cm.sup.3 to about 0.50 g/cm.sup.3. In yet another
embodiment, the bulk density may be in the range of about 0.20
g/cm.sup.3 to about 0.47 g/cm.sup.3.
[0127] In addition to the foregoing binder particles, other
conventional thermoplastics may be used as binder particles. Such
thermoplastics include, but are not limited to, polyolefins,
polyesters, polyamides (or nylons), polyacrylics, polystyrenes,
polyvinyls, polytetrafluoroethylene (PTFE), polyether ether ketone
(PEEK), any copolymer thereof, any derivative thereof, and any
combination thereof. Non-fibrous plasticized cellulose derivatives
may also be suitable for use as binder particles in the present
invention. Examples of suitable polyolefins include, but are not
limited to, polyethylene, polypropylene, polybutylene,
polymethylpentene, any copolymer thereof, any derivative thereof,
any combination thereof, and the like. Examples of suitable
polyethylenes further include low-density polyethylene, linear
low-density polyethylene, high-density polyethylene, any copolymer
thereof, any derivative thereof, any combination thereof, and the
like. Examples of suitable polyesters include polyethylene
terephthalate, polybutylene terephthalate, polycyclohexylene
dimethylene terephthalate, polytrimethylene terephthalate, any
copolymer thereof, any derivative thereof, any combination thereof,
and the like. Examples of suitable polyacrylics include, but are
not limited to, polymethyl methacrylate, any copolymer thereof, any
derivative thereof, any combination thereof, and the like. Examples
of suitable polystyrenes include, but are not limited to,
polystyrene, acrylonitrile-butadiene-styrene,
styrene-acrylonitrile, styrene-butadiene, styrene-maleic anhydride,
any copolymer thereof, any derivative thereof, any combination
thereof, and the like. Examples of suitable polyvinyls include, but
are not limited to, ethylene vinyl acetate, ethylene vinyl alcohol,
polyvinyl chloride, any copolymer thereof, any derivative thereof,
any combination thereof, and the like. Examples of suitable
cellulosics include, but are not limited to, cellulose acetate,
cellulose acetate butyrate, plasticized cellulosics, cellulose
propionate, ethyl cellulose, any copolymer thereof, any derivative
thereof, any combination thereof, and the like. In some
embodiments, a binder particle may be any copolymer, any
derivative, and any combination of the above listed binders.
[0128] In some embodiments, matrix materials and/or porous masses
may comprise active particles, binder particles, and additives. In
some embodiments, the matrix material or porous masses may comprise
additives in an amount ranging from a lower limit of about 0.01 wt
%, 0.05 wt %, 0.1 wt %, 1 wt %, 5 wt %, or 10 wt % of the matrix
material or porous masses to an upper limit of about 25 wt %, 15 wt
%, 10 wt %, 5 wt %, or 1 wt % of the matrix material or porous
masses, and wherein the amount of additives can range from any
lower limit to any upper limit and encompass any subset
therebetween. It should be noted that porous masses as referenced
herein include porous mass lengths, porous masses, and porous mass
sections (wrapped or otherwise).
[0129] Suitable additives may include, but not be limited to,
active compounds, ionic resins, zeolites, nanoparticles, microwave
enhancement additives, ceramic particles, glass beads, softening
agents, plasticizers, pigments, dyes, flavorants, aromas,
controlled release vesicles, adhesives, tackifiers, surface
modification agents, vitamins, peroxides, biocides, antifungals,
antimicrobials, antistatic agents, flame retardants, degradation
agents, and any combination thereof.
[0130] Suitable active compounds may be compounds and/or molecules
suitable for removing components from a smoke stream including, but
not limited to, malic acid, potassium carbonate, citric acid,
tartaric acid, lactic acid, ascorbic acid, polyethyleneimine,
cyclodextrin, sodium hydroxide, sulphamic acid, sodium sulphamate,
polyvinyl acetate, carboxylated acrylate, and any combination
thereof. It should be noted that an active particle may also be
considered an active compound, and vice versa. By way of
nonlimiting example, fullerenes and some carbon nanotubes may be
considered to be a particulate and a molecule.
