Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUSES, SYSTEMS, AND ASSOCIATED METHODS FOR
FORMING POROUS MASSES FOR SMOKE FILTERS
BACKGROUND
[0001] The exemplary embodiments described herein relates to
apparatuses, systems, and associated methods for manufacturing porous
masses that may be used in smoke filters, including high-throughput production
embodiments thereof.
[0002] The Centers for Disease Control and Prevention reports that in
2012 over 300 billion cigarettes and over 13 billion cigars were sold in the
United
States alone. Thus there is a continuing demand for cigarettes and cigars
world-
wide.
[0003] Increasingly, governmental regulations potentially could require
higher filtration efficacies in removing harmful components from tobacco
smoke.
With present cellulose acetate, higher filtration efficacies can be achieved
by
doping the filter with increasing concentrations of particles like activated
carbon.
However, increasing particulate concentration changes draw characteristics for
smokers.
[0004] One measure of draw characteristics is the encapsulated
pressure drop. As used herein, the term "encapsulated pressure drop" or "EPD"
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
volumetric
flow is 17.5 ml/sec at the output end and 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. Higher EPD values translate to the smoker having to draw
on a smoking device with greater force.
[0005] Because increasing filter efficacy changes the EPD of the filters,
the public, and consequently manufactures, have been slow to adopt
significantly different technologies. Therefore, despite continued research,
there
remains an interest in developing improved and more effective compositions
that
minimally effect draw characteristics while removing higher levels of certain
constituents in mainstream tobacco smoke. Further, such solutions should have
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the high volume production methods needed to meet commercial demand for
smoking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following figures are included to illustrate certain aspects of
the present invention, and should not be viewed as exclusive embodiments. The
subject matter disclosed is capable of considerable modification, alteration,
and
equivalents in form and function, as will occur to those skilled in the art
and
having the benefit of this disclosure.
[0007] Figures 1A-B illustrate nonlinniting examples of systems for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
[0008] Figures 2A-B illustrate nonlinniting examples of systems for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
[0009] Figure 3 illustrates a nonlinniting example of a system for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
[0010] Figure 4 illustrates a nonlinniting example of a system for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
[0011] Figure 5 illustrates a nonlinniting example of a system for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
[0012] Figure 6A illustrates a nonlinniting example of a system for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
[0013] Figure 6B illustrates a nonlinniting example of a system for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
[0014] Figure 7A illustrates a nonlinniting example of a system for
forming porous masses according to at least one embodiment described herein
(not necessarily to scale).
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[0015] Figure 7B illustrates a nonlimiting example of a system for forming
porous masses according to at least one embodiment described herein (not
necessarily to scale).
[0016] Figure 8 illustrates a nonlimiting example of a system for forming
porous masses according to at least one embodiment described herein (not
necessarily to scale).
[0017] Figure 9 illustrates a nonlimiting example of a system for forming
porous masses according to at least one embodiment described herein (not
necessarily to scale).
[0018] Figure 10 illustrates a nonlimiting example of a system for forming
porous masses according to at least one embodiment described herein (not
necessarily to scale).
[0019] Figure 11 illustrates a nonlimiting example of a system for forming
porous masses according to at least one embodiment described herein (not
necessarily to scale).
[0020] Figure 12 illustrates a nonlimiting example of a system for forming
porous masses according to at least one embodiment described herein (not
necessarily to scale).
[0021] Figure 13 shows an illustrative diagram of the process of producing
combined filter rods according to at least some embodiments described herein.
[0022] Figure 14 shows an illustrative diagram of relating to at least some
methods of the described herein for forming filters according to at least some
embodiments described herein.
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DETAILED DESCRIPTION
[0023] The exemplary embodiments described herein relates to apparatuses,
systems, and associated methods for manufacturing porous masses that may be
used in smoke filters, including high-throughput production embodiments
thereof.
[0023a] According to one aspect of the present invention, there is provided a
method comprising: feeding via pneumatic dense phase feeding a matrix material
into
a mold cavity to form a desired cross-sectional shape, the matrix material
comprising
a plurality of binder particle and a plurality of active particles; heating at
least a
portion of the matrix material so as to bind at least a portion of the matrix
material at a
plurality of sintered contact points, thereby forming a porous mass length;
cooling the
porous mass length; and cutting the porous mass length, thereby producing a
porous
mass, wherein pneumatic dense phase feeding occurs at a feeding rate of about
1
m/min to about 800 m/min and the mold cavity has a diameter of about 3 mm to
about 25 mm.
[0023b] According to another aspect of the present invention, there is
provided a method comprising: feeding via pneumatic dense phase feeding a
matrix
material into a mold cavity to form a desired cross-sectional shape, the
matrix
material comprising a plurality of active particles and a plurality of binder
particles
having a hydrophilic surface modification; heating at least a portion of the
matrix
material so as to bind at least a portion of the matrix material at a
plurality of sintered
contact points, thereby forming a porous mass length; reshaping the cross-
sectional
shape of the porous mass length after heating; cooling the porous mass length;
and
cutting the porous mass length, thereby producing a porous mass, wherein
pneumatic dense phase feeding occurs at a feeding rate of about 1 m/min to
about
800 m/min and the mold cavity has a diameter of about 3 mm to about 25 mm.
[0023c] According to another aspect of the present invention, there is
provided a method comprising: feeding via pneumatic dense phase feeding a
matrix
material into a mold cavity to form a desired cross-sectional shape, the
matrix
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material comprising a plurality of active particles, a plurality of binder
particles having
a hydrophilic surface modification, and a microwave enhancement additive;
heating
at least a portion of the matrix material by irradiating the matrix material
with
microwave irradiation so as to bind at least a portion of the matrix material
at a
plurality of sintered contact points, thereby forming a porous mass length;
reshaping
the cross-sectional shape of the porous mass length after heating; cooling the
porous
mass length; and cutting the porous mass length, thereby producing a porous
mass,
wherein pneumatic dense phase feeding occurs at a feeding rate of about 1
m/min to
about 800 m/min and the mold cavity has a diameter of about 3 mm to about 25
mm.
[0024] The exemplary embodiments described herein provide for methods
and apparatuses (and/or systems) for high-throughput production of porous
masses
that can be used in smoking device filters with increased filtration efficacy
of smoke
stream components and with acceptable draw characteristics.
[0025] Porous masses described in co-pending PCT Application Number
PCT/US11/56388 filed on October 14, 2011, generally comprise a plurality of
binder
particles (e.g., polyethylene) and a plurality of active particles (e.g.,
carbon particles
or zeolites) mechanically bound at a plurality of contact points. The contact
points
may be active particle-binder contact points, binder-binder contact points,
active
particle-active particle contact points, and any combination thereof. As used
herein,
the terms "mechanical bond," "mechanically bonded," "physical bond," and the
like
refer to a physical connection that holds two particles at least partially
together.
Mechanical bonding is generally a result of sintering. As such, when described
herein, mechanical bonding encompasses embodiments where the plurality of
binder
particles and the plurality of active particles are mechanically bound at a
plurality of
sintered contact points. Mechanical bonds may be rigid or flexible depending
on the
bonding material. Mechanical bonding may or may not involve chemical bonding.
It
should be understood that as used herein, the terms "particle" and
"particulate" may
be used interchangeably and include all known shapes of materials, including
spherical and/or ovular, substantially spherical and/or ovular, discus and/or
platelet,
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flake, ligamental, acicular, fibrous, polygonal (such as cubic), randomly
shaped (such
as the shape of crushed rocks), faceted (such as the shape of crystals), or
any hybrid
thereof. Additional nonlimiting examples of porous masses are described in
detail in
co-pending applications PCT/US2011/043264, PCT/US2011/043268,
PCT/US2011/043269, and PCT/US2011/043271 all filed on July 7, 2012.
[0026] Porous masses may be produced through a variety of methods. For
example, some embodiments may involve forming the matrix material (e.g., the
active
particles and binder particles) into a desired shape (e.g., with a mold),
heating the
matrix material to mechanically bond the matrix material together, and
finishing the
porous masses (e.g., cutting the porous masses to a desired length). Of the
various
processes/steps involved in the production of porous masses, forming the
matrix
material into a desired shape while maintaining a homogenous dispersion and
heating may be two of the steps that limits high-throughput manufacturing.
Accordingly, methods that employ pneumatic dense phase feed may be involved in
preferred methods for high-throughput manufacturing of porous masses described
herein (e.g., a linear flow
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rate of about 1 nn/min to about 800 nn/min or about 300 nn/min to about 800
nn/min). Further, methods that employ rapid heating (e.g., microwave and
optionally with the inclusions of a microwave enhancement additive in the
matrix
material) optionally with a preheating step (e.g., indirect heating or direct
contact with heated gases) may be involved in some preferred methods for high-
throughput manufacturing of porous masses described herein. Further, in
additional preferred high-throughput manufacturing embodiments, a secondary
sintering or heating may be used for quality control or to complete sintering
when the rapid heating portion of the method is designed to sinter or
mechanically bind a portion of the matrix material (e.g., the outer portion).
[0027] As used herein, the term "smoking device" refers to articles or
devices including, but not limited to, cigarettes, cigarette holders, cigars,
cigar
holders, pipes, water pipes, hookahs, electronic smoking devices, roll-your-
own
cigarettes, and/or cigars.
[0028] It should be noted that when "about" is provided herein in
reference to a number in a numerical list, the term "about" modifies each
number of the numerical list. It should be noted that in some numerical
listings
of ranges, some lower limits listed may be greater than some upper limits
listed.
One skilled in the art will recognize that the selected subset will require
the
selection of an upper limit in excess of the selected lower limit.
I. Methods and Apparatuses for Forming Porous Masses
[0029] The process of forming porous masses may include continuous
processing methods, batch processing methods, or hybrid continuous-batch
processing methods. As used herein, "continuous processing" refers to
manufacturing or producing materials without interruption. Material flow may
be
continuous, indexed, or combinations of both. As used herein, "batch
processing" refers to manufacturing or producing materials as a single
component or group of components at individual stations before the single
component or group proceeds to the next station. As used herein, "continuous-
batch processing" refers to a hybrid of the two where some processes, or
series
of processes, occur continuously and others occur by batch.
[0030] Generally porous masses may be formed from matrix materials.
As used herein, the term "matrix material" refers to the precursors, e.g.,
binder
particles and active particles, used to form porous masses. In some
embodiments, the matrix material may comprise, consist of, or consist
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essentially of binder particles and active particles. In some embodiments, the
matrix material may comprise binder particles, active particles, and
additives.
Nonlimiting examples of suitable binder particles, active particles, and
additives
are provided in this disclosure.
[0031] Forming porous masses may generally include forming a matrix
material into a desired shape (e.g., suitable for incorporating into as
smoking
device filter, a water filter, an air filter, or the like) and mechanically
bonding
(e.g., sintering) at least a portion of the matrix material at a plurality of
contact
points.
