Note: Descriptions are shown in the official language in which they were submitted.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
SMOKE FILTERS FOR SMOKING DEVICES WITH POROUS MASSES HAVING A
CARBON PARTICLE LOADING AND AN ENCAPSULATED PRESSURE DROP
Held of the lovtittion
The instant application is directed to a smoke filter for a smoking device
having an
element that enhances the smoke flowing thereover.
Background of the Invention
The World Health Organization (WHO) has set forth recommendations for the
reduction of certain components of tobacco smoke in 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. 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.
The use of carbon loaded tobacco smoke filters for removing tobacco smoke
components is known. These filters include carbon-on-tow filters and carbon
particulate
contained within chambers of the filter. U.S. Patent No. 5,423,336 discloses a
cigarette filter
with a chamber loaded with activated carbon. U.S. Publication No. 2010/0147317
discloses a
cigarette filter with a spiral channel where activated carbon is adhered to
the channel's walls.
GB1,592,952 discloses a cigarette filter where a body of continuous filaments
surrounds a
core of sorbent particles (e.g., activated carbon) bonded together with a
thermoplastic binder
(e.g., polyethylene and polypropylene). WO 2008/142420 discloses a cigarette
filter where
the absorbent material (e.g., activated carbon) is coated with a polymer
material (e.g., 0.4-5
wt % polyethylene). WO 2009/112591 discloses a cigarette filter that produces
little to no
dust with a composite material comprising at least one polymer (e.g.,
polyethylene) and at
least one other compound (e.g., activated carbon).
Carbon block technology where activated carbon is formed into a monolithic
porous
block with a binder is known. In U.S. Patent Nos. 4,753,728, 6,770,736,
7,049,382,
CA 02813575 2014-04-14
54242-3
2
7,160,453, and 7,112,280, carbon block technology, using low melt flow polymer
binders, are
principally used as water filters.
Accordingly, there is a need for a porous mass having active particulates that
can be used in a smoke filter, the smoke filter having an encapsulated
pressure drop that is
suitable for consumer use.
Summary of the Invention
The instant application is directed to a filter comprising a porous mass
having
an element that enhances the smoke flowing thereover. In some embodiments, the
filter is
incorporated within a smoking device.
In one embodiment, the present invention provides for a filter comprising: a
porous mass that comprises an active particle and a non-fibrous binder
particle, wherein the
non-fibrous binder particle has a melt flow index of 0 to 3.5 g/10 min at 190
C at 15 kG as
measured by ASTM D1238, wherein the porous mass is wrapped along its
longitudinal axis
with a compressible wrapping material and wherein encapsulated pressure drop
of the
wrapping material is greater than the encapsulated pressure drop of the porous
mass.
CA 02813575 2014-04-14
54242-3
2a
=
in one embodiment, the present invention provides a filter comprising: a
porous mass
that comprises an active particle and a binder particle, wherein the active
particle comprises
an element selected from the group consisting of: a nano-scaled carbon
particle, a carbon
nan.olube having at least one wall, a carbon nartohom, a bamboo-like carbon
nanostructure, a
fullerene, a thllerene aggregate, graphene, a few layer graphene, oxidized
graphene, a 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 superparamaenetic 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 in:in oxide nanoparticle, and any combination thereof.
In one embodiment, the present invention provides a smoking device comprising:
a
housing for a smokeable substance; and a filter comprising a porous mass that
comprises an
active particle and a binder particle, wherein the active particle comprises
an element selected
from the grow consisting of: a nano-scaled carbon particle, a carbon nanotube
having at
least one wall, a carbon nanohom, a bamboo-like carbon nanostructure, a
fullerene, a
fullerene aggregate, graphene, a few layer graphene, oxidized graphene, a iron
oxide
nanoparticle, a nanoparticle, a metal nanoparticle, a gold nanoparticle, a
silver nanoparticle,
metal oxide nanoparticle, an alumina nanoparticle, a magnetic nanoparticle, a
paramagnetic
nanoparticle, a supetparamaenetic nanoparticle, a gadolinium oxide
nanoparticle, a hematite
nanoparticle, a magnetite nanoparticle, a gado-nan.otube, an endofullerene,
Gd@C60, a core-
shell nanoparticle, an onionated nanoparticle, a :nanoshell, an onionated iron
oxide
nanoparticle, and any combination thereof.
=
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
3
In one embodiment, the present invention provides a smoking device filter
comprising: at least two neighboring in-series sections, wherein a first
section comprises a
porous mass that comprises an active particle and a binder particle, wherein
the active
particle comprises an element selected from the group consisting of: a nano-
scaled carbon
particle, a carbon nanotube having at least one wall, a carbon nanohom, a
bamboo-like
carbon nanostructure, a fullerene, a fullerene aggregate, graphene, a few
layer graphene,
oxidized graphene, a 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;
and wherein a
second section comprises a section that comprises an element selected from the
group
consisting of: a cavity, cellulose acetate, polypropylene, polyethylene,
polyolefin tow,
polypropylene tow, polyethylene terephthalate, polybutylene terephthalate,
random oriented
acetate, a paper, a corrugated paper, a concentric filter, carbon-on-tow,
silica, magnesium
silicate, a zeolite, a molecular sieve, a metallocene, a salt, a catalyst,
sodium chloride, nylon,
a flavorant, tobacco, a capsule, cellulose, a cellulosic derivative, a
catalytic converter, iodine
pentoxide, a coarse powder, a carbon particle, a carbon fiber, a fiber, a
glass bead, a
nanoparticle, a void chamber, a baffled void chamber, and any combination
thereof.
In one embodiment, the present invention provides a smoking device comprising:
a
filter that comprises a porous mass that comprises an active particle and a
binder particle,
wherein the active particle comprises 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, a 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
4
combination thereof; and a housing capable of maintaining a smokeable
substance in fluid
contact with the filter.
In one embodiment, the present invention provides a pack of filters
comprising: a
pack comprising at least one filter, wherein the filter comprises a porous
mass that comprises
an active particle and a binder particle, and wherein the active particle
comprises an element
selected from the group consisting of: a nano-scaled carbon particle, a carbon
nanotube
having at least one wall, a carbon nanohom, a bamboo-like carbon
nanostructure, a fullerene,
a fullerene aggregate, graphene, a few layer graphene, oxidized graphene, a
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:
In one embodiment, the present invention provides a pack of smoking devices
comprising: a pack comprising at least one smoking device that comprises a
filter that
comprises a porous mass that comprises an active particle and a binder
particle, wherein the
active particle comprises 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, a 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.
In one embodiment, the present invention provides a carton of smoking device
packs
comprising: a carton comprising at least one pack, the pack comprising at
least one smoking
device that comprises a filter that comprises a porous mass that comprises an
active particle
and a binder particle, wherein the active particle comprises an element
selected from the
group consisting of: a nano-scaled carbon particle, a carbon nanotube having
at least one
wall, a carbon nanohom, a bamboo-like carbon nanostructure, a fullerene, a
fullerene
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
aggregate, graphene, a few layer graphene, oxidized graphene, a 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,
5 a magnetite nanoparticle, a gado-nanotube, an endoftillerene, Gd@C60, a core-
shell
nanoparticle, an onionated nanoparticle, a nanoshell, an onionated iron oxide
nanoparticle,
and any combination thereof:
In one embodiment, the present invention provides a method of smoking a
smoking
device, the method comprising:
heating or lighting a smoking device to form smoke,
wherein the smoking device comprises at least one filter section comprising a
porous mass
that comprises an active particle and a binder particle, and wherein the
active particle
comprises 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 ftillerene aggregate, graphene, a few layer
graphene, oxidized
graphene, a 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; drawing the
smoke through
the smoking device, wherein the filter section reduces the presence of at
least one component
in the smoke as compared to a filter without the porous mass.
In one embodiment, the present invention provides a method of making a porous
mass, the method comprising: providing a blend comprising active particles and
a binder
particles; wherein the binder particles comprise a thermoplastic and the
active particles
comprise 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
nanostructire, a fullerene, a ftillerene aggregate, graphene, a few layer
graphene, oxidized
graphene, a 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
6
endofullerene, GdaC60, a core-shell nanoparticle, an onionated nanoparticle, a
nanoshell, an
onionated iron oxide nanoparticle, and any combination thereof; placing the
blend in a
mold; heating the blend in the mold to a temperature at or above the melting
point of the
binder particles so as to form a porous mass; and removing the porous mass
from the mold.
In one embodiment, the present invention provides a method of making a porous
mass, the method comprising: providing a blend comprising active particles and
binder
particles, wherein the binder particles comprise a thermoplastic and the
active particles
comprise an element selected from the group consisting of: a nano-scaled
carbon particle, a
carbon nanotube having at least one wall, a carbon nanohom, a bamboo-like
carbon
nanostructure, a fullerene, a fullerene aggregate, graphene, a few layer
graphene, oxidized
graphene, a 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, GdaC60, a core-shell nanoparticle, an onionated nanoparticle, a
nanoshell, an
onionated iron oxide nanoparticle, and any combination thereof; heating the
blend; and
extruding the blend while at an elevated temperature so as to form a porous
mass.
In one embodiment, the present invention provides a method for making a filter
rod,
the method comprising: providing a first filter section; providing at least
one second filter
section, wherein the second filter section comprises a porous mass that
comprises an active
particle and a binder particle, and wherein the active particle comprises an
element selected
from the group consisting of: a nano-scaled carbon particle, a carbon nanotube
having at
least one wall, a carbon nanohom, a bamboo-like carbon nanostructure, a
fullerene, a
fullerene aggregate, graphene, a few layer graphene, oxidized graphene, a 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; and joining the first filter
section and at least one
second filter section so as to form a filter rod.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
7
In one embodiment, the present invention provides a method comprising:
providing a
container that comprises at least a plurality of first filter section pieces;
providing a second
container comprising at least a plurality of second filter section pieces,
wherein the second
filter section pieces comprise a porous mass that comprises an active particle
and a binder
particle, and wherein the active particle comprises an element selected from
the group
consisting of: a nano-scaled carbon particle, a carbon nanotube having at
least one wall, a
carbon nanohom, a bamboo-like carbon nanostmcture, a fullerene, a fullerene
aggregate,
graphene, a few layer graphene, oxidized graphene, a 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; joining a first filter section piece and a second
filter section
piece end-to-end along the longitudinal axis of the first filter section piece
and the second
filter section piece to form an unwrapped filter rod; and wrapping the first
filter section piece
and the second filter section piece with a paper to form a filter rod.
In one embodiment, the present invention provides a method of making a smoking
device, the method comprising: providing a filter rod comprising at least one
filter section
that comprises a porous mass that comprises an active particle and a binder
particle, wherein
the active particle comprises an element selected from the group consisting
of: a nano-scaled
carbon particle, a carbon nanotube having at least one wall, a carbon nanohom,
a bamboo-
like carbon nanostructure, a fullerene, a fullerene aggregate, graphene, a few
layer graphene,
oxidized graphene, a 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 endoffillerene, Gd@C60, a core-shell nanoparticle, an onionated
nanoparticle, a
nanoshell, an onionated iron oxide nanoparticle, and any combination thereof;
providing a
tobacco column; cutting the filter rod transverse to its longitudinal axis
through the center of
the rod to form at least two smoking device filters having at least one filter
section that
comprises a porous mass that comprises an active particle and a binder
particle; and joining at
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
8
least one of the smoking device 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.
In one embodiment, the present invention provides a method of making a smoking
device, the method comprising: providing a tobacco column; joining a filter to
the tobacco
column, wherein the filter comprises a porous mass having an active particle
and a binder
particle, wherein the active particle comprises 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, a 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:
In one embodiment, the present invention provides an apparatus comprising: a
container area comprising at least a plurality of first filter section pieces;
a second container
area comprising at least a plurality of second filter section pieces, wherein
the second filter
section pieces comprises a porous mass that comprises an active particle and a
binder
particle, wherein the active particle comprises 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, a 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; a joiner area wherein a first filter section
piece and a second
filter section piece are joined; a wrapping area wherein the first filter
section piece and the
second filter section piece are wrapped with a paper to form a smoking device
filter; and a
conveyor to transport the smoking device filter to a subsequent area for
storage or use.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
9
In one embodiment, the present invention provides a smoking device filter
comprising: a filter section, the filter section comprising a porous mass that
comprises an
active particle and a binder particle, wherein the porous mass has a void
volume of about
40% to about 90%.
In one embodiment, the present invention provides a smoking device comprising:
a
housing for a smokeable substance, and a filter comprising a porous mass that
comprises an
active particle and a binder particle, wherein the porous mass has a void
volume of about
40% to about 90%.
In one embodiment, the present invention provides a smoking device filter
comprising: at least two neighboring longitudinal in-series sections, wherein
a first section
comprises a porous mass that comprises an active particle and a binder
particle, wherein
the porous mass has a void volume of about 40% to about 90%; and wherein a
second section
comprises a section that is selected from the group consisting of: a cavity,
cellulose acetate,
polypropylene, polyethylene, polyolefin tow, polypropylene tow, polyethylene
terephthalate,
polybutylene terephthalate, random oriented acetate, a paper, a corrugated
paper, a concentric
filter, carbon-on-tow, silica, magnesium silicate, a zeolite, a molecular
sieve, a metallocene, a
salt, a catalyst, sodium chloride, nylon, a flavorant, tobacco, a capsule,
cellulose, a cellulosic
derivative, a catalytic converter, iodine pentoxide, a coarse powder, a carbon
particle, a
carbon fiber, a fiber, a glass bead, a nanoparticle, a void chamber, a baffled
void chamber,
and any combination thereof.
In one embodiment, the present invention provides a smoking device comprising:
a
filter that comprises a porous mass that comprises an active particle and a
binder particle,
wherein the porous mass has a void volume of about 40% to about 90%; and a
housing
capable of maintaining a smokeable substance in fluid contact with the filter.
In one embodiment, the present invention provides a pack of filters
comprising: a
pack comprising at least one filter that comprises a porous mass that
comprises an active
particle and a binder particle, and wherein the porous mass has a void volume
of about 40%
to about 90%.
In one embodiment, the present invention provides a pack of smoking devices
comprising: a pack comprising at least one smoking device that comprises a
filter that
comprises a porous mass that comprises an active particle and a binder
particle, wherein the
porous mass has a void volume of about 40% to about 90%.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
In one embodiment, the present invention provides a smoking device carton
comprising: a container comprising at least one pack that comprises at least
one smoking
device, wherein the smoking device comprises a filter that comprises a porous
mass that
comprises an active particle and a binder particle, and wherein the porous
mass has a void
5 volume of about 40% to about 90%.
In one embodiment, the present invention provides a method of smoking a
smoking
device, the method comprising: heating or lighting a smoking device to form
smoke, wherein
the smoking device comprises at least one filter section comprising a porous
mass that
comprises an active particle and a binder particle, and wherein the porous
mass has a void
10 volume of about 40% to about 90%; drawing the smoke through the smoking
device, wherein
the filter section reduces the presence of at least one component in the smoke
as compared to
a filter without the porous mass.
In one embodiment, the present invention provides a method of making a filter,
the
method comprising: providing a blend comprising active particles and binder
particles;
placing the blend in a mold; heating the blend in the mold to a temperature at
or above the
melting point of the binder particles so as to form a porous mass, wherein the
porous mass
has a void volume of about 40% to about 90%; removing the porous mass from the
mold; and
forming a filter comprising the porous mass.