[0131] Suitable ionic resins may include, but not be limited to,
polymers with a backbone, such as styrene-divinyl benzene (DVB)
copolymer, acrylates, methacrylates, phenol formaldehyde
condensates, and epichlorohydrin amine condensates; a plurality of
electrically charged functional groups attached to the polymer
backbone; and any combination thereof.
[0132] Zeolites may include crystalline aluminosilicates having
pores, e.g., channels, or cavities of uniform, molecular-sized
dimensions. Zeolites may include natural and synthetic materials.
Suitable zeolites may include, but not be limited to, zeolite BETA
(Na.sub.7(Al.sub.7Si.sub.57O.sub.128) tetragonal), zeolite ZSM-5
(Na.sub.n(Al.sub.nSi.sub.96-nO.sub.192) 16 H.sub.2O, with n<27),
zeolite A, zeolite X, zeolite Y, zeolite K-G, zeolite ZK-5, zeolite
ZK-4, mesoporous silicates, SBA-15, MCM-41, MCM48 modified by
3-aminopropylsilyl groups, alumino-phosphates, mesoporous
aluminosilicates, other related porous materials (e.g., such as
mixed oxide gels), and any combination thereof.
[0133] Suitable nanoparticles may include, but not be limited to,
nano-scaled carbon particles like carbon nanotubes of any number of
walls, carbon nanohorns, bamboo-like carbon nanostructures,
fullerenes and fullerene aggregates, and graphene including few
layer graphene and oxidized graphene; metal nanoparticles like gold
and silver; metal oxide nanoparticles like alumina, silica, and
titania; magnetic, paramagnetic, and superparamagnetic
nanoparticles like gadolinium oxide, various crystal structures of
iron oxide like hematite and magnetite, about 12 nm
Fe.sub.3O.sub.4, gado-nanotubes, and endofullerenes like
Gd@C.sub.60; and core-shell and onionated nanoparticles like gold
and silver nanoshells, onionated iron oxide, and other
nanoparticles or microparticles with an outer shell of any of said
materials) and any combination of the foregoing (including
activated carbon). It should be noted that nanoparticles may
include nanorods, nanospheres, nanorices, nanowires, nanostars
(like nanotripods and nanotetrapods), hollow nanostructures, hybrid
nanostructures that are two or more nanoparticles connected as one,
and non-nano particles with nano-coatings or nano-thick walls. It
should be further noted that nanoparticles may include the
functionalized derivatives of nanoparticles including, but not
limited to, nanoparticles that have been functionalized covalently
and/or non-covalently, e.g., pi-stacking, physisorption, ionic
association, van der Waals association, and the like. Suitable
functional groups may include, but not be limited to, moieties
comprising amines (1.degree., 2.degree., or 3.degree.), amides,
carboxylic acids, aldehydes, ketones, ethers, esters, peroxides,
silyls, organosilanes, hydrocarbons, aromatic hydrocarbons, and any
combination thereof; polymers; chelating agents like
ethylenediamine tetraacetate, diethylenetriaminepentaacetic acid,
triglycollamic acid, and a structure comprising a pyrrole ring; and
any combination thereof. Functional groups may enhance removal of
smoke components and/or enhance incorporation of nanoparticles into
a porous mass.
[0134] Suitable microwave enhancement additives may include, but
not be limited to, microwave responsive polymers, carbon particles,
fullerenes, carbon nanotubes, metal nanoparticles, water, and the
like, and any combination thereof.
[0135] Suitable ceramic particles may include, but not be limited
to, oxides (e.g., silica, titania, alumina, beryllia, ceria, and
zirconia), nonoxides (e.g., carbides, borides, nitrides, and
silicides), composites thereof, and any combination thereof.
Ceramic particles may be crystalline, non-crystalline, or
semi-crystalline.