[0032] Forming a matrix material into a shape may involve a mold
cavity. In some embodiments, a mold cavity may be a single piece or a
collection of single pieces, either with or without end caps, plates, or
plugs. In
some embodiments, a mold cavity may be multiple mold cavity parts that when
assembled form a mold cavity. In some embodiments, mold cavity parts may be
brought together with the assistance of conveyors, belts, and the like. In
some
embodiments, mold cavity parts may be stationary along the material path and
configured to allow for conveyors, belts, and the like to pass therethrough,
where the mold cavity may expand and contract radially to provide a desired
level of compression to the matrix material.
[0033] A mold cavity may have any cross-sectional shape including, but
not limited to, circular, substantially circular, ovular, substantially
ovular,
polygonal (like triangular, square, rectangular, pentagonal, and so on),
polygonal with rounded edges, donut, and the like, or any hybrid thereof. In
some embodiments, porous masses may have a cross-sectional shape
comprising holes, which may be achieved by the use of one or more dies, by
machining, by an appropriately shaped mold cavity, or any other suitable
method (e.g., degradation of a degradable material). In some embodiments, the
porous mass may have a specific shape for a cigarette holder or pipe that is
adapted to fit within the cigarette holder or pipe to allow for smoke passage
through the filter to the consumer. When discussing the shape of a porous mass
herein, with respect to a traditional smoking device filter, the shape may be
referred to in terms of diameter or circumference (wherein the circumference
is
the perimeter of a circle) of the cross-section of the cylinder. But in
embodiments where a porous mass described herein is in a shape other than a
true cylinder, it should be understood that the term "circumference" is used
to
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mean the perimeter of any shaped cross-section, including a circular cross-
section.
[0034] Generally, mold cavities may have a longitudinal direction and a
radial direction perpendicular to the longitudinal direction, e.g., a
substantially
cylindrical shape. One skilled in the art should understand how to translate
the
embodiments presented herein to mold cavities without defined longitudinal and
radial direction, e.g., spheres and cubes, where applicable. In some
embodiments, a mold cavity may have a cross-sectional shape that changes
along the longitudinal direction, e.g., a conical shape, a shape that
transitions
from square to circular, or a spiral. In some embodiments with a sheet-shaped
mold cavity (e.g., formed by an opening between two plates), the longitudinal
direction would be the machine direction or flow of matrix material direction.
In
some embodiments, a mold cavity may be paper rolled or shaped into a desired
cross-sectional shape, e.g., a cylinder. In some embodiments, a mold cavity
may
be a cylinder of paper glued at the longitudinal seam.
[0035] In some embodiments, mold cavities may have a longitudinal
axis having an opening as a first end and a second end along said longitudinal
axis. In some embodiments, matrix material may pass along the longitudinal
axis of a mold cavity during processing. By way of nonlinniting example,
Figure 1
shows mold cavity 120 with a longitudinal axis along material path 110.
[0036] In some embodiments, mold cavities may have a longitudinal
axis having a first end and a second end along said longitudinal axis wherein
at
least one end is closed. In some embodiments, said closed end may be capable
of opening.
[0037] In some embodiments, individual mold cavities may be filled
with a matrix material prior to mechanical bonding. In some embodiments, a
single mold cavity may be used to continuously produce porous masses by
continuously passing matrix material therethrough before and/or during
mechanical bonding. In some embodiments, a single mold cavity may be used to
produce an individual porous mass. In some embodiments, said single mold
cavity may be reused and/or continuously reused to produce a plurality of
individual porous masses.
[0038] In some embodiments, mold cavities may be at least partially
lined with wrappers and/or coated with release agents. In some embodiments,
wrappers may be individual wrappers, e.g., pieces of paper. In some
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embodiments, wrappers may be spoolable-length wrappers, e.g., a 50 ft roll of
paper.
[0039] In some embodiments, mold cavities may be lined with more
than one wrapper. In some embodiments, forming porous masses may include
lining a mold cavity(s) with a wrapper(s). In some embodiments, forming porous
masses may include wrapping the matrix material with wrappers so that the
wrapper effectively forms the mold cavity. In such embodiments, the wrapper
may be preformed as a mold cavity, formed as a mold cavity in the presence of
the matrix material, or wrapped around matrix material that is in a preformed
shape (e.g., with the aid of a tackifier). In some embodiments, wrappers may
be
continuously fed through a mold cavity. Wrappers may be capable of holding the
porous mass in a shape, capable of releasing the porous masses from the mold
cavities, capable of assisting in passing matrix material through the mold
cavity,
capable of protecting the porous mass during handling or shipment, and any
combination thereof.
[0040] Suitable wrappers may include, but not be limited to, papers
(e.g., wood-based papers, papers containing flax, flax papers, papers produced
from other natural or synthetic fibers, functionalized papers, special marking
papers, colorized papers), plastics (e.g., fluorinated polymers like
polytetrafluoroethylene, silicone), films, coated papers, coated plastics,
coated
films, and the like, and any combination thereof. In some embodiments,
wrappers may be papers suitable for use in smoking device filters.
[0041] In some embodiments, a wrapper may be adhered (e.g., glued)
to itself to assist in maintaining a desired shape, e.g., in a substantially
cylindrical configuration. In some embodiments, mechanical bonding of the
matrix material may also mechanically bind (or sinter) the matrix material to
the
wrapper which may alleviate the need for adhering the wrapper to itself.
[0042] Suitable release agents may be chemical release agents or
physical release agents. Nonlimiting examples of chemical release agents may
include oils, oil-based solutions and/or suspensions, soapy solutions and/or
suspensions, coatings bonded to the mold surface, and the like, and any
combination thereof. Nonlimiting examples of physical release agents may
include papers, plastics, and any combination thereof. Physical release
agents,
which may be referred to as release wrappers, may be implemented similar to
wrappers as described herein.
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[0043] Once formed into a desired cross-sectional shape with the mold
cavity, the matrix material may be mechanically bound at a plurality of
contact
points. Mechanical bonding may occur during and/or after the matrix material
is
in the mold cavity. Mechanical bonding may be achieved with heat and/or
pressure and without adhesive (i.e., forming a sintered contact points). In
some
instances, an adhesive may optionally be included.
[0044] Heat may be radiant heat, conductive heat, convective heat, and
any combination thereof. Heating may involve thermal sources including, but
not
limited to, heated fluids internal to the mold cavity, heated fluids external
to the
mold cavity, steam, heated inert gases, secondary radiation from a component
of the porous mass (e.g., nanoparticles, active particles, and the like),
ovens,
furnaces, flames, conductive or thermoelectric materials, ultrasonics, and the
like, and any combination thereof. By way of nonlinniting example, heating may
involve a convection oven or heating block. Another nonlinniting example may
involve heating with microwave energy (single-mode or multi-mode applicator).
In another nonlinniting example, heating may involve passing heated air,
nitrogen, or other gas through the matrix material while in the mold cavity.
In
some embodiments, heated inert gases may be used to mitigate any unwanted
oxidation of active particles and/or additives. Another nonlinniting example
may
involve mold cavities made of thermoelectric materials so that the mold cavity
heats. In some embodiments, heating may involve a combination of the
foregoing, e.g., passing heated gas through the matrix material while passing
the matrix material through a microwave oven.
[0045] Secondary radiation from a component of the porous mass (e.g.,
nanoparticles, active particles, and the like) may, in some embodiments, be
achieved by irradiating the component with electromagnetic radiation, e.g.,
gamma-rays, x-rays, UV light, visible light, IR light, microwaves, radio
waves,
and/or long radio waves. By way of nonlinniting example, the matrix material
may comprise carbon nanotubes that when irradiated with radio frequency
waves emit heat. In another nonlinniting example, the matrix material may
comprise active particles like carbon particles that are capable of converting
microwave irradiation into heat that mechanically bonds or assists in
mechanically bonding (e.g., sintering) the binder particles together. In some
embodiments, the electromagnetic radiation may be tuned by the frequency and
power level so as to appropriately interact with the component of choice. For
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example, activated carbon may be used in conjunction with microwaves at a
frequency ranging from about 900 MHz to about 2500 MHz with a fixed or
adjustable power setting that is selected to match a target rate of heating.
[0046] One skilled in the art, with the benefit of this disclosure, should
understand that different wavelengths of electromagnetic radiation penetrate
materials to different depths. Therefore, when employing primary or secondary
radiation methods one should consider the mold cavity material, configuration
and composition, the matrix material composition, the component that converts
the electromagnetic radiation to heat, the wavelength of electromagnetic
radiation, the intensity of the electromagnetic radiation, the irradiation
methods,
and the desired amount of secondary radiation, e.g., heat.
[0047] The residence time for heating (including by any method
described herein, e.g., convection oven or exposure to electromagnetic
radiation) and/or applying pressure that causes the mechanical bonding (e.g.,
sintered contact points) to occur may be for a length of time ranging from a
lower limit of about a hundredth of a second, a tenth of a second, 1 second, 5
seconds, 30 seconds, or 1 minute to an upper limit of about 30 minutes, 15
minutes, 5 minutes, 1 minute, or 1 second, and wherein the residence time may
range from any lower limit to any upper limit and encompasses any subset
therebetween. It should be noted that for continuous processes that utilize
faster
heating methods, e.g., exposure to electromagnetic radiation like microwaves,
short residence times may be preferred, e.g., about 10 seconds or less, or
more
preferably about 1 second or less. Further, processing methods that utilize
processes like convection heating may provide for longer residence times on
the
tinnescale of minutes, which may include residence times of greater than 30
minutes. One of ordinary skill in the art should understand that longer times
can
be applicable, e.g., seconds to minutes to hours or longer provided that an
appropriate temperature and heating profile may be selected for a given matrix
material. It should be noted that preheating or pretreating methods and/or
steps
that are not to a sufficient temperature and/or pressure to allow for
mechanical
bonding are not considered part of the residence time, as used herein.
[0048] In some embodiments, heating to facilitate mechanical bonding
may be to a softening temperature of a component of the matrix material. As
used herein, the term "softening temperature" refers to the temperature above
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which a material becomes pliable, which is typically below the melting point
of
the material.
[0049] In some embodiments, mechanical bonding may be achieved at
temperatures ranging from a lower limit of about 90 C, 100 C, 110 C, 120 C,
130 C, or 140 C or an upper limit of about 300 C, 275 C, 250 C, 225 C, 200 C,
175 C, or 150 C, and wherein the temperature may range from any lower limit
to any upper limit and encompass any subset therebetween. In some
embodiments, the heating may be accomplished by subjecting material to a
single temperature. In another embodiment the temperature profile may vary
with time. By way of nonlinniting example, a convection oven may be used. In
some embodiments, heating may be localized within the matrix material. By way
of nonlinniting example, secondary radiation from nanoparticles may heat only
the matrix material proximal to the nanoparticle.
[0050] In some embodiments, matrix materials may be preheated
before entering mold cavities. In some embodiments, matrix material may be
preheated to a temperature below the softening temperature of a component of
the matrix material. In some embodiments, matrix material may be preheated
to a temperature about 10%, about 5%, or about 1% below the softening
temperature of a component of the matrix material. In some embodiments,
matrix material may be preheated to a temperature about 10 C, about 5 C, or
about 1 C below the softening temperature of a component of the matrix
material. Preheating may involve heat sources including, but not limited to,
those listed as heat sources above for achieving mechanical bonding.