In one embodiment, the present invention provides a method of making a smoking
device filter, the method comprising: providing a blend comprising active
particles and
binder particles; heating the blend; extruding the blend while at an elevated
temperature so as
to form a porous mass, wherein the porous mass has a void volume of about 40%
to about
90%; and forming a filter comprising the porous mass.
In one embodiment, the present invention provides a method for making a
smoking
device, the method comprising: providing a first filter section; providing at
least one second
filter section, wherein the second filter section comprises a porous mass that
comprises an
active particle and a binder particle, and wherein the porous mass has a void
volume of about
40% to about 90%; joining the first filter section and at least one second
filter section so as to
form a filter rod; and joining at least a portion of the filter rod with a
tobacco column to form
a smoking device.
In one embodiment, the present invention provides a method of making a filter
rod,
the method comprising: providing a container that comprises at least a
plurality of first filter
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
11
section pieces; providing a second container comprising at least a plurality
of second filter
section pieces, wherein the second filter section pieces comprise a porous
mass that
comprises an active particle and a binder particle, and wherein the porous
mass has a void
volume of about 40% to about 90%; joining a first filter section piece and a
second filter
section piece end-to-end along the longitudinal axis of the first filter
section piece and the
second filter section piece to form an unwrapped filter rod; and wrapping the
first filter
section piece and the second filter section piece with a paper to form a
filter rod.
In one embodiment, the present invention provides a method of making a smoking
device, the method comprising: providing a filter rod comprising at least one
filter section
that comprises a porous mass that comprises an active particle and a binder
particle, wherein
the porous mass has a void volume of about 40% to about 90%; providing a
tobacco column;
cutting the filter rod transverse to its longitudinal axis through the center
of the rod to form at
least two smoking device filters having at least one filter section that
comprises a porous
mass that comprises an active particle and a binder particle; and joining at
least one of the
smoking device 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.
In one embodiment, the present invention provides a method of making a smoking
device, the method comprising: providing a tobacco column; joining a filter to
the tobacco
column, wherein the filter comprises a porous mass that comprises an active
particle and a
binder particle, and wherein the porous mass has a void volume of about 40% to
about 90%.
In one embodiment, the present invention provides an apparatus comprising: a
container area comprising at least a plurality of first filter section pieces;
a second container
area comprising at least a plurality of second filter section pieces, wherein
the second filter
section pieces comprises a porous mass that comprises an active particle and a
binder
particle, wherein the porous mass has a void volume of about 40% to about 90%;
a joiner
area wherein a first filter section piece and a second filter section piece
are joined; a wrapping
area wherein the first filter section piece and the second filter section
piece are wrapped with
a paper to form a smoking device filter; and a conveyor to transport the
smoking device filter
to a subsequent area for storage or use.
In one embodiment, the present invention provides a filter comprising: a
porous mass
that comprises an active particle and a binder particle, wherein the porous
mass has an active
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
12
particle loading of at least about 1 mg/mm and an encapsulated pressure drop
of about 20 mm
of water or less per mm of porous mass, and wherein the active particle is not
carbon.
In one embodiment, the present invention provides a smoking device comprising:
a
smokeable substance; and a filter comprising a porous mass that comprises an
active particle
and a binder particle, wherein the porous mass has an active particle loading
of at least about
1 mg/mm and an encapsulated pressure drop of about 20 mm of water or less per
mm of
porous mass.
In one embodiment, the present invention provides a smoking device filter
comprising: at least two neighboring longitudinal in-series filter sections,
wherein a first
filter section comprises a porous mass that comprises an active particle and a
binder particle,
wherein the porous mass has an active particle loading of at least about 1
mg/mm and an
encapsulated pressure drop of about 20 mm of water or less per mm of porous
mass; and
wherein a second filter section comprises a section that is selected from the
group consisting
of: a cavity, cellulose acetate, polypropylene, polyethylene, polyolefin tow,
polypropylene
tow, polyethylene terephthalate, polybutylene terephthalate, random oriented
acetate, a paper,
a corrugated paper, a concentric filter, carbon-on-tow, silica, magnesium
silicate, a zeolite, a
molecular sieve, a metallocene, a salt, a catalyst, sodium chloride, nylon, a
flavorant, tobacco,
a capsule, cellulose, a cellulosic derivative, a catalytic converter, iodine
pentoxide, a coarse
powder, a carbon particle, a carbon fiber, a fiber, a glass bead, a
nanoparticle, a void
chamber, a baffled void chamber, and any combination thereof
In one embodiment, the present invention provides a smoking device comprising:
a
filter that comprises a porous mass that comprises an active particle and a
binder particle,
wherein the porous mass has an active particle loading of at least about 1
mg/mm and an
encapsulated pressure drop of about 20 mm of water or less per mm of porous
mass; and a
housing capable of maintaining a smokeable substance in fluid contact with the
filter.
In one embodiment, the present invention provides a pack of filters
comprising: a
pack comprising at least one filter, wherein the filter comprises a porous
mass that comprises
an active particle and a binder particle, and wherein the porous mass has an
active particle
loading of at least about 1 mg/mm and an encapsulated pressure drop of about
20 min of
water or less per mm of porous mass.
In one embodiment, the present invention provides a pack comprising: a
container
comprising at least one smoking device that comprises a filter, the filter
comprising a porous
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
13
mass that comprises an active particle and a binder particle, and wherein the
porous mass has
an active particle loading of at least about 1 mg/mm. and an encapsulated
pressure drop of
about 20 mm of water or less per mm of porous mass.
In one embodiment, the present invention provides a carton of smoking device
packs
comprising: a container comprising at least one pack that comprises at least
one smoking
device that comprises a porous mass that comprises a filter that comprises an
active particle
and a binder particle, and wherein the porous mass has an active particle
loading of at least
about I mg/mm and an encapsulated pressure drop of about 20 mm of water or
less per mm
of porous mass.
In one embodiment, the present invention provides a method of smoking a
smoking
device, the method comprising: heating or lighting a smoking device to form
smoke, wherein
the smoking device comprise at least one filter section comprising a porous
mass that
comprises an active particle and a binder particle, and wherein the porous
mass has an active
particle loading of at least about 1 mg/ram and an encapsulated pressure drop
of about 20 mm
of water or less per mm of porous mass; and drawing the smoke through the
smoking device,
wherein the filter section reduces the presence of at least one component in
the smoke as
compared to a filter without the porous mass.
In one embodiment, the present invention provides a method of making a filter,
the
method comprising: providing a blend comprising active particles and binder
particles;
placing the blend in a mold; heating the blend in the mold to a temperature at
or above the
melting point of the binder particle so as to form a porous mass, wherein the
porous mass has
an active particle loading of at least about 1 mg/mm and an encapsulated
pressure drop of
about 20 mm of water or less per mm of porous mass; removing the porous mass
from the
mold; and forming a filter comprising the porous mass.
In one embodiment, the present invention provides a method of making a smoking
device filter, the method comprising: providing a blend comprising active
particles and
binder particles; heating the blend; extruding the blend while at an elevated
temperature so as
to form a porous mass, wherein the porous mass has an active particle loading
of at least
about I mg/mm and an encapsulated pressure drop of about 20 mm of water or
less per mm
of porous mass; and forming a filter comprising the porous mass.
In one embodiment, the present invention provides a method for producing a
smoking
device, the method comprising: providing a first filter section; providing at
least one second
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
14
filter section, wherein the second filter section comprises a porous mass that
comprises an
active particle and a binder particle, and wherein the porous mass has an
active particle
loading of at least about 1 mg/mm and an encapsulated pressure drop of about
20 mm of
water or less per mm of porous mass; joining the first filter section and at
least one second
filter section so as to form. a filter rod; and joining at least a portion of
the filter rod with a
tobacco column to form a smoking device.
In one embodiment, the present invention provides a method of making a filter
rod,
the method comprising: providing a container that comprises at least a
plurality of first filter
section pieces; providing a second container comprising at least a plurality
of second filter
section pieces, wherein the second filter section pieces comprise a porous
mass that
comprises an active particle and a binder particle, and wherein the porous
mass has an active
particle loading of at least about 1 mg/mm and an encapsulated pressure drop
of about 20 mm
of water or less per mm of porous mass; joining a first filter section piece
and a second filter
section piece end-to-end along the longitudinal axis of the first filter
section piece and the
second filter section piece to form an unwrapped filter rod; wrapping the
first filter section
piece and the second filter section piece with a paper to form a filter rod;
and transporting the
filter rod to a subsequent area for storage or use.
In one embodiment, the present invention provides a method of making a smoking
device, the method comprising: providing a filter rod comprising at least one
filter section
that comprises a porous mass that comprises an active particle and a binder
particle, wherein
the porous mass has an active particle loading of at least about 1 mg/mm and
an encapsulated
pressure drop of about 20 mm of water or less per mm of porous mass; providing
a tobacco
column; cutting the filter rod transverse to its longitudinal axis through the
center of the rod
to form at least two smoking device filters having at least one filter section
that comprises a
porous mass that comprises an active particle and a binder particle; and
joining at least one of
the smoking device 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.
In one embodiment, the present invention provides a method of making a smoking
device, the method comprising: providing a tobacco column; joining a filter to
the tobacco
column, wherein the filter comprises an active particle and a binder particle,
wherein the
porous mass has an active particle loading of at least about 1 mg/mm and an
encapsulated
pressure drop of about 20 mm of water or less per mm of porous mass.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
In one embodiment, the present invention provides an apparatus comprising: a
container area comprising at least a plurality of first filter section pieces;
a second container
area comprising at least a plurality of second filter section pieces, wherein
the second filter
section pieces comprises a porous mass that comprises an active particle and a
binder
5
particle, wherein the porous mass has an active particle loading of at least
about 1 mg/mm
and an encapsulated pressure drop of about 20 mm of water or less per mm of
porous mass; a
joiner area wherein a first filter section piece and a second filter section
piece are joined; a
wrapping area wherein the first filter section piece and the second filter
section piece are
wrapped with a paper to form a smoking device filter; and a conveyor to
transport the
10 smoking device filter to a subsequent area for storage or use.
In one embodiment, the present invention provides a filter comprising: a
porous mass
that comprises an active particle and a binder particle, wherein the active
particle comprises
carbon and 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 porous
mass.
15 In one
embodiment, the present invention provides a smoking device comprising: a
smokeable substance; and a filter comprising a porous mass that comprises an
active particle
and a binder particle, wherein the active particle comprises carbon and 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 porous mass.
in one embodiment, the present invention provides a smoking device filter
comprising: at least two neighboring longitudinal in-series sections, wherein
a first section
comprises a porous mass that comprises an active particle and a binder
particle; wherein the
active particle is carbon and 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
porous mass;
and wherein a second section comprises a section that is selected from the
group consisting
of a cavity, cellulose acetate, polypropylene, polyethylene, polyolefin tow,
polypropylene
tow, polyethylene terephthalate, polybutylene terephthalate, random oriented
acetate, a paper,
a corrugated paper, a concentric filter, carbon-on-tow, silica, magnesium
silicate, a zeolite, a
molecular sieve, a metallocene, a salt, a catalyst, sodium chloride, nylon, a
flavorant, tobacco,
a capsule, cellulose, a cellulosic derivative, a catalytic converter, iodine
pentoxide, a coarse
powder, a carbon particle, a carbon fiber, a fiber, a glass bead, a
nanoparticle, a void
chamber, a baffled void chamber, and any combination thereof
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
16
In one embodiment, the present invention provides a smoking device comprising:
a
filter that comprises a porous mass that has a carbon loading of at least
about 6 mg/111m and
an encapsulated pressure drop of about 20 mm of water or less per mm of porous
mass; and a
housing capable of maintaining a smokeable substance in fluid contact with the
filter.
In one embodiment, the present invention provides a pack of filters
comprising: a
pack comprising at least one filter, the filter comprising a porous mass that
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 porous mass.
In one embodiment, the present invention provides a pack of smoking devices
comprising: a pack comprising at least one smoking device that comprises a
filter, wherein
the filter comprises a porous mass that comprises an active particle and a
binder particle, and
wherein the active particle comprises carbon, and 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 porous mass.
In one embodiment, the present invention provides a carton of smoking device
packs
comprising: a container comprising at least one pack that comprises at least
one smoking
device, the smoking device comprising a filter that comprises a porous mass,
the porous mass
comprising an active particle and a binder particle, and wherein the active
particle comprises
carbon and the porous mass has a carbon loading of at least about 6 mg/mu; and
an
encapsulated pressure drop of about 20 mm of water or less per mm of porous
mass.
In one embodiment, the present invention provides a method of smoking a
smoking
device, the method comprising: heating or lighting a smoking device to form
smoke, wherein
the smoking device comprises a smokeable substance and at least one filter
section
comprising a porous mass that comprises an active particle and a binder
particle, wherein the
active particle comprises carbon, and 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 porous
mass; drawing the smoke through the smoking device to form a smoke stream; and
allowing
the filter section to at least reduce the presence of at least one component
in the smoke stream
as compared to a filter without the porous mass.
In one embodiment, the present invention provides a method of making a filter,
the
method comprising: providing a blend comprising active particles and binder
particles;
placing the blend in a mold; heating the blend in the mold to a temperature at
or above the
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
17
melting point of the binder particles so as to form a porous mass, wherein the
active particle
comprises carbon and 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 porous
mass;
removing the porous mass from the mold; and forming a filter comprising the
porous mass.
In one embodiment, the present invention provides a method of making a smoking
device filter, the method comprising: providing a blend comprising active
particles and
binder particles; heating the blend; extruding the blend while at an elevated
temperature so as
to form a porous mass, wherein the active particles comprise carbon and 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 porous mass; forming a smoking device filter
comprising the
porous mass.
In one embodiment, the present invention provides a method for producing a
smoking
device, the method comprising: providing a first filter section; providing at
least one second
filter section, wherein the second filter section comprises a porous mass that
has a carbon
loading of at least about 6 mg/nun and an encapsulated pressure drop of about
20 mm of
water or less per mm of porous mass; joining the first filter section and at
least one second
filter section longitudinally so as to form a filter rod; and joining at least
a portion of the filter
rod with a tobacco column to form a smoking device.
In one embodiment, the present invention provides a method of making a filter
rod,
the method comprising: providing a container that comprises at least a
plurality of first filter
section pieces; providing a second container comprising at least a plurality
of second filter
section pieces, wherein the second filter section pieces comprise a porous
mass that 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 porous mass; joining a first filter section piece
and a second filter
section piece end-to-end along the longitudinal axis of the first filter
section piece and the
second filter section piece to form an unwrapped filter rod; and wrapping the
first filter
section piece and the second filter section piece with a paper to form a
filter rod.
In one embodiment, the present invention provides a method of making a smoking
device, the method comprising: providing a filter rod comprising at least one
filter section
that comprises a porous mass that 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 porous
mass;
providing a tobacco column; cutting the filter rod transverse to its
longitudinal axis to form at
CA 02813575 2013-05-21
54242-3
18
least two smoking device filters having at least one filter section that
comprises a porous
mass; and joining at least one of the smoking device 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.
In one embodiment, the present invention provides a method of making a
smoking device, the method comprising: providing a tobacco column; and joining
a filter to
the tobacco column, the filter comprising having 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
porous mass.
In one embodiment, the present invention provides an apparatus comprising: a
container area comprising at least a plurality of first filter section pieces;
a second container
area comprising at least a plurality of second filter section pieces, wherein
the second filter
section pieces comprises a porous mass that comprises an active particle and a
binder particle,
wherein the active particle comprises carbon and 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 porous mass; a joiner area wherein a first filter section piece and a
second filter section
piece are joined along their longitudinal axes; a wrapping area wherein the
first filter section
piece and the second filter section piece are wrapped with a paper to form a
smoking device
filter; and a conveyor to transport the smoking device filter to a subsequent
area for storage or
use.