[0136] As used herein, pigments refer to compounds and/or particles
that impart color and are incorporated throughout the matrix
material and/or a component thereof. Suitable pigments may include,
but not be limited to, titanium dioxide, silicon dioxide,
tartrazine, E102, phthalocyanine blue, phthalocyanine green,
quinacridones, perylene tetracarboxylic acid di-imides, dioxazines,
perinones disazo pigments, anthraquinone pigments, carbon black,
titanium dioxide, metal powders, iron oxide, ultramarine, and any
combination thereof.
[0137] As used herein, dyes refer to compounds and/or particles
that impart color and are a surface treatment. Suitable dyes may
include, but not be limited to, CARTASOL.RTM. dyes (cationic dyes,
available from Clariant Services) in liquid and/or granular form
(e.g., CARTASOL.RTM. Brilliant Yellow K-6G liquid, CARTASOL.RTM.
Yellow K-4GL liquid, CARTASOL.RTM. Yellow K-GL liquid,
CARTASOL.RTM. Orange K-3GL liquid, CARTASOL.RTM. Scarlet K-2GL
liquid, CARTASOL.RTM. Red K-3BN liquid, CARTASOL.RTM. Blue K-5R
liquid, CARTASOL.RTM. Blue K-RL liquid, CARTASOL.RTM. Turquoise
K-RL liquid/granules, CARTASOL.RTM. Brown K-BL liquid),
FASTUSOL.RTM. dyes (an auxochrome, available from BASF) (e.g.,
Yellow 3GL, Fastusol C Blue 74L).
[0138] Suitable flavorants may be any flavorant suitable for use in
smoking device filters including those that impart a taste and/or a
flavor to the smoke stream. Suitable flavorants may include, but
not be limited to, organic material (or naturally flavored
particles), carriers for natural flavors, carriers for artificial
flavors, and any combination thereof. Organic materials (or
naturally flavored particles) include, but are not limited to,
tobacco, cloves (e.g., ground cloves and clove flowers), cocoa,
coffee, teas, and the like. Natural and artificial flavors may
include, but are not limited to, menthol, cloves, cherry,
chocolate, orange, mint, mango, vanilla, cinnamon, tobacco, and the
like. Such flavors may be provided by menthol, anethole (licorice),
anisole, limonene (citrus), eugenol (clove), and the like, and any
combination thereof. In some embodiments, more than one flavorant
may be used including any combination of the flavorants provided
herein. These flavorants may be placed in the tobacco column or in
a section of a filter. Additionally, in some embodiments, the
porous masses of the present invention may comprise a flavorant.
The amount to include will depend on the desired level of flavor in
the smoke taking into account all filter sections, the length of
the smoking device, the type of smoking device, the diameter of the
smoking device, as well as other factors known to those of skill in
the art.
[0139] Suitable aromas may include, but not be limited to, methyl
formate, methyl acetate, methyl butyrate, ethyl acetate, ethyl
butyrate, isoamyl acetate, pentyl butyrate, pentyl pentanoate,
octyl acetate, myrcene, geraniol, nerol, citral, citronellal,
citronellol, linalool, nerolidol, limonene, camphor, terpineol,
alpha-ionone, thujone, benzaldehyde, eugenol, cinnamaldehyde, ethyl
maltol, vanilla, anisole, anethole, estragole, thymol, furaneol,
methanol, spices, spice extracts, herb extracts, essential oils,
smelling salts, volatile organic compounds, volatile small
molecules, methyl formate, methyl acetate, methyl butyrate, ethyl