[0051] In some embodiments, bonding the matrix material may yield
porous mass or porous mass lengths. As used herein, the term "porous mass
length" refers to a continuous porous mass (i.e., a porous mass that is not
never-ending, but rather long compared to porous masses, which may be
produced continuously). By way of nonlinniting example, porous mass lengths
may be produced by continuously passing matrix material through a heated
mold cavity. In some embodiments, the binder particles may retain their
original
physical shape (or substantially retained their original shape, e.g., no more
that
10% variation (e.g., shrinkage) in shape from original) during the mechanical
bonding process, i.e., the binder particles may be substantially the same
shape
in the matrix material and in the porous mass (or lengths). For simplicity and
readability, unless otherwise specified, the term "porous mass" encompasses
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porous mass sections, porous masses, and porous mass lengths (wrapped or
otherwise).
[0052] In some embodiments, porous mass lengths may be cut to yield
porous mass. Cutting may be achieved with a cutter. Suitable cutters may
include, but not be limited to, blades, hot blades, carbide blades, stellite
blades,
ceramic blades, hardened steel blades, diamond blades, smooth blades, serrated
blades, lasers, pressurized fluids, liquid lances, gas lances, guillotines,
and the
like, and any combination thereof. In some embodiments with high-speed
processing, cutting blades or similar devices may be positioned at an angle to
match the speed of processing so as to yield porous masses with ends
perpendicular to the longitudinal axis. In some embodiments, the cutter may
change position relative to the porous mass lengths along the longitudinal
axis of
the porous mass lengths.
[0053] In some embodiments, porous masses and/or porous mass
lengths may be extruded. In some embodiments, extrusion may involve a die. In
some embodiments, a die may have multiple holes being capable of extruding
porous masses and/or porous mass lengths.
[0054] Some embodiments may involve cutting porous masses and/or
porous mass lengths radially to yield porous masses and/or porous mass
sections. One skilled in the art would recognize how radial cutting translates
to
and encompasses the cutting of shapes like sheets. Cutting may be achieved by
any known method with any known apparatus including, but not limited to,
those described above in relation to cutting porous mass lengths into porous
masses.
[0055] The length of a porous mass, or sections thereof, may range
from a lower limit of about 2 mm, 3 mm, 5 mm, 10 mm, 15 mm, 20 mm, 25
mm, or 30 mm to an upper limit of about 150 mm, 100 mm, 50 mm, 25 mm, 15
mm, or 10 mm, and wherein the length may range from any lower limit to any
upper limit and encompass any subset therebetween.
[0056] The circumference of a porous mass length, a porous mass, or
sections thereof (wrapped or otherwise) may range from a lower limit of about
5
mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, 15
mm, 16 mm, 17 mm, 18 mm, 19 mm, 20 mm, 21 mm, 22 mm, 23 mm, 24 mm,
25 mm, or 26 mm to an upper limit of about 60 mm, 50 mm, 40 mm, 30 mm,
20 mm, 29 mm, 28 mm, 27 mm, 26 mm, 25 mm, 24 mm, 23 mm, 22 mm, 21
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mm, 20 mm, 19 mm, 18 mm, 17 mm, or 16 mm, wherein the circumference
may range from any lower limit to any upper limit and encompass any subset
there between.
[0057] One skilled in the art would recognize the dimensional
requirements for porous masses configured for filtration devices other than
smoking articles. By way of nonlinniting example, porous masses configured for
use in concentric fluid filters may be hollow cylinders with an outer diameter
of
about 250 mm or greater. By way of another nonlinniting example, porous
masses configure for use as a sheet in an air filter may have a relatively
thin
thickness (e.g., about 5 mm to about 50 mm) with a length and width that are
tens of centimeters.
[0058] Some embodiments may involve wrapping porous masses with a
wrapper after the matrix material has been mechanically bound, e.g., after
removal from the mold cavity or exiting an extrusion die. Suitable wrappers
include those disclosed above.
[0059] Some embodiments may involve cooling porous masses. Cooling
may be active or passive, i.e., cooling may be assisted or occur naturally.
Active
cooling may involve passing a fluid over and/or through the mold cavity,
porous
masses; decreasing the temperature of the local environment about the mold
cavity, porous masses, e.g., passing through a refrigerated component; and any
combination thereof. Active cooling may involve a component that may include,
but not be limited to, cooling coils, fluid jets, thermoelectric materials,
and any
combination thereof. The rate of cooling may be random or it may be
controlled.
[0060] Some embodiments may involve transporting porous masses to
another location. Suitable forms of transportation may include, but not be
limited to, conveying, carrying, rolling, pushing, shipping, robotic movement,
and the like, and any combination thereof.
[0061] One skilled in the art, with the benefit of this disclosure, should
understand the plurality of apparatuses and/or systems capable of producing
porous masses. By way of nonlinniting examples, Figures 1-12 illustrate a
plurality of apparatuses and/or systems capable of producing porous masses.
[0062] It should be noted that where a system is used, it is within the
scope of this disclosure to have an apparatus with the components of a system,
and vice versa.
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[0063] For ease of understanding, the term "material path" is used
herein to identify the path along which matrix material, porous mass lengths,
and/or porous masses will travel in a system and/or apparatus. In some
embodiments, a material path may be contiguous. In some embodiments, a
material path may be noncontiguous. By way of nonlinniting example, systems
for batch processing with multiple, independent mold cavities may be
considered
to have a noncontiguous material path.
[0064] Referring now to Figures 1A-B, system 100 may include
hopper 122 operably connected to material path 110 to feed the matrix
material (not shown) to material path 110. System 100 may also include paper
feeder 132 operably connected to material path 110 so as to feed paper 130
into material path 110 to form a wrapper substantially surrounding the matrix
material between mold cavity 120 and the matrix material. Heating element
124 is in thermal communication with the matrix material while in mold cavity
120. Heating element 124 may cause the matrix material to mechanically bond
at a plurality of points (e.g., form sintered contact points) thereby yielding
a
wrapped porous mass length (not shown). After the wrapped porous mass
length exits mold cavity 120 and is suitably cooled, cutter 126 cuts the
wrapped
porous mass length radially, i.e., perpendicular to the longitudinal axis,
thereby
yielding wrapped porous masses and/or wrapped porous mass sections.
[0065] Figures 1A-B, demonstrate that system 100 may be at any
angle. One skilled in the art, with the benefit of this disclosure, should
understand the configurational considerations when adjusting the angle at
which
system 100, or any component thereof, is placed. By way of nonlinniting
example, Figure 1B shows hopper 122 may be configured such that the outlet
of hopper 122 (and any corresponding matrix feed device) is within mold cavity
120. In some embodiments, a mold cavity may be at an angle at or between
vertical and horizontal.
[0066] In some embodiments, feeding matrix material to a material
path may involve any suitable feeder system including, but not limited to,
hand
feeding, volumetric feeders, mass flow feeders, gravinnetric feeders,
pressurized
vessel (e.g., pressurized hopper or pressurized tank), augers or screws,
chutes,
slides, conveyors, tubes, conduits, channels, and the like, and any
combination
thereof. In some embodiments, the material path may include a mechanical
component between the hopper and the mold cavity including, but not limited
to,
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garnitures, compression molds, flow-through compression molds, ram presses,
pistons, shakers, extruders, twin screw extruders, solid state extruders, and
the
like, and any combination thereof. In some embodiments, feeding may involve,
but not be limited to, forced feeding, controlled rate feeding, volumetric
feeding,
mass flow feeding, gravinnetric feeding, vacuum-assisted feeding, fluidized
powder feeding, pneumatic dense phase feeding (e.g., via slug flow, dune or
irregular dune flow, shearing-bed or ripple flow, and extrusion flow),
pneumatic
dilute phase feeding, and any combination thereof.
[0067] In some embodiments, feeding the matrix material to a material
path involving pneumatic dense phase feeding may advantageously allow for
high-throughput processing. Pneumatic dense phase feeding has been performed
at high flow rates with large diameter outlets, but here has unexpectedly been
shown to be effective with small diameters at high speeds. For example,
surprisingly, the use of pneumatic dense phase feeding has been demonstrated
at small diameters (e.g., about 5 mm to about 25 mm and about 5 mm to about
10 mm) with high-throughput (e.g., about 575 kg/hour or about 500 nn/min for
a tubing outlet (described further herein) of about 6.1 mm). By comparison
gravity feeding typically produces less than about 10 nn/min at similar
diameters
and pneumatic dense phase feeding may be performed at similar speeds with
outlets sized at 50 mm or greater. The combination of small diameter and high-
throughput for a matrix material, especially a granular or particulate matrix
material, has been unexpected. One skilled in the art would recognize the
appropriate size and shape for the outlet of a pneumatic dense phase feeding
apparatus to accommodate the mold cavity. By way of nonlinniting example, the
outlet may be similar in shape to the mold cavity but smaller than the mold
cavity and extend into the mold cavity. In another example, the outlet may be
shaped to accommodate mold cavities for sheet porous masses (e.g., a long,
rectangular-shaped outlet) or for hollow cylinder porous masses (e.g., a donut-
shaped outlet).
[0068] Further, the process of pneumatic dense phase feeding may
advantageously mitigate particle migration and segregation, which can be
especially problematic when the binder and active particles are sized and/or
shaped differently. Without being limited by theory, it is believed that the
air
pressure applied in the pressurized hopper creates a plug flow of matrix
material, which minimizes particulate separation and, consequently, provides
for
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a more homogeneous and consistent matrix material composition at the outlet of
the feeder. In some embodiments, the pressurized hopper may be designed for
mass flow. Mass flow conditions may depend on, inter alia, the slope of the
internal walls of the pressurized hopper, the material of the walls, and the
composition of the matrix material.
[0069] In some embodiments, the feeding rate of matrix material to a
material path may range from a lower limit of about 1 nn/min, 10 nn/min, 25
nn/min, 100 nn/min, or 150 nn/min to an upper limit of about 800 nn/min, 600
nn/min, 500 nn/min, 400 nn/min, 300 nn/min, 200 nn/min, or 150 nn/min, and
wherein the feeding rate may range from any lower limit to any upper limit and
encompass any subset therebetween. In some embodiments, the feeding rate of
matrix material to a material path may range from a lower limit of about 1
nn/min, 10 nn/min, 25 nn/min, 100 nn/min, or 150 nn/min to an upper limit of
about 800 nn/min, 600 nn/min, 500 nn/min, 400 nn/min, 300 nn/min, 200 nn/min,
or 150 nn/min in combination with a mold cavity having a diameter ranging from
a lower limit of about 0.5 mm, 2 mm, 3 mm, 4 mm, 5 mm, or 6 mm to an
upper limit of about 10 mm, 9, mm, 8 mm, 7 mm, or 6 mm, and wherein each
of the feeding rate and mold cavity diameter may independently range from any
lower limit to any upper limit and encompass any subset therebetween. One of
ordinary skill in the art should understand that the diameter (or shape) and
feeding rate combination achievable may depend on, inter alia, the size and
shape of the particles in the matrix material, the other components of the
matrix
material (e.g., additives), the matrix material permeability and deaeration
constant, the distance conveyed (e.g., the length of the tubing, described
further
herein), the conveying system configuration, and the like, and any combination
thereof.