=
In one embodiment, the present invention provides a compressible wrap
surrounding the longitudinal axis of a porous mass filter section.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that itself comprises a plurality of active
particles and a plurality of
non-fibrous binder particles, wherein the active particles and the non-fibrous
binder particles
are bound together at a plurality of sintered contact points, and wherein the
active particles
comprises 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
CA 02813575 2013-05-21
=
54242-3
18a
graphene, a 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.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that comprises active particles and non-fibrous
binder particles,
wherein the active particles and the non-fibrous binder particles are bound
together at a
plurality of sintered contact points, wherein the active particle is not
carbon, and wherein the
porous mass has an active particle loading of at least about 1 mg/mm and an
encapsulated
pressure drop of about 20 mm of water or less per mm of porous mass.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that comprises active particles and non-fibrous
binder particles,
wherein the active particles and the non-fibrous binder particles are bound
together at a
plurality of sintered contact points, wherein the active particle comprises
carbon, and 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 porous mass.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that comprises a plurality of active particles and a
plurality of non-
fibrous binder particles, wherein the porous mass has a void volume of about
40% to about
90%, and wherein the active particles and the non-fibrous binder particles are
bound together
at a plurality of sintered contact points.
In one embodiment, the present invention provides a smoking device
comprising: a smokeable substance, and a filter in fluid communication with
the smokeable
substance, the filter comprising a porous mass that comprises a plurality of
active particles
and a plurality of non-fibrous binder particles, wherein the porous mass has a
void volume of
CA 02813575 2016-01-07
54242-3
18b
In one embodiment, the present invention provides a smoking device
comprising: a filter that comprises a porous mass that comprises active
particles and non-
fibrous binder particles, wherein the non-fibrous binder particles have a melt
flow index of 0
to 3.5 g/10 min at 190 C at 15 kg as measured by ASTM D1238, wherein the
porous mass is
wrapped along its longitudinal axis with a compressible wrapping material and
wherein
encapsulated pressure drop of the wrapping material is greater than the
encapsulated pressure
drop of the porous mass; wherein the active particles and the non-fibrous
particles are bound
together at a plurality of sintered contact points by heating the porous mass
contained by the
wrapping material, and wherein the wrapping material is bonded to the porous
mass at a
second plurality of contact points; and a housing that maintains a smokeable
substance in fluid
contact with the filter.
In one embodiment, the present invention provides a method for producing a
smoking device, the method comprising: providing a first filter section;
providing at least one
second filter section, wherein the second filter section comprises a porous
mass that comprises
active particles and non-fibrous binder particles, wherein the non-fibrous
binder particles have
a melt flow index of 0 to 3.5 g/10 min at 190 C at 15 kg as measured by ASTM
D1238,
wherein the porous mass is wrapped along its longitudinal axis with a
compressible wrapping
material and wherein encapsulated pressure drop of the wrapping material is
greater than the
encapsulated pressure drop of the porous mass; wherein the active particles
and the non-
fibrous particles are bound together at a plurality of sintered contact points
by heating the
porous mass contained by the wrapping material, and wherein the wrapping
material is
bonded to the porous mass at a second plurality of contact points; joining the
first filter
section and at least one second filter section longitudinally so as to form a
filter rod; and
joining at least a portion of the filter rod with a tobacco column to form a
smoking device.
In one embodiment, the present invention provides a method of making a filter
rod, the method comprising: providing a container that comprises at least a
plurality of first
filter section pieces; providing a second container comprising at least a
plurality of second
filter section pieces, wherein the second filter section pieces comprise a
porous mass that
comprises active particles and non-fibrous binder particles, wherein the non-
fibrous binder
particles have a melt flow index of 0 to 3.5 g/10 min at 190 C at 15 kg as
measured by
CA 02813575 2016-01-07
54242-3
18c
ASTM D1238, wherein the porous mass is wrapped along its longitudinal axis
with a=
compressible wrapping material and wherein encapsulated pressure drop of the
wrapping
material is greater than the encapsulated pressure drop of the porous mass;
wherein the active
particles and the non-fibrous particles are bound together at a plurality of
sintered contact
points by heating the porous mass contained by the wrapping material, and
wherein the
wrapping material is bonded to the porous mass at a second plurality of
contact points; joining
a first filter section piece and a second filter section piece end-to-end
along the longitudinal
axis of the first filter section piece and the second filter section piece to
form an unwrapped
filter rod; and wrapping the first filter section piece and the second filter
section piece with a
paper to form a filter rod.
In one embodiment, the present invention provides a method of making a
smoking device, the method comprising: providing a filter rod comprising at
least one filter
section that comprises a porous mass that comprises active particles and non-
fibrous binder
particles, wherein the non-fibrous binder particles have a melt flow index of
0 to 3.5 g/10 min
at 190 C at 15 kg as measured by ASTM D1238, wherein the porous mass is
wrapped along
its longitudinal axis with a compressible wrapping material and wherein
encapsulated pressure
drop of the wrapping material is greater than the encapsulated pressure drop
of the porous
mass; wherein the active particles and the non-fibrous particles are bound
together at a
plurality of sintered contact points by heating the porous mass contained by
the wrapping
material, and wherein the wrapping material is bonded to the porous mass at a
second
plurality of contact points; providing a tobacco column; cutting the filter
rod transverse to its
longitudinal axis to form at least two smoking device filters having at least
one filter section
that comprises a porous mass; and joining at least one of the smoking device
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.
In one embodiment, the present invention provides a method of making a
smoking device, the method comprising: providing a tobacco column; joining a
filter to the
tobacco column, the filter comprising a porous mass that comprises active
particles and non-
fibrous binder particles, wherein the non-fibrous binder particles have a melt
flow index of 0
to 3.5 g/10 min at 190 C at 15 kg as measured by ASTM D1238, wherein the
porous mass is
CA 02813575 2016-01-07
54242-3
18d
wrapped along its longitudinal axis with a compressible wrapping material and
wherein
encapsulated pressure drop of the wrapping material is greater than the
encapsulated pressure
drop of the porous mass; wherein the active particles and the non-fibrous
particles are bound
together at a plurality of sintered contact points by heating the porous mass
contained by the
wrapping material, and wherein the wrapping material is bonded to the porous
mass at a
second plurality of contact points.
In one embodiment, the present invention provides an apparatus comprising: a
container area comprising at least a plurality of first filter section pieces;
a second container
area comprising at least a plurality of second filter section pieces, wherein
the second filter
section pieces comprise a porous mass that comprises active particles and non-
fibrous binder
particles, wherein the non-fibrous binder particles have a melt flow index of
0 to 3.5 g/10 min
at 190 C at 15 kg as measured by ASTM D1238, wherein the porous mass is
wrapped along
its longitudinal axis with a compressible wrapping material and wherein
encapsulated pressure
drop of the wrapping material is greater than the encapsulated pressure drop
of the porous
mass; wherein the active particles and the non-fibrous particles are bound
together at a
plurality of sintered contact points by heating the porous mass contained by
the wrapping
material, and wherein the wrapping material is bonded to the porous mass at a
second=
plurality of contact points; a joiner area wherein a first filter section
piece and a second filter
section piece are joined along their longitudinal axes; a wrapping area
wherein the first filter
section piece and the second filter section piece are wrapped with a paper to
form a smoking
device filter; and a conveyor to transport the smoking device filter to a
subsequent area for
storage or use.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that itself comprises a plurality of active
particles and a plurality of
non-fibrous binder particles, wherein the active particles and the non-fibrous
binder particles
are bound together at a plurality of sintered contact points by heating the
porous mass
contained by a wrapping material, and wherein the wrapping material is bonded
to the porous
mass at a second plurality of contact points; and wherein the active particles
comprises 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,
CA 02813575 2016-01-07
54242-3
18e
a fullerene aggregate, graphene, a few layer graphene, oxidized graphene, a
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.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that comprises active particles and non-fibrous
binder particles,
wherein the active particles and the non-fibrous binder particles are bound
together at a
plurality of sintered contact points by heating the porous mass contained by a
wrapping
= material, and wherein the wrapping material is bonded to the porous mass
at a second
plurality of contact points, wherein the non-fibrous binder particles have a
melt flow index
of 0 to 3.5 g/10 min at 190 C at 15 kg as measured by ASTM D1238 wherein the
active
particles are free of carbon, and wherein the porous mass has an active
particle loading of at
least about 1 mg/mm and an encapsulated pressure drop of about 20 mm of water
or less per
mm of porous mass.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that comprises active particles and non-fibrous
binder particles,
wherein the active particles and the non-fibrous binder particles are bound
together at a
plurality of sintered contact points by heating the porous mass contained by a
wrapping
material, and wherein the wrapping material is bonded to the porous mass at a
second
plurality of contact points, wherein the non-fibrous binder particles have a
melt flow index
of 0 to 3.5 g/10 min at 190 C at 15 kg as measured by ASTM D1238 wherein the
active
particle comprises carbon, and 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 porous mass.
In one embodiment, the present invention provides a smoking device filter
comprising: a porous mass that comprises a plurality of active particles and a
plurality of non-
CA 02813575 2016-01-07
54242-3
18f
fibrous binder particles by heating the porous mass contained by a wrapping
material, and
wherein the wrapping material is bonded to the porous mass at a second
plurality of contact
points, wherein the non-fibrous binder particles have a melt flow index of 0
to 3.5 g/10 min
at 190 C at 15 kg as measured by ASTM D1238 wherein the porous mass has a void
volume
of about 40% to about 90%, and wherein the active particles and the non-
fibrous binder
particles are bound together at a plurality of sintered contact points.
In one embodiment, the present invention provides a smoking device
comprising: a smokeable substance, and a filter in fluid communication with
the smokeable
substance, the filter comprising a porous mass that comprises a plurality of
active particles
and a plurality of non-fibrous binder particles by heating the porous mass
contained by a
wrapping material, and wherein the wrapping material is bonded to the porous
mass at a
second plurality of contact points, wherein the non-fibrous binder particles
have a melt flow
index of 0 to 3.5 g/10 min at 190 C at 15 kg as measured by ASTM D1238;
wherein the
porous mass has a void volume of about 40% to about 90%, and wherein the
active particles
and the non-fibrous binder particles are bound together at a plurality of
sintered contact
points.
In one embodiment, the present invention provides a smoking device
comprising a smokeable substance in fluid communication with the smoking
device filter as
described above.
The features and advantages of the present invention will be readily apparent
to
one of ordinary skill in the art upon a reading of the description of the
preferred embodiments
that follows.
Description of the Drawings
For the purpose of illustrating the invention, there is shown in the drawings
a
form that is presently preferred; it being understood, however, that this
invention is not
limited to the precise arrangements and instrumentalities shown.
CA 02813575 2016-01-07
54242-3
18g
Figure 1 is a cross-sectional view of an embodiment of a cigarette including a
filter section according to the present invention.
Figure 2 is a cross-sectional view of another embodiment of a cigarette
including a filter section according to the present invention.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
19
Figure 3 is a cross-sectional view of another embodiment of a cigarette
including a
filter section according to the present invention.
Figure 4 is a cross-sectional view of a smoking device including a filter
section
according to the present invention.
Figure 5 is a photomicrograph of a section of an embodiment of a porous mass
of the
present invention.
Figure 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.
Figure 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.
Figure 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.
Figure 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.
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
Detailed Description of the Invention
The porous mass described hereinafter may be used with a smoking device, such
as a
tobacco smoking device. The porous mass includes active particles and non-
fibrous binder
particles and may form a portion of a filter section of a smoking device. The
term "porous
5 mass"
as used herein refers to a mass comprising active particles and nonfibrous
binder
particles that form a structure bound by the binder particles and that
includes void spaces
therein, whereby smoke can travel through the porous mass and interact with
the active
particles. In some embodiments, the structure may be formed through the
application of heat
so that the binder particles soften to bind to the active particles at various
contact points.
10 While
reference is made herein to "tobacco," it should be understood that the porous
mass
described herein is also suitable for use with other substances that produce
smoke when
burned or heated (i.e., smokeable substances).
It should be noted that when "about" is provided below in reference to a
number, the
term "about" modifies each number of the numerical list. It should be noted
that in some
15
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.
Referring to Figures 1-4, there is shown several embodiments of a smoking
device
(these are representative, but not limiting on the smoking devices
contemplated hereinafter).
20 The
term "smoking device," as used herein, most often refers to a cigarette, but
it is not so
limited and could be used with other smoking devices, such as cigarette
holders, cigars, cigar
holders, pipes, water pipes, hookahs, electronic smoking devices, roll-your-
own cigarettes or
cigars, etc. Hereinafter, reference will be to a cigarette as a generic term
covering all of these
smoking devices (unless otherwise specified).
in some embodiments, a smoking device may comprise a housing capable of
maintaining a smokeable substance in fluid contact 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, and a paper.
In Figure I , cigarette 10 includes a tobacco column 12 and a filter 14.
Filter 14 may
comprise at least two sections, first section 16 and second section 18. For
example, the first
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
21
section 16 may comprise conventional filter material (discussed in greater
detail below) and
the second section 18 comprises a porous mass (discussed in greater detail
below).
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, a carob bean gum, carob bean extracts, and any
combination thereof.
In still other embodiments, the tobacco column may further comprise
flavorants, menthol,
licorice extract, dianunonium 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.
In Figure 2, cigarette 20 has a tobacco column 12 and filter 22. Filter 22 is
multi-
segmented with three sections. In this embodiment, conventional filter
materials 24 (or other
alternative filter sections) may flank the porous mass 26.
in Figure 3, cigarette 30 has a tobacco column 12 and a filter 32. Filter 32
is multi-
segmented with four sections. In this embodiment, end section 34 is a
conventional material,
but sections 36, 37, and 38 may be any combination of other filter materials
and porous mass
(so long as at least one of those sections is a porous mass of the present
invention).
The foregoing embodiments are representative and not limiting. The inventive
filters
may have any number of sections, for example, 2, 3, 4, 5, 6, or more sections,
and the
sections may be placed in any suitable configuration. It is preferred that at
least one of the
filter sections comprise a porous mass of the present invention. Moreover, the
sections may
be the same as one another or different from one another.
Examples of sections that may incorporated with the porous masses of the
present
invention to form filters may include, but are not limited to, sections that
comprise at least
one element selected from the following: cellulose acetate, polypropylene,
polyethylene,
polyolefin tow, polypropylene tow, polyethylene terephthalate, polybutylene
terephthalate,
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
22
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, molecular sieves,
metallocenes, salts,
catalysts, sodium chloride, nylon, flavorants, tobacco, capsules, cellulose,
cellulosic
derivatives, 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. If a
zeolite is used,
examples of suitable zeolites include, but are not limited to, BETA, SBA-15,
MCM-41,
MCM-48 modified by 3-aminopropylsily1 groups, and any combination thereof. 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. Also included are fibrous tows and papers
with active
materials (adhered thereto or impregnated therein or otherwise incorporated
therewith). Such
active materials include activated carbon (or charcoal), ion exchange resins,
zeolites,
desiccants, catalysts, or other materials adapted to affect the tobacco smoke.
If used, void
chambers may be filled (or partially filled) with active ingredients or
materials incorporating
the active ingredients. Such active ingredients include activated carbon (or
charcoal), ion
exchange resins, desiccants, or other materials adapted to affect the tobacco
smoke.