acetate, ethyl butyrate, isoamyl acetate, pentyl butyrate, pentyl
pentanoate, octyl acetate, myrcene, geraniol, nerol, citral,
citronellal, citronellol, linalool, nerolidol, limonene, camphor,
terpineol, alpha-ionone, thujone, benzaldehyde, eugenol,
cinnamaldehyde, ethyl maltol, vanilla, anisole, anethole,
estragole, thymol, furaneol, methanol, rosemary, lavender, citrus,
freesia, apricot blossoms, greens, peach, jasmine, rosewood, pine,
thyme, oakmoss, musk, vetiver, myrrh, blackcurrant, bergamot,
grapefruit, acacia, passiflora, sandalwood, tonka bean, mandarin,
neroli, violet leaves, gardenia, red fruits, ylang-ylang, acacia
farnesiana, mimosa, tonka bean, woods, ambergris, daffodil,
hyacinth, narcissus, black currant bud, iris, raspberry, lily of
the valley, sandalwood, vetiver, cedarwood, neroli, bergamot,
strawberry, carnation, oregano, honey, civet, heliotrope, caramel,
coumarin, patchouli, dewberry, helonial, bergamot, hyacinth,
coriander, pimento berry, labdanum, cassie, bergamot, aldehydes,
orchid, amber, benzoin, orris, tuberose, palmarosa, cinnamon,
nutmeg, moss, styrax, pineapple, bergamot, foxglove, tulip,
wisteria, clematis, ambergris, gums, resins, civet, peach, plum,
castoreum, myrrh, geranium, rose violet, jonquil, spicy carnation,
galbanum, hyacinth, petitgrain, iris, hyacinth, honeysuckle,
pepper, raspberry, benzoin, mango, coconut, hesperides, castoreum,
osmanthus, mousse de chene, nectarine, mint, anise, cinnamon,
orris, apricot, plumeria, marigold, rose otto, narcissus, tolu
balsam, frankincense, amber, orange blossom, bourbon vetiver,
opopanax, white musk, papaya, sugar candy, jackfruit, honeydew,
lotus blossom, muguet, mulberry, absinthe, ginger, juniper berries,
spicebush, peony, violet, lemon, lime, hibiscus, white rum, basil,
lavender, balsamics, fo-ti-tieng, osmanthus, karo karunde, white
orchid, calla lilies, white rose, rhubrum lily, tagetes, ambergris,
ivy, grass, seringa, spearmint, clary sage, cottonwood, grapes,
brimbelle, lotus, cyclamen, orchid, glycine, tiare flower, ginger
lily, green osmanthus, passion flower, blue rose, bay rum, cassie,
African tagetes, Anatolian rose, Auvergne narcissus, British broom,
British broom chocolate, Bulgarian rose, Chinese patchouli, Chinese
gardenia, Calabrian mandarin, Comoros Island tuberose, Ceylonese
cardamom, Caribbean passion fruit, Damascena rose, Georgia peach,
white Madonna lily, Egyptian jasmine, Egyptian marigold, Ethiopian
civet, Farnesian cassie, Florentine iris, French jasmine, French
jonquil, French hyacinth, Guinea oranges, Guyana wacapua, Grasse
petitgrain, Grasse rose, Grasse tuberose, Haitian vetiver, Hawaiian
pineapple, Israeli basil, Indian sandalwood, Indian Ocean vanilla,
Italian bergamot, Italian iris, Jamaican pepper, May rose,
Madagascar ylang-ylang, Madagascar vanilla, Moroccan jasmine,
Moroccan rose, Moroccan oakmoss, Moroccan orange blossom, Mysore
sandalwood, Oriental rose, Russian leather, Russian coriander,
Sicilian mandarin, South African marigold, South American tonka
bean, Singapore patchouli, Spanish orange blossom, Sicilian lime,
Reunion Island vetiver, Turkish rose, Thai benzoin, Tunisian orange
blossom, Yugoslavian oakmoss, Virginian cedarwood, Utah yarrow,
West Indian rosewood, and the like, and any combination
thereof.
