U.S. patent application number 13/955979 was filed with the patent office on 2014-02-06 for methods of producing filters and filter rods comprising porous masses and articles relating thereto.
This patent application is currently assigned to Celanese Acetate LLC. The applicant listed for this patent is Celanese Acetate LLC. Invention is credited to Davy Biesmans, Charles O. Flotten, Raymond Robertson.
Application Number | 20140034072 13/955979 |
Document ID | / |
Family ID | 50024263 |
Filed Date | 2014-02-06 |
United States Patent
Application |
20140034072 |
Kind Code |
A1 |
Robertson; Raymond ; et
al. |
February 6, 2014 |
Methods of Producing Filters and Filter Rods Comprising Porous
Masses and Articles Relating Thereto
Abstract
Porous masses that comprise a plurality of active particles and
binder particles bound together at a plurality of sintered contact
points may be useful in filters, including articles (like smoking
devices) and methods relating thereto. The production of such
filters may involve the production of filter rods that involves
forming a desired abutting configuration that comprises a plurality
of sections, the plurality of sections comprising at least one
porous mass section and at least one other filter section; securing
the desired abutting configuration so as to yield a segmented
filter rod length; and cutting the segmented filter rod length into
segmented filter rods, wherein the steps of forming, securing, and
cutting are performed so as to produce the segmented filter rods at
a rate of about 25 m/min or greater.
Inventors: |
Robertson; Raymond;
(Blacksburg, VA) ; Biesmans; Davy; (Lanaken,
BE) ; Flotten; Charles O.; (Fort Mill, SC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Celanese Acetate LLC |
Irving |
TX |
US |
|
|
Assignee: |
Celanese Acetate LLC
Irving
TX
|
Family ID: |
50024263 |
Appl. No.: |
13/955979 |
Filed: |
July 31, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61678335 |
Aug 1, 2012 |
|
|
|
Current U.S.
Class: |
131/341 ;
493/45 |
Current CPC
Class: |
A24D 3/04 20130101; A24D
3/0229 20130101; A24D 3/066 20130101 |
Class at
Publication: |
131/341 ;
493/45 |
International
Class: |
A24D 3/02 20060101
A24D003/02; A24D 3/04 20060101 A24D003/04 |
Claims
1. A method comprising: providing a porous mass rod that comprises
a plurality of active particles and a plurality of binder particles
bound together at a plurality of sintered contact points; providing
a filter rod with a composition different than the porous mass rod;
cutting the porous mass rod and the filter rod into porous mass
sections and filter sections, respectively; forming a desired
abutting configuration that comprises a plurality of sections, the
plurality of sections comprising at least some of the porous mass
sections and at least some of the filter sections; securing the
desired abutting configuration with a paper wrapper so as to yield
a segmented filter rod length; and cutting the segmented filter rod
length into segmented filter rods; wherein the steps of forming,
securing, and cutting are performed so as to produce the segmented
filter rods at a rate of about 25 m/min or greater.
2. The method of claim 1, wherein the steps of forming, securing,
and cutting are performed so as to produce the segmented filter
rods at a rate of about 100 m/min or to about 600 m/min.
3. The method of claim 1, wherein the desired abutting
configuration is alternating the porous mass sections and the
filter sections.
4. The method of claim 1, wherein a length of the porous mass
sections is different than a length of the filter section.
5. The method of claim 1 further comprising: providing a second
filter rod with a composition different than the porous mass rod
and the filter rod; cutting the second filter rod into second
filter sections; and wherein the plurality of sections of the
desired abutting configuration further comprise at least some of
the second filter sections.
6. The method of claim 5, wherein the abutting configuration is
repeating series of a first filter segment, a porous mass segment,
a first second filter segment, and a porous mass segment.
7. The method of claim 1, wherein the securing the desired abutting
configuration involves adhering the paper wrapper to itself along a
seam line.
8. The method of claim 1, wherein the active particles comprise at
least one selected from the group consisting of: activated carbon,
an ion exchange resin, a desiccant, a silicate, a molecular sieve,
a silica gel, activated alumina, a zeolite, perlite, sepiolite,
Fuller's Earth, magnesium silicate, a metal oxide, iron oxide, and
any combination thereof.
9. The method of claim 1, wherein the active particles comprise at
least one selected from the group consisting of: a nano-scaled
carbon particle, a carbon nanotube having at least one wall, a
carbon nanohorn, a bamboo-like carbon nanostructure, a fullerene, a
fullerene aggregate, graphene, a few layer graphene, oxidized
graphene, an iron oxide nanoparticle, a nanoparticle, a metal
nanoparticle, a gold nanoparticle, a silver nanoparticle, a metal
oxide nanoparticle, an alumina nanoparticle, a magnetic
nanoparticle, a paramagnetic nanoparticle, a superparamagnetic
nanoparticle, a gadolinium oxide nanoparticle, a hematite
nanoparticle, a magnetite nanoparticle, a gado-nanotube, an
endofullerene, Gd@C60, a core-shell nanoparticle, an onionated
nanoparticle, a nanoshell, an onionated iron oxide nanoparticle,
and any combination thereof.
10. The method of claim 1, wherein the porous mass has a void
volume of about 40% to about 90%.
11. The method of claim 1, wherein the porous mass has an active
particle loading of at least about 1 mg/mm and an encapsulated
pressure drop less than about 20 mm of water per mm length of
porous mass.
12. The method of claim 1, wherein the porous mass has a carbon
loading of at least about 6 mg/mm and an encapsulated pressure drop
of about 20 mm of water or less per mm of length.
13. The method of claim 1, wherein the active particles comprise
activated carbon and the binder particles comprise polyethylene,
and wherein the matrix material comprises the active particles and
the binder particles in a ratio of about 50:50 to about 90:10 by
weight.
14. A method comprising: providing a porous mass rod that comprises
a plurality of active particles and binder particles bound together
at a plurality of sintered contact points; providing a filter rod
with a composition different than the porous mass rod; cutting the
porous mass rod and the filter rod into porous mass sections and
filter sections, respectively; forming a desired abutting
configuration that comprises a plurality of sections, the plurality
of sections comprising at least some of the porous mass sections
and at least some of the filter sections; securing the desired
abutting configuration with an adhesive so as to yield a segmented
filter rod length; and cutting the segmented filter rod length into
segmented filter rods; wherein the steps of forming, securing, and
cutting are performed so as to produce the segmented filter rods at
a rate of about 25 m/min or greater.
15. The method of claim 13, wherein the steps of forming, securing,
and cutting are performed so as to produce the segmented filter
rods at a rate of about 100 m/min or to about 600 m/min.
16. The method of claim 13, wherein the desired abutting
configuration is alternating the porous mass sections and the
filter sections.
17. The method of claim 13, wherein a length of the porous mass
sections is different than a length of the filter section.
18. The method of claim 13 further comprising: providing a second
filter rod with a composition different than the porous mass rod
and the filter rod; cutting the second filter rod into second
filter sections; and wherein the plurality of sections of the
desired abutting configuration further comprise at least some of
the second filter sections.
19. The method of claim 1, wherein the active particles comprise
activated carbon and the binder particles comprise polyethylene,
and wherein the matrix material comprises the active particles and
the binder particles in a ratio of about 50:50 to about 90:10 by
weight.
20. A segmented filter rod produced by the process of: providing a
plurality of porous mass sections that comprise a plurality of
active particles and binder particles bound together at a plurality
of sintered contact points; providing a plurality of filter
sections that does not have the same composition as the porous mass
sections; forming a desired abutting configuration that comprises a
plurality of sections, the plurality of sections comprising at
least one of the porous mass sections and at least one of the
filter sections; securing the desired abutting configuration with
an adhesive and a wrapper so as to yield a segmented filter rod
length; cutting the segmented filter rod length into segmented
filter rods; cutting the segmented filter rods into segmented
filters; wherein the steps of forming, securing, and cutting the
segmented filter rod length are performed so as to produce the
segmented filter rods at a rate of about 25 m/min or greater.
Description
BACKGROUND
[0001] The present application relates to porous masses for use in
filters for smoking devices, and articles and methods relating
thereto.
[0002] The World Health Organization (WHO) has set forth
recommendations for the reduction of certain components of tobacco
smoke. See: WHO Technical Report Series No. 951, The Scientific
Basis of Tobacco Product Regulation, World Health Organization
(2008). Therein, the WHO recommends that certain components, such
as acetaldehyde, acrolein, benzene, benzoapyrene, 1,3-butadiene,
and formaldehyde, among others, be reduced to a level below 125% of
the median values of the data set. (Ibid., Table 3.10, page 112).
In view of new international recommendations related to tobacco
product regulation, there is a need for new tobacco smoke filters
and materials used to make tobacco smoke filters that are able to
meet these regulations.
[0003] The use of carbon loaded tobacco smoke filters for removing
tobacco smoke components has generally been limited to
carbon-on-tow filters and carbon particulate contained within
chambers of the filter. However, the incorporation of such
components into segmented filters have technical challenges like
the production of high levels of dust that can contaminate other
filter sections. Further, such components have limited
technological flexibility for the incorporation of other active
particles, the design of unique filter configurations, and the
removal of high amounts of some smoke stream components.
SUMMARY OF THE INVENTION
[0004] The present application relates to porous masses for use in
filters for smoking devices, and articles and methods relating
thereto.
[0005] In one embodiment of the present invention, a method
comprises providing a porous mass rod that comprises a plurality of
active particles and binder particles bound together at a plurality
of sintered contact points; providing a filter rod that does not
have the same composition as the porous mass rod; cutting the
porous mass rod and the filter rod into porous mass sections and
filter sections, respectively; forming a desired abutting
configuration that comprises a plurality of sections, the plurality
of sections comprising at least some of the porous mass sections
and at least some of the filter sections; securing the desired
abutting configuration with a paper wrapper so as to yield a
segmented filter rod length; and cutting the segmented filter rod
length into segmented filter rods; wherein the steps of forming,
securing, and cutting are performed so as to produce the segmented
filter rods at a rate of about 25 m/min or greater.