[0070] In some embodiments, the pneumatic flow may be characterized
by a solid to fluid ratio of about 15 or greater. In some embodiments, the
pneumatic flow may be characterized by a solid to fluid ratio ranging from a
lower limit of about 15, 20, 30, 40, or 50 to an upper limit of about 500,
400,
300, 200, 150, 130, 100, or 70, and wherein the solid to fluid ratio may range
from any lower limit to any upper limit and encompass any subset
therebetween. The solid to fluid ratio may depend on, inter alia, the type of
pneumatic dense phase feeding where extrusion dense phase feeding occurs
typically at higher values.
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[0071] In some embodiments, pneumatic dense phase feeding may
involve applying an air pressure from a lower limit of about 1 psig, 2 psig, 5
psig, 10 psig, or 25 psig to about 150 psig, 125 psig, 100 psig, 50 psig, or
25
psig, and wherein the air pressure may range from any lower limit to any upper
limit and encompass any subset therebetween. It should be noted that the air
pressure may be applied with a plurality of gases, e.g., an inert gas (e.g.,
nitrogen, argon, helium, and the like), an oxygenated gas, a heated gas, a dry
gas (i.e., less than about 6 ppm water), and the like, and any combination
thereof (e.g., a heated, dry, inert gas like nitrogen or argon). Examples of
systems that include pneumatic dense phase feeding are included herein.
[0072] In some embodiments, feeding may be indexed to enable the
insertion of a spacer material at predetermined intervals. Suitable spacer
materials may comprise additives, solid barriers (e.g., mold cavity parts),
porous
barriers (e.g., papers and release wrappers), filters, cavities, and the like,
and
any combination thereof. In some embodiments, feeding may involve shaking
and/or vibrating. One skilled in the art, with the benefit of this disclosure,
should
understand the degree of shaking and/or vibrating that is appropriate, e.g., a
honnogenously distributed matrix material comprising large binder particles
and
small active particles may be adversely affected by vibrating, i.e.,
homogeneity
may be at least partially lost. Further, one skilled in the art should
understand
the effects of feeding parameters and/or feeders on the final properties of
the
porous masses produced, e.g., the effects on at least void volume (discussed
further below), encapsulated pressure drop (discussed further below), and
compositional homogeneity.
[0073] In some embodiments, the matrix material or components
thereof may be dried before being introduced into the material path and/or
while
along the material path. Drying may be achieved, in some embodiments, with
heating the matrix material or components thereof, blowing dry gas over the
matrix material or components thereof, and any combination thereof. In some
embodiments, the matrix material may have a moisture content of about 10%
by weight or less, about 5% by weight or less, or more preferably about 2% by
weight or less, and in some embodiments as low as 0.01% by weight. Moisture
content may be analyzed by known methods that involve freeze drying or weight
loss after drying.
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[0074] Referring now to Figures 2A-B, system 200 may include
hopper 222 operably connected to material path 210 to feed the matrix
material to material path 210. System 200 may also include paper feeder 232
operably connected to material path 210 so as to feed paper 230 into material
path 210 to form a wrapper substantially surrounding the matrix material
between mold cavity 220 and the matrix material. Further, system 200 may
include release feeder 236 operably connected to material path 210 so as to
feed release wrapper 234 into material path 210 to form a wrapper between
paper 230 and mold cavity 220. In some embodiments, release feeder 236
may be configured as conveyor 238 that continuously cycles release wrapper
234. Heating element 224 is in thermal communication with the matrix material
while in mold cavity 220. Heating element 224 may cause the matrix material
to mechanically bond at a plurality of points (e.g., form sintered contact
points)
thereby yielding a wrapped porous mass length. After the wrapped porous mass
length exits mold cavity 220 and is suitably cooled, cutter 226 cuts the
wrapped
porous mass length radially thereby yielding wrapped porous masses and/or
wrapped porous mass sections. In embodiments where release wrapper 234 is
not configured as conveyor 238, release wrapper 234 may be removed from the
wrapped porous mass length before cutting or from the wrapped porous masses
and/or wrapped porous mass sections after cutting.
[0075] Referring now to Figure 3, system 300 may include component
hoppers 322a and 322b that feed components of the matrix material into
hopper 322. The matrix material may be mixed and preheated in hopper 322
with mixer 328 and preheater 344. Hopper 322 may be operably connected to
material path 310 to feed the matrix material to material path 310. System
300 may also include paper feeder 332 operably connected to material path
310 so as to feed paper 330 into material path 310 to form a wrapper
substantially surrounding the matrix material between mold cavity 320 and the
matrix material. Mold cavity 320 may include fluid connection 346 through
which heated fluid (liquid or gas) may pass into material path 310 and
mechanically bond the matrix material at a plurality of points (e.g., form
sintered contact points) thereby yielding a wrapped porous mass length. It
should be noted that fluid connection 346 can be located at any location along
mold cavity 320 and that more than one fluid connection 346 may be disposed
along mold cavity 320. After the wrapped porous mass length exits mold cavity
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320 and is suitably cooled, cutter 326 cuts the wrapped porous mass length
radially thereby yielding wrapped porous masses and/or wrapped porous mass
sections.
[0076] One skilled in the art with the benefit of this disclosure should
understand that preheating can also take place for individual feed components
before hopper 322 and/or with the mixed components after hopper 322.
[0077] Suitable mixers may include, but not be limited to, ribbon
blenders, paddle blenders, plow blenders, double cone blenders, twin shell
blenders, planetary blenders, fluidized blenders, high intensity blenders,
rotating
drums, blending screws, rotary mixers, and the like, and any combination
thereof.
[0078] In some embodiments, component hoppers may hold individual
components of the matrix material, e.g., two component hoppers with one
holding binder particles and the other holding active particles. In some
embodiments, component hoppers may hold mixtures of components of the
matrix material, e.g., two component hoppers with one holding a mixture of
binder particles and active particles and the other holding an additive like
flavorant. In some embodiments, the components within component hoppers
may be solids, liquids, gases, or combinations thereof. In some embodiments,
the components of different component hoppers may be added to the hopper at
different rates to achieve a desired blend for the matrix material. By way of
nonlinniting example, three component hoppers may separately hold active
particles, binder particles, and active compounds (an additive described
further
below) in liquid form. Binder particles may be added to the hopper at twice
the
rate of the active particles, and the active compounds may be sprayed in so as
to form at least a partial coating on both the active particles and the binder
particles.
[0079] In some embodiments, fluid connections to mold cavities may be
to pass a fluid into the mold cavity, pass a fluid through a mold cavity,
and/or
drawing on a mold cavity. As used herein, the term "drawing" refers to
creating
a negative pressure drop across a boundary and/or along a path, e.g., sucking.
Passing a heated fluid into and/or through a mold cavity may assist in
mechanically bonding the matrix material therein (e.g., at a plurality of
sintered
contact points). Drawing on a mold cavity that has a wrapper disposed therein
may assist in lining the mold cavity evenly, e.g., with less wrinkles.
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[0080] Referring now to Figure 4, system 400 may include hopper
422 operably connected to material path 410 to feed the matrix material to
material path 410. Hopper 422 may be configured along material path 410
such that the outlet of hopper 422, or an extension from its outlet, is within
mold cavity 420. This may advantageously allow for the matrix material to be
fed into mold cavity 420 at a rate to control the packing of the matrix
material
and consequently the void volume of resultant porous masses. In this
nonlinniting example, mold cavity 420 comprises a thermoelectric material and
therefore includes power connection 448. System 400 may also include release
feeder 436 operably connected to material path 410 so as to feed release
wrapper 434 into material path 410 to form a wrapper substantially surrounding
the matrix material between mold cavity 420 and the matrix material. Mold
cavity 420 may be made of a thermoelectric material so that mold cavity 420
may provide the heat to mechanically bond the matrix material at a plurality
of
points (e.g., form sintered contact points), thereby yielding a wrapped porous
mass length. Along material path 410 after mold cavity 420, roller 440 may be
operably capable of assisting the movement of the wrapped porous mass length
through mold cavity 420. After the wrapped porous mass length exits mold
cavity 420 and is suitably cooled, cutter 426 cuts the wrapped porous mass
length radially thereby yielding wrapped porous masses and/or wrapped porous
mass sections. After cutting, the porous masses continue along material path
410 on porous mass conveyor 462, e.g., for packaging or further processing.
Release wrapper 434 may be removed from the wrapped porous mass length
before cutting or from the wrapped porous masses and/or wrapped porous mass
sections after cutting.
[0081] Suitable rollers and/or substitutes for rollers may include, but
not be limited to, cogs, cogwheels, wheels, belts, gears, and the like, and
any
combination thereof. Further rollers and the like may be flat, toothed,
beveled,
and/or indented.
[0082] Referring now to Figure 5, system 500 may include hopper
522 operably connected to material path 510 to feed the matrix material to
material path 510. Heating element 524 is in thermal communication with the
matrix material while in mold cavity 520. Heating element 524 may cause the
matrix material to mechanically bond at a plurality of points (e.g., form
sintered
contact points), thereby yielding a porous mass length. After the porous mass
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length exits mold cavity 520, die 542 may be used for extruding the porous
mass length into a desired cross-sectional shape. Die 542 may include a
plurality of dies 542' (e.g., multiple dies or multiple holes within a single
die)
through which the porous mass length may be extruded. After the porous mass
length is extruded through die 542 and suitably cooled, cutter 526 cuts the
porous mass length radially, thereby yielding porous masses and/or porous mass
sections.
[0083] Referring now to Figure 6A, system 600 may include paper
feeder 632 operably connected to material path 610 so as to feed paper 630
into material path 610. Hopper 622 (or other matrix material delivery
apparatus, e.g., an auger) may be operably connected to material path 610 so
as to place matrix material on paper 630. Paper 630 may wrap around the
matrix material, at least in part, because of passing-through mold cavity 620
(or
compression mold sometimes referred to a garniture device in relation to
cigarette filter forming apparatuses), which provide the desired cross-
sectional
shape (or optional, in some embodiments, the matrix material may be combined
with paper 630 after formation of the desired cross-section has begun or is
complete). In some embodiments, the paper seam may be glued. Heating
element 624 (e.g., a microwave source, a convection oven, a heating block, and
the like, or hybrids thereof) is in thermal communication with the matrix
material while and/or after being in mold cavity 620. Heating element 624 may
cause the matrix material to mechanically bond at a plurality of points (e.g.,
form sintered contact points), thereby yielding a wrapped porous mass length.
After the wrapped porous mass length exits mold cavity 620 and is suitably
cooled, cutter 626 cuts the wrapped porous mass length radially, thereby
yielding wrapped porous masses and/or wrapped porous mass sections.
Movement through system 600 may be aided by conveyor 658 with mold cavity
620 being stationary. It should be noted that while not shown, a similar
embodiment may include paper 630 as part of a looped conveyor that unwraps
from the porous mass length before cutting, which would yield porous masses
and/or porous mass sections.