[0140] Suitable tackifiers may include, but not be limited to,
methylcellulose, ethylcellulose, hydroxyethylcellulose, carboxy
methylcellulose, carboxy ethylcellulose, water-soluble cellulose
acetate, amides, diamines, polyesters, polycarbonates,
silyl-modified polyamide compounds, polycarbamates, urethanes,
natural resins, shellacs, acrylic acid polymers,
2-ethylhexylacrylate, acrylic acid ester polymers, acrylic acid
derivative polymers, acrylic acid homopolymers, anacrylic acid
ester homopolymers, poly(methyl acrylate), poly(butyl acrylate),
poly(2-ethylhexyl acrylate), acrylic acid ester co-polymers,
methacrylic acid derivative polymers, methacrylic acid
homopolymers, methacrylic acid ester homopolymers, poly(methyl
methacrylate), poly(butyl methacrylate), poly(2-ethylhexyl
methacrylate), acrylamido-methyl-propane sulfonate polymers,
acrylamido-methyl-propane sulfonate derivative polymers,
acrylamido-methyl-propane sulfonate co-polymers, acrylic
acid/acrylamido-methyl-propane sulfonate co-polymers, benzyl coco
di-(hydroxyethyl) quaternary amines, p-T-amyl-phenols condensed
with formaldehyde, dialkyl amino alkyl (meth)acrylates,
acrylamides, N-(dialkyl amino alkyl) acrylamide, methacrylamides,
hydroxy alkyl (meth)acrylates, methacrylic acids, acrylic acids,
hydroxyethyl acrylates, and the like, any derivative thereof, and
any combination thereof.
[0141] Suitable vitamins may include, but not be limited to,
vitamin A, vitamin B1, vitamin B2, vitamin C, vitamin D, vitamin E,
and any combination thereof.
[0142] Suitable antimicrobials may include, but not be limited to,
anti-microbial metal ions, chlorhexidine, chlorhexidine salt,
triclosan, polymoxin, tetracycline, amino glycoside (e.g.,
gentamicin), rifampicin, bacitracin, erythromycin, neomycin,
chloramphenicol, miconazole, quinolone, penicillin, nonoxynol 9,
fusidic acid, cephalosporin, mupirocin, metronidazolea secropin,
protegrin, bacteriolcin, defensin, nitrofurazone, mafenide,
acyclovir, vanocmycin, clindamycin, lincomycin, sulfonamide,
norfloxacin, pefloxacin, nalidizic acid, oxalic acid, enoxacin
acid, ciprofloxacin, polyhexamethylene biguanide (PHMB), PHMB
derivatives (e.g., biodegradable biguanides like polyethylene
hexaniethylene biguanide (PEHMB)), clilorhexidine gluconate,
chlorohexidine hydrochloride, ethylenediaminetetraacetic acid
(EDTA), EDTA derivatives (e.g., disodium EDTA or tetrasodium EDTA),
the like, and any combination thereof.
[0143] Antistatic agents may, in some embodiments, comprise any
suitable anionic, cationic, amphoteric or nonionic antistatic
agent. Anionic antistatic agents may generally include, but not be
limited to, alkali sulfates, alkali phosphates, phosphate esters of
alcohols, phosphate esters of ethoxylated alcohols, and any
combination thereof. Examples may include, but not be limited to,
alkali neutralized phosphate ester (e.g., TRYFAC.RTM. 5559 or
TRYFRAC.RTM. 5576, available from Henkel Corporation, Mauldin,
S.C.). Cationic antistatic agents may generally include, but not be
limited to, quaternary ammonium salts and imidazolines which
possess a positive charge. Examples of nonionics include the
poly(oxyalkylene) derivatives, e.g., ethoxylated fatty acids like
EMEREST.RTM. 2650 (an ethoxylated fatty acid, available from Henkel
Corporation, Mauldin, S.C.), ethoxylated fatty alcohols like
TRYCOL.RTM. 5964 (an ethoxylated lauryl alcohol, available from
Henkel Corporation, Mauldin, S.C.), ethoxylated fatty amines like
TRYMEEN.RTM. 6606 (an ethoxylated tallow amine, available from
Henkel Corporation, Mauldin, S.C.), alkanolamides like EMID.RTM.