[0006] In one embodiment of the present invention, a method
comprises providing a porous mass rod that comprises a plurality of
active particles and binder particles bound together at a plurality
of sintered contact points; providing a filter rod that does not
have the same composition as the porous mass rod; cutting the
porous mass rod and the filter rod into porous mass sections and
filter sections, respectively; forming a desired abutting
configuration that comprises a plurality of sections, the plurality
of sections comprising at least some of the porous mass sections
and at least some of the filter sections; securing the desired
abutting configuration with an adhesive so as to yield a segmented
filter rod length; and cutting the segmented filter rod length into
segmented filter rods; wherein the steps of forming, securing, and
cutting are performed so as to produce the segmented filter rods at
a rate of about 25 m/min or greater.
[0007] In one embodiment of the present invention, a segmented
filter rod may be produced by the process of: providing a plurality
of porous mass sections that comprise a plurality of active
particles and binder particles bound together at a plurality of
sintered contact points; providing a plurality of filter sections
that does not have the same composition as the porous mass
sections; forming a desired abutting configuration that comprises a
plurality of sections, the plurality of sections comprising at
least one of the porous mass sections and at least one of the
filter sections; securing the desired abutting configuration with
an adhesive so as to yield a segmented filter rod length; cutting
the segmented filter rod length into segmented filter rods; cutting
the segmented filter rods into segmented filters; wherein the steps
of forming, securing, and cutting the segmented filter rod length
are performed so as to produce the segmented filter rods at a rate
of about 25 m/min or greater.
[0008] 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
[0009] 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 modifications, alterations, combinations, and
equivalents in form and function, as will occur to those skilled in
the art and having the benefit of this disclosure.
[0010] FIG. 1 is a cross-sectional view of an embodiment of a
cigarette including a filter section according to the present
invention.
[0011] FIG. 2 is a cross-sectional view of another embodiment of a
cigarette including a filter section according to the present
invention.
[0012] FIG. 3 is a cross-sectional view of another embodiment of a
cigarette including a filter section according to the present
invention.
[0013] FIG. 4 is a cross-sectional view of a smoking device
including a filter section according to the present invention.
[0014] FIG. 5 is a photomicrograph of a section of an embodiment of
a porous mass of the present invention.
[0015] FIG. 6 is a comparative document that shows the results of
encapsulated pressure drop testing for carbon-on-tow filters having
an average circumference of about 24.5 mm.
[0016] FIG. 7 shows the results of encapsulated pressure drop
testing for porous mass filters of the present invention
(comprising polyethylene and carbon) having an average
circumference of about 24.5 mm.
[0017] FIG. 8 is a comparative document that shows the results of
encapsulated pressure drop testing for carbon-on-tow filters having
an average circumference of about 16.9 mm.
[0018] FIG. 9 shows the results of encapsulated pressure drop
testing for porous mass filters of the present invention
(comprising polyethylene and carbon) having an average
circumference of about 16.9 mm.
[0019] FIG. 10 shows an illustrative diagram of the process of
producing the filter rods according to at least some embodiments of
the present invention.
[0020] FIG. 11 is a photograph of a plurality of filter rods
produced using at least one method of the present invention.
[0021] FIG. 12 shows an illustrative diagram of relating to at
least some methods of the present invention for forming filters
according to at least some embodiments described herein.
DETAILED DESCRIPTION
[0022] The present application relates to porous masses for use in
filters for smoking devices, and articles and methods relating
thereto.
[0023] The present invention provides for, in some embodiments,
filters and smoking devices having porous masses incorporated
therein. The term "porous mass" as used herein refers to a mass
comprising active particles and nonfibrous binder particles that
form a structure bound by the binder particles with void spaces
therein, whereby smoke can travel through the porous mass and
interact with the active particles. The porous masses described
herein may advantageously reduce the concentration of at least some
of the harmful components in a smoke stream, e.g., a cigarette
smoke stream. Further, the porous masses described herein may be
configured to allow for use in standard cigarette manufacturing
equipment, e.g., filter combining machines to produce segmented
filter rods. The binding of the active particles to the binder
particles may, in some embodiments, advantageously significantly
reduce particulate contamination to other components of a
filter.
[0024] The porous masses described herein further provide for a
plurality of filter rod configurations and active particles so as
to achieve increased reduction of smoke stream components, while
maintaining the draw characteristics consumers are familiar
with.
[0025] It should be noted that when "about" is provided herein at
the beginning of a numerical list, "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.
[0026] I. Porous Masses
[0027] In some embodiments, the porous masses described herein
comprise active particles that are at least partially bonded
together with binder particles. For example, FIG. 5, described in
more detail in the Examples Section below, is a photomicrograph of
an embodiment of the porous mass comprising active particles 50
(e.g., activated carbon particles) and binder particles 52. As
shown, the binder particles and active particles are joined at a
plurality of sintered contact points 54. In some embodiments, the
sintered contact points 54 are randomly distributed throughout the
porous mass, and the binder particles may retain their original
physical shape (or substantially retain their original shape, e.g.,
no more than 10% variation (e.g., shrinkage) in shape from
original). Although not wishing to be limited to any theory, it is
believed that the sintered contact points form when the binder
particles are heated to their softening temperature, but not hot
enough to reach a true melt. Further, in some embodiments, it is
believed that the porous masses described herein are constructed so
as to exhibit a minimal encapsulated pressure drop (described in
more detail below) while maximizing the active particles' surface
area, which enables incorporation in smoking devices because of the
minimal impact on the draw characteristics of the filter.
[0028] Active particles suitable for use in conjunction with porous
masses described herein may include any material adapted to enhance
a smoke stream by removing, reducing, and/or adding components to
the smoke stream. The removal, 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.
Examples of smoke stream components that may advantageously be
reduced or removed may, in some embodiments, include, but are not
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-.alpha.-C, mercury, methyl ethyl ketone,
5-methylchrysene, 4-(methylnitrosamnino)-1-(3-pyridyl)-1-butanone
(NNK), 4-(methylnitrosannino)-1-(3-pyridyl)-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.
[0029] In some embodiments, the active particles suitable for use
in conjunction with porous masses described herein may comprise
active carbon particles, for example, activated carbon (or
activated charcoal or active coal). The activated carbon may, in
some embodiments, be low activity (about 50% to about 75% CCl.sub.4
adsorption), high activity (about 75% to about 95% CCl.sub.4
adsorption), or a mixture thereof. In some embodiments, the active
carbon particles may be nano-scaled carbon particles, e.g., 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.
[0030] Additional exemplary examples of active particles suitable
for use in conjunction with porous masses described herein may
include, but are not limited to, ion exchange resins, desiccants,
silicates, molecular sieves, silica gels, activated alumina,
zeolites, ion exchange resins (e.g., a polymer with a backbone
(e.g., styrene-divinyl benezene (DVB) copolymer, acrylates,
methacrylates, phenol formaldehyde condensates, and epichlorohydrin
amine condensates) and a plurality of electrically charged
functional groups attached to the polymer backbone), 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 superparamagentic 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 thereof. In some embodiments, combinations of any
of the aforementioned active particles, including the active carbon
particles, may be suitable.
[0031] It should be noted that nanoparticles, as used herein,
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 are not 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, in some
embodiments, enhance removal of smoke components and/or enhance
incorporation of nanoparticles into a porous mass.
[0032] In some embodiments, the active particles are a combination
of various active particles. In some embodiments, the porous mass
may comprise multiple active particles.
[0033] In some embodiments, the porous masses described herein may
be effective at the reduction or removal of smoke stream components
(e.g., those described herein). In some embodiments, a porous mass
described herein may be used to reduce the delivery to the smoking
device user of certain tobacco smoke components targeted by the
WHO. For 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 recommendations.
(See Table 13, below.)
[0034] In some embodiments, porous masses described herein that
comprise 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.
[0035] In some embodiments, porous masses described herein that
comprise ion exchange resins may reduce the delivery of certain
tobacco smoke components to below the WHO recommendations. In some
embodiments, porous masses described herein that comprise ion
exchange resins 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.
[0036] In one embodiment, the active particles suitable for use in
conjunction with porous masses described herein have particle sizes
ranging from particles having at least one dimension of about less
than one nanometer, e.g., graphene, to as large as a particle
having a diameter in at least one dimension of about 5000 microns.
The active particles may, in some embodiments, have a diameter in
at least one dimension ranging from a lower limit 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 to
an upper limit 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, and wherein the diameter in at least
one dimension may range from any lower limit to any upper limit and
encompass any subset therebetween. In some embodiments, the active
particles may be a mixture of particle sizes.
[0037] The binder particles suitable for use in conjunction with
porous masses described herein may be any suitable thermoplastic
binder particles. In some embodiments, the binder particles
suitable for use in conjunction with porous masses described herein
may exhibit virtually very little flow at their 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 (UHMWPE), very high molecular weight
polyethylene (VHMWPE), high molecular weight polyethylene (HMWPE),
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 an MFI of less than or equal to about 2.0 g/10 min
at 190.degree. C. and 15 kg (or about 0-2.0 g/10 min at 190.degree.
C. and 15 kg). Examples of low melt flow index binders may include,
but are not limited to, UHMWPE with virtually no polymer flow,
UHMWPE with an MFI of about 0-1.0 at 190.degree. C. and 15 kg,
VHMWPE with an MFI of about 1.0-2.0 g/10 min at 190.degree. C. and
15 kg, HMWPE with an MFI of about 2.0-3.5 g/10 min at 190.degree.
C. and 15 kg, and the like, and any combination thereof. In some
embodiments, it may be preferable to use a mixture of binder
particles having different molecular weights and/or different melt
flow indexes.
[0038] In terms of molecular weight, UHMWPE encompasses
polyethylene compositions with a weight-average molecular weight of
at least about 3.times.10.sup.6 g/mol. In some embodiments, the
molecular weight of the UHMWPE may range from a lower limit of
about 3.times.10.sup.6 g/mol or 6.times.10.sup.6 g/mol to an upper
limit of about 30.times.10.sup.6 g/mol, 20.times.10.sup.6 g/mol,
10.times.10.sup.6 g/mol, or 6.times.10.sup.6 g/mol, and wherein the
molecular weight may range from any lower limit to any upper limit
and encompass any subset therebetween. In terms of molecular
weight, VHMWPE encompasses 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. In terms of molecular weight, HMWPE
encompasses polyethylene compositions with weight-average molecular
weight of at least about 3.times.10.sup.5 g/mol to about
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").