Additionally, the section may be a porous mass of binder particles (i.e.,
binder particles alone
without any active particles). For example, this porous mass without active
particles may be
made with thermoplastic particles (such as polyolefin powders, including the
binder particles
discussed below) that are bonded or molded together into a porous cylindrical
shape.
In another embodiment, a section may comprise a space that defines a cavity
between
two filter sections (one section including a porous mass of the present
invention). The cavity
may be filled with granulated carbon, for example, or a flavorant, as another
example. The
cavity may contain a capsule, e.g., a polymeric capsule, that itself contains
a flavorant or
catalyst. The cavity, in some embodiments, may also contain a molecular sieve
that reacts
with selected components in the smoke to remove or reduce the concentration of
the
components without adversely affecting desirable flavor constituents of the
smoke. In an
embodiment, the cavity may include tobacco as an additional flavorant. One
should note that
if the cavity is insufficiently filled with a chosen substance, in some
embodiments, this may
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
23
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).
Flavorants that may be suitable for use in the present invention include any
flavorant
suitable for use in smoking devices including those that to impart a taste
and/or a flavor to the
smoke stream. The flavorants may include, but not be limited to, organic
material (or
naturally flavored particles), carriers for natural flavors, carriers for
artificial flavors, and any
combination thereof. Organic materials (or naturally flavored particles)
include, but are not
limited to, tobacco, cloves (e.g., ground cloves and clove flowers), cocoa,
and the like.
Natural and artificial flavors may include, but are not limited to, menthol,
cloves, cherry,
chocolate, orange, mint, mango, vanilla, cinnamon, tobacco, and the like. Such
flavors may
be provided by menthol, anethole (licorice), limonene (citrus), eugenol
(clove), and the like.
In some embodiments, more than one flavorant may be used including any
combination of
the flavorants provided herein. These flavorants may be placed in the tobacco
column or in a
section of a filter. Additionally, in some embodiments, the porous masses of
the present
invention may comprise a flavorant. The amount to include will depend on the
desired level
of flavor in the smoke taking into account all filter sections, the length of
the smoking device,
the type of smoking device, the diameter of the smoking device, as well as
other factors
known to those of skill in the art.
The sections that comprise a filter may be wrapped with paper to form filter
rods.
The term "paper" as used herein refers collectively to any wrapping papers
that are used in
the production of smoking devices, including tipping paper, plug wrap paper,
tipping base
paper, and the like. Suitable papers for use in conjunction with present
invention include
wood-based papers, papers containing flax, flax papers, 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, the
papers may comprise additives, sizing, and/or printability agents. In some
embodiments, the
filter rods that comprise a porous mass of the present invention may have
lengths ranging
from about 80 mm to about 150 mm. During processing, the filter rods may be
subsequently
split into about 4 or about 6 individual segments of about 5 to about 35 mm in
length during a
smoking device tipping operation. For dual or triple filters, the filters may
be first cut into
segments and combined with paper and/or charcoal segments prior to tipping.
The filter rods
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
24
may be attached to tobacco column with paper or other smoking apparatus to
produce a
finished smoking device. By way of example, in traditional cigarette
manufacturing, at least
three papers are used: plug wrap, cigarette paper, and tipping paper. Plug
wrap refers to the
paper that is used to cover the filter section of the cigarette as that filter
is produced and
before it is joined to a tobacco column. Cigarette paper refers to the paper
that is used to
cover the tobacco column section of the cigarette as that tobacco column is
produced and
before it is joined to a filter section. Finally, tipping paper refers to the
paper that is used to
cover the filter section and a portion of the tobacco column as the two
sections are joined to
form a cigarette. The seams of the various papers used to form a cigarette are
joined using at
least one adhesive, and more than one type of adhesive may be used in the
formation of the
cigarette. By way of example, as a traditional cellulose acetate filter
section is formed, a
polyvinyl alcohol adhesive may be used to anchor the filter to the paper and a
hot melt glue
may be used at the edge of the paper to keep the filter wrapped. Also,
cigarette paper may
use a starch adhesive to join the edges of the paper. Finally tipping paper
may be more fully
coated, that is coated over most of the surface rather than only at the seam
area, with a hot
melt adhesive to ensure that the filter section and the tobacco section remain
properly joined.
In some cigarette products, ventilation holes are made through the tipping
paper, or through
both the tipping paper and the plug wrap in order to allow air to be drawn
into the smoke
stream.
In some embodiments, the filters may have a diameter in the range of about 5
mm to
about 10 mm and a length of from about 5 mm to about 35 mm. In some
embodiments, for
example for ultra-slim or super-slim cigarettes, the filters may have a
diameter in the range of
less than 5 mm, for example, 3 mm or less, including, but not limited to, a
lower diameter
limit of 0.5 mm. For cigar embodiments, the filters may have a diameter larger
than 20 mm,
for example about 30 mm, as desired. Similarly, the size of the filter for
other smoking
devices may vary based on the intended use and consumer demand (e.g., in a
pipe).
In Figure 4, a 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.
Cavity 47 is adapted for receipt of a filter 48. Filter 48 may be a multi-
segmented filter as
discussed above or may consist solely of the porous mass. The size of the
filter may vary
based on the dimensions of cavity 47. In some embodiments, filter 48 may be
removable,
replaceable, disposable, recyclable, and/or degradable.
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
In the foregoing embodiments, the conventional materials and porous mass are
"joined." The term "joined," as used herein, means that the porous mass is in-
line (or in
series) neighboring a tobacco column or another filter section, so that when
the cigarette is
smoked, smoke from the tobacco column must pass through (e.g., in series) the
porous mass
5 to
arrive at its intended recipient (e.g., a smoker). As noted above, the porous
mass may be
joined to the tobacco column through paper wrapping techniques, e.g., using
paper and/or an
adhesive. Additionally, in some embodiments, the porous mass may be joined to
the tobacco
column using an adhesive, which preferably is free from components that, upon
burning,
would interfere with the purposes of the invention.
10 As
shown in Figures 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). But, 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
15
envisioned that porous mass will be, most often, used in a combined or multi-
segmented
cigarette filter configuration, as shown in Figures 1-3; the invention is not
so limited and a
smoking device may comprise only a porous mass of the present invention, as
discussed
above with regard to Figure 4. Further, although in some embodiments, the
porous mass will
be juxtaposed to the tobacco column, as shown in Figure I, the present
disclosure is not so
20
limited. For example, a porous mass of the present invention may be separated
from the
tobacco by a hollow cavity (e.g., a tube, or channel, such as in a pipe or
hookah or a cigarette
or cigar holder), for example, see Figure 4. In other embodiments, a porous
mass of the
present invention may be separated from a tobacco column by a bendable
element, allowing a
consumer to shape the smoking device.
25 In some
embodiments, the porous masses of the present invention comprise active
particles that are at least partially bonded together with binder particles.
For example, see
Figure 5, a photomicrograph of an embodiment of the porous mass where active
particles
(e.g., activated carbon particles) 50 and binder particles 52. Shown at 54 is
an example of a
point of contact. Note: in this embodiment (Figure 5), binder particles and
active particles
are joined at points of contact, the points of contact are randomly
distributed throughout the
porous mass, and the binder particles have retained their original physical
shape (or
substantially retained their original shape, e.g., no more that 10% variation
(e.g., shrinkage)
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
26
in shape from original). (The active particles and the binder particles are
discussed in greater
detail below.) Although not wishing to be limited to any theory, it is
believed that the points
of contact form when the binder particles are heated to their softening
temperature, but not
hot enough to reach a true melt. In some embodiments, it is believed that the
porous masses
of the present invention are constructed so that they exhibit a minimal
encapsulated pressure
drop (defined below) while maximizing the active particles' surface area.
There may be any weight ratio of active particles to binder particles in the
porous
mass. In some embodiments, the ratio may be about I to about 99 weight %
active particles
and about 99 to about 1 weight % binder particles. In some embodiments, the
ratio may be
about 25 to about 99 weight % active particles and about I to about 75 weight
% binder
particles. In some embodiments, the ratio may be about 40 to about 99 weight
A) active
particles and about 1 to about 60 weight % binder particles. In one embodiment
of th.e porous
mass, the active particles comprise about 50 to about 99 weight % of the mass
while the
binder particles comprise about 1 to about 50 weight % of the mass. In another
embodiment,
the active particles comprise about 60 to about 95 weight % of the mass while
the binder
particles comprise about 5 to about 40 weight % of the mass. Moreover, in yet
another
embodiment, the active particles comprise about 75 to about 90 weight % of the
mass while
the binder particles comprise about 10 to about 25 weight A) of the mass.
In one embodiment of the porous mass, the porous mass has a void volume in the
range of about 40% to about 90%. In another embodiment, it has a void volume
of about
60% to about 90%. In yet another embodiment, it has a void volume of about 60%
to about
85%. Void volume is the free space left after accounting for the space taken
by the active
particles.
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:
CA 02813575 2013-04-03
WO 2(112/(15-1111 PCT/US2011/044142
27
Void Volume [(porous mass volume, cm3) (Weight of active particles,
gm)/(density of the
= 1 - active particles, g,m/cm3)]* 100
(%)
porous mass volume, cm3
In one embodiment, the porous mass has an encapsulated pressure drop (EPD) in
the
range of about 0.10 to about 25 mm of water per mm length of porous mass. 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 other 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).
To obtain the
desired EPD, the active particles must have a greater particle size than the
binder particles. In
one embodiment, the ratio of binder particle size to active particle size is
in the range of about
1:1.5 to about 1:4.
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, II 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
28
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. By way of 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.
Depending on how the porous mass is made, the porous mass may have any desired
length. In a batch molding process, for example, the length would likely match
the
dimension of the mold(s) used. Additionally, in a continuous production
process, the porous
mass may be one long continuous cylinder of any desired length. In either
event, the porous
mass could subsequently be cut into desired smaller lengths or sections. The
desired length
may depend on the particular application in which the porous mass may be used.
In one
embodiment, the porous mass may have a length of about 1 mm to about 35 mm. In
another
embodiment, the porous mass may have a length of about 2 mm to about 30 mm. In
another,
the porous mass may have a length of about 7 mm to about 20 mm.
The porous mass may have any physical shape. The porous mass may have a
helical
shape, a triangular shape, a disk shape, or a square shape, in some
embodiments. In one
embodiment, it is in the shape of a cylinder. A hybrid shape of these shapes
may be suitable
as well. In some embodiments, the porous mass may be machined to be lighter in
weight, if
desired, for example, by drilling out a portion of the porous mass. In one
embodiment, the
porous mass may have a specific shape for a cigarette holder or pipe that is
adapted to fit
within the cigarette holder or pipe to allow for smoke passage through the
filter to the
consumer. When discussing the shape of a porous mass herein, with respect to a
traditional
smoking device filter, the shape may be referred to in terms of diameter or
circumference
(wherein the circumference is the perimeter of a circle) of the cross section
of the cylinder.
But in embodiments where a porous mass of the present invention is in a shape
other than a
true cylinder, it should be understood that the term "perimeter" is used to
mean the perimeter
of any shaped cross-section, including a circular cross-section.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
29
The active particles may be any material adapted to enhance smoke flowing
thereover. Adapted to enhance smoke flowing thereover refers to any material
that can
remove, reduce, or add components to a smoke stream. The removal or reduction
(or
addition) may be selective. By way of example, in the smoke stream from a
cigarette,
compounds such as those shown below in the following listing may be
selectively removed or
reduced. This table is available from the U.S. FDA as a Draft Proposed Initial
List of
Harmful/Potentially Harmful Constituents in Tobacco Products, including
Tobacco Smoke;
any abbreviations in the below listing are well-known chemicals in the art. in
some
embodiments, the active particle may reduce or remove at least one component
selected from
the listing of components in smoke below, including any combination thereof.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
_____________________________________________________________________ =
Acetaldehyde Dibentl,a,hjanthracene N-
Acetamide Dibenzo(c,g)carbazole Nitrosodiethanolamine
Acetone j Dibenzoia,elpyrene (NDELA)
Acrolein Dibenzo0,hipyrene , N-Nitrosodiethylamine
Acrylamide Dibenzo[aApyrene N-nitrosodimethylamine
Acrylonitrile Dibenzo0,11pyrenc I (NDMA)
A flatoxin B-1 2,6-Dimethylanil i II :' N-
4-Aminobiphenyl Ethyl Carbamate Nitrosoethylmethylamin
I -A minonaphthalene (urethane) e
2-Aminonapht hal Clli:! Ethylbenzene N-nitrosomorpholine
Ammonia Ethylene oxide (NMOR.)
Ammonium Salts Eugenol N-nitrosonomicotine
(NN )
Anabasine Formaldehyde N.
Anatabine Furan N-Nitrosopiperidine
Glu-P-1 (NPIP)
N-nitrosopyffolidine
0-Anisidine Glu-P-2
(NPYR)
Arsenic Hydrazine
N-nitrososarcosine
A-a-C Hydrogen cyanide ------ (N SA R)
Bertz[alanthracene j Hydroquirione Phenol
Benkbrluoroanthenc Indenol 1,2,3 -cdipyrette ¨ph IP
.
Benzrflacearithrylene IQ Polonium-210 (Radio-
Benkkrluoroanthene Isoprene isotope)
Benzene Lead Propionaldehyde
Benzo(b)furan MeA- a-C Propylene oxide
Benzo[a]pyrene Mercury Pyridine
Benzolciphenanthrene Methyl ethyl ketone --- , Quinoline
Beryllium 5-Methylchryserie Resorcinol
I ,3-Butadiene 4-(methylnitrosamino)- Selenium .
Butyraldehyde 1 -(3-pyridy1)-1-butain one . Styrene
Cadmium (NNK) -I Tar ...
Caffeic acid 4-(methylnitrosamino)-
2-Toluidine
Carbon monoxide 1-(3-pyridy1)-1-butanol
Toluene
Catechol (NN.AL)
T rp-P- I
Naphthalene ..
Chlorinated l icke 'Fip-P-2 .
dioxins/furans N Uranium-235 (Radio-
Nicotine
Chromium
Chrysene Nitrate isotope) .