6545 (an oleic diethanolamine, available from Henkel Corporation,
Mauldin, S.C.), and any combination thereof. Anionic and cationic
materials tend to be more effective antistatic agents.
[0144] It should be noted that while porous masses, and the like,
are discussed herein primarily for smoking device filters, porous
masses, and the like, may be used as fluid filters (or parts
thereof) in other applications including, but not limited to,
liquid filtration, water purification, air filters in motorized
vehicles, air filters in medical devices, air filters for household
use, and the like. One skilled in the arts, with the benefit of
this disclosure, should understand the necessary modification
and/or limitations to adapt this disclosure for other filtration
applications, e.g., size, shape, size ratio of matrix material
components, and composition of matrix material components. By way
of nonlimiting example, matrix materials could be molded to other
shapes like hollow cylinders for a concentric water filter
configuration or pleated sheets for an air filter.
[0145] In some embodiments, a system may include a material path
with a mold cavity disposed along the material path, at least one
hopper before at least a portion of the mold cavity for feeding a
matrix material to the material path, a heat source in thermal
communication with at least a first portion of the material path,
and a cutter disposed along the material path after the first
portion of the material path.
[0146] Some embodiments may include continuously introducing a
matrix material into a mold cavity and disposing a release wrapper
as a liner of the mold cavity. Further, said embodiments may
include heating at least a portion of the matrix material so as to
bind the matrix material at a plurality of contact points thereby
forming a porous mass length and cutting the porous mass length
radially thereby yielding a porous mass.
[0147] Some embodiments may include continuously introducing a
matrix material into a mold cavity, heating at least a portion of
the matrix material so as to bind the matrix material at a
plurality of contact points thereby forming a porous mass length,
and extruding the porous mass length through a die.
[0148] In some embodiments, a system may include a mold cavity
comprising at least two mold cavity parts where a first conveyer
includes a first mold cavity part and a second conveyer include a
second mold cavity part. Said first conveyer and second conveyer
may be capable of bringing together the first mold cavity part and
the second mold cavity part to form the mold cavity and then
separating the first mold cavity part from the second mold cavity
part in a continuous fashion. The system may further include a
hopper capable for filling the mold cavity with a matrix material
and a heat source in thermal communication with at least a first
portion of the mold cavity for transforming the matrix material
into a porous mass.
[0149] Some embodiments may include introducing a matrix material
into a plurality of mold cavities and heating the matrix material
in the mold cavities so as to bind the matrix material at a
plurality of contact points, thereby forming a porous mass.
[0150] To facilitate a better understanding of the present
invention, the following examples of representative embodiments are
given. In no way should the following examples be read to limit, or
to define, the scope of the invention.
EXAMPLES
Example 1
[0151] To measure integrity, samples are placed in a French square
glass bottle and shaken vigorously using a wrist action shaker for
5 minutes. Upon completion, the weight of the samples before and
after shaking are compared. The difference is converted to a
percent loss value. This test simulates deterioration under extreme
circumstances. Less than 2% weight loss is assumed to be acceptable
quality.
[0152] Porous mass samples were produced with GUR 2105 with carbon
additive and GUR X192 with carbon additive were produced both with
and without paper wrappings. Said samples were cylinders measuring
8 mm.times.20 mm. The results of the integrity test are given below
in Table 1.
TABLE-US-00001 TABLE 1 Carbon:GUR Percent Loss Percent Loss GUR
Ratio (with paper) (no paper) 2105 85:15 0.94% 2.64% 2105 80:20
0.59% 3.45% 2105 75:25 0.23% 0.57% 2105 70:30 0.14% 1.00% X192
80:20 34.51% 60.89% X192 75:25 13.88% 43.78% X192 70:30 8.99%
14.33% plasticized 4.01 mg/mm 0.98% n/a carbon-on- carbon tow
filter
[0153] This example demonstrates that increasing the percent of
binder (GUR) in the porous mass and including a wrapper (paper)
enhances the integrity of the porous mass. Further, porous masses
can be designed to have comparable integrity to a Dalmatian filter
(plasticized carbon-on-tow filter), which is used for increased
removal of smoke components.