[0039] Examples of commercially available polyethylene products may
include, but are not limited to, GUR.RTM. UHMWPE products
(available from Ticona Polymers LLC, e.g., GUR.RTM. 2000 series
(e.g., 2105, 2122, 2122-5, 2126), GUR 4000.RTM. series (e.g., 4120,
4130, 4150, 4170, 4012, 4122-5, 4022-6, 4050-3/4150-3), GUR
8000.RTM. series (e.g., 8110, 8020), GUR X.RTM. series (e.g., X143,
X184, X168, X172, X192). Combinations of any of the aforementioned
commercially available polyethylene products may be suitable, in
some embodiments.
[0040] In some embodiments, polyethylene suitable for use in
conjunction with the binder described herein may have 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, e.g., as described in
U.S. Patent Application Publication No. 2008/0090081, the entirety
of which is incorporated herein by reference. In some embodiments,
polyethylene suitable for use in conjunction with the binder
described herein may have 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.
[0041] The binder particles suitable for use in conjunction with
porous masses described herein may be of any shape. Such shapes may
include, but are not limited to, spherical, hyperion, asteroidal,
chrondular or interplanetary dust-like, granulated, potato,
popcorn, irregular, any hybrid thereof, and any combination
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 having different
shapes.
[0042] In some embodiments, the binder particles suitable for use
in conjunction with porous masses described herein have a diameter
in at least one dimension ranging from a lower limit 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 to
an upper limit 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, and wherein the diameter in at least
one dimension may range from any lower limit to any upper limit and
encompass any subset therebetween. In some embodiments, the binder
particles may be a mixture of particle sizes.
[0043] In some embodiments, the binder particles suitable for use
in conjunction with porous masses described herein 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.
[0044] In addition to the foregoing binder particles, in some
embodiments, other conventional thermoplastics may be used as
binder particles for use in conjunction with porous masses
described herein. Such thermoplastics may 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 may include, but are not limited to, polyethylene,
polypropylene, polybutylene, polymethylpentene, and the like, any
copolymer thereof, any derivative thereof, and any combination
thereof. Examples of suitable polyethylenes may further include,
but are not limited to, low-density polyethylene, linear
low-density polyethylene, high-density polyethylene, and the like,
any copolymer thereof, any derivative thereof, and any combination
thereof. Examples of suitable polyesters may include, but are not
limited to, polyethylene terephthalate, polybutylene terephthalate,
polycyclohexylene dimethylene terephthalate, polytrimethylene
terephthalate, and the like, any copolymer thereof, any derivative
thereof, and any combination thereof. Examples of suitable
polyacrylics may include, but are not limited to, polymethyl
methacrylate, and the like, any copolymer thereof, any derivative
thereof, and any combination thereof. Examples of suitable
polystyrenes may include, but are not limited to, polystyrene,
acrylonitrile-butadiene-styrene, styrene-acrylonitrile,
styrene-butadiene, styrene-maleic anhydride, and the like, any
copolymer thereof, any derivative thereof, and any combination
thereof. Examples of suitable polyvinyls may include, but are not
limited to, ethylene vinyl acetate, ethylene vinyl alcohol,
polyvinyl chloride, and the like, any copolymer thereof, any
derivative thereof, and any combination thereof. Examples of
suitable cellulosics may include, but are not limited to, cellulose
acetate, cellulose acetate butyrate, plasticized cellulosics,
cellulose propionate, ethyl cellulose, and the like, any copolymer
thereof, any derivative thereof, and any combination thereof. In
some embodiments, a binder particle may comprise any copolymer, any
derivative, and any combination of the exemplary binders described
herein and the like.
[0045] Active particles and binder particles may be included in
porous masses described herein in any weight ratio. In some
embodiments, the weight ratio of active particles to binder
particles may range from any lower limit of about 1:99, 10:90,
25:75, 40:60, or 50:50 to an upper limit of about 90:10, 75:25,
60:40, or 50:50, and wherein the weight ratio may range from any
lower limit to any upper limit and encompass any subset
therebetween.
[0046] In some embodiments, the porous masses described herein may
be characterized by properties such as void volume, encapsulated
pressure drop, and any combination thereof.
[0047] In some embodiments, porous masses described herein may have
a void volume ranging from a lower limit of about 40%, 50%, or 60%
to an upper limit of about 90%, 85%, 80%, or 75%, and wherein the
void volume may range from any lower limit to any upper limit and
encompass any subset therebetween.
[0048] 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) and using the density of the active material. Then, the
percentage void volume is calculated as follows:
Void Volume ( % ) = 1 - [ ( porous mass volume , cm 3 ) - ( weight
of active particles , g ) / ( density of the active particles , g /
cm 3 ) ] * 100 ( porous mass volume , cm 3 ) ##EQU00001##
[0049] As used herein, the term "encapsulated pressure drop" refers
to the static pressure difference between the two ends of a
specimen when it is traversed by an air flow under steady
conditions when the volume flow is 17.5 ml/sec at the output end
when the specimen is completely encapsulated in a measuring device
so that no air can pass through the wrapping. EPD has been measured
herein under the CORESTA ("Cooperation Centre for Scientific
Research Relative to Tobacco") Recommended Method No. 41, dated
June 2007. In another embodiment, a porous mass of the present
invention 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, a
porous mass of the present invention 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).
[0050] In some embodiments, the porous masses described herein may
have as an encapsulated pressure drop (EPD) ranging from a lower
limit of about 0.10 mm of water per mm length of porous mass, 0.5
mm of water per mm length of porous mass, 1 mm of water per mm
length of porous mass, or 5 mm of water per mm length of porous
mass to an upper limit of about 25 mm of water per mm length of
porous mass, 15 mm of water per mm length of porous mass, 10 mm of
water per mm length of porous mass, or 5 mm of water per mm length
of porous mass, and wherein the EPD may range from any lower limit
to any upper limit and encompass any subset therebetween.
[0051] In some embodiments, the porous mass of the present
invention 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
porous mass, 19 mm of water or less per mm of porous mass, 18 mm of
water or less per mm of porous mass, 17 mm of water or less per mm
of porous mass, 16 mm of water or less per mm of porous mass, 15 mm
of water or less per mm of porous mass, 14 mm of water or less per
mm of porous mass, 13 mm of water or less per mm of porous mass, 12
mm of water or less per mm of porous mass, 11 mm of water or less
per mm of porous mass, 10 mm of water or less per mm of porous
mass, 9 mm of water or less per mm of porous mass, 8 mm of water or
less per mm of porous mass, 7 mm of water or less per mm of porous
mass, 6 mm of water or less per mm of porous mass, 5 mm of water or
less per mm of porous mass, 4 mm of water or less per mm of porous
mass, 3 mm of water or less per mm of porous mass, 2 mm of water or
less per mm of porous mass, or 1 mm of water or less per mm of
porous mass.
[0052] By way of nonlimiting example, in some 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 porous
mass. 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 porous mass, 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 porous mass.
[0053] 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 0.001 wt
%, 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).
[0054] Suitable additives may include, but are not limited to,
active compounds, ionic resins, zeolites, nanoparticles, 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, microcapsules, and any combination
thereof.
[0055] 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.
[0056] Suitable ionic resins may include, but are not limited to,
polymers with a backbone of styrene-divinyl benezene (DVB)
copolymer, acrylates, methacrylates, phenol formaldehyde
condensates, epichlorohydrin amine condensates, and the like, and
any combination thereof; a plurality of electrically charged
functional groups attached to the polymer backbone; and any
combination thereof.
[0057] 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 are not 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), or any combination thereof.
[0058] Suitable nanoparticles may include, but are not 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 superparamagentic
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 are not 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.
[0059] Suitable ceramic particles may include, but are not limited
to, oxides (e.g., silica, titania, alumina, beryllia, ceria, and
zirconia), nonoxides (e.g., carbides, borides, nitrides, and
silicides), composites thereof, or any combination thereof. Ceramic
particles may be crystalline, non-crystalline, or
semi-crystalline.
[0060] 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 are not 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, or any
combination thereof.
[0061] As used herein, dyes refer to compounds and/or particles
that impart color and are a surface treatment. Suitable dyes may
include, but are not 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).
[0062] 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
are not 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, and
the like. Natural and artificial flavors may include, but are not
limited to, menthol, cloves, cherry, chocolate, cardamom, 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, or 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. 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.
[0063] Suitable aromas may include, but are not limited to, 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, 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, cedarwood, neroli, bergamot,
strawberry, carnation, oregano, honey, civet, heliotrope, caramel,
coumarin, patchouli, dewberry, helonial, hyacinth, cardamom,
coriander, pimento berry, labdanum, cassie, aldehydes, orchid,
amber, benzoin, orris, tuberose, palmarosa, cinnamon, nutmeg, moss,
styrax, pineapple, bergamot, foxglove, tulip, wisteria, clematis,
ambergris, gums, resins, peach, plum, castoreum, geranium, rose
violet, jonquil, spicy carnation, galbanum, hyacinth, petitgrain,
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.
[0064] Suitable tackifiers may include, but are not 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, or
any combination thereof.
[0065] Suitable vitamins may include, but are not limited to,
vitamin A, vitamin B1, vitamin B2, vitamin C, vitamin D, vitamin E,
or any combination thereof.
[0066] Suitable antimicrobials may include, but are not 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.
[0067] Antistatic agents may comprise any suitable anionic,
cationic, amphoteric or nonionic antistatic agent. Anionic
antistatic agents may generally include, but are not limited to,
alkali sulfates, alkali phosphates, phosphate esters of alcohols,
phosphate esters of ethoxylated alcohols, or any combination
thereof. Examples may include, but are not 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 are not 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.),
or any combination thereof. Anionic and cationic materials tend to
be more effective antistatic agents.
[0068] As used herein, "microcapsules" refer to porous
microparticles (spherical or otherwise) having exterior surface
pores and having diameters of less than about 1 micron to about
1000 microns. In some embodiments, microcapsules may comprise any
of the additives described herein (singularly or in combination)
provided the additives are suitably sized to fit within the inner
contents and maintain operability of the microcapsule. Suitable
microcapsules for use in conjunction with the present invention may
be those formed by any suitable technique, which may include, but
is not limited to, those described in U.S. Pat. No. 5,064,949
entitled "Cellulose Ester Microparticles and Processes for Making
the Same," and U.S. Pat. No. 5,047,180 entitled "Process for Making
Cellulose Ester Microparticles," the relevant disclosures of which
are incorporated herein by reference. Suitable microcapsules for
use in conjunction with the present invention may be formed of any
suitable materials, which may include, but are not limited to,
gelatins, celluloses, modified celluloses, methylcellulose,
hydroxypropylmethyl cellulose, chlorophyllin, polyvinylalcohol,
polyvinyl pyrrolidone, and the like, or any combination
thereof.