Ni Uranium-238 (Radio-
Cobalt Nitric oxide/nitrogen
isotope)
oxides ______________________________________
Coumarin Vinyl Acetate
Nitrite _____________________________________
Cresols Vinyl Chloride
Crotonaldehyde Nitrobenzene ______
, Cyclopenta[c,d]pyrene Nitromethane ____
Dibenz(a,h)acridine 2-Nitropropane ____
N
Dibenz(a,j)acridine -nitrosoanabasine
(NAB)
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
31
One example of an active material is activated carbon (or activated charcoal
or active
coal). The activated carbon may be low activity (about 50% to about 75% CC14
adsorption)
or high activity (about 75% to about 95% CCI4 adsorption) or a combination of
both. In
some embodiments, the active carbon may be nano-scaled carbon particle, such
as carbon
nanotubes of any number of walls, carbon nanohoms, bamboo-like carbon
nanostructures,
fullerenes and fullerene aggregates, and graphene including few layer graphene
and oxidized
graphene. Other examples of such materials include ion exchange resins,
desiccants,
silicates, molecular sieves, metallocenes, silica gels, metallocene, activated
alumina, zeolites,
perlite, sepiolite, Fuller's Earth, magnesium silicate, metal oxides (e.g.,
iron oxide and iron
oxide nanoparticles like about 12 nm Fe304), 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(cC6a; and
core-shell and onionated nanoparticles like gold and silver nanoshells,
onionated iron oxide,
and others nanoparticles or microparticles with an outer shell of any of said
materials) and
any combination of the foregoing (including activated carbon). It should be
noted that
nanoparticles include nanorods, nanospheres, nanorices, nanowires, nanostars
(like
nanotripods and nanotetrapods), hollow nanostructures, hybrid nanostructures
that are two or
more nanoparticles connected as one, and non-nano particles with nano-coatings
or nano-
thick walls. It should be further noted that nanoparticles include the
flmctionalized
derivatives of nanoparticles including, but not limited to, nanoparticles that
have been
functionalized covalently and/or non-covalently, e.g., pi-stacking,
physisorption, ionic
association, van der Waals association, and the like. Suitable functional
groups may include,
but not be limited to, moieties comprising amines (1 , 2 , or 30), amides,
carboxylic acids,
aldehydes, ketones, ethers, esters, peroxides, silyls, organosilanes,
hydrocarbons, aromatic
hydrocarbons, and any combination thereof; polymers; chelating agents like
ethylenediamine
tetraacetate, diethylenetriaminepentaacetic acid, triglycollamic acid, and a
structure
comprising a pyrrole ring; and any combination thereof. Functional groups may
enhance
removal of smoke components and/or enhance incorporation of nanoparticles into
a porous
mass. Ion exchange resins include, for example, a polymer with a backbone,
such as styrene-
divinyl benzene (DVB) copolymer, acrylates, methacrylates, phenol formaldehyde
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
32
condensates, and epichlorohydrin amine condensates; and a plurality of
electrically charged
functional groups attached to the polymer backbone. In some embodiments, the
active
particles are a combination of various active particles. In some embodiments,
the porous
mass may comprise multiple active particles. In some embodiments, an active
particle may
comprise at least one element selected from the group of active particles
disclosed herein. It
should be noted that "element" is being used as a general term to describe
items in a list. In
some embodiments, the active particles are combined with at least one
flavorant.
In some embodiments, a mixture of active particles may be used to remove
multiple
harmful substances from. a smoke stream. For example, while activated charcoal
has been
shown to be successful in removing substances such as formaldehyde and acetone
from
cigarette smoke, it is ineffective in removing carbon monoxide. However,
carbon monoxide
may be removed from a gaseous stream by exposure to iodine pentoxide, a
molecular sieve
(such as a metallocene), a molecular oxide, a metal catalyst (such as
palladium), and the like.
In one embodiment, the active particles have a particle sizes ranging from
particles
having at least one dimension of about less than one nanometer, such as
graphene, to as large
as a particle having a diameter of about 5000 microns. The active particles
may range from a
lower size limit in at least one dimension of about: 0.1 nanometers, 0.5
nanometers, 1
nanometer, 10 nanometers, 100 nanometers, 500 nanometers, 1 micron, 5 microns,
10
microns, 50 microns, 100 microns, 150 microns, 200 microns, and 250 microns.
The active
particles may range from an upper size limit in at least one dimension of
about: 5000
microns, 2000 microns, 1000 microns, 900 microns, 700 microns, 500 microns,
400 microns,
300 microns, 250 microns, 200 microns, 150 microns, 100 microns, 50 microns,
10 microns,
and 500 nanometers. Any combination of lower limits and upper limits above may
be
suitable for use in the present invention, wherein the selected maximum size
is greater than
the selected minimum size. In some embodiments, the active particles may be a
mixture of
particle sizes ranging from the above lower and upper limits.
The binder particles may be any suitable thermoplastic binder particles. In
one
embodiment, the binder particles exhibit virtually no flow at its melting
temperature. This
means a material that when heated to its melting temperature exhibits little
to no polymer
flow. Materials meeting these criteria include, but are not limited to,
ultrahigh molecular
weight polyethylene, very high molecular weight polyethylene, high molecular
weight
polyethylene, and combinations thereof. In one embodiment, the binder
particles have a melt
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
33
flow index (MFI, ASTM D1238) of less than or equal to about 3.5 g/10min at 190
C and 15
Kg (or about 0-3.5 g/10min at 190 C and 15 Kg). In another embodiment, the
binder
particles have a melt flow index (MFI) of less than or equal to about 2.0
g/10min at 190 C
and 15 Kg (or about 0-2.0 g/10min at 190 C and 15 Kg). One example of such a
material is
ultra high molecular weight polyethylene, UHMWPE (which has no polymer flow,
MFI of
about 0, at 190 C and 15 Kg, or an MF1 of about 0-1.0 at 190 C and 15 Kg);
another material
may be very high molecular weight polyethylene, VHMWPE (which may have MFIs in
the
range of, for example, about 1.0-2.0 WI Omin at 190 C and 15 Kg); or high
molecular weight
polyethylene, HMWPE (which may have MFIs of, for example, about 2.0-3.5
g/lOmin at
190 C and 15 Kg). In some embodiments, it may be preferable to use a mixture
of binder
particles having different molecular weights and/or different melt flow
indexes.
In terms of molecular weight, "ultra-high molecular weight polyethylene" as
used
herein refers to polyethylene compositions with weight-average molecular
weight of at least
about 3 x 106 g/mol. In some embodiments, the molecular weight of the ultra-
high molecular
weight polyethylene composition is between about 3 x 106 g/mol and about 30 x
106 g/mol,
or between about 3 x 106 g/mol and about 20 x 106 g/mol, or between about 3 x
106 g/mol
and about 10 x 106 g/mol, or between about 3 x 106 g/mol and about 6 x 106
g/mol. "Very-
high molecular weight polyethylene" refers to polyethylene compositions with a
weight
average molecular weight of less than about 3 x 106 g/mol and more than about
1 x 106
g/mol. In some embodiments, the molecular weight of the very-high molecular
weight
polyethylene composition is between about 2 x 106 g/mol and less than about 3
x 106 g/mol.
"High molecular weight polyethylene" refers to polyethylene compositions with
weight-
average molecular weight of at least about 3 x 105 g/mol to 1 x 106 g/mol. For
purposes of
the present specification, the molecular weights referenced herein are
determined in
accordance with the Margolies equation ("Margolies molecular weight").
Suitable polyethylene materials are commercially available from several
sources
including GUR UHMWPE from Ticona Polymers LLC, a division of Celanese
Corporation
of Dallas, TX, and DSM (Netherland), Braskem (Brazil), Beijing Factory No. 2
(BAAF),
Shanghai Chemical, and Qilu (People's Republic of China), Mitsui and Asahi
(Japan).
Specifically, GUR polymers may include: GUR 2000 series (2105, 2122, 2122-5,
2126),
GUR 4000 series (4120, 4130, 4150, 4170, 4012, 4122-5, 4022-6, 4050-3/4150-
3), GUR
8000 series (8110, 8020), GUR X series (X143, X184, X168, X172, X192).
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
34
One example of a suitable polyethylene material is that having an intrinsic
viscosity in
the range of about 5 dl/g to about 30 dl/g and a degree of crystallinity of
about 80% or more
as described in U.S. Patent Application Publication No. 2008/0090081. Another
example of
a suitable polyethylene material is that having a molecular weight in the
range of about
300,000 g/mol to about 2,000,000 g/mol as determined by ASTM-D 4020, an
average
particle size, D50, between about 300 um and about 1500 um, and a bulk density
between
about 0.25 g/ml and about 0.5 g/m1 as described in U.S. Provisional
Application No.
61/330,535 filed May 3, 2010.
The binder particles may assume any shape. Such shapes include spherical,
hyperion,
asteroidal, chrondular, or interplanetary dust-like, granulated, potato,
irregular, or
combinations thereof. In preferred embodiments, the binder particles suitable
for use in the
present invention are non-fibrous. In some embodiments the binder particles
are in the form
of a powder, pellet, or particulate. In some embodiments, the binder particles
are a
combination of various binder particles.
In some embodiments, the binder particles may range from a lower size limit in
at
least one dimension of about: 0.1 nanometers, 0.5 nanometers, 1 nanometer, 10
nanometers,
100 nanometers, 500 nanometers, 1 micron, 5 microns, 10 microns, 50 microns,
100 microns,
150 microns, 200 microns, and 250 microns. The binder particles may range from
an upper
size limit in at least one dimension of about: 5000 microns, 2000 microns,
1000 microns, 900
microns, 700 microns, 500 microns, 400 microns, 300 microns, 250 microns, 200
microns,
150 microns, 100 microns, 50 microns, 10 microns, and 500 nanometers. Any
combination
of lower limits and upper limits above may be suitable for use in the present
invention,
wherein the selected maximum size is greater than the selected minimum size.
In some
embodiments, the binder particles may be a mixture of particle sizes ranging
from the above
lower and upper limits.
Additionally, the binder particles may have a bulk density in the range of
about 0.10
g/cm3 to about 0.55 g/cm3. In another embodiment, the bulk density may be in
the range of
about 0.17 g/cm3 to about 0.50 g/cm3. In yet another embodiment, the bulk
density may be in
the range of about 0.20 g/cm3 to about 0.47 g/cm3.
In addition to the foregoing binder particles, other conventional
thermoplastics may
be used as binder particles. Such thermoplastics include, but are not limited
to, polyolefins,
polyesters, polyamides (or nylons), polyacrylics, polystyrenes, polyvinyls,
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
polytetrafluoroethylene (PTFE), polyether ether ketone (PEEK), any copolymer
thereof, any
derivative thereof, and any combination thereof. Non-
fibrous plasticized cellulose
derivatives may also be suitable for use as binder particles in the present
invention.
Examples of suitable polyolefins include, but are not limited to,
polyethylene, polypropylene,
5 polybutylene, polymethylpentene, any copolymer thereof, any derivative
thereof, any
combination thereof and the like. Examples of suitable polyethylenes further
include low-
density polyethylene, linear low-density polyethylene, high-density
polyethylene, any
copolymer thereof, any derivative thereof, any combination thereof and the
like. Examples of
suitable polyesters include polyethylene terephthalate, polybutylene
terephthalate,
10 polycyclohexylene dimethylene terephthalate, polytrimethylene
terephthalate, any copolymer
thereof, any derivative thereof, any combination thereof and the like.
Examples of suitable
polyacrylics include, but are not limited to, polymethyl methacrylate, any
copolymer thereof,
any derivative thereof, any combination thereof and the like. Examples of
suitable
polystyrenes include, but are not limited to, polystyrene, acrylonitrile-
butadiene-styrene,
15 styrene-acrylonitrile, styrene-butadiene, styrene-maleic anhydride, any
copolymer thereof,
any derivative thereof, any combination thereof and the like. Examples of
suitable polyvinyls
include, but are not limited to, ethylene vinyl acetate, ethylene vinyl
alcohol, polyvinyl
chloride, any copolymer thereof, any derivative thereof, any combination
thereof and the like.
Examples of suitable cellulosics include, but are not limited to, cellulose
acetate, cellulose
20 acetate butyrate, plasticized cellulosics, cellulose propionate, ethyl
cellulose, any copolymer
thereof, any derivative thereof, any combination thereof and the like. In some
embodiments,
a binder particle may be any copolymer, any derivative, and any combination of
the above
listed binders.
The porous mass is effective at the removal of components from smoke, for
example,
25 those in the listing above. A porous mass can be used to reduce the
delivery 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.) In one embodiment, the porous mass, where activated carbon is used,
has a length in
30 the range of about 4 mm. to about 11 ram.. The components include:
acetaldehyde, acrolein,
benzene, benzo[a]pyrene, 1,3-butadiene, and formaldehyde. The porous mass with
activated
carbon may reduce acetaldehydes in a smoke stream by about 3.0% to about
6.5%/mm length
CA 02813575 2014-04-14
54242-3
36
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 I1.0%/mm length of
porous
mass. In another example, a porous mass Where an ion exchange resin is used as
the active
particles can be used to reduce the delivery of certain tobacco smoke
components to below
the WHO recommendations. See Table 14, below. In one embodiment, the porous
mass,
where ion exchange resins are used, has a length in the range of about 7 mm to
about 1 mm.
The components include: acetaldehyde, acrolein, and formaldehyde. In some
embodiments, 'a
porous mass. of the present invention having an ion exchange resin may reduce:
acetaldehydes in a smoke stream by about 5.0% to about 7.0%/mm length of
porous mass;
acrolein in a .smoke stream by about 4.0% to about 6.5%/mm length of porous
mass; and
formaldehyde in a smoke stream by about 9.0% to about 11.0%/mm length of
porous mass.
The porous mass may be made by any suitable means. In some embodiments, this
may be a batch process. In others, this may be a continuous process.
In one embodiment of a suitable method, the active particles and binder
particles are
blended together and introduced into a mold. The mold is heated to a
temperature at or above
the melting point of the binder particles, e.g., in one embodiment about 150 C
to 300 C and
held at the temperature for a period of time sufficient to heat the mold and
its contents to the
desired temperature. Thereafter, the mass is removed from the mold and cooled
to room
temperature. These methods may be done in small batches or large batches that
may be
suitable for commercial production.
In some embodiments, a suitable process may be a free sintering process,
because the
binder particles do not flow (or flow very little) at the sintering
temperature and no pressure
is applied to the blended materials .in the mold. In this embodiment, point
bonds are formed
between the active particles and the binder particles. This is believed to
enable the formation
of superior bonding and maximizing the interstitial space, while minimizing
the blinding of
the surface of the active particles by free flowing molten binder. Also see,
U.S. Patents
6,770,736, 7,049,382, and 7,160,453.
Alternatively, a porous mass of the present invention may be made by a process
involving sintering under pressure. As the mixture of the active particles and
the binder
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
37
particles are heated (or at a temperature which may be below, at, or above the
melting
temperature of the binder particles) a pressure is exerted on the mixture to
facilitate
coalescence of the porous mass.
Also, in some embodiments, the porous mass may be made by an extrusion
sintering
process where the mixture is heated in an extruder barrel and extruded into
the porous mass.
Any suitable method for forming a smoking device filter comprising a porous
mass of
the present invention may be used in conjunction with the porous masses. For
example, in
one embodiment, an apparatus for producing a smoking device filter may be used
that has at
least a plurality of areas comprising: a container area comprising at least a
plurality of first
filter section pieces; a second container area comprising at least a plurality
of second filter
section pieces, the second filter section pieces comprising a porous mass
having an active
particle and a binder particle, the porous mass having: an active particle
loading of at least
about 1 mg/mm, an EPD of about 20 mm of water or less per mm of porous mass; a
joiner
area wherein a first filter section piece and a second filter section piece
are joined; a wrapping
area wherein the first filter section piece and the second filter section
piece are wrapped with
a paper to form. a smoking device filter; and a conveyor to transport the
smoking device filter
to a subsequent area for storage or use. In some embodiments, a filter rod may
be formed in
this process that comprises a plurality of filters that when cut can be used
to form multiple
smoking devices (e.g., 4 cigarettes per 1 filter rod).
In some embodiments, the smoking device filters 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 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.