Example 2
[0154] To measure the amount of particles released when a fluid is
drawn through a filter (or porous mass), samples are dry puffed and
the particles released are collected on a Cambridge pad.
[0155] The particle release characteristics of porous masses were
compared to a Dalmatian filter (plasticized carbon-on-tow filter).
Samples were cylinders measuring 8 mm.times.20 mm of (1) a porous
mass with 333 mg of carbon, (2) a porous mass with 338 mg of carbon
having been water washed, and (3) a Dalmatian filter with 74 mg of
carbon. Table 2 below shows the results of the particle release
test.
TABLE-US-00002 TABLE 2 Initial Carbon mg Carbon/ Carbon mg Carbon
Loss/ Loading mm filter Loss g Initial Carbon Sample (mg) length
(mg) Loading porous mass 333 16.65 0.18 0.53 washed 338 16.9 0.073
0.22 porous mass Dalmatian 74 3.7 0.15 2.07 filter
[0156] This example demonstrates that porous masses have comparable
particle amounts that are released upon drawing as compared to
Dalmatian filters even with many times more carbon loading, 4.5
times more in this example. Further, particle release can be
mitigated with porous masses with treatments like washing. Other
mitigating steps could be increasing the binder concentration in
the porous mass, increasing the degree of mechanical binding in the
porous mass (e.g., by increasing the time at binding temperatures),
optimizing the size and shape of the additive (e.g., carbon), and
the like.
Example 3
[0157] A matrix material of 80% carbon (PICATIF, 60% active carbon
available from Jacobi) and 20% GUR.RTM. 2105 were mixed and poured
into paper tubes plugged at one end. The filled tubes were placed
irradiated for 75 seconds in a microwave (about 300 W and about
2.45 GHz). A significant portion of the matrix material had bonded
together and was cut into two sections, 17 mm and 21 mm. The
sections of porous mass were analyzed and demonstrated EPDs of 8.4
mm of water/mm of length and 2.7 mm of water/mm of length,
respectively.
[0158] This example demonstrates the applicability of microwave
irradiation in the production of porous masses and the like. As
discussed above, microwave irradiation may, in some embodiments, be
used in addition to other heating techniques in the formation of
porous masses and the like described herein.
[0159] Therefore, the present invention is well adapted to attain
the ends and advantages mentioned as well as those that are
inherent therein. The particular embodiments disclosed above are
illustrative only, as the present invention may be modified and
practiced in different but equivalent manners apparent to those
skilled in the art having the benefit of the teachings herein.
Furthermore, no limitations are intended to the details of
construction or design herein shown, other than as described in the
claims below. It is therefore evident that the particular
illustrative embodiments disclosed above may be altered, combined,
or modified and all such variations are considered within the scope
and spirit of the present invention. The invention illustratively
disclosed herein suitably may be practiced in the absence of any
element that is not specifically disclosed herein and/or any
optional element disclosed herein. While compositions and methods
are described in terms of "comprising," "containing," or
"including" various components or steps, the compositions and
methods can also "consist essentially of" or "consist of" the
various components and steps. All numbers and ranges disclosed
above may vary by some amount. Whenever a numerical range with a
lower limit and an upper limit is disclosed, any number and any
included range falling within the range is specifically disclosed.
In particular, every range of values (of the form, "from about a to
about b," or, equivalently, "from approximately a to b," or,
equivalently, "from approximately a-b") disclosed herein is to be
understood to set forth every number and range encompassed within
the broader range of values. Also, the terms in the claims have
their plain, ordinary meaning unless otherwise explicitly and
clearly defined by the patentee. Moreover, the indefinite articles
"a" or "an," as used in the claims, are defined herein to mean one
or more than one of the element that it introduces. If there is any
conflict in the usages of a word or term in this specification and
one or more patent or other documents that may be incorporated
herein by reference, the definitions that are consistent with this
specification should be adopted.
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