[0069] The length of a porous mass described herein may, in some
embodiments, 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.
[0070] The porous mass may have any physical shape, e.g., in some
embodiments, helical, triangular, discus, square, rectangular,
cylindrical, and any hybrid thereof. In some embodiments, the
porous mass may be machined for, inter alia, to be lighter in
weight, if desired, for example, by drilling out a portion of the
porous mass. In one embodiment, the porous mass may have a specific
shape 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, 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. However, the term "circumference" refers generally to
the perimeter of any shaped cross-section, unless otherwise
specified, including a circular and polyagonal cross-sections.
[0071] The circumference of a porous mass described herein 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.
[0072] In some embodiments, a porous mass may have at least one
paper disposed thereabout. Unless otherwise specified, embodiments
described herein that pertain to porous masses also pertain to
wrapped porous masses. Examples of papers that may be disposed
about porous masses described herein may include, but are not
limited to, papers (e.g., wood-based papers, papers containing
flax, flax papers, cotton paper, 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, the papers may be high porosity, corrugated,
and/or have a high surface strength. In some embodiments, papers
may be substantially non-porosity less, e.g., than about 10 CORESTA
units.
[0073] Porous masses described herein may be produced by any
suitable method and with any suitable apparatus and/or system
including, but not limited to, the methods, systems, and
apparatuses described in co-pending application PCT/US11/56388
filed Oct. 14, 2011, the entirety of which is incorporated herein
by reference. For example, porous masses may be produced utilizing
mold cavities in continuous, batch, or hybrid processes.
[0074] II. Articles Comprising Porous Masses
[0075] The porous mass described hereinafter may be used as a
filter or a filter segment, including use in conjunction with
smoking device filters. As used herein, the term "smoking device"
refers to an article capable of maintaining a smokable substance
and a filter in fluid communication and when in operation allows
for a user to draw on the smoking device causing the smoke from the
smokable passes through the filter and to the user (e.g., a human).
The term smoking device encompasses, but is not limited to,
cigarettes, cigarette holders, cigars, cigar holders, pipes, water
pipes, hookahs, electronic smoking devices, roll-your-own
cigarettes or cigars, and the like, and any hybrid thereof.
[0076] In some embodiments, a smoking device may comprise a housing
capable of maintaining a smokeable substance in fluid communication
with the filter. Suitable housings may include, but are not limited
to, a cigarette, a cigarette holder, a cigar, a cigar holder, a
pipe, a water pipe, a hookah, an electronic smoking device, a
roll-your-own cigarette, a roll-your-own cigar, a paper, and the
like, any hybrid thereof, and any combination thereof.
[0077] Referring to the nonlimiting example illustrated in FIG. 1,
smoking device 10 includes filter 14 and a smokable substance
illustrated as tobacco column 12. Filter 14 may comprise at least
two sections, first section 16 and second section 18. For example,
the first section 16 may comprise conventional filter material
(discussed in greater detail herein) and the second section 18
comprises a porous mass (discussed in greater detail herein).
[0078] Referring now to the nonlimiting example illustrated in FIG.
2, smoking device 20 has filter 22 and a smokable substance
illustrated as tobacco column 12. Filter 22 illustrates a
multi-segmented with three sections, sometimes referred to as a
dual offset filter, that include in order filter section 24, porous
mass 26, and filter section 24. Filter section 24 may include, in
some embodiments, any of the filter section materials and/or
attributes described herein.
[0079] Referring now to the nonlimiting example illustrated in FIG.
3, smoking device 30 has filter 32 and a smokable substance
illustrated as tobacco column 12. Filter 32 is multi-segmented with
sections 34,36,37,38, where section 34 is the mouth and a smoking
device 30. In some embodiments, section 34 may comprise
conventional filter materials so as to provide a normal mouth-feel
to a user, and sections 36,37,38 may independently comprise any
filter material and/or attributes described herein, such that at
least one of sections 36,37,38 is a porous mass described
herein.
[0080] Referring now to the nonlimiting example illustrated in FIG.
4, a smoking device illustrated as pipe 40 has a burning bowl 42, a
mouth piece 44, and a channel 46 interconnecting burning bowl 42
and mouth piece 44. Channel 46 includes a cavity 47 adapted for
receipt of a filter 48. Filter 48 may, in some embodiments, be a
porous mass or a multi-segmented filter, e.g., as illustrated in
filter 14 of FIG. 1, filter 22 of FIG. 2, or filter 32 of FIG. 3.
The size of filter 48 may vary based on the dimensions of cavity
47. In some embodiments, filter 48 may be removable, replaceable,
disposable, recyclable, and/or degradable.
[0081] In some embodiments, filters that comprise porous masses
described herein may have any number of sections, e.g., 2, 3, 4, 5,
6, or more sections, and the sections may be placed in any suitable
configuration and independently comprise materials and attributes
as described.
[0082] Materials suitable for use in filters and/or filter sections
that are not porous masses may include, but are not limited to,
cellulose acetate, cellulose esters, polypropylene, polyethylene,
polyolefin tow, polypropylene tow, polyethylene terephthalate,
polybutylene terephthalate, random oriented acetate, papers,
corrugated papers, concentric filters (e.g., a peripheral filter of
fibrous tow and a core of a web material), carbon-on-tow (sometimes
referred to as a "Dalmatian filter"), silica, magnesium silicate,
zeolites (e.g., BETA, SBA-15, MCM-41, and MCM-48 modified by
3-aminopropylsilyl groups), molecular sieves, salts, catalysts,
sodium chloride, nylon, flavorants, tobacco, capsules, cellulose,
cellulosic derivatives, cellulose ester microspheres, catalytic
converters, iodine pentoxide, coarse powders, carbon particles,
carbon fibers, fibers, glass beads, nanoparticles, void chambers
(e.g., formed by rigid elements, such as paper or plastic), baffled
void chambers, and any combination thereof. Further, filters and/or
filter sections that that are not porous masses may include
additives described herein.
[0083] In some embodiments, a filter comprising a porous mass
described herein may comprise a cavity between two filter sections,
e.g., between two porous mass sections, between two sections not
being porous masses, or between a porous mass section and another
section. The cavity may be filled with active particles and/or
additives described herein, e.g., granulated carbon, flavorants,
and the like. The cavity may contain a capsule, e.g., a polymeric
capsule, that itself contains active particles and/or additives
described herein. In some embodiments, 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).
[0084] In some embodiments, a filter comprising a porous mass
described herein may be characterized by EPD. In some embodiments,
a filter comprising a porous mass described herein may have an EPD
of less than about 20 mm of water or less per mm of porous mass, 19
mm of water or less per mm of porous mass, 18 mm of water or less
per mm of porous mass, 17 mm of water or less per mm of porous
mass, 16 mm of water or less per mm of porous mass, 15 mm of water
or less per mm of porous mass, 14 mm of water or less per mm of
porous mass, 13 mm of water or less per mm of porous mass, 12 mm of
water or less per mm of porous mass, 11 mm of water or less per mm
of porous mass, 10 mm of water or less per mm of porous mass, 9 mm
of water or less per mm of porous mass, 8 mm of water or less per
mm of porous mass, 7 mm of water or less per mm of porous mass, 6
mm of water or less per mm of porous mass, 5 mm of water or less
per mm of porous mass, 4 mm of water or less per mm of porous mass,
3 mm of water or less per mm of porous mass, 2 mm of water or less
per mm of porous mass, or 1 mm of water or less per mm of porous
mass.
[0085] In some embodiments, the filter may be substantially
degradable over time (e.g., over about 2 to about 5 years), either
naturally or in the presence of a catalyst, that in some
embodiments, may be present in a filter section itself.
[0086] As illustrated in FIGS. 1-3, in some embodiments, a filter
section comprising a porous mass and at least one other filter
section may be co-axial, juxtaposed, abutting, and have equivalent
cross-sectional areas (or substantially equivalent cross-sectional
areas). However, it is understood that the porous mass and the
conventional materials need not be joined in such a fashion, and
that there may be other possible configurations. Moreover, while it
is envisioned that porous masses will be, most often, used in a
combined or multi-segmented filter configuration, e.g., as shown in
FIGS. 1-3., in some embodiments, the filter may consist essentially
of a porous mass of the present invention, as discussed above with
regard to FIG. 4.
[0087] As described above, filters comprising porous masses
described herein may be utilized in conjunction with a smoking
device. In some embodiments, the filter may abut the smokeable
substance of the smoking device, e.g., a cigarette or a cigar. In
some embodiments, the filter may be in fluid communication but not
abutting the smokeable substance, e.g., a hookah, a pipe, a cigar
holder, a cigarette holder, or a cigarette or cigar with a cavity
disposed between the filter and the smokeable substance.
[0088] In some embodiments, a smokeable substance may be in the
form of 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 beans, carob bean
extracts, and any combination thereof. In still other embodiments,
the tobacco column may further comprise flavorants, menthol,
licorice extract, diammonium phosphate, ammonium hydroxide, and any
combination thereof. Examples of suitable types of tobacco that may
be used in the tobacco columns may include, but are not limited to,
bright leaf tobacco, burley tobacco, Oriental tobacco (also known
as Turkish tobacco), Cavendish tobacco, corojo tobacco, criollo
tobacco, Perique tobacco, shade tobacco, white burley tobacco, and
any combination thereof. The tobacco may be grown in the United
States, or may be grown in a jurisdiction outside the United
States.
[0089] III. Methods of Forming Filters and Smoking Devices
[0090] In some embodiments, filter sections may be combined or
joined so as to form a filter or a filter rod. As used herein the
term "filter rod" refers to a length of filter that is suitable for
being cut into two or more filters. By way of nonlimiting example,
the filter rods that comprise a porous mass described herein may,
in some embodiments, have lengths ranging from about 80 mm to about
150 mm and may be cut into filters having lengths about 5 to about
35 mm in length during a smoking device tipping operation (the
addition of a tobacco column to a filter).