In traditional cigarette manufacturing, the machines that join the filter
section to the
tobacco column, as well as the machines that join together the section of the
multi-component
filter, tend to compress the sections of the cigarette as they progress
through the joining
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
38
process. In some embodiments, the porous mass of the present invention may be
non-
compressible or less compressible than a traditional cellulose acetate filter
section, which
may lead to difficulty in some manufacturing processes. In embodiments where
ultra high
molecular weight polymers, such as ultra high molecular weight polyethylene,
are used the
porous mass of the present invention tends to be incompressible. In such
cases, it may be
desirable to wrap or encase the porous mass section with a material that is
compressible. The
wrapping or encasing material is placed along the longitudinal axis of the
porous mass filter
section such that the wrapping or encasing material is between the porous mass
and the plug
wrap paper. The wrapping or encasing material should be selected such that it
provides the
desired compressibility while also exhibiting a relatively high pressure drop
such that smoke
drawn through the section preferentially travels through the porous mass
rather than the
wrapping or encasing material or encasing material is greater than the
encapsulated pressure
drop of the porous mass. In some embodiments, the wrapping material may have
an
encapsulated pressure drop that is 1% higher than the encapsulated pressure
drop of the
porous mass, in other embodiments the difference may be 5% higher, 10% higher,
25%
higher, 50% higher, 75% higher, 100% higher, 125% higher, 150% higher, 175%
higher,
200% higher, 225% higher, 250% higher, 275% higher, or 300% higher. One of
skill in the
art will recognize that the difference in the encapsulated pressure drop
between the wrapping
or encasing material and the porous mass may go even higher so long as the
user is not
negatively effected and so long as the wrapping or encasing material continues
to provide the
desired compressibility. In some embodiments, the wrapping or encasing
material may
comprise cellulose acetate, polypropylene, polyethylene, polyolefin tow,
polypropylene tow,
polyethylene terephthalate, polybutylene tf...rephthalate, random oriented
acetate, paper,
corrugated paper, carbon-on-tow, silica, magnesium silicate, nylon, cellulose,
and any
combination thereof. IN other embodiments, the wrapping or encasing material
is placed
along the longitudinal axis of the porous mass filter section such that the
wrapping or
encasing material is on the outside of the plug wrap paper. One skilled will
recognize that the
porous mass diameter must be selected to compensate for the diameter increase
as layer of
papers or wrappings or encasing materials are added. The final filter diameter
must match
the tobacco column diameter for the filter/tobacco column combine step. In
other
embodiments, the wrapping or encasing material is placed along the
longitudinal axis of the
porous mass filter section such that the wrapping or encasing material is in
direct contact with
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
39
the porous mass. This configuration can eliminate paper use in the sintering
process. In
other embodiments, the smoking device filters 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. Storage and transportation containers used with the porous mass
filter sections of
the present invention may need to be altered to account for presence of the
porous mass. By
way of example, cylindrical and other shaped rods or cigarettes incorporating
porous mass
filter sections of the present invention may be heavier in weight, or more
brittle than a
cellulose acetate filter section. In addition, due to the active nature of the
porous mass, it may
be desirable to ship porous mass sections or cigarettes incorporating porous
mass sections
such that the porous mass is not exposed to environmental contamination.
In some embodiments, a method of making a filter may comprise: providing a
blend
comprising active particles and binder particles; placing the blend in a mold;
heating the
blend in the mold to a temperature at or above the melting point of the binder
particles so as
to form a porous mass selected from at least one porous mass of the present
invention;
removing the porous mass from the mold; and forming a filter comprising the
porous mass.
In some embodiments, a method of making a smoking device filter may comprise:
providing a blend comprising an active particle and a binder particle; heating
the blend;
extruding the blend while at an elevated temperature so as to form a porous
mass selected
from at least one porous mass of the present invention; and forming a filter
comprising the
porous mass.
In some embodiments, a method for producing a smoking device may comprise:
providing a first filter section; providing at least one second filter
section, wherein the second
filter section comprises a porous mass selected from at least one porous mass
of the present
invention; joining the first filter section and at least one second filter
section so as to form a
filter rod; and joining at least a portion of the filter rod with a tobacco
column to form a
smoking device.
In some embodiments, a method of making a filter rod may comprise: providing a
container that comprises at least a plurality of first filter section pieces;
providing a second
container comprising at least a plurality of second filter section pieces,
wherein the second
filter section pieces comprise a porous mass selected from at least one porous
mass of the
present invention; joining a first filter section piece and a second filter
section piece end-to-
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
end along the longitudinal axis of the first filter section piece and the
second filter section
piece to form an unwrapped filter rod; wrapping the first filter section piece
and the second
filter section piece with a paper to form a filter rod; and transporting the
filter rod to a
subsequent area for storage or use.
5 In some
embodiments, a method of making a smoking device may comprise:
providing a filter rod comprising at least one filter section that comprises a
porous mass
selected from at least one porous mass of the present invention; providing a
tobacco column;
cutting the filter rod transverse to its longitudinal axis through the center
of the rod to form at
least two smoking device filters having at least one filter section that
comprises a porous
10 mass that comprises an active particle and a binder particle; and
joining at least one of the
smoking device 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.
In some embodiments, a method of making a smoking device may comprise:
providing a tobacco column; joining a filter to the tobacco column, wherein
the filter
15 comprises a porous mass selected from at least one porous mass of the
present invention.
An apparatus comprising: a container area comprising at least a plurality of
first filter section
pieces; a second container area comprising at least a plurality of second
filter section pieces,
wherein the second filter section pieces comprises a porous mass selected from
at least one
porous mass of the present invention; a joiner area wherein a first filter
section piece and a
20 second filter section piece are joined; a wrapping area wherein the
first filter section piece
and the second filter section piece are wrapped with a paper to form a smoking
device filter;
and a conveyor to transport the smoking device filter to a subsequent area for
storage or use.
In some embodiments, the present invention provides a pack of filters that
comprises
a porous mass of the present invention. The pack may be a hinge-lid pack, a
slide-and-shell
25 pack, a hard cup pack, a soft cup pack, or any other suitable pack
container. In one
embodiment, the present invention provides a pack comprising a pack and at
least one filter
that comprises at least one filter section having a porous mass that comprises
an active
particle and a binder particle, the porous mass having: an active particle
loading of at least
about 1 mg/mm, an EPD of about 20 mm of water or less per mm of porous mass.
In one
30 embodiment, the present invention provides a pack comprising a pack and
at least one filter
that comprises at least one filter section having a porous mass that comprises
an active
particle and a binder particle, the porous mass having: an active particle
loading of at least
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
41
about 1 mg/mm, an EPD of about 20 mm of water or less per mm of porous mass.
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 may be sealed as a
bundle inside a
pack. A bundle may contain a number of filters, for example, 20 or more.
However, a
bundle may include a single filter, in some embodiments, such as exclusive
filter
embodiments like those for individual sale, or a filter comprising a specific
spice, like vanilla,
clove, or cinnamon.
In some embodiments, the present invention provides a pack of smoking devices
that
includes at least one smoking device having a filter that comprises a porous
mass of the
present invention. 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 one embodiment, the
present
invention provides a cigarette pack comprising a pack and at least one
cigarette comprising a
filter that comprises at least one filter section having a porous mass that
comprises an active
particle and a binder particle, the porous mass having: 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 one
embodiment, the present invention provides a cigar pack comprising a pack and
at least one
cigar comprising a filter that comprises at least one filter section having a
porous mass that
comprises an active particle and a binder particle, the porous mass having: 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 some embodiments, the packs may have an outer wrapping, such
as a
polypropylene wrapper, and optionally a tear tab. In some embodiments, the
smoking
devices may be sealed as a bundle inside a pack. A bundle may contain a number
of smoking
devices, for example, 20 or more. However, a bundle may include a single
smoking device,
in some embodiments, such as exclusive smoking embodiments like a cigar, or a
smoking
device comprising a specific spice, like vanilla, clove, or cinnamon.
In some embodiments, the present invention provides a carton of smoking device
packs that includes at least one pack of smoking devices that includes at
least one smoking
device having a porous mass of the present invention. For example, in one
embodiment, the
present invention provides a cigarette carton, the cigarette carton comprising
at least one
cigarette pack, the cigarette pack comprising a pack and at least one
cigarette comprising a
filter that comprises at least one filter section having a porous mass that
comprises an active
particle and a binder particle, the porous mass having: an active particle
loading of at least
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
42
about 1 mg/mm, and an EPD of about 20 mm of water or less per mm of porous
mass. 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.
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
such a smoking device. 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 section having a
porous mass
having an active particle and a binder particle, the porous mass having: an
active particle
loading of at least about 1 mg/mm, an EPD of about 20 mm of water or less per
mm of
porous mass; and drawing the smoke through the smoking device, wherein the
filter section
reduces the presence of at least one component in the smoke as compared to a
filter without
the porous mass. In some embodiments, the smoking device is a cigarette. In
other
embodiments, the smoking device is a cigar, a cigar holder, a pipe, a water
pipe, a hookah, an
electronic smoking device, a smokeless smoking device, a roll-your-own
cigarette, a roll-
your-own cigar, or another smoking device.
In one embodiment, a smoking device is provided that comprises a porous mass
of
active particles adapted to enhance a tobacco smoke flowing over said active
particles and
binder particles. The active particles comprise about PA to about 99% weight
of the porous
mass, and the binder particles comprise about 1% to about 99% weight of said
porous mass.
The active particles and said binder particles are bound together at randomly
distributed
points throughout the porous mass. The active particles have a greater
particle size than the
binder particles.
In another embodiment, the present invention provides a filter comprising a
porous
mass that comprises an active particle and a binder particle, 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 nanohom, a bamboo-like carbon
nanostmcture, a
fullerene, a fullerene aggregate, graphene, a few layer graphene, oxidized
graphene, a 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
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
43
nanoparticle, a hematite nanoparticle, a magnetite nanoparticle, a gado-
nanotube, an
endofullerm, Gd@C60, a core-shell nanoparticle, an onionated nanoparticle, a
nanoshell, an
onionated iron oxide nanoparticle, and any combination thereof.
In one embodiment, the present invention provides a filter comprising a porous
mass
that comprises an active particle and a binder particle, the porous mass
having a carbon
loading of at least about 6 mg/mm, and an encapsulated pressure drop ("EPD")
of about 20
mm of water or less per mm of porous mass.
In one embodiment, the present invention provides a filter comprising a porous
mass
that comprises an active particle and a binder particle, the porous mass
having: 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, and wherein the active particle is not carbon.
In one embodiment, the present invention provides a method of making a tobacco
smoke filter for a smoking device comprising mixing binder particles and
active particles so
as to produce a porous mass having 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, and wherein the
active
particle is not carbon.
In one embodiment, the present invention provides a method of making a tobacco
smoke filter for a smoking device comprising the steps of mixing binder
particles and active
particles, 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(a)C60, a core-shell
nanoparticle, an
onionated nanoparticle, a nanoshell, an onionated iron oxide nanoparticle, and
any
combination thereof
In one embodiment, the present invention provides a method of making a tobacco
smoke filter for a smoking device comprising mixing binder particles and
active particles so
as to produce a porous mass having a carbon loading of at least about 6 mg/mm,
an EPD of
about 20 mm of water or less per mm of porous mass.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
44
In one embodiment, the present invention provides a smoking device filter
having at
least one filter section having a porous mass that comprises an active
particle and a binder
particle, the porous mass having: 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 one embodiment, the present invention provides a smoking device filter
having at
least one filter section having a porous mass that comprises an active
particle and a binder
particle, 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 nanostnicture, 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 endoftillerene, Gd@C60, a core-shell
nanoparticle, an
onionated nanoparticle, a nanoshell, an onionated iron oxide nanoparticle, and
any
combination thereof.
In one embodiment, the present invention provides a smoking device filter
having at
least one filter section having a porous mass that comprises carbon and a
binder particle, the
porous mass having a carbon loading of at least about 6 mg/mm, an EPD of about
20 min of
water or less per mm of porous mass.
In one embodiment, the present invention provides a smoking device comprising
a
filter that comprises at least one filter section having a porous mass, the
porous mass having
an active particle and a binder particle, the porous mass having: and an
active particle loading
of at least about 1 mg/mm, an EPD of about 20 mm of water or less per mm of
porous mass.
In one embodiment, the present invention provides a smoking device comprising
a
filter that comprises at least one filter section having a porous mass, the
porous mass having
an active particle and a binder particle, 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
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.
5 In one
embodiment, the present invention provides a smoking device comprising a
filter that comprises at least one filter section having a porous mass, 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.
In one embodiment, the present invention provides a method of making a
cigarette,
10
comprising: providing a tobacco column; attaching a filter to the tobacco
column, the filter
comprising a section that comprises a porous mass having an active particle
and a binder
particle, the porous mass having: active particle loading of at least about 1
mg/mm, an EPD
of about 20 mm of water or less per mm of porous mass, and wherein the active
particle is not
carbon; and forming a cigarette.
15 In one
embodiment, the present invention provides a smoking device that comprises a
filter that comprises an active particle, 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 nanohom, a bamboo-like carbon nanostructire, a
fullerene, a
fullerene aggregate, graphene, a few layer graphene, oxidized graphene, an
iron oxide
20
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
25 nanoparticle, and any combination thereof.
In one embodiment, the present invention provides a smoking device that
comprises a
tobacco column that comprises tobacco and optionally an element selected from
the group
consisting of sugar, sucrose, brown sugar, invert sugar, high fructose corn
syrup, propylene
glycol, glycerol, cocoa, a cocoa product, a carob bean gum, a carob bean
extract, and any
30
combination thereof, and a filter that comprises an active particle, 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
46
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 supemaramagentic
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.
In one embodiment, the present invention provides a smoking device that
comprises a
tobacco column that comprises tobacco and optionally an element selected from
the group
consisting of: sugar, sucrose, brown sugar, invert sugar, high fructose corn
syrup, propylene
glycol, glycerol, cocoa, a cocoa product, a carob bean gum, a carob bean
extract, a flavorant,
menthol, licorice extract, diammonium phosphate, ammonium hydroxide, and any
combination thereof, and a filter that comprises an active particle, the
active particle
comprising a element selected from the group consisting of: a nano-scaled
carbon particle, a
carbon nanotube having at least one wall, a carbon nanohom, 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 endoffillerene, Gd@C60, a core-shell nanoparticle, an onionated
nanoparticle, a
nanoshell, an onionated iron oxide nanoparticle, and any combination thereof.
In one embodiment, the present invention provides a smoking device that
comprises a
tobacco column that comprises a tobacco source selected from the group
consisting of bright
leaf tobacco, burley tobacco, Oriental tobacco, Cavendish tobacco, corojo
tobacco, criollo
tobacco, Perique tobacco, shade tobacco, white burley tobacco, and any
combination thereof,
and optionally an element selected from the group consisting of. sugar,
sucrose, brown
sugar, invert sugar, high fructose corn syrup, propylene glycol, glycerol,
cocoa, a cocoa
product, a carob bean gum, a carob bean extract, a flavorant, menthol,
licorice extract,
diammonium phosphate, ammonium hydroxide, and any combination thereof, and a
filter that
comprises an active particle, the active particle comprising an element
selected from the
group consisting of a nano-scaled carbon particle, a carbon nanotube having at
least one
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
47
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 superpammagentic 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:
In one embodiment, the present invention provides a method of making a
cigarette
comprising: providing a tobacco column; attaching a filter to the tobacco
column, the filter
comprising a section that comprises a porous mass, the porous mass having an
active particle
and a binder particle, 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 nanohom, a bamboo-like carbon nanostmcture, 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-rianotube, an endofullerene, Gd@C60, a core-
shell
nanoparticle, an onionated nanoparticle, a nanoshell, an onionated iron oxide
nanoparticle,
and any combination thereof:
In one embodiment, the present invention provides a method of making a
cigarette,
comprising: providing a tobacco column; attaching a filter to the tobacco
column, the filter
comprising a section that comprises a porous mass, 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.