[0084] Referring now to Figure 6B, system 600' may include paper
feeder 632' operably connected to material path 610' so as to feed paper 630'
into material path 610'. Hopper 622' (or other matrix material delivery
apparatus, e.g., an auger) may be operably connected to material path 610' so
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as to place matrix material on paper 630'. Paper 630' may wrap around the
matrix material, at least in part, because of passing-through mold cavity 620'
(e.g., a compression mold sometimes referred to a garniture device in relation
to
cigarette filter forming apparatuses), which provide the desired cross-
sectional
shape (or optional, in some embodiments, the matrix material may be combined
with paper 630' after formation of the desired cross-section has begun or is
complete). In some embodiments, the paper seam may be glued.
[0085] System 600' may comprise more than one heating element
624'. The first heating element 624a' is in thermal communication with the
matrix material while and/or after being in mold cavity 620', and may cause at
least a portion of the matrix material to mechanically bond at a plurality of
points (e.g., form sintered contact points). The porous mass length may then
be
sized to a desired cross-sectional shape or size with compression mold 656'
(e.g., for reshaping the cross-sectional shape the wrapped porous mass length
)
and then reheated with a second heating element 624b' (which may be a
heating element similar to that of the first heating element 624a', e.g., both
microwaves, or different, e.g., first a microwave and second an oven) to form
additional mechanical bonding (e.g., sintered contact point). Optionally, not
shown, the wrapped porous mass length after the second heating element 624b'
may again be sized to a desired cross-sectional shape or size. The resultant
wrapped porous mass length may then be suitably cooled, radially cut with
cutter 626 into wrapped porous masses and/or wrapped porous mass sections.
Movement through system 600' may be aided by conveyor 658' with mold
cavity 620' being stationary.
[0086] In some instances, depending on the degree of the first sintering
or heating step, the porous mass length may be cooled and cut, then, reheated.
One skilled in the art would recognize how to modify the other systems and
methods described herein to provide for two or more sintering (or heating)
steps.
[0087] In some embodiments, while the matrix material is at an
elevated temperature, the porous mass or the like may be resized and/or
reshaped with the application of pressure. Compression molding may consist of
a
driven or non-driven sizing or forming roller, a series of rollers, or a die
or series
of dies, and any combination thereof suitable for bringing the rod to final
shape
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or dimension. Resizing and/or reshaping may be performed after each heating
step of the method.
[0088] Referring now to Figure 7A, system 700 may include paper
feeder 732 operably connected to material path 710 so as to feed paper 730
into material path 710. As shown, mold cavity 720, a cylindrically-rolled
paper
glued at the longitudinal seam, may be formed on-the-fly with forming mold
756a (or forming mold sometimes referred to a garniture device, including
paper tube folders, in relation to cigarette filter forming apparatuses)
causing
paper 730 to roll with glue 752 applied with glue-application device 754
(e.g., a
glue gun), optionally followed by a glue seam heater (not shown). During the
formation of mold cavity 720, matrix material may be introduced along material
path 710 from hopper 722. Heating element 724 (e.g., a microwave source, a
convection oven, a heating block, and the like, or hybrids thereof) in thermal
communication with mold cavity 720 may cause the matrix material to
mechanically bond at a plurality of points (e.g., form sintered contact
points),
thereby yielding a wrapped porous mass length. Then, compression mold 756b
may be used before complete cooling of the matrix material to size the wrapped
porous mass length into a desired cross-sectional size, which may
advantageously be used for uniformity in the circumference and shape (e.g.,
ovality) of the wrapped porous mass. After the wrapped porous mass length is
suitably cooled, cutter 726 cuts the wrapped porous mass length radially,
thereby yielding wrapped porous masses and/or wrapped porous mass sections.
Movement through system 700 may be aided by rollers, conveyors, or the like,
not shown. One skilled in the art with the benefit of this disclosure should
understand that the processes described may occur in a single apparatus or in
multiple apparatus. For example, rolling the paper, introducing the matrix
material, exposing to heat (e.g., by applying microwaves or heating in a
conventional oven), and resizing may be performed in a single apparatus and
the resultant porous mass length may be conveyed to a second apparatus for
cutting. System 700 may be oriented in any direction, for example vertical or
horizontal or anywhere in between.
[0089] In some embodiments, glue or other adhesives used to seal a
paper mold cavity (or other flexible mold cavity material like plastics) may
be a
cold melt adhesive, a hot melt adhesive, a pressure sensitive adhesive, a
curable
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adhesive, and the like. Cold melt adhesives may be preferred so as to mitigate
failure of the glue during a subsequent heating process (e.g., during
sintering).
[0090] Referring now to Figure 7B, system 700' may include paper
feeder 732' operably connected to material path 710' so as to feed paper 730'
into material path 710'. As shown, mold cavity 720', a cylindrically-rolled
paper
glued at the longitudinal seam, may be formed on-the-fly with forming mold
756a' (or forming mold sometimes referred to a garniture device, including
paper tube folders, in relation to cigarette filter forming apparatuses)
causing
paper 730' to roll with glue 752' applied with glue-application device 754'
(e.g.,
a glue gun). During the formation of mold cavity 720', matrix material may be
introduced along material path 710' from hopper 722' (e.g., a pressurized
hopper of a pneumatic dense phase feeder) operably connected to tubing 722a'
by joint 722b', which may be a flexible joint. Heating element 724' (e.g., a
microwave source, a convection oven, a heating block, and the like, or hybrids
thereof) in thermal communication with mold cavity 720' (as shown in close
proximity to the end of tubing 722a') may cause the matrix material to
mechanically bond at a plurality of points (e.g., form sintered contact
points),
thereby yielding a wrapped porous mass length. Then, compression mold 756b'
(shown as rollers) may be cooled to assist in the cooling of the matrix
material
while shaping the wrapped porous mass length into a desired more uniform
circumference and shape (e.g., ovality). After the wrapped porous mass length
is suitably cooled, cutter 726' cuts the wrapped porous mass length radially,
thereby yielding wrapped porous masses and/or wrapped porous mass sections.
[0091] In some embodiments, a mold cavity may be non-porous or
varying degrees of porosity to allow for removal of fluid from the matrix
material. Further, the forming mold and/or material path may be operably
connected to passageways to allow fluid passage from the porous paper in
desired orientation. In some instances, these fluid passages may be connected
to a source below atmospheric pressure. Removal of fluid from the mix may, in
some embodiments, improve system run-ability and minimize matrix material
particle segregation.
[0092] In some embodiments, a feeder may include an elongated
portion designed to fit into the mold cavity. In some embodiments, the outlet
of
a feeder (e.g., the outlet of tubing 722a') may be sized to be slightly
smaller
(e.g., about 5% smaller) than the inner diameter of the mold cavity. Further,
the
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feeder or elongated portion thereof may include a flexible portion that allows
the
outlet to move within the mold cavity. During pneumatic dense phase feeding,
such movement may be advantageous by allowing for the outlet to move within
the mold cavity. Such movement may advantageously allow the outlet to freely
find the center in the mold cavity, which may provide for a fit that enhances
run-
ability and minimizes matrix mix segregation. In some embodiments, a feeder
(e.g., the outlet of tubing 722a') may terminate before forming mold 756a',
within forming mold 756a', or after forming mold 756a' and optionally after a
glue seem heater.
[0093] Further, the outlet may, in some embodiments, be designed to
have a variable cross-sectional area, which may be advantageous in pneumatic
dense phase feeding to aid matrix mix packing density, to minimize particle
segregation, and to allow for varying pressures and flow rates in a single
system.
[0094] In some embodiments, the outlet may be vented with a mesh
that does not allow matrix material to flow therethrough but does allow for
fluid
to pass therethrough. Such ventilation may allow for the pressure to dissipate
in
a controlled manner over a longer length and mitigate significant particle
migration (which may lead to matrix material inhonnogeneity) as the matrix
material exits the outlet, especially at high flow rates and high pressures.
[0095] Referring now to Figure 8, mold cavity 820 of system 800 may
be formed from mold cavity parts 820a and 820b operably connected to mold
cavity conveyors 860a and 860b, respectively. Once mold cavity 820 is formed,
matrix material may be introduced along material path 810 from hopper 822.
Heating element 824 is in thermal communication with the matrix material while
in mold cavity 820. Heating element 824 may cause the matrix material to
mechanically bond at a plurality of points (e.g., form sintered contact
points),
thereby yielding a porous mass. After mold cavity 820 is suitably cooled and
separated into mold cavity parts 820a and 820b, the porous mass may be
removed from mold cavity parts 820a and/or 820b and continue along material
path 810 via porous mass conveyor 862. It should be noted that Figure 8
illustrates a nonlinniting example of a noncontiguous material path.
[0096] In some embodiments, removing porous masses from mold
cavities and/or mold cavity parts may involve pulling mechanisms, pushing
mechanisms, lifting mechanisms, gravity, any hybrid thereof, and any
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combination thereof. Removing mechanisms may be configured to engage
porous masses at the ends, along the side(s), and any combination thereof.
Suitable pulling mechanisms may include, but not be limited to, suction cups,
vacuum components, tweezers, pincers, forceps, tongs, grippers, claws, clamps,
and the like, and any combination thereof. Suitable pushing mechanisms may
include, but not be limited to, ejectors, punches, rods, pistons, wedges,
spokes,
rams, pressurized fluids, and the like, and any combination thereof. Suitable
lifting mechanisms may include, but not be limited to, suction cups, vacuum
components, tweezers, pincers, forceps, tongs, grippers, claws, clamps, and
the
like, and any combination thereof. In some embodiments, mold cavities may be
configured to operably work with various removal mechanisms. By way of
nonlinniting example, a hybrid push-pull mechanism may include pushing
longitudinally with a rod, so as to move the porous mass partially out the
other
end of the mold cavity, which can then be engaged by forceps to pull the
porous
mass from the mold cavity.
[0097] Referring now to Figure 9, mold cavity 920 of system 900 is
formed from mold cavity parts 920a and 920b or 920c and 920d operably
connected to mold cavity conveyors 960a, 960b, 960c, and 960d, respectively.
Once mold cavity 920 is formed, or during forming, sheets of paper 930 are
introduced into mold cavity 920 via paper feeder 932. Then matrix material is
introduced into paper 930 from hopper 922 along material path 910 lined mold
cavity 920 and mechanically bound into porous masses with heat from heating
element 924 (e.g., heated to form a plurality of sintered contact points).
After
suitable cooling, removal of the porous masses may be achieved by insertion of
ejector 964 into ejector ports 966a and 966b of mold cavity parts 920a, 920b,
920c, and 920d. The porous masses may then continue along material path
910 via porous mass conveyor 962. Again, Figure 9 illustrates a nonlinniting
example of a noncontiguous material path.
[0098] Quality control of porous mass production may be assisted with
cleaning of mold cavities and/or mold cavity parts. Referring again to Figure
8,
cleaning instruments may be incorporated into system 800. As mold cavity parts
820a and 820b return from forming porous masses, mold cavity parts 820a
and 820b pass a series of cleaners including liquid jet 870 and air or gas jet
872. Similarly in Figure 9, as mold cavity parts 960a, 960b, 960c, and 960d
return from forming porous masses, mold cavity parts 960a, 960b, 960c, and
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960d pass a series of cleaners that include heat from heating element 924 and
air or gas jet 972.