[0091] Tipping operations may involve combining or joining a filter
or filter rod described herein with a tobacco column. During
tipping operations, the filter rods that comprise a porous mass
described herein may, in some embodiments, be first cut into
filters or cut into filters during the tipping process. Further, in
some embodiments, tipping methods may further involve combining or
joining additional sections that comprise paper and/or charcoal to
the filter, filter rods, or tobacco column.
[0092] In the production of filters, filter rods, and/or smoking
devices, some embodiments may involve wrapping a paper about the
various components thereof so as to maintain the components in the
desired configuration and/or contact. For example, producing filter
and/or filter rods may involve wrapping paper about a series of
abutting filter sections. In some embodiments, porous masses
wrapped with a paper wrapping may have an additional wrapping
disposed thereabout to maintain contact between the porous mass and
another section of the filter. Suitable papers for producing
filters, filter rods, and/or smoking devices may include any paper
described herein in relation to wrapping porous masses. In some
embodiments, the papers may comprise additives, sizing, and/or
printing agents.
[0093] In the production of filters, filter rods, and/or smoking
devices, some embodiments may involve adhering adjacent components
thereof (e.g., a porous mass to an adjacent filter section, tobacco
column, and the like, or any combination thereof). Preferable
adhesives may include those that do not impart flavor or aroma
under ambient conditions and/or under burning conditions. In some
embodiments, wrapping and adhering may be utilized in the
production of filters, filter rods, and/or smoking devices.
[0094] Some embodiments of the present invention may involve
providing a porous mass rod that comprise a plurality of active
particles and binder particles bound together at a plurality of
sintered contact points; providing a filter rod that does not have
the same composition as the porous mass rod; cutting the porous
mass rod and the filter rod into porous mass sections and filter
sections, respectively; forming a desired abutting configuration
that comprises a plurality of sections, the plurality of sections
comprising at least some of the porous mass sections and at least
some of the filter sections; securing the desired abutting
configuration with a paper wrapper and/or an adhesive so as to
yield a segmented filter rod length; cutting the segmented filter
rod length into segmented filter rods; and wherein the method is
performed so as to produce the segmented filter rods at a rate of
about 600 m/min or less. Some embodiments may further involve
forming a smoking device with at least a portion of the segmented
filter rod.
[0095] As used herein, the term "abutting configuration" refers to
a configuration where two filter sections (or the like) are axially
aligned so as to touch one end of the first section to one end of
the second section. One skilled in the art would understand that
this abutting configuration can be continuous (i.e., not
never-ending, rather very long) with a large number of sections or
short in length with at least two to many sections.
[0096] It should be noted that in some method embodiments described
herein, the term "segmented" is used for clarity to modify various
articles and should be viewed to be encompassed by various
embodiments described herein with reference to articles (e.g.,
filters and filter rods) comprising porous masses.
[0097] Some embodiments of the present invention may involve
providing a plurality of porous mass sections that comprise a
plurality of active particles and binder particles bound together
at a plurality of sintered contact points; providing a plurality of
filter sections that does not have the same composition as the
porous mass sections; forming a desired abutting configuration that
comprises a plurality of sections, the plurality of sections
comprising at least one of the porous mass sections and at least
one of the filter sections; securing the desired abutting
configuration with a paper wrapper and/or adhesive so as to produce
a segmented filter or a segmented filter rod length; and wherein
the method is performed so as to produce the segmented filter or
the segmented filter rod at a rate of about 600 m/min or less. Some
embodiments may further involve forming a smoking device with the
segmented filter or at least a portion of the segmented filter
rod.
[0098] In some embodiments, the foregoing method of the present
invention may be adapted to accommodate three or more filter
sections. For example, a desired configuration of a filter rod
length may be a first porous mass section, a first filter section,
and a second filter section in series a first porous mass section,
a first second filter section, a first first filter section, a
second second filter section, a second porous mass section, a third
second filter section, a second first filter section, and a fourth
second filter section in series. Such a configuration may be at
least one embodiment useful for producing filters that comprise
three sections, as illustrated in FIG. 12, which illustrates a
filter rod length being cut into a filter rod that is then cut two
additional times so as to yield a filter section comprising three
sections.
[0099] In some embodiments, a capsule may be included so as to be
nested between two abutting sections. As used herein, the term
"nested" or "nesting" refers to being inside and not directly
exposed to the exterior of the article produced. Accordingly,
nesting between two abutting sections allows for the adjacent
sections to be touching, i.e., abutting. In some embodiments, a
capsule may be in a portion
[0100] In some embodiments, filters described herein may be
produced using known instrumentation, e.g., greater than about 25
m/min in automated instruments and lower for hand production
instruments. While the rate of production may be limited by the
instrument capabilities only, in some embodiments, filter sections
described herein may be combined to form a filter rod at a rate
ranging from a lower limit of about 25 m/min or less, 50 m/min or
less, or 100 m/min or less to an upper limit of about 600 m/min or
less, about 400 m/min or less, about 300 m/min or less, or about
250 m/min or less.
[0101] In some embodiments, porous masses utilized in the
production of filter and/or filter rods described herein may be
wrapped with a paper. The paper may, in some embodiments, reduce
damage and particulate production due to the mechanical
manipulation of the porous masses. Paper suitable for use in
conjunction with protecting porous masses during manipulation may
include, but are not limited to, wood-based papers, papers
containing flax, flax papers, cotton paper, functionalized papers
(e.g., those that are functionalized so as to reduce tar and/or
carbon monoxide), special marking papers, colorized papers, and any
combination thereof. In some embodiments, the papers may be high
porosity, corrugated, and/or have a high surface strength. In some
embodiments, papers may be substantially non-porosity less, e.g.,
than about 10 CORESTA units.
[0102] In some embodiments, the filters and/or filter rods
comprising porous masses described herein may be directly
transported to a manufacturing line whereby they will be combined
with tobacco columns to form smoking devices. An example of such a
method includes a process for producing a smoking device
comprising: providing a filter rod comprising at least one filter
section comprising a porous mass described herein that comprises an
active particle and a binder particle; providing a tobacco column;
cutting the filter rod transverse to its longitudinal axis through
the center of the rod to form at least two filters having at least
one filter section, each filter section comprising a porous mass
that comprises an active particle and a binder particle; and
joining at least one of the filters to the tobacco column along the
longitudinal axis of the filter and the longitudinal axis of the
tobacco column to form at least one smoking device.
[0103] In other embodiments, the device filters and/or filter rods
comprising porous masses may be placed in a suitable container for
storage until further use. Suitable storage containers include
those commonly used in the smoking device filter art including, but
not limited to, crates, boxes, drums, bags, cartons, and the
like.
[0104] In some embodiments, filters and/or smoking devices
comprising porous masses as described herein may be incorporated
into packs of the filters and/or smoking devices. The pack may be a
hinge-lid pack, a slide-and-shell pack, a hard cup pack, a soft cup
pack, 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 for
individual sale or for preserving flavors.
[0105] In some embodiments, a carton of packs that includes at
least one pack filters and/or smoking devices comprising porous
masses as described herein. In some embodiments, the carton (e.g.,
a container) has the physical integrity to contain the weight from
the packs of cigarettes. This may be accomplished through thicker
cardstock being used to form the carton or stronger adhesives being
used to bind elements of the carton.
[0106] Because it is expected that a consumer will smoke a smoking
device that includes a porous mass as described herein, the present
invention also provides methods of smoking the smoking devices
described herein. For example, in one embodiment, the present
invention provides a method of smoking a smoking device comprising:
heating or lighting a smoking device to form smoke, the smoking
device comprising at least one filter that comprises a porous mass
described herein; and drawing the smoke through the smoking device,
wherein the filter reduces the presence of at least one component
in the smoke as compared to a filter without the porous mass.
[0107] In some embodiments, a filter and/or a filter rod may
comprise or consist essentially of a porous mass (having a desired
shape, length, circumference, void space, and encapsulated pressure
drop as described herein including combinations thereof) that
comprises active particles, binder particles, and optionally
further comprises additives according to any combination of
compositions, sizes, shapes, and/or concentrations of the active
particles, binder particles, and additives as described herein. In
some embodiments, a filter and/or a filter rod, according to any of
the foregoing embodiments, may further comprise a desired number
and composition of additional filter segments (including additional
porous masses) and may have a desired shape, length, circumference,
encapsulated pressure drop, and combination thereof. In some
embodiments, a filter and/or a filter rod, according to any of the
foregoing embodiments, may comprise a porous mass that comprises an
active particle and a binder particle, the filter having at least
one of the following or any combination thereof:
[0108] (a) the active particle comprising an element selected from
the group consisting of: a nano-scaled carbon particle, a carbon
nanotube having at least one wall, a carbon nanohorn, a bamboo-like
carbon nanostructure, a fullerene, a fullerene aggregate, graphene,
a few layer graphene, oxidized graphene, an iron oxide
nanoparticle, a nanoparticle, a metal nanoparticle, a gold
nanoparticle, a silver nanoparticle, a metal oxide nanoparticle, an
alumina nanoparticle, a magnetic nanoparticle, a paramagnetic
nanoparticle, a superparamagentic nanoparticle, a gadolinium oxide
nanoparticle, a hematite nanoparticle, a magnetite nanoparticle, a
gado-nanotube, an endofullerene, Gd@C60, a core-shell nanoparticle,
an onionated nanoparticle, a nanoshell, an onionated iron oxide
nanoparticle, and any combination thereof;
[0109] (b) the porous mass having a void volume in the range of
about 40% to about 90%;
[0110] (c) the active particle comprising carbon, and the porous
mass having a carbon loading of at least about 6 mg/mm, and an EPD
of about 20 mm of water or less per mm of porous mass; and
[0111] (d) the porous mass having an active particle loading of at
least about 1 mg/mm and an EPD of 20 mm of water or less per mm of
porous mass.