In one embodiment, the present invention provides a method of making a cigar,
comprising: providing a tobacco column, attaching a filter to the tobacco
column, the filter
comprising a section that comprises a porous mass having an active particle
and a binder
particle, the porous mass having: 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.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
48
In one embodiment, the present invention provides a method of making a cigar
comprising: providing a tobacco column; attaching a filter to the tobacco
column, the filter
comprising a section that comprises a porous mass having an active particle
and a binder
particle, 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 nanohom, 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
supemaramagentic
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; and forming a cigar.
In one embodiment, the present invention provides a method of making a cigar
comprising: providing a tobacco column; attaching a filter to the tobacco
column, the filter
comprising a section that comprises a porous mass that comprises activated
carbon and a
binder particle, 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 forming a
cigar.
In one embodiment, the present invention provides a cigarette pack comprising
a pack
and at least one cigarette comprising a filter that comprises at least one
filter section having a
porous mass that comprises an active particle and a binder particle, the
porous mass having:
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, and wherein the active particle is not carbon.
In one embodiment, the present invention provides a cigarette pack comprising
a pack
and at least one cigarette comprising a filter that comprises at least one
filter section having a
porous mass that comprises an active particle and a binder particle, 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 nanohom, 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
49
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
In one embodiment, the present invention provides a cigarette pack comprising
a pack
and at least one cigarette comprising a filter that comprises at least one
filter section having a
porous mass that comprises an active particle and a binder particle, 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.
In one embodiment, the present invention provides a cigar pack comprising a
pack
and at least one cigar comprising a filter that comprises at least one filter
section having a
porous mass that comprises an active particle and a binder particle, the
porous mass having:
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 one embodiment, the present invention provides a cigar comprising a filter
that
comprises at least one filter section having a porous mass that comprises an
active particle
and a binder particle, the porous mass having: 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 one embodiment, the present invention provides a cigar pack comprising a
pack
and at least one cigar comprising a filter that comprises at least one filter
section having a
porous mass that comprises an active particle and a binder particle, 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 nanohom, a bamboo-like
carbon
nanostructure, a fullerene, a fifflerene 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 endoffillerene, Gd@C60, a core-shell nanoparticle, an onionated
nanoparticle, a
nanoshell, an onionated iron oxide nanoparticle, and any combination thereof.
In one embodiment, the present invention provides a cigarette carton, the
cigarette
carton comprising at least one cigarette pack, the cigarette pack comprising a
pack and at
least one cigarette comprising a filter that comprises at least one filter
section having a porous
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
mass that comprises an active particle and a binder particle, the porous mass
having: an active
particle loading of at least about 1 mg/mm, an EPD of about 20 mm of water or
less per mm
of porous mass, and wherein the active particle is not carbon.
In one embodiment, the present invention provides a cigarette carton, the
cigarette
5 carton comprising at least one cigarette pack, the cigarette pack
comprising a pack and at
least one cigarette comprising a filter that comprises at least one filter
section having a porous
mass that comprises an active particle and a binder particle, 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 nanohom, a bamboo-like carbon
nanostructure, a
10 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
15 endofullerene, GdaC60, a core-shell nanoparticle, an onionated
nanoparticle, a nanoshell, an
onionated iron oxide nanoparticle, and any combination thereof.
In one embodiment, the present invention provides a cigarette carton, the
cigarette
carton comprising at least one cigarette pack, the cigarette pack comprising a
pack and at
least one cigarette comprising a filter that comprises at least one filter
section having a porous
20 mass that comprises an active particle and a binder particle, 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.
In one embodiment, the present invention provides a cigar carton, the cigar
carton
comprising at least one cigar pack, the cigar pack comprising a pack and at
least one cigar
25 comprising a filter that comprises at least one filter section having a
porous mass that
comprises an active particle and a binder particle, the porous mass having: 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 one embodiment, the present invention provides a cigar carton, the cigar
carton
30 comprising at least one cigar pack, the cigar pack comprising a pack and
at least one cigar
comprising a filter that comprises at least one filter section having a porous
mass that
comprises an active particle and a binder particle, the active particle
comprising a element
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
51
selected from the group consisting of: a nano-scaled carbon particle, a carbon
nanotube
having at least one wall, a carbon nanohom, 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 endofifflerene,
Gd@C60, a core-
shell nanoparticle, an onionated nanoparticle, a nanoshell, an onionated iron
oxide
nanoparticle, and any combination thereof.
In one embodiment, the present invention provides a cigar carton, the cigar
carton
comprising at least one cigar pack, the cigar pack comprising a pack and at
least one cigar
comprising a filter that comprises at least one filter section having a porous
mass that
comprises an active particle and a binder particle, 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.
In one embodiment, the present invention provides a method of making a smoking
device filter, comprising incorporating into the smoking device filter a
filter that comprises at
least one filter section having a porous mass having an active particle and a
binder particle,
the porous mass having: an active particle loading of at least about 1 mg/mm,
an EPD of
about 20 mm of water or less per mm of porous mass, and wherein the active
particle is not
carbon.
In one embodiment, the present invention provides a method of making a smoking
device filter, comprising incorporating into the smoking device filter a
filter that comprises at
least one filter section having a porous mass having an active particle and a
binder particle,
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
nanohom, 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
supemaramagentic
nanoparticle, a gadolinium oxide nanoparticle, a hematite nanoparticle, a
magnetite
nanoparticle, a gado-nanotube, an endofullerene, Gd@C60, a core-shell
nanoparticle, an
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
52
onionated nanoparticle, a nanoshell, an onionated iron oxide nanoparticle, and
any
combination thereof.
In one embodiment, the present invention provides a method of making a smoking
device filter comprising: incorporating into the smoking device filter a
filter that comprises at
least one filter section having a porous mass having an active particle and a
binder particle,
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.
In one embodiment, the present invention provides a process for producing a
smoking
device filter comprising: providing a first filter section, providing at least
a second filter
section, the second filter section having a porous mass having an active
particle and a binder
particle, the porous mass having: an active particle loading of at least about
1 mg/mm, an
EPD of about 20 mm of water or less per mm of porous mass; joining the first
filter section
and the at least one second filter so as to form a smoking device filter.
In one embodiment, the present invention provides a process for producing a
smoking
device filter comprising: providing a first filter section, providing at least
a second filter
section, the second filter section having a porous mass having an active
particle and a binder
particle, 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; joining the first filter section and the at least one
second filter so as to
form a smoking device filter.
In one embodiment, the present invention provides a process for producing a
smoking
device filter comprising: providing a first filter section, providing at least
a second filter
section, the second filter section having a porous mass having an active
particle and a binder
particle, the porous mass having: a carbon loading of at least about 6 mg/mm,
an EPD of
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
53
about 20 mm of water or less per mm of porous mass; joining the first filter
section and the at
least one second filter so as to form a smoking device filter.
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 section having a porous mass having an active
particle and a
binder particle, the porous mass having: an active particle loading of at
least about 1 mg/mm,
an EPD of about 20 mm of water or less per mm of porous mass; and drawing the
smoke
through the smoking device, wherein the filter section reduces the presence of
at least one
component in the smoke as compared to a filter without the porous mass.
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 section having a porous mass having an active
particle and a
binder particle, 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
nanohom, 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; and drawing the smoke through the smoking device,
wherein
the filter section reduces the presence of at least one component in the smoke
as compared to
a filter without the porous mass.
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 section having a porous mass having an active
particle and a
binder particle, the porous mass having: a carbon loading of at least about 6
mg/mm, an EPD
of about 20 mm of water or less per mm of porous mass; and drawing the smoke
through the
smoking device, wherein the filter section reduces the presence of at least
one component in
the smoke as compared to a filter without the porous mass.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
54
In one embodiment, the present invention provides an apparatus for producing a
smoking device filter having at least a plurality of sections comprising: a
container
comprising at least a plurality of first filter section pieces; a second
container comprising at
least a plurality of second filter section pieces, the second filter section
pieces comprising a
porous mass having an active particle and a binder particle, the porous mass
having: an active
particle loading of at least about 1 mg/mm, an EPD of about 20 or less mm of
water or less
per mm of porous mass; a joiner section wherein a first filter section piece
and a second filter
section piece are joined; a wrapping area wherein the first filter section
piece and the second
filter section piece are wrapped to form a smoking device filter; and a
conveyor to transport
the smoking device filter to a subsequent area for storage or use.
In one embodiment, the present invention provides an apparatus for producing a
smoking device filter having at least a plurality of sections comprising: a
container
comprising at least a plurality of first filter section pieces; a second
container comprising at
least a plurality of second filter section pieces, the second filter section
pieces comprising a
porous mass having an active particle and a binder particle, 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 nanohom, a bamboo-like carbon
nanostructure, a
flillerene, a ffillerene 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; a joiner
section wherein a
first filter section piece and a second filter section piece are joined; a
wrapping area wherein
the first filter section piece and the second filter section piece are wrapped
to form a smoking
device filter; and a conveyor to transport the smoking device filter to a
subsequent area for
storage or use.
In one embodiment, the present invention provides an apparatus for producing a
smoking device filter having at least a plurality of sections comprising: a
container
comprising at least a plurality of first filter section pieces; a second
container comprising at
least a plurality of second filter section pieces, the second filter section
pieces comprising a
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
porous mass having an active particle and a binder particle, the porous mass
having: a carbon
loading of at least about 6 mg/mm, an EPD of about 20 mm of water or less per
mm of
porous mass; a joiner section wherein a first filter section piece and a
second filter section
piece are joined; a wrapping area wherein the first filter section piece and
the second filter
5 section piece are wrapped to form a smoking device filter; a conveyor to
transport the
smoking device filter to a subsequent area for storage or use.
In one embodiment, the present invention provides a method of making a smoking
device filter comprising: providing a container that comprises at least a
plurality of first filter
section pieces; providing a second container comprising at least a plurality
of second filter
10 section pieces, wherein the second filter section pieces comprise a
porous mass that
comprises an active particle and a binder particle; joining a first filter
section piece and a
second filter section piece end-to-end along the longitudinal axis of the
first filter section
piece and the second filter section piece to form an unwrapped filter rod;
wrapping the first
filter section piece and the second filter section piece with a paper to form
a filter rod; and
15 transporting the filter rod to a subsequent area for storage or use.
In one embodiment, the present invention provides a process for producing a
smoking
device comprising: providing a filter rod comprising at least one filter
section comprising a
porous mass that comprises an active particle and a binder particle, the
porous mass having:
an active particle loading of at least about 1 mg/mm, an EPD of about 20 mm of
water or less
20 per nun of porous mass; 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
25 one smoking device.
In one embodiment, the present invention provides a process for producing a
smoking
device comprising: providing a filter rod comprising at least one filter
section comprising a
porous mass that comprises an active particle and a binder particle, the
active particle
comprising an element selected from the group consisting of: a nano-scaled
carbon particle, a
30 carbon nanotube having at least one wall, a carbon nanohom, 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
56
nanoparticle, a silver nanoparticle, a metal oxide nanoparticle, an alumina
nanoparticle, a
magnetic nanoparticle, a paramagnetic nanoparticle, a supemaramagentic
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;
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.
In one embodiment, the present invention provides a smoking device holder
comprising a filter that comprises at least one filter section having 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 one embodiment, the present invention provides a smoking device holder
comprising a filter that comprises at least one filter section having an
active particle, 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 nanohom,
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
In one embodiment, the present invention provides a smoking device holder
comprising a filter that comprises at least one filter section 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.
In one embodiment, the present invention provides a pipe comprising a filter
that
comprises at least one filter section having a porous mass, 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.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
57
In one embodiment, the present invention provides a pipe comprising a filter
that
comprises at least one filter section having a porous mass that comprises an
active particle
and a binder particle, 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 nanohom, 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 supeiparamagentic 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.
In one embodiment, the present invention provides a smoking device filter
comprising
at least three neighboring in-series sections, wherein a first section has an
active particle
loading of at least about 1 mg/film and an EPD of about 20 mm of water or less
per mm of
porous mass, and a second section and a third section that each comprise a
section that is
selected from the group consisting of: a
cavity, cellulose acetate, polypropylene,
polyethylene, polyolefin tow, polypropylene tow, polyethylene terephthalate,
polybutylene
terephthalate, random oriented acetate, a paper, a corrugated paper, a
concentric filter,
carbon-on-tow, silica, magnesium silicate, a zeolite, a molecular sieve, a
metallocene, a salt, a
catalyst, sodium chloride, nylon, a flavorant, tobacco, a capsule, cellulose,
a cellulosic
derivative, a catalytic converter, iodine pentoxide, a coarse powder, a carbon
particle, a
carbon fiber, a fiber, a glass bead, a nanoparticle, a void chamber, a baffled
void chamber,
and any combination thereof
In one embodiment, the present invention provides a smoking device filter
comprising
at least three neighboring in-series sections, wherein a first section has a
porous mass that
comprises an active particle and a binder particle, 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 nanohom, 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
58
nanoparticle, a superparamagentic nanoparticle, a gadolinium oxide
nanoparticle, a hematite
nanoparticle, a magnetite nanoparticle, a gado-nanotube, an endofidlerene,
Gd@C60, a core-
shell nanoparticle, an onionated nanoparticle, a nanoshell, an onionated iron
oxide
nanoparticle, and any combination thereof; and a second section and a third
section that each
comprise a section that is selected from the group consisting of: a cavity,
cellulose acetate,
polypropylene, polyethylene, polyolefin tow, polypropylene tow, polyethylene
terephthalate,
polybutylene terephthalate, random oriented acetate, a paper, a corrugated
paper, a concentric
filter, carbon-on-tow, silica, magnesium silicate, a zeolite, a molecular
sieve, a metallocene, a
salt, a catalyst, sodium chloride, nylon, a flavorant, tobacco, a capsule,
cellulose, a cellulosic
derivative, a catalytic converter, iodine pentoxide, a coarse powder, a carbon
particle, a
carbon fiber, a fiber, a glass bead, a nanoparticle, a void chamber, a baffled
void chamber,
and any combination thereof.
In one embodiment, the present invention provides a smoking device having a
filter
that comprises a porous mass that comprises an active particle and a binder
particle, the
active particle being capable of removing or reducing at least one smoke
component from a
smoke stream, the smoke component being selected from the group consisting of:
acetaldehyde, acetamide, acetone, acrolein, acrylamide, acrylonitrile,
aflatoxin B-1, 4-
aminobiphenyl, 1-aminonaphthalene, 2-aminonaphthalene, ammonia, ammonium
salts,
anabasine, anatabine, 0-anisidine, arsenic, A-a-C, benz[a]anthracene,
benz[b]fluoroanthene,
benzplaceanthrylene, 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,Dacridine, dibenz[a,h]anthracene, dibenzo(c,g)carbazole,
dibenzo[a,e]pyrene,
dibenzo[a,h]pyrene, dibenzo[aMpyrene, dibenzo[aMpyrene, 2,6-dimethylaniline,
ethyl
carbamate (urethane), ethylbenzene, ethylene oxide, eugenol, formaldehyde,
furan, glu-P-I,
glu-P-2, hydrazine, hydrogen cyanide, hydroquinone, indeno[1,2,3-cd]pyrene,
IQ, isoprene,
lead, MeA-a-C, mercury, methyl ethyl ketone, 5-methylchrysene, 4-
(methylnitrosamino)-1-
(3-pyridy1)-1-butanone (NNK), 4-(methylni trosamino)-143-pyridy1)-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-
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
59
nitrosoethylmethylamine, N-nitrosommpholine (NMOR), N-nitrosonomicotine (NNN),
N-
nitrosopiperidine (NPIP), N-nitrosopyffolidine (NF'YR) , N-nitrososarcosine
(NSAR),
phenol, Ph1P, polonium-210 (radio-isotope), propionaldehyde, propylene oxide,
pyridine,
quinoline, resorcinol, selenium, styrene, tar, 2-toluidine, toluene, Tip-P-1,
Tip-P-2, uranium-
235 (radio-isotope), uranium-238 (radio-isotope), vinyl acetate, vinyl
chloride, and any
combination thereof.