[0099] Other suitable cleaners may include, but not be limited to,
scrubbers, brushes, baths, showers, insert fluid jets (tubes that insert into
mold
cavities capable of jetting fluids radially), ultrasonic apparatuses, and any
combination thereof.
[0100] In some embodiments, porous masses may comprise cavities.
By way of nonlinniting example, referring now to Figure 10, mold cavity parts
1020a and 1020b operably connected to mold cavity conveyors 1060a and
1060b operably connect to form mold cavity 1020 of system 1000. Hopper
1022 is operably attached to two volumetric feeders 1090a and 1090b such
that each volumetric feeder 1090a and 1090b fills mold cavity 1020 partially
with the matrix material along material path 1010. Between the addition of
matrix material from volumetric feeder 1090a and volumetric feeder 1090b,
injector 1088 places a capsule (not shown) into mold cavity 1020, thereby
yielding a capsule surrounded by matrix material. Heating element 1024, in
thermal contact with mold cavity 1020, causes the matrix material to
mechanically bond at a plurality of points (e.g., form sintered contact
points),
thereby yielding a porous mass with a capsule disposed therein. After the
porous
mass is formed and suitably cooled, rotary grinder 1092 is inserted into mold
cavity 1020 along the longitudinal direction of mold cavity 1020. Rotary
grinder
1092 is operably capable of grinding the porous mass to a desired length in
the
longitudinal direction. After mold cavity 1020 separates into mold cavity
parts
1020a and 1020b, the porous mass is removed from mold cavity parts 1020a
and/or 1020b and continues along material path 1010 via porous mass
conveyor 1062.
[0101] Suitable capsules for use within porous masses and the like may
include, but not be limited to, polymeric capsules, porous capsules, ceramic
capsules, and the like. Capsules may be filled with an additive, e.g.,
granulated
carbon or a flavorant (more examples provided below). The capsules, in some
embodiments, may also contain a molecular sieve that reacts with selected
components in the smoke to remove or reduce the concentration of the
components without adversely affecting desirable flavor constituents of the
smoke. In some embodiments, the capsules may include tobacco as an
additional flavorant. One should note that if the capsule is insufficiently
filled
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with a chosen substance, in some filter embodiments, this may create a lack of
interaction between the components of the mainstream smoke and the
substance in the capsules.
[0102] One skilled in the art, with the benefit of this disclosure, should
understand that other methods described herein may be altered to produce
porous masses with capsules therein. In some embodiments, more than one
capsule may be within a porous mass section, porous mass, and/or porous mass
length.
[0103] In some embodiments, the shape, e.g., length, width, diameter,
and/or height, of porous masses may be adjusted by operations other than
cutting including, but not limited to, sanding, milling, grinding, smoothing,
polishing, rubbing, and the like, and any combination thereof. Generally,
these
operations will be referred to herein as grinding. Some embodiments may
involve grinding the sides and/or ends of porous masses to achieve smooth
surfaces, roughened surfaces, grooved surfaces, patterned surfaces, leveled
surfaces, and any combination thereof. Some embodiments may involve grinding
the sides and/or ends of porous masses to achieve desired dimensions within
specification limitations. Some embodiments may involve grinding the sides
and/or ends of porous masses while in or exiting mold cavities, after cutting,
during further processing, and any combination thereof. One skilled in the art
should understand that dust, particles, and/or pieces may be produced from
grinding. As such, grinding may involve removing the dust, particles, and/or
pieces by methods like vacuuming, blowing gases, rinsing, shaking, and the
like,
and any combination thereof.
[0104] Any component and/or instrument capable of achieving the
desired level of grinding may be used in conjunction with systems and methods
disclosed herein. Examples of suitable components and/or instruments capable
of achieving the desired level of grinding may include, but not be limited to,
lathes, rotary sanders, brushes, polishers, buffers, etchers, scribes, and the
like,
and any combination thereof.
[0105] 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.
[0106] One skilled in the art, with the benefit of this disclosure, should
understand the component and/or instrument configurations necessary to
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engage porous masses at various points with the systems described herein. By
way of nonlinniting example, grinding instruments and/or drilling instruments
used while porous masses are in mold cavities (or porous mass lengths are
leaving mold cavities) should be configured so as not to deleteriously affect
the
mold cavity.
[0107] Referring now to Figure 11, hopper 1122 is operably attached
to chute 1182 and feeds the matrix material to material path 1110. Along
material path 1110, mold cavity 1120 is configured to accept ram 1180, which
is capable of pressing the matrix material in mold cavity 1120. Heating
element
1124, in thermal communication with the matrix material while in mold cavity
1120, causes the matrix material to mechanically bond at a plurality of points
(e.g., form sintered contact points), thereby yielding a porous mass length.
Inclusion of ram 1180 in system 1100 may advantageously assist in ensuring
the matrix material is properly packed so as to form a porous mass length with
a
desired void volume. Further, system 1100 comprises cooling area 1194, while
the porous mass length is still contained within mold cavity 1120. In this
nonlinniting example, cooling is achieved passively.
[0108] Referring now to Figure 12, hopper 1222 of system 1200
operably feeds the matrix material to extruder 1284 (e.g., screw) along
material
path 1210. Extruder 1284 moves matrix material to mold cavity 1220. System
1200 also includes heating element 1224 in thermal communication with the
matrix material while in mold cavity 1220 that causes the matrix material to
mechanically bond at a plurality of points (e.g., form sintered contact
points),
thereby yielding a porous mass length. Further, system 1200 includes cooling
element 1286 in thermal communication porous mass length while in mold
cavity 1220. Movement of the porous mass length out of mold cavity 1220 is
assisted and/or directed by roller 1240.
[0109] In some embodiments, a control system may interface with
components of the systems and/or apparatuses disclosed herein. As used herein,
the term "control system" refers to a system that can operate to receive and
send electronic or pneumatic signals and may include functions of interfacing
with a user, providing data readouts, collecting data, storing data, changing
variable setpoints, maintaining setpoints, providing notifications of
failures, and
any combination thereof. Suitable control systems may include, but are not
limited to, variable transformers, ohmmeters, programmable logic controllers,
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digital logic circuits, electrical relays, computers, virtual reality systems,
distributed control systems, and any combination thereof. Suitable system
and/or apparatus components that may be operably connected to a control
system may include, but not be limited to, hoppers, heating elements, cooling
elements, cutters, mixers, paper feeders, release feeders, release conveyors,
cleaning elements, rollers, mold cavity conveyors, conveyors, ejectors, liquid
jets, air jets, rams, chutes, extruders, injectors, matrix material feeders,
glue
feeders, grinders, and the like, and any combination thereof. It should be
noted
that systems and/or apparatuses disclosed herein may have more than one
control system that can interface with any number of components.
[0110] One skilled in the art, with the benefit of this disclosure, should
understand the interchangeability of the various components of the systems
and/or apparatuses disclosed herein. By way of nonlinniting example, heating
elements may be interchanged with electromagnetic radiation sources (e.g., a
microwave source, a convection oven, a heating block, and the like, or hybrids
thereof) when the matrix material comprises a component capable of converting
electromagnetic radiation to heat (e.g., nanoparticles, carbon particles, and
the
like). Further, by way of nonlinniting example, paper wrappers may be
interchanged with release wrappers.
[0111] In some embodiments, porous masses may be produced at
linear speeds of about 800 nn/min or less, including by methods that involve
very slow linear speeds of less than about 1 nn/min. As used herein, the term
"linear speed" refers to the speed along a single production line in contrast
to a
production speed that may encompass several production lines in parallel,
which
may be along individual apparatuses, within a single apparatus, or a
combination
thereof. In some embodiments, porous masses may be produced by methods
described herein at linear speeds that range from a lower limit of about 1
nn/min, 10 nn/min, 50 nn/min, or 100 nn/min to an upper limit of about 800
nn/min, 600 nn/min, 500 nn/min, 300 nn/min, or 100 nn/min, and wherein the
linear speed may range from any lower limit to any upper limit and encompass
any subset therebetween. One skilled in the art would recognized that
productivity advancements in machinery may enable linear speeds of greater
than 800 nn/min (e.g., 1000 nn/min or greater). One of ordinary skill in the
art
should also understand that a single apparatus may include multiple lines
(e.g.,
two or more lines of Figure 7 or other lines illustrated herein) in parallel
so as to
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increase the overall production rate of porous masses and the like, e.g., to
several thousand nn/min or greater.
[0112] Some embodiments may involve further processing of porous
masses. Suitable further processing may include, but not be limited to, doping
with a flavorant or other additive, grinding, drilling out, further shaping,
forming
multi-segmented filters, forming smoking devices, packaging, shipping, and any
combination thereof.
[0113] Some embodiments may involve doping matrix materials,
porous masses with an additive. Nonlimiting examples of additives are provided
below. Suitable doping methods may include, but not be limited to, including
the
additives in the matrix material; by applying the additives to at least a
portion of
the matrix material before mechanical bonding; by applying the additives after
mechanical bonding while in the mold cavity; by applying the additives after
leaving the mold cavity; by applying the additives after cutting; and any
combination thereof. It should be noted that applying includes, but is not
limited
to, dipping, immersing, submerging, soaking, rinsing, washing, painting,
coating,
showering, drizzling, spraying, placing, dusting, sprinkling, affixing, and
any
combination thereof. Further, it should be noted that applying includes, but
is
not limited to, surface treatments, infusion treatments where the additive
incorporates at least partially into a component of the matrix material, and
any
combination thereof. One skilled in the art with the benefit of this
disclosure
should understand the concentration of the additive will depend at least on
the
composition of the additive, the size of the additive, the purpose of the
additive,
and the point in the process in which the additive is included.
[0114] In some embodiments, doping with an additive may occur
before, during, and/or after mechanically bonding the matrix materials. One
skilled in the art with the benefit of this disclosure should understand that
additives which degrade, change, or are otherwise affected by the mechanical
bonding process and associated parameter (e.g., elevated temperatures and/or
pressures) should be added after mechanical bonding and/or the parameters
should be adjusted accordingly (e.g., use of inert gases or reduced
temperatures). By way of nonlinniting example, glass beads may be an additive
in the matrix material. Then, after mechanical bonding, the glass beads may be
functionalized with other additives like flavorants and/or active compounds.
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[0115] Some embodiments may involve grinding porous masses after
being produced. Grinding includes those methods and apparatuses/components
described above.
II. Methods of Forming Filters and Smoking Devices Comprising
Porous Masses
[0116] Some embodiments may involve operably connecting porous
masses to filters and/or filter sections. Suitable filters and/or filter
sections may
comprise at least one of cellulose, cellulosic derivatives, cellulose ester
tow,
cellulose acetate tow, cellulose acetate tow with less than about 10 denier
per
filament, cellulose acetate tow with about 10 denier per filament or greater,
random oriented acetates, papers, corrugated papers, polypropylene,
polyethylene, polyolefin tow, polypropylene tow, polyethylene terephthalate,
polybutylene terephthalate, coarse powders, carbon particles, carbon fibers,
fibers, glass beads, zeolites, molecular sieves, a second porous mass, and any
combination thereof.