[0112] Exemplary embodiments described herein may include, but are
not limited to:
[0113] A: a method that includes providing a porous mass rod that
comprises a plurality of active particles and a plurality of binder
particles bound together at a plurality of sintered contact points;
providing a filter rod with a composition different than the porous
mass rod; cutting the porous mass rod and the filter rod into
porous mass sections and filter sections, respectively; forming a
desired abutting configuration that comprises a plurality of
sections, the plurality of sections comprising at least some of the
porous mass sections and at least some of the filter sections;
securing the desired abutting configuration with a paper wrapper so
as to yield a segmented filter rod length; and cutting the
segmented filter rod length into segmented filter rods; wherein the
steps of forming, securing, and cutting are performed so as to
produce the segmented filter rods at a rate of about 25 m/min or
greater
[0114] B: a method that includes providing a porous mass rod that
comprises a plurality of active particles and binder particles
bound together at a plurality of sintered contact points; providing
a filter rod with a composition different than the porous mass rod;
cutting the porous mass rod and the filter rod into porous mass
sections and filter sections, respectively; forming a desired
abutting configuration that comprises a plurality of sections, the
plurality of sections comprising at least some of the porous mass
sections and at least some of the filter sections; securing the
desired abutting configuration with an adhesive so as to yield a
segmented filter rod length; and cutting the segmented filter rod
length into segmented filter rods; wherein the steps of forming,
securing, and cutting are performed so as to produce the segmented
filter rods at a rate of about 25 m/min or greater; and
[0115] C: providing a plurality of porous mass sections that
comprise a plurality of active particles and binder particles bound
together at a plurality of sintered contact points; providing a
plurality of filter sections that does not have the same
composition as the porous mass sections; forming a desired abutting
configuration that comprises a plurality of sections, the plurality
of sections comprising at least one of the porous mass sections and
at least one of the filter sections; securing the desired abutting
configuration with an adhesive and a wrapper so as to yield a
segmented filter rod length; cutting the segmented filter rod
length into segmented filter rods; cutting the segmented filter
rods into segmented filters; wherein the steps of forming,
securing, and cutting the segmented filter rod length are performed
so as to produce the segmented filter rods at a rate of about 25
m/min or greater.
[0116] Embodiments A, B, and C may each independently, optionally
include the following elements: Element 1: wherein the steps of
forming, securing, and cutting are performed so as to produce the
segmented filter rods at a rate of about 100 m/min or to about 600
m/min; Element 2: wherein the desired abutting configuration is
alternating the porous mass sections and the filter sections;
Element 3: wherein a length of the porous mass sections is
different than a length of the filter section; Element 4: the
method further including providing a second filter rod with a
composition different than the porous mass rod and the filter rod;
cutting the second filter rod into second filter sections; and
wherein the plurality of sections of the desired abutting
configuration further comprise at least some of the second filter
sections; Element 5: Element 4 wherein the abutting configuration
is repeating series of a first filter segment, a porous mass
segment, a first second filter segment, and a porous mass segment;
Element 6: wherein the securing the desired abutting configuration
involves adhering the paper wrapper to itself along a seam line;
Element 7: wherein the active particles comprise at least one
selected from the group consisting of: activated carbon, an ion
exchange resin, a desiccant, a silicate, a molecular sieve, a
silica gel, activated alumina, a zeolite, perlite, sepiolite,
Fuller's Earth, magnesium silicate, a metal oxide, iron oxide, and
any combination thereof; Element 8: wherein the active particles
comprise at least one selected from the group consisting of: a
nano-scaled carbon particle, a carbon nanotube having at least one
wall, a carbon nanohorn, a bamboo-like carbon nanostructure, a
fullerene, a fullerene aggregate, graphene, a few layer graphene,
oxidized graphene, an iron oxide nanoparticle, a nanoparticle, a
metal nanoparticle, a gold nanoparticle, a silver nanoparticle, a
metal oxide nanoparticle, an alumina nanoparticle, a magnetic
nanoparticle, a paramagnetic nanoparticle, a superparamagnetic
nanoparticle, a gadolinium oxide nanoparticle, a hematite
nanoparticle, a magnetite nanoparticle, a gado-nanotube, an
endofullerene, Gd@C60, a core-shell nanoparticle, an onionated
nanoparticle, a nanoshell, an onionated iron oxide nanoparticle,
and any combination thereof; Element 9: wherein the porous mass has
a void volume of about 40% to about 90%; Element 10: the porous
mass has an active particle loading of at least about 1 mg/mm and
an encapsulated pressure drop less than about 20 mm of water per mm
length of porous mass; Element 11: wherein the porous mass has a
carbon loading of at least about 6 mg/mm and an encapsulated
pressure drop of about 20 mm of water or less per mm of length;
Element 12: wherein the active particles comprise activated carbon
and the binder particles comprise polyethylene, and wherein the
matrix material comprises the active particles and the binder
particles in a ratio of about 50:50 to about 90:10 by weight.
[0117] In some embodiments, a filter and/or a filter rod, according
to any of the foregoing embodiments, may be included in and/or used
in conjunction with forming a smoking device described herein, in
any configuration and by any methods described herein.
[0118] To facilitate a better understanding of the present
invention, the following examples of preferred or representative
embodiments are given. In no way should the following examples be
read to limit, or to define, the scope of the invention.
EXAMPLES
[0119] In the following example, the effectiveness of a porous mass
in removing certain components of the cigarette smoke is
illustrated. The porous mass was made from 25 weight % GUR 2105
from Ticona, LLC, and 75 weight % PICA RC 259 (95% active carbon)
from PICA USA, Inc. of Columbus, Ohio. The porous mass has a % void
volume of 72% and an encapsulated pressure drop (EPD) of 2.2 mm of
water/mm of porous mass length. The porous mass has a circumference
of about 24.5 mm. The PICA RC 259 carbon had an average particle
size of 569 microns (.mu.). The porous mass was made by mixing the
resin (GUR 2105) and carbon (PICA RC 259) and then filling a mold
with the mixture without pressure on the heated mixture (free
sintering). Then, the mold was heated to 200.degree. C. for 40
minutes. Thereafter, the porous mass was removed from the mold and
allowed to cool. A defined-length section of the porous mass was
combined with a sufficient amount of cellulose acetate tow to yield
a filter with a total encapsulated pressure drop of 70 mm of water.
All smoke assays were performed according to tobacco industry
standards. All cigarettes were smoked using the Canadian intense
protocol (i.e., T-115, "Determination of "Tar," Nicotine and Carbon
Monoxide in Mainstream Tobacco Smoke," Health Canada, 1999) and a
Cerulean 450 smoking machine.
TABLE-US-00001 TABLE 1 5 mm 10 mm 15 mm porous mass porous mass
porous mass Carbonyls 20 mm 15 mm 13 mm .mu.g/cigarette Control Tow
% Tow % Tow % formaldehyde 10.4 5.1 -51 0.0 -100 0.0 -100
acetaldehyde 295.3 211.2 -28 186.8 -37 188.5 -36 acetone 601.0
287.7 -52 104.7 -83 95.4 -84 propionaldehyde 100.2 42.4 -58 16.0
-84 14.9 -85 crotonaldehyde 101.7 29.4 -71 0.0 -100 0.0 -100
butyraldehyde 114.8 43.3 -62 0.0 -100 0.0 -100 methyl ethyl 178.8
64.2 -64 20.8 -88 21.5 -88 ketone acrolein 101.8 45.3 -56 13.6 -87
14.8 -85
TABLE-US-00002 TABLE 2 5 mm 10 mm 15 mm porous porous porous mass
mass mass Other 20 mm 15 mm 13 mm compounds Control Tow % Tow % Tow
% benzene 79.0 54.0 -32 22.0 -72 20.0 -75 (.mu.g/cig) 1,3 220.0
192.0 -13 162.0 -26 98.0 -55 butadiene (.mu.g/cig) benzo[a]- 5.0
0.0 -100 0.0 -100 0.0 -100 Pyrene (ng/cig)
TABLE-US-00003 TABLE 3 5 mm 10 mm porous porous 15 mm Tar, mass
mass porous nicotine, 20 mm 15 mm mass 13 mm etc Control Tow
Control Tow Control Tow tar 39.0 37.1 35.8 34.4 33.7 34.9 (mg/cig)
nicotine 2.8 2.8 2.5 2.6 2.6 2.7 (mg/cig) water 17.7 17.0 14.0 13.3
14.7 11.2 (mg/cig) CO 34.4 35.4 32.6 32.1 31.4 31.2 (mg/cig)
[0120] In the following example, the effectiveness of a porous mass
in removing certain components of the cigarette smoke is
illustrated. The porous mass was made from 30 weight % GUR X192
from Ticona, of Dallas, Tex. and 70 weight % PICA 30.times.70 (60%
active carbon) from PICA USA, Inc. of Columbus, Ohio. The porous
mass has a % void volume of 75% and an encapsulated pressure drop
(EPD) of 3.3 mm of water/mm of porous mass length. The porous mass
has a circumference of about 24.5 mm. The PICA 30.times.70 carbon
had an average particle size of 405 microns (.mu.). The porous mass
was made by mixing the resin (GUR X192) and carbon (PICA
30.times.70) and then filling a mold with the mixture without
pressure on the heated mixture (free sintering). Then, the mold was
heated to 220.degree. C. for 60 minutes. Thereafter, the porous
mass was removed from the mold and allowed to cool. A
defined-length section of the porous mass was combined with a
sufficient amount of cellulose acetate tow to yield a filter with a
total encapsulated pressure drop of 70 mm of water. All smoke
assays were performed according to tobacco industry standards. All
cigarettes were smoked using the Canadian intense protocol (i.e.,
T-115, "Determination of "Tar," Nicotine and Carbon Monoxide in
Mainstream Tobacco Smoke," Health Canada, 1999) and a Cerulean 450
smoking machine.