In one embodiment, the present invention provides a process for producing a
smoking
device filter comprising: providing a first filter section, providing at least
a second filter
section, the second filter section having a porous mass having an active
particle and a binder
particle, the active particle being capable of removing or reducing at least
one smoke
component from a smoke stream, the smoke component being selected from the
group
consisting of: acetaldehyde, acetamide, acetone, acrolein, acrylamide,
aczylonitrile, aflatoxin
B-1, 4-aminobiphenyl, 1-aminonaphthalene, 2-aminonaphthalene, ammonia,
ammonium
salts, anabasine, anatabine, 0-anisidine, arsenic, A-a-C, benz[i]anthracene,
benz[b]fluoroanthene, benzplaceanthrylene, 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 dioxinsifurans, 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[aApyrene, dibenzo[aMpyrene, 2,6-dimethylaniline,
ethyl
carbamate (urethane), ethylbenzene, ethylene oxide, eugenol, formaldehyde,
furan, glu-P-1,
glu-P-2, hydrazine, hydrogen cyanide, hydroquinone, indeno[1,2,3-cd]pyrene,
IQ, isoprene,
lead, MeA-a-C, mercury, methyl ethyl ketone, 5-methylchlysene, 4-
(methylnitrosamino)-1-
(3-pridy1)-1-butanone (NNK), 4-(methylnitrosamino)-1-(3-pyridy1)-1-butanol (NN
AL),
naphthalene, nickel, nicotine, nitrate, nitric oxide, a nitrogen oxide,
nitrite, nitrobenzene,
n i tromethane, 2-n itropropane, N-ni trosoanabasine (NAB), N-
nitrosodiethanolamine
(NDELA), N-nitrosodiethylamine, N -nitrosodimethylamine
(NDMA), N
nitrosoethylmethylamine, N-nitrosomoipholine (NMOR), N-nitrosonomicotine
(NNN), N-
nitrosopiperidine (NPIP), N-nitrosopyrrolidine (NPYR) , N-nitrososarcosine
(NSAR),
phenol, Phil), 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
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
combination thereof; and joining the first filter section and the at least one
second filter so as
to form a smoking device filter.
In one embodiment, the present invention provides a porous mass having a void
volume in the range of about 40% to about 90%.
5 In one
embodiment, the present invention provides a filter that comprises a porous
mass having a void volume in the range of about 40% to about 90%.
In one embodiment, the present invention provides a smoking device that
comprises a
filter that comprises a porous mass having a void volume in the range of about
40% to about
90%.
10 In some
embodiments, the present invention provide a filter that may be used in a
smoking device, the filter comprising 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:
(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
15 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
20
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;
(b) the porous mass having a void volume in the range of about 40% to about
90%;
(c) the active particle comprising carbon, and the porous mass having a carbon
25 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
(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.
To facilitate a better understanding of the present invention, the following
examples
30 of
representative embodiments are given. In no way should the following examples
be read
to limit, or to define, the scope of the invention.
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
61
Examples,
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, of Dallas, TX and 75 weight % PICA RC 259 (95% active
carbon) from PICA U.S.A, Inc. of Columbus, OFT. 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 (p.). 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 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 sm.oking machine.
Table 1
Carbonyls Control 5 mm 10 mm % 15 mm
gaicigarefte porous porous porous
mass 20 mass 15 mass 13
mm Tow mm mm
Tow Tow
Formaldehyde 10.4 5.1 -51 0.0 -100 0.0 -100
A.cetaldehyde 295.3 211.2 -28 186.8 -37 188.5 -36
Acetone 601.0 287.7 104.7 -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
Ketone 178.8 64.2 -64 20.8 -88 21.5 -88
Acrolein 101.8 45.3 -56 13.6 -87 14.8 -85
CA 02813575 2013-04-03
WO 2(112/(154111
PCT/US2011/044142
62
Table 2
Other compounds Control 5 mm 0/0 10 mm % 15 mm
porous porous porous
mass 20 mass 15 mass 13
mm Tow mm Tow mm Tow
Benzene (pg/cig) 79.0 54.0 -32 22.0 -72 20.0 -75
1,3 butadiene
(1.1g/cig) 220.0 192.0 -13 162.0 -26 98.0 -55
Benzo[a]Pyrene
(nglcig) 5.0 0.0 -100 0.0 -100 0.0 -
100
Table 3
Tar. nicotine, Control 5 mm Control 10 mm Control 15 mm
etc porous porous porous
mass 20 mass 15 mass 13
mm Tow mm Tow mm Tow
Tar (mg/cig) 39.0 37.1 35.8 34.4 33.7 34.9
Nicotine
(mg/cig) 2.8 2.8 2.5 2.6 2.6 2.7
Water (mg/cig) 17.7 17.0 14.0 13.3 14.7 11.2
CO (mg/cig) 34.4 35.4 32.6 32.1 31.4 31.2
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
% OUR X192 from Ticona, of Dallas, TX and 70 weight % PICA. 30x70 (60% active
carbon)
from PICA USA, Inc. of Columbus, OH. 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 30x70 carbon had an
average
particle size of 405 microns (11). The porous mass was made by mixing the
resin (GUR
X192) and carbon (PICA 30x70) and then filling a mold with the mixture without
pressure on
the heated mixture (free sintering). Then, the mold was heated to 220 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 "Mr,"
Nicotine and
CA 02813575 2013-04-03
WO 2012/054111 PCT/US2011/044142
63
Carbon Monoxide in Mainstream Tobacco Smoke," Health Canada, 1999) and a
Cerulean
450 smoking machine.
Table 4
Carbonyls Control 5 mm % 10 mm % 15 mm
%
peicieurefte porous porous porous
mass 20 mass 15 mass 13
mm Tow mm mm
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
Ketone 195.7 100.8 -49 37.1 -81 19.2 -90
Acrolein 84.0 55.5 -34 22.5 -73 13.3 -84
Table 5
Other compounds Control 5 mm % 10 mm % 15 mm %
porous porous porous
mass 20 mass 15 mass 13
mm Tow mm Tow mm Tow
Benzene (Agleig) 118.7 81.7 -30 40.1 -66 23.5 -
80
1,3 butadiene
(ptgicig) 257.3 259.1 1 204.4 _11 148.7 -
42
BenzoraiPyrene
(nglcie) 6.4 3.0 -53 0.0 -100 0.0 -
100
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
64
Table 6
Tar, nicotine, Control 5 mm 10 mm 15 mm
etc porous porous porous
mass 20 mass 15 mass 13
mm Tow mm Tow mm Tow
Tar (m.g/cig) 41.5 41.5 41.2 38.4
Nicotine
(mg/cig) 2.8 2.8 2.9 2.8 ..
Water (mg/cig) 16.7 17.0 17.7 12.6
CO (m.g/cig) 30.8 33.2 35.5 31.6
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, of Dallas, TX 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 7
Carbonyls Control Ion Exchange Resin % change
J.12/ci2arette
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
Cro tonal dehy de 83.0 45.0 -45
Methyl Ethyl
Ketone 179.0 184.0 3
Butyraldehyde , 54.0 61.0 13
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 %
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
OUR 2105 from Ticona, of Dallas, TX and 80 weight % of desiccant (calcium
sulfate,
DRIERITE from W. A. Hammond DRIERITE Co. Ltd. of Xenia, OH). 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
5 according to tobacco industry standards. All cigarettes were smoked using
the Canadian
intense protocol (i.e., T-115, "Determination of "Tan" Nicotine and Carbon
Monoxide in
Mainstream Tobacco Smoke," Health Canada, 1999) and a Cerulean 450 smoking
machine.
10 Table 8
mg/cigarette Control Desiccant A) Desiccant
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
In the following example, a carbon-on-tow filter element is compared to the
inventive
15 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
20 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
30x70,
60% active PICA carbon. All cigarettes were smoked using the Canadian intense
protocol
CA 02813575 2013-04-03
WO 2(112/(154111 PCT/US2011/044142
66
(i.e., T-115, "Determination of "Tar," Nicotine and Carbon Monoxide in
Mainstream
Tobacco Smoke," Health Canada, 1999).
Table 9
_______________________________________________________________________
Total Carbon Loading = 39 mg Total Carbon loading.= 56 mg
Carbonyls Carbon-on-tow(10 porous mass
Carbon-on-tow (10 porous mass
mm) % change (2 mm) mm) (3 mm)
____________________________________________________ % change % change
'!4k 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
Crotonaldebyde -64.5 -57.3 -71.0 -
68.0
Butyraldehyde 7.9 -34.4 -8.2 -
54.4 ,
Methyl Ethyl
Ketone -35.4 -48.3 -45.6 -
63.2
Acrolein -22.5 -40.3 -31.3 -
52.6
In the following example, a porous mass made with a highly active carbon (95%
CC14
absorption) is compared with a porous mass made with a lower active carbon
(60% CCL4
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 (i.e., T-115, "Determination of "Tan" Nicotine and Carbon Monoxide in
Mainstream Tobacco Smoke," Health Canada, 1999). The high active carbon was
PICA RC
259, particle size 20x50, 95% activity (CCI4 adsorption). The low active
carbon was PICA
PCA, particle size 30x70, 60% activity (CC14 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.
CA 02813575 2013-04-03
WO 2(112/(15-1111
PCT/US2011/044142
67
Table 10
Carbonyls 60% active 95% active
carbon % carbon %
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
Ketone -100.0 -88.0
Acrolein -90.7 -87.0
Table 11
Other 60% active 95% active
compounds carbon % carbon %
change change
Benzene 2.6 -72.0
1,3 butadiene -3.2 -26.0
Benzo[a]Pyrene -100.0 -100.0
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 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.
CA 02813575 2013-04-03
WO 2012/054111
PCT/US2011/044142
68
Table 12
Carbon:GUR Average Average
Weight Ratio Particle EPD
Size
Carbon (it) (mm of
water/mm
of porous
mass
length)
RC 259 75:25 569.0 2./
PICA 80:20 402.5 3.5
NC506 75:25 177.5 25.0
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 13
Upper
limit Highes
(125% t Amount
of deliver
Amount delivere
Median median y reduction reduction delivere
d 10
(PO bran&
25 mm 2 10 mm d 5 mm mm
1,3Butadiene 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]pyre 9.1 11.4 13.8 100 100 0.0 0.0
ne
Formaldehyde 37.7 47.1 90.5 51 100 44.4 0.0
1 Information based on data in Counts, ME, et al., (2004) Mainstream smoke
toxicant yields
and predicting relationships from a worldwide market sample qf cigarette
brands: ISO
CA 02813575 2013-04-03
WO 2(112/(15-1111 PCT/US2011/044142
69
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.
2 % reductions obtained from Tables 1-3 above.
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 14
Upper
limit
(125% Highest Amount
of delivery reduction2 delivered
(PO Median' median) brand' 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
Information 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.
2 % reductions obtained from Table 4 above.
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
CA 02813575 2013-04-03
WO 2(112/(15-1111 PCT/US2011/044142
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
5 top of the mold is then sealed and placed in an oven and heated, without
the addition of
pressure, to a temperature of 220 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
10 Polymers LLC, a division of Celanese Corporation of Dallas, TX under the
following
tradenames, the molecular weights are in parentheses: OUR 2126 (approximately
4 x 106
g/mol), OUR 4050-3 (approximately 8-9 x 106 g/mol), OUR 2105 (approximately
0.47 x
106 g/mol), OUR X192 (approximately 0.60 x 106 g/mol), GUR 4012
(approximately 1.5
x 106 g/mol), and OUR 4022-6 (approximately 4 x 106 g/mol).
15 Table 15
Comparative Examples
Carbon Loading for Comparative Example Comparative Example Comparative
Comparative 1 2 Example 3
Examples (30x70 Pica (OUR 2126) (OUR 4050-3) (1:1 Blend:
Carbon) Average mg Average mg OUR 2126:
Carbon:Binder Carbon/mm Carbon/mm OUR 4050-3)
Particle Weight Ratio Average mg
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 16
20 Comparative Examples
Encapsulated Pressure Comparative Example Comparative Example Comparative
Drop .for Comparative 1 2 Example 3
Examples (OUR 2126) (OUR 4050-3) (1:1 Blend OUR
(30x70 Pica Carbon) Average mm of Average mm of 2126: GUR
Carbon:Binder Particle water/mm water/mm 4050-3)
Weight Ratio Average mm of
water/mm
CA 02813575 2013-04-03
WO 2012/054111
PCT/US2011/044142
71
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
CA 02813575 2013-04-03
WO 2012/054111
PCT/US2011/044142
72
Table 17
Porous Masses of the Present Invention
Carbon Loading Binder Particle Binder Particle Binder Particle
Binder Particle
(30x70 Pica 1 (GUR 2105) 2 (OUR X192) 3 (GUR 4012) 4 (GUR 4022-
Carbon) Average mg Average mg Average mg 6)
Carbon:Binder Carbon/mm Carbon/mm Carbon/mm Average mg
Particle Weight Carbon/mm
Ratio
50/50 NA NA 11.66 10.51
60140 10.61 11.16 ---- 13.35 12.66
-i
65/35 11.70 11.23 --- NA NA
......
70/30 12.70 13.22 15.01 i 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 18
Porous Masses of the Present Invention
Encapsulated Binder Particle Binder Particle
2 Binder Particle Binder Particle
Pressure Drop 1 (OUR 2105) (GUROX I 92) 3 (OUR 4012) 4 (OUR 4022-
(30x70 Pica Average mm of Average mm of Average mm of 6)
Carbon) water/mm water/mm water/mm Average mm of
Carbon:Binder water/mm
Particle Weight
Ratio
50/50 NA NA --------- 18.48 7.87
_
60/40 0.94 232 -------- 15.71 ---------- 8.00
65/3" 1.48 2A0 -------- 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.
CA 02813575 2013-04-03
WO 2(112/(154111 PCT/US2011/044142
73
Table 19
Porous Masses of the Present Invention
Carbon Binder Particle Average Average
Pica Carbon Weight % Blend' Carbon mg/mm EPD mm of
water/mm of
Mesh Weight % porous mass
80x325 50 50 9.14
2.0
80x325 60 40 12.24
6.4
80x325 70 30 14.05
11.4
80x325 80 20 17.02
19.3
1. The binder blend was a 1:1 weight mixture of GUR 2105 and GUR. X192.
Table 20
Additional Comparative Examples
Commercial Length (mm) Average of 20 filters EPD/nint of
porous
cigarette filters EPD mm of mass length
(Cellulose acetate) water/mm
Marlboro 21 70 3.3
Winston 27 79 2.9
The data shown in Figures 6 through 9 were generated from additional EPD
testing of
porous masses of the present invention 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 2105, GUR X192, GUR 4012, and
GUR. 8020), 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 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 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
CA 02813575 2014-04-14
54242=3
74
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.
Figure 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.
Figure. 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 nun.
Figure 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.
Figure 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.
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.
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
CA 02813575 2014-04-14
54242-3
a word or term in this specification and one or more patent or other documents
referred to
herein, the definitions that are consistent with this specification should be
adopted.