[0117] In some embodiments, porous masses and other filter sections
may independently have features like a concentric filter design, a paper
wrapping, a cavity, a void chamber, a baffled void chamber, capsules,
channels,
and the like, and any combination thereof.
[0118] In some embodiments, porous masses and other filter sections
may have substantially the same cross-sectional shape and/or circumference.
[0119] In some embodiments, a filter section may comprise a space
that defines a cavity between two filter sections. The cavity may, in some
embodiments, be filled with an additive, e.g., granulated carbon. The cavity
may, in some embodiments, contain a capsule, e.g., a polymeric capsule, that
itself contains a catalyst. The cavity, in some embodiments, may also contain
a
molecular sieve that reacts with selected components in the smoke to remove or
reduce the concentration of the components without adversely affecting
desirable flavor constituents of the smoke. In an embodiment, the cavity may
include tobacco as an additional flavorant. One should note that if the cavity
is
insufficiently filled with a chosen substance, in some embodiments, this may
create a lack of interaction between the components of the mainstream smoke
and the substance in the cavity and in the other filter section(s).
[0120] In some embodiments, filter sections may be combined or joined
so as to form a filter or a filter rod. As used herein the term "filter rod"
refers to
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a length of filter that is suitable for being cut into two or more filters. By
way of
nonlinniting example, the filter rods that comprise an porous mass described
herein may, in some embodiments, have lengths ranging from about 80 mm to
about 150 mm and may be cut into filters having lengths about 5 to about 35
mm in length during a smoking device tipping operation (the addition of a
tobacco column to a filter).
[0121] Tipping operations may involve combining or joining a filter or
filter rod described herein with a tobacco column. During tipping operations,
the
filter rods that comprise a porous mass described herein may, in some
embodiments, be first cut into filters or cut into filters during the tipping
process.
Further, in some embodiments, tipping methods may further involve combining
or joining additional sections that comprise paper and/or charcoal to the
filter,
filter rods, or tobacco column.
[0122] In the production of filters, filter rods, and/or smoking devices,
some embodiments may involve wrapping a paper about the various
components thereof so as to maintain the components in the desired
configuration and/or contact. For example, producing filter and/or filter rods
may
involve wrapping paper about a series of abutting filter sections. In some
embodiments, porous masses wrapped with a paper wrapping may have an
additional wrapping disposed thereabout to maintain contact between the porous
mass and another section of the filter. Suitable papers for producing filters,
filter rods, and/or smoking devices may include any paper described herein in
relation to wrapping porous masses. In some embodiments, the papers may
comprise additives, sizing, and/or printing agents.
[0123] In the production of filters, filter rods, and/or smoking devices,
some embodiments may involve adhering adjacent components thereof (e.g., an
porous mass to an adjacent filter section, tobacco column, and the like, or
any
combination thereof). Preferable adhesives may include those that do not
impart
flavor or aroma under ambient conditions and/or under burning conditions. In
some embodiments, wrapping and adhering may be utilized in the production of
filters, filter rods, and/or smoking devices.
[0124] Some embodiments described herein may involve providing a
porous mass rod that comprises a plurality of organic particles and binder
particles bound together at a plurality of contact points; providing a filter
rod
that does not have the same composition as the porous mass rod; cutting the
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porous mass rod and the filter rod into porous mass sections and filter
sections,
respectively; forming a desired abutting configuration that comprises a
plurality
of sections, the plurality of sections comprising at least some of the porous
mass
sections and at least some of the filter sections; securing the desired
abutting
configuration with a paper wrapper and/or an adhesive so as to yield a
segmented filter rod length; cutting the segmented filter rod length into
segmented filter rods; and wherein the method is performed so as to produce
the segmented filter rods at a rate of about 800 rn/rnin or less. Some
embodiments may further involve forming a smoking device with at least a
portion of the segmented filter rod.
[0125] As used herein, the term "abutting configuration" refers to a
configuration where two filter sections (or the like) are axially aligned so
as to
touch one end of the first section to one end of the second section. One
skilled in
the art would understand that this abutting configuration can be continuous
(i.e.,
not never-ending, rather very long) with a large number of sections or short
in
length with at least two to many sections.
[0126] It should be noted that in some method embodiments described
herein, the term "segmented" is used for clarity to modify various articles
and
should be viewed to be encompassed by various embodiments described herein
with reference to articles (e.g., filters and filter rods) comprising
porous
masses.
[0127] Some embodiments described herein may involve providing a
plurality of porous mass sections that comprise a plurality of organic
particles
and binder particles bound together at a plurality of contact points;
providing a
plurality of filter sections that do not have the same composition as the
porous
mass sections; forming a desired abutting configuration that comprises a
plurality of sections, the plurality of sections comprising at least one of
the
porous mass sections and at least one of the filter sections; securing the
desired
abutting configuration with a paper wrapper and/or adhesive so as to produce a
segmented filter or a segmented filter rod length; and wherein the method is
performed so as to produce the segmented filter or the segmented filter rod at
a
rate of about 800 rn/rnin or less. Some embodiments may further involve
forming a smoking device with the segmented filter or at least a portion of
the
segmented filter rod.
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[0128] Referring now to Figure 13, a diagram of the process of
producing the segmented filters in this example, a cellulose acetate filter
rod
1310 is cut into 8 sections (about 15 mm each) and porous mass filter rod
1312 is cut into 10 sections (about 12 mm each) to yield segments 1314 and
1316, respectively. The segments 1314,1316 are then aligned end-on-end in
an alternating configuration, pushed together, and wrapped with paper and
glued at the seam line so as to yield a segmented filter length 1318. In some
instances, the segmented filter length 1318 can then cut in about the middle
of
every fourth cellulose acetate segment 1314 so as to yield segmented filter
rod
1320 having portions of a cellulose acetate segment 1314 disposed on each
end. One skilled in the art with the benefit of this disclosure will
understand that
other sizes and configurations of cellulose acetate segments and porous mass
segments may be used to yield the segmented filter lengths and can then be cut
at any point to yield a desired segmented filter rod, e.g., segmented filter
rod
1320', which includes five segments where the porous mass segments are at
the ends. One skilled in the art should recognize that these examples are two
of
many potential configurations a segmented filter rod.
[0129] In some embodiments, the foregoing method may be adapted to
accommodate three or more filter sections. For example, a desired
configuration
of a filter rod length may be a first porous mass section, a first filter
section, and
a second filter section in series a first porous mass section, a first second
filter
section, a first first filter section, a second second filter section, a
second porous
mass section, a third second filter section, a second first filter section,
and a
fourth second filter section in series. Such a configuration may be at least
one
embodiment useful for producing filters that comprise three sections, as
illustrated in Figure 14, which illustrates a filter rod length being cut into
a filter
rod that is then cut two additional times so as to yield a filter section
comprising
three sections.
[0130] In some embodiments, a capsule may be included so as to be
nested between two abutting sections. As used herein, the term "nested" or
"nesting" refers to being inside and not directly exposed to the exterior of
the
article produced. Accordingly, nesting between two abutting sections allows
for
the adjacent sections to be touching, i.e., abutting. In some embodiments, a
capsule may be in a portion
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[0131] In some embodiments, filters described herein may be produced
using known instrumentation, e.g., greater than about 25 nn/min in automated
instruments and lower for hand production instruments. While the rate of
production may be limited by the instrument capabilities only, in some
embodiments, filter sections described herein may be combined to form a filter
rod at a rate ranging from a lower limit of about 25 nn/min, 50 nn/min, or 100
nn/min to an upper limit of about 800 nn/min, 600 nn/min, 400 nn/min, 300
nn/min, or 250 nn/min, and wherein the combining rate may range from any
lower limit to any upper limit and encompasses any subset therebetween.
[0132] In some embodiments, porous masses utilized in the production
of filter and/or filter rods described herein may be wrapped with a paper. The
paper may, in some embodiments, reduce damage and particulate production
due to the mechanical manipulation of the porous masses. Paper suitable for
use
in conjunction with protecting porous masses during manipulation may include,
but are not limited to, wood-based papers, papers containing flax, flax
papers,
cotton paper, functionalized papers (e.g., those that are functionalized so as
to
reduce tar and/or carbon monoxide), special marking papers, colorized papers,
and any combination thereof. In some embodiments, the papers may be high
porosity, corrugated, and/or have a high surface strength. In some
embodiments, papers may be substantially non-porosity less, e.g., than about
10 CORESTA units.
[0133] In some embodiments, the filters and/or filter rods comprising
porous masses described herein may be directly transported to a manufacturing
line whereby they will be combined with tobacco columns to form smoking
devices. An example of such a method includes a process for producing a
smoking device comprising: providing a filter rod comprising at least one
filter
section comprising an porous mass described herein that comprises an organic
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
an
porous mass that comprises an organic 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.
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[0134] In other embodiments, the device filters and/or filter rods
comprising porous masses may be placed in a suitable container for storage
until
further use. Suitable storage containers include those commonly used in the
smoking device filter art including, but not limited to, crates, boxes, drums,
bags, cartons, and the like.
[0135] Some embodiments may involve operably connecting smokeable
substances to porous masses (or segmented filters comprising at least one of
the foregoing). In some embodiments, porous masses (or segmented filters
comprising at least one of the foregoing) may be in fluid communication with a
smokeable substance. In some embodiments, a smoking device may comprise
porous masses (or segmented filters comprising at least one of the foregoing)
in
fluid communication with a smokeable substance. In some embodiments, a
smoking device may comprise a housing operably capable of maintaining porous
masses (or segmented filters comprising at least one of the foregoing) in
fluid
communication with a smokeable substance. In some embodiments, filter rods,
filters, filter sections, sectioned filters, and/or sectioned filter rods may
be
removable, replaceable, and/or disposable from the housing.
[0136] As used herein, the term "smokeable substance" refers to a
material capable of producing smoke when burned or heated. Suitable
smokeable substances may include, but not be limited to, tobaccos, e.g.,
bright
leaf tobacco, Oriental tobacco, Turkish tobacco, Cavendish tobacco, corojo
tobacco, criollo tobacco, Perique tobacco, shade tobacco, white burley
tobacco,
flue-cured tobacco, Burley tobacco, Maryland tobacco, Virginia tobacco; teas;
herbs; carbonized or pyrolyzed components; inorganic filler components; and
any combination thereof. Tobacco may have the form of tobacco lamina in cut
filler form, processed tobacco stems, reconstituted tobacco filler, volume
expanded tobacco filler, or the like. Tobacco, and other grown smokeable
substances, may be grown in the United States, or may be grown in a
jurisdiction outside the United States.