TABLE-US-00004 TABLE 4 5 mm 10 mm 15 mm porous mass porous mass
porous mass Carbonyls 20 mm 15 mm 13 mm .mu.g/cigarette Control Tow
% Tow % Tow % formaldehyde 7.9 5.3 -32 0.0 -100 0.0 -100
acetaldehyde 477.7 478.0 -0 413.5 -13 337.8 -29 acetone 557.4 433.4
-22 214.0 -62 121.2 -78 propionaldehyde 118.5 72.5 -39 31.6 -73
17.4 -85 crotonaldehyde 83.0 38.5 -54 14.5 -83 10.7 -87
butyraldehyde 86.8 39.7 -54 10.7 -88 5.9 -93 methyl ethyl 195.7
100.8 -49 37.1 -81 19.2 -90 ketone acrolein 84.0 55.5 -34 22.5 -73
13.3 -84
TABLE-US-00005 TABLE 5 5 mm 10 mm 15 mm porous porous porous mass
mass mass Other 20 mm 15 mm 13 mm compounds Control Tow % Tow % Tow
% benzene 118.7 82.7 -30 40.1 -66 23.5 -80 (.mu.g/cig) 1,3 257.3
259.1 1 204.4 -21 148.7 -42 butadiene (.mu.g/cig) benzo[a]- 6.4 3.0
-53 0.0 -100 0.0 -100 Pyrene (ng/cig)
TABLE-US-00006 TABLE 6 Tar, 5 mm 10 mm 15 mm nicotine, porous mass
porous mass porous mass etc Control 20 mm Tow 15 mm Tow 13 mm Tow
tar (mg/cig) 41.5 41.5 41.2 38.4 nicotine 2.8 2.8 2.9 2.8 (mg/cig)
water 16.7 17.0 17.7 12.6 (mg/cig) CO (mg/cig) 30.8 33.2 35.5
31.6
[0121] In the following example, the effectiveness of a porous ion
exchange resin mass in removing certain components of the cigarette
smoke is illustrated. The porous mass was made from 20 weight % GUR
2105 from Ticona LLC and 80 weight % of an amine based resin
(AMBERLITE IRA96RF from Rohm & Haas of Philadelphia, Pa.). A 10
mm section of the porous mass was combined with a sufficient amount
of cellulose acetate tow (12 mm) to yield a filter with a total
encapsulated pressure drop of 70 mm of water. All smoke assays were
performed according to tobacco industry standards. All cigarettes
were smoked using the Canadian intense protocol (i.e., T-115,
"Determination of "Tar," Nicotine and Carbon Monoxide in Mainstream
Tobacco Smoke," Health Canada, 1999) and a Cerulean 450 smoking
machine.
TABLE-US-00007 TABLE 7 Carbonyls Ion Exchange .mu.g/cigarette
Control Resin % change formaldehyde 8.0 ND -100 acetaldehyde 491.0
192.0 -61 acetone 519.0 589.0 14 acrolein 65.0 28.0 -56
propionaldehyde 114.0 72.0 -37 crotonaldehyde 83.0 45.0 -45 methyl
ethyl 179.0 184.0 3 ketone butyraldehyde 54.0 61.0 13
[0122] In the following example, the effectiveness of a porous
desiccant mass in removing water from the cigarette smoke is
illustrated. The porous mass was made from 20 weight % GUR 2105
from Ticona, of Dallas, Tex. and 80 weight % of desiccant (calcium
sulfate, DRIERITE from W. A. Hammond DRIERITE Co. Ltd. of Xenia,
Ohio). A 10 mm section of the porous mass was combined with a
sufficient amount of cellulose acetate tow (15 mm) to yield a
filter with a total pressure drop of 70 mm of water. All smoke
assays were performed according to tobacco industry standards. All
cigarettes were smoked using the Canadian intense protocol (i.e.,
T-115, "Determination of "Tar," Nicotine and Carbon Monoxide in
Mainstream Tobacco Smoke," Health Canada, 1999) and a Cerulean 450
smoking machine.
TABLE-US-00008 TABLE 8 Desiccant % Desiccant % mg/cigarette Control
Conditioned Change Unconditioned Change Cambridge 62.0 55.6 -10.3
54.0 -12.8 particular matter water 15.0 12.8 -15.1 11.2 -25.6
deliveries nicotine 2.7 2.9 8.0 2.9 8.0 deliveries tar deliveries
44.2 39.9 -9.7 40.0 -9.7 carbon 35.0 35.9 2.5 35.0 0.1 monoxide
tar/nicotine 16.5 13.8 -16.4 13.8 -16.4 ratio
[0123] In the following example, a carbon-on-tow filter element is
compared to the inventive porous mass. In this comparison, equal
total carbon loadings are compared. In other words, the amount of
carbon in each element is the same; the length of the element is
allowed to change so that equal amounts of carbon were obtained.
The reported change in smoke component is made in relation to
conventional cellulose acetate filter (the % change is in relation
to a conventional cellulose acetate filter). All filter tips
consisted of the carbon element and cellulose acetate tow. All
filter tips were tipped with a sufficient length of cellulose
acetate filter tow to obtain a targeted filter pressure drop of 70
mm of water. The total filter length was 20 mm (carbon element and
tow element). The carbon was 30.times.70, 60% active PICA carbon.
All cigarettes were smoked using the Canadian intense protocol
(i.e., T-115, "Determination of "Tar," Nicotine and Carbon Monoxide
in Mainstream Tobacco Smoke," Health Canada, 1999).
TABLE-US-00009 TABLE 9 Total Carbon Total Carbon Loading = 39 mg
loading = 56 mg Carbon- porous Carbon- porous on-tow mass on-tow
mass (10 mm) (2 mm) (10 mm) (3 mm) Carbonyls % change % change %
change % change formaldehyde -24.6 -13.7 -32.3 -27.6 acetaldehyde
-4.5 -3.4 -6.3 -12.5 acetone -19.7 -33.1 -27.3 -49.2
propionaldehyde -32.0 -42.2 -38.6 -55.7 crotonaldehyde -64.5 -57.3
-71.0 -68.0 butyraldehyde 7.9 -34.4 -8.2 -54.4 methyl ethyl -35.4
-48.3 -45.6 -63.2 ketone acrolein -22.5 -40.3 -31.3 -52.6
[0124] In the following example, a porous mass made with a highly
active carbon (95% CCl.sub.4 absorption) is compared with a porous
mass made with a lower active carbon (60% CCl.sub.4 absorption).
The combined filters were made using a 10 mm section of the porous
mass plus a sufficient length of cellulose acetate to reach a
targeted combined encapsulated pressure drop of 69-70 mm of water.
These filters were attached to a commercial tobacco column and
smoked on a Cerulean SM 450 smoking machine using the Canadian
intense smoking protocol, T-115, "Determination of "Tar," Nicotine
and Carbon Monoxide in Mainstream Tobacco Smoke," Health Canada,
1999. The high active carbon was PICA RC 259, particle size
20.times.50, 95% activity (CCl.sub.4 adsorption). The low active
carbon was PICA PCA, particle size 30.times.70, 60% activity
(CCl.sub.4 adsorption). The carbon loading of each porous mass
element was 18.2 mg/mm, low active carbon, and 16.7 mg/mm, high
active carbon. The data is reported in relation to a conventional
cellulose acetate filter.
TABLE-US-00010 TABLE 10 60% active carbon 95% active carbon
Carbonyls (% change) (% change) formaldehyde -100.0 -100.0
acetaldehyde -65.8 -37.0 acetone -89.9 -83.0 propionaldehyde -91.0
-84.0 crotonaldehyde -100.0 -100.0 butyraldehyde -100.0 -100.0
methyl ethyl -100.0 -88.0 ketone acrolein -90.7 -87.0
TABLE-US-00011 TABLE 11 Other 60% active carbon 95% active carbon
compounds (% change) (% change) benzene 2.6 -72.0 1,3 butadiene
-3.2 -26.0 benzo[a]pyrene -100.0 -100.0
[0125] In the following example, the effect of particle size on
encapsulated pressure drop (EPD) is illustrated. Porous masses with
carbons of various particle sizes were molded into rods (length=39
mm and circumference=24.5 mm) by adding the mixture of carbon and
resin (GUR 2105) into a mold and heating (free sintering) the
mixture at 200.degree. C. for 40 minutes. Thereafter, the porous
mass was removed from the mold and allowed to cool to room
temperature. The EPD's were determined for 10 porous masses and
averaged.
TABLE-US-00012 TABLE 12 Carbon:GUR Average Average EPD Weight
Particle (mm of water/mm of Carbon Ratio Size (.mu.) porous mass
length) RC 259 75:25 569.0 2.2 PICA 80:20 402.5 3.5 NC506 75:25
177.5 25.0
[0126] In the following example, porous masses, as set forth in
Tables 1-3, are used to demonstrate that filters made with such
porous masses can be used to manufacture cigarettes that meet World
Health Organization (WHO) standards for cigarettes. WHO standards
may be found in WHO Technical Report Series No. 951, The Scientific
Basis of Tobacco Product Regulation, World Health Organization
(2008), Table 3.10, page 112. The results reported below, show that
the porous mass can be used to reduce the listed components from
tobacco smoke to a level below that recommended by the WHO.
TABLE-US-00013 TABLE 13 Highest % % Amt. Amt. Upper limit delivery
red..sup.2 red..sup.2 deliv. deliv. (.mu.g) Median.sup.1 (125% of
median) brand.sup.1 5 mm 10 mm 5 mm 10 mm 1,3-butadiene 53.3 66.7
75.5 13 26 65.7 55.9 acetaldehyde 687.6 859.5 997.2 28 37 718.0
628.2 acrolein 66.5 83.2 99.5 56 87 43.8 12.9 benzene 38.0 47.5
51.1 32 72 34.7 14.3 benzo[a]pyrene 9.1 11.4 13.8 100 100 0.0 0.0
formaldehyde 37.7 47.1 90.5 51 100 44.4 0.0 .sup.1Information based
on data in Counts, ME, et al., (2004) Mainstream smoke toxicant
yields and predicting relationships from a worldwide market sample
of cigarette brands: ISO smoking conditions, Regulatory Toxicology
and Pharmacology, 39: 111-134, and Counts ME, et al., (2005) Smoke
composition and predicting relationships for international
commercial cigarettes smoked with three machine-smoking conditions,
Regulatory Toxicology and Pharmacology, 41: 185-227. .sup.2%
reductions obtained from Tables 1-3 above.
[0127] In the following example, porous mass where ion exchange
resins are used as the active particles, as set forth in Table 4,
are used to demonstrate that filters made with such porous masses
can be used to manufacture cigarettes that meet World Health
Organization (WHO) standards for cigarettes. WHO standards may be
found in WHO Technical Report Series No. 951, The Scientific Basis
of Tobacco Product Regulation, World Health Organization (2008),
Table 3.10, page 112. The results reported below, show that the
porous mass can be used to reduce the certain components from
tobacco smoke to a level below that recommended by the WHO.
TABLE-US-00014 TABLE 14 Upper limit Highest % re- Amount (125% of
delivery duction.sup.2 delivered (.mu.g) Median.sup.1 median)
brand.sup.1 10 mm 10 mm acetaldehyde 687.6 859.5 997.2 61 388.9
acrolein 66.5 83.2 99.5 56 43.8 formaldehyde 37.7 47.1 90.5 100 0.0
.sup.1Information based on data in Counts, M E, et al., (2004)
Mainstream smoke toxicant yields and predicting relationships from
a worldwide market sample of cigarette brands: ISO smoking
conditions, Regulatory Toxicology and Pharmacology, 39: 111-134,
and Counts M E, et al., (2005) Smoke composition and predicting
relationships for international commercial cigarettes smoked with
three machine-smoking conditions, Regulatory Toxicology and
Pharmacology, 41: 185-227. .sup.2% reductions obtained from Table 4
above.
[0128] In the following example, the encapsulated pressure drop was
measured for a filter. The porous masses were formed by mixing the
binder particles (ultra high molecular weight polyethylene) and
active particles (carbon) at a desired weight ratio in a tumbled
jar until well mixed. A mold formed of stainless steel tube having
a length of 120 mm, an inside diameter of 7.747 mm, and a
circumference of 24.34 mm. The circumference of each of the molds
was lined with a standard, non-porous filter plug wrap. With a
fitting on the bottom to close off the bottom of the mold, the
mixture was then placed into the paper-lined molds to reach to the
top of the mold. The mold is tamped (bounced) ten times off of a
rubber stopper and then topped off to again reach the top of the
paper within the mold and bounced three times. The top of the mold
is then sealed and placed in an oven and heated, without the
addition of pressure, to a temperature of 220.degree. C. for 25 to
45 minutes, depending on the mold design, the molecular weight of
the binder particles, and the heat transfer. The encapsulated
pressure drop was measured in mm of water. Those components of the
mixtures and test results are listed below in Tables 15-20 below.
The polyethylene binder particles used are from Ticona Polymers
LLC, a division of Celanese Corporation of Dallas, Tex. under the
following tradenames, the molecular weights are in parentheses:
GUR.RTM. 2126 (approximately 4.times.10.sup.6 g/mol), GUR.RTM.
4050-3 (approximately 8-9.times.10.sup.6 g/mol), GUR.RTM. 2105
(approximately 0.47.times.10.sup.6 g/mol), GUR.RTM. X192
(approximately 0.60.times.10.sup.6 g/mol), GUR.RTM. 4012
(approximately 1.5.times.10.sup.6 g/mol), and GUR.RTM. 4022-6
(approximately 4.times.10.sup.6 g/mol).
TABLE-US-00015 TABLE 15 Comparative Examples Comparative Carbon
Loading for Comparative Comparative Example 3 Comparative Examples
Example 1 Example 2 (1:1 Blend: GUR .RTM. (30 .times. 70 Pica
Carbon) (GUR .RTM. 2126) (GUR .RTM. 4050-3) 2126:GUR .RTM. 4050-3)
Carbon:Binder Particle Average mg Average mg Average mg Weight
Ratio Carbon/mm Carbon/mm Carbon/mm 50/50 11.10 20.65 12.66 60/40
13.90 20.40 15.41 70/30 17.15 19.89 18.30 80/20 20.52 16.61 20.66
90/10 21.01 13.99 21.11
TABLE-US-00016 TABLE 16 Comparative Examples Encapsulated
Comparative Pressure Drop for Comparative Comparative Example 3
Comparative Examples Example 1 Example 2 (1:1 Blend GUR .RTM. (30
.times. 70 Pica Carbon) (GUR .RTM. 2126) (GUR .RTM. 4050-3)
2126:GUR .RTM. 4050-3) Carbon:Binder Particle Average mm of Average
mm of Average mm of Weight Ratio water/mm water/mm water/mm 50/50
20.0 11.9 20.1 60/40 20.0 19.8 20.0 70/30 20.0 20.0 20.0 80/20 19.9
19.8 20.3 90/10 16.0 20.0 15.2
TABLE-US-00017 TABLE 17 Porous masses described herein Carbon
Loading Binder Particle Binder Particle Binder Particle Binder
Particle (30 .times. 70 Pica Carbon) 1 (GUR .RTM. 2105) 2 (GUR
.RTM. X192) 3 (GUR .RTM. 4012) 4 (GUR .RTM. 4022-6) Carbon:Binder
Particle Average mg Average mg Average mg Average mg Weight Ratio
Carbon/mm Carbon/mm Carbon/mm Carbon/mm 50/50 NA* NA 11.66 10.51
60/40 10.61 11.16 13.35 12.66 65/35 11.70 12.23 NA NA 70/30 12.70
13.22 15.01 14.55 75/25 13.81 14.30 NA NA 80/20 14.75 15.34 16.20
16.57 *Where NA is noted, rods were not made for these cells.
TABLE-US-00018 TABLE 18 Porous masses described herein Encapsulated
Pressure Drop Binder Particle Binder Particle Binder Particle
Binder Particle (30 .times. 70 Pica Carbon) 1 (GUR .RTM. 2105) 2
(GUR .RTM.X192) 3 (GUR .RTM. 4012) 4 (GUR .RTM. 4022-6)
Carbon:Binder Particle Average mm Average mm Average mm Average mm
of Weight Ratio of water/mm of water/mm of water/mm water/mm 50/50
NA* NA 18.48 7.87 60/40 0.94 2.32 15.71 8.00 65/35 1.48 2.40 NA NA
70/30 1.59 2.52 11.43 6.22 75/25 1.88 2.74 NA NA 80/20 2.64 3.25
7.81 5.41 *Where NA is noted, rods were not made for these
cells.
TABLE-US-00019 TABLE 19 Porous Masses Described Herein Average
Carbon Binder Particle Average EPD mm of Pica Carbon Weight
Blend.sup.1 Carbon water/mm of Mesh % Weight % mg/mm porous mass 80
.times. 325 50 50 9.14 2.0 80 .times. 325 60 40 12.24 6.4 80
.times. 325 70 30 14.05 11.4 80 .times. 325 80 20 17.02 19.3
.sup.1The binder blend was a 1:1 weight mixture of GUR .RTM. 2105
and GUR .RTM. X192.
TABLE-US-00020 TABLE 20 Additional Comparative Examples Average of
Commercial 20 filters EPD/mm of cigarette filters Length EPD mm of
porous mass (Cellulose acetate) (mm) water/mm length Marlboro 21 70
3.3 Winston 27 79 2.9
[0129] The data shown in FIGS. 6 through 9 were generated from
additional EPD testing of porous masses described herein based on
carbon loading and comparative samples. The porous masses were
formed by mixing the binder particles, specifically ultra high
molecular weight polyethylene chosen from GUR.RTM. 2105, GUR.RTM.
X192, GUR.RTM. 4012, and GUR.RTM. 8020), and active particles
(carbon) at a desired weight ratio in a tumbler jar until well
mixed. A mold formed of stainless steel tube having a length of
about 120 mm, an inside diameter of about 7.747 mm, and a
circumference of about 24.5 mm (theoretical) or about 17.4
(theoretical). The circumference of each of the molds was lined
with a standard, non-porous filter plug wrap. With a fitting on the
bottom to close off the bottom of the mold, the mixture was then
placed into the paper-lined molds to reach to the top of the mold.
The mold is tapped (bounced) ten times off of a rubber stopper and
then topped off to again reach the top of the paper within the mold
and bounced three times. The top of the mold is then sealed and
placed in an oven and heated, without the addition of pressure, to
a temperature of 220.degree. C. for 25 to 45 minutes, depending on
the mold design, the molecular weight, and the heat transfer. The
length of the filter is then cut down to 100 mm. The circumference
of the filters tested is reported. These were substantially
circular in shape. The encapsulated pressure drop was measured in
mm of water according to the CORESTA procedure.
[0130] FIG. 6 is a comparative document that shows the results of
encapsulated pressure drop testing for carbon-on-tow filters having
an average circumference of about 24.5 mm.
[0131] FIG. 7 shows the results of encapsulated pressure drop
testing for porous mass filters of the present invention
(comprising polyethylene and carbon) having an average
circumference of about 24.5 mm.
[0132] FIG. 8 is a comparative document that shows the results of
encapsulated pressure drop testing for carbon-on-tow filters having
an average circumference of about 16.9 mm.
[0133] FIG. 9 shows the results of encapsulated pressure drop
testing for porous mass filters of the present invention
(comprising polyethylene and carbon) having an average
circumference of about 16.9 mm.
[0134] In the following example, porous mass segments were combined
with cellulose acetate filter segments to yield a segmented filter
rod that could then be used to produce segmented filters and,
optionally, cigarettes comprising segmented filters. The porous
mass rods and cellulose acetate filter rods utilized in this
example had dimensions of about 23.75 mm (+/1 0.15 mm)
circumference and about 120 mm length. Referring now to FIG. 10, a
diagram of the process of producing the segmented filters in this
example, cellulose acetate filter rods 1010 1012 were cut into 8
sections (about 15 mm each) to yield cellulose acetate segments
1014 and porous mass rods 1012 into 10 segments (about 12 mm each)
to yield porous mass segments 1016. The segments 1014, 1016 were
then aligned end-on-end in an alternating configuration, push
together, and wrapped with paper that was glued at the same line so
as to yield a segmented filter length 1018. The segmented filter
length 1018 was then cut in about the middle of every fourth
cellulose acetate segment 1014 so as to yield segmented filter rod
1020 having portions of a cellulose acetate segment 1014 disposed
on each end. One skilled in the art with the benefit of this
disclosure will understand that other sizes and configurations of
cellulose acetate segments and porous mass segments may be used to
yield the segmented filter lengths and can then be cut at any point
to yield a desired segmented filter rod, e.g., segmented filter rod
1020'.
[0135] In this example, the segmented filter rod 1020 described
above and shown in FIG. 11 was produced using a SOLARIS.RTM.
instrument (a filter combining machine, available from
International Tobacco Machine group) with minor modifications to
accommodate the weight and mechanical strength of the porous
masses. Combining speeds of up to 400 m/min were achieved. It was
observed that the cutting into segments, paper wrapping, and gluing
steps proceeded without issue. Further it was observed that the
amount of dust produced by the mechanical manipulation of the
porous masses was less than is typically produced with Dalmatian
filter rods are used in place of porous mass filter rods in the
combiner. Further, upon visual inspection of the segmented filter
rods produced the cellulose acetate segments were minimally, if at
all, contaminated with dust produced from the mechanical
manipulation of the porous masses.
[0136] 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.
* * * * *