[0137] In some embodiments, a smokeable substance may be in a
column format, e.g., a tobacco column. As used herein, the term "tobacco
column" refers to the blend of tobacco, and optionally other ingredients and
flavorants that may be combined to produce a tobacco-based smokeable article,
such as a cigarette or cigar. In some embodiments, the tobacco column may
comprise ingredients selected from the group consisting of: tobacco, sugar
(such
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as sucrose, brown sugar, invert sugar, or high fructose corn syrup), propylene
glycol, glycerol, cocoa, cocoa products, carob bean gums, carob bean extracts,
and any combination thereof. In still other embodiments, the tobacco column
may further comprise flavorants, aromas, menthol, licorice extract,
diannnnoniunn
phosphate, ammonium hydroxide, and any combination thereof. In some
embodiments, tobacco columns may comprise additives. In some embodiments,
tobacco columns may comprise at least one bendable element.
[0138] Suitable housings may include, but not be limited to, cigarettes,
cigarette holders, cigars, cigar holders, pipes, water pipes, hookahs,
electronic
smoking devices, roll-your-own cigarettes, roll-your-own cigars, papers, and
any
combination thereof.
[0139] Packaging porous masses may include, but not be limited to,
placing in trays or boxes or protective containers, e.g., trays typically used
for
packaging and transporting cigarette filter rods.
[0140] In some embodiments, a pack of filters and/or smoking devices
with filters may comprise porous masses. The pack may be a hinge-lid pack, a
slide-and-shell pack, a hard-cup pack, a soft-cup pack, a plastic bag, or any
other suitable pack container. In some embodiments, the packs may have an
outer wrapping, such as a polypropylene wrapper, and optionally a tear tab. In
some embodiments, the filters and/or smoking devices may be sealed as a
bundle inside a pack. A bundle may contain a number of filters and/or smoking
devices, for example, 20 or more. However, a bundle may include a single
filter
and/or smoking device, in some embodiments, such as exclusive filter and/or
smoking device embodiments like those for individual sale, or a filter and/or
smoking device comprising a specific spice, like vanilla, clove, or cinnamon.
[0141] In some embodiments, a carton of smoking device packs may
include at least one pack of smoking devices that includes at least one
smoking
device with a filter (multi-segmented or otherwise) that comprises porous
masses. In some embodiments, the carton (e.g., a container) has the physical
integrity to contain the weight from the packs of smoking devices. This may be
accomplished through thicker cardstock being used to form the carton or
stronger adhesives being used to bind elements of the carton.
[0142] Some embodiments may involve shipping porous masses. Said
porous masses may be as individuals, as at least a portion of filters, as at
least a
portion of smoking devices, in packs, in carton, in trays, and any combination
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thereof. Shipping may be by train, truck, airplane, boat/ship, and any
combination thereof.
III. Porous Masses
[0143] There may be any weight ratio of active particles to binder
particles in the matrix material. In some embodiments, the matrix material may
comprise active particles in an amount ranging from a lower limit of about 1
wt%, 5 wt%, 10 wt%, 25 wt%, 40 wt%, 50 wt%, 60 wt%, or 75 wt% of the
matrix material to an upper limit of about 99 wt%, 95 wt%, 90 wt%, or 75 wt%
of the matrix material, and wherein the amount of active particles can range
from any lower limit to any upper limit and encompass any subset
therebetween. In some embodiments, the matrix material may comprise binder
particles in an amount ranging from a lower limit of about 1 wt%, 5 wt%, 10
wt%, or 25 wt% of the matrix material to an upper limit of about 99 wt%, 95
wt%, 90 wt%, 75 wt%, 60 wt%, 50 wt%, 40 wt%, or 25 wt% of the matrix
material, and wherein the amount of binder particles can range from any lower
limit to any upper limit and encompass any subset therebetween.
[0144] The active particles may be any material adapted to enhance
smoke flowing thereover. Adapted to enhance smoke flowing thereover refers to
any material that can remove, reduce, or add components to a smoke stream.
The removal or reduction (or addition) may be selective. By way of example, in
the smoke stream from a cigarette, compounds such as those shown below in
the following listing may be selectively removed or reduced. This table is
available from the U.S. FDA as a Draft Proposed Initial List of
Harmful/Potentially
Harmful Constituents in Tobacco Products, including Tobacco Smoke; any
abbreviations in the below listing are well-known chemicals in the art. In
some
embodiments, the active particle may reduce or remove at least one component
selected from the listing of components in smoke below, including any
combination thereof. Smoke stream components may include, but not be limited
to, acetaldehyde, acetannide, acetone, acrolein, acrylannide, acrylonitrile,
aflatoxin B-1, 4-anninobiphenyl, 1-anninonaphthalene, 2-anninonaphthalene,
ammonia, ammonium salts, anabasine, anatabine, 0-anisidine, arsenic, A-a-C,
benz[a]anthracene, benz[b]fluoroanthene,
benz[j]aceanthrylene,
benz[k]fluoroanthene, benzene, benzo(b)fu ran,
benzo[a]pyrene,
benzo[c]phenanthrene, beryllium, 1,3-butadiene, butyraldehyde, cadmium,
caffeic acid, carbon monoxide, catechol, chlorinated dioxins/furans, chromium,
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chrysene, cobalt, counnarin, a cresol, crotonaldehyde, cyclopenta[c,d]pyrene,
dibenz(a,h)acridine, dibenz(a,j)acridine,
dibenz[a,h]anthracene,
dibenzo(c,g)carbazole, dibenzo[a,e]pyrene,
dibenzo[a,h]pyrene,
dibenzo[a,i]pyrene, dibenzo[aMpyrene, 2,6-dinnethylaniline, ethyl carbannate
(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-nnethylchrysene,
4-(nnethylnitrosannino)-1-(3-pyridyI)-1-butanone (NNK), 4-
(nnethylnitrosannino)-
1-(3-pyridy1)-1-butanol (NNAL), naphthalene, nickel, nicotine, nitrate, nitric
oxide, a nitrogen oxide, nitrite, nitrobenzene, nitronnethane, 2-nitropropane,
N-
nitrosoanabasine (NAB), N-
nitrosodiethanolannine (NDELA), N-
nitrosodiethylannine, N-nitrosodinnethylannine (NDMA), N-
nitrosoethylnnethylannine, N-nitrosonnorpholine (NMOR), N-nitrosonornicotine
(NNN), N-nitrosopiperidine (NPIP), N-
nitrosopyrrolidine (NPYR), N-
nitrososarcosine (NSAR), phenol, PhIP, polonium-210 (radio-isotope),
propionaldehyde, propylene oxide, pyridine, quinoline, resorcinol, selenium,
styrene, tar, 2-toluidine, toluene, Trp-P-1, Trp-P-2, uranium-235 (radio-
isotope),
uranium-238 (radio-isotope), vinyl acetate, vinyl chloride, and any
combination
thereof.
[0145] One example of an active particle is activated carbon (or
activated charcoal or active coal). The activated carbon may be low activity
(about 50% to about 75% CCI4adsorption) or high activity (about 75% to about
95% CCI4 adsorption) or a combination of both. Activated carbons may include
those derived from (e.g., pyrolyzed from) coconut shells, coal, synthetic
resins,
and the like. Examples of commercially available carbon may include, but are
not limited to, product grades offered by Calgon, Jacobi, Norit, and other
similar
suppliers. By way of nonlinniting example, one of Norit's granular activated
carbon products is NORIT GCN 3070. In another example, Jacobi offers
activated carbons in grades that include CZ, CS, CR, CT, CX, and GA-Plus in a
variety of particles sizes.
[0146] In some embodiments, the active carbon may be nano-scaled
carbon particle, such as carbon nanotubes of any number of walls, carbon
nanohorns, bamboo-like carbon nanostructures, fullerenes and fullerene
aggregates, and graphene including few layer graphene and oxidized graphene.
Other examples of active particles may include, but are not limited to, ion
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exchange resins, desiccants, silicates, molecular sieves, silica gels,
activated
alumina, zeolites, perlite, sepiolite, Fuller's Earth, magnesium silicate,
metal
oxides (e.g., iron oxide, iron oxide nanoparticles like about 12 nnn Fe304,
manganese oxide, copper oxide, and aluminum oxide), gold, platinum, iodine
pentoxide, phosphorus pentoxide, nanoparticles (e.g., metal nanoparticles like
gold and silver; metal oxide nanoparticles like alumina; magnetic,
paramagnetic,
and superparannagnetic nanoparticles like gadolinium oxide, various crystal
structures of iron oxide like hematite and magnetite, gado-nanotubes, and
endofullerenes like Gd C60; and core-shell and onionated nanoparticles like
gold
and silver nanoshells, onionated iron oxide, and others nanoparticles or
nnicroparticles with an outer shell of any of said materials) and any
combination
of the foregoing (including activated carbon). Ion exchange resins include,
for
example, a polymer with a backbone, such as styrene-divinyl benzene (DVB)
copolymer, acrylates, nnethacrylates, phenol formaldehyde condensates, and
epichlorohydrin amine condensates; and a plurality of electrically charged
functional groups attached to the polymer backbone. In some embodiments, the
active particles are a combination of various active particles. In some
embodiments, the porous mass may comprise multiple active particles. In some
embodiments, an active particle may comprise at least one element selected
from the group of active particles disclosed herein. It should be noted that
"element" is being used as a general term to describe items in a list. In some
embodiments, the active particles are combined with at least one flavorant.
[0147] Suitable active particles may have at least one dimension of
about less than one nanonneter, such as graphene, to as large as a particle
having a diameter of about 5000 microns. Active particles may range from a
lower size limit in at least one dimension of about: 0.1 nanonneters, 0.5
nanonneters, 1 nanonneter, 10 nanonneters, 100 nanonneters, 500 nanonneters, 1
micron, 5 microns, 10 microns, 50 microns, 100 microns, 150 microns, 200
microns, or 250 microns. The active particles may range from an upper size
limit
in at least one dimension of about: 5000 microns, 2000 microns, 1000 microns,
900 microns, 700 microns, 500 microns, 400 microns, 300 microns, 250
microns, 200 microns, 150 microns, 100 microns, 50 microns, 10 microns, or
500 nanonneters. Any combination of lower limits and upper limits above may be
suitable for use in the embodiments described herein, wherein the selected
maximum size is greater than the selected minimum size. In some
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embodiments, the active particles may be a mixture of particle sizes ranging
from the above lower and upper limits. In some embodiments, the size of the
active particles may be polynnodal.
[0148] The binder particles may be any suitable thermoplastic binder
particles. In one embodiment, the binder particles exhibit virtually no flow
at its
melting temperature. This means a material that when heated to its melting
temperature exhibits little to no polymer flow. Materials meeting these
criteria
include, but are not limited to, ultrahigh molecular weight polyethylene, very
high molecular weight polyethylene, high molecular weight polyethylene, and
combinations thereof. In one embodiment, the binder particles have a melt flow
index (MFI, ASTM D1238) of less than or equal to about 3.5 g/10nnin at 190 C
and 15 kg (or about 0-3.5 g/10nnin 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/10nnin at 190 C and 15 Kg (or about 0-2.0 g/10nnin 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 MFI 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 g/10nnin 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/10nnin 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.
[0149] 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/nnol. In some
embodiments, the molecular weight of the ultra-high molecular weight
polyethylene composition is between about 3 x 106 g/nnol and about 30 x 106
g/nnol, or between about 3 x 106 g/nnol and about 20 x 106 g/nnol, or between
about 3 x 106 g/nnol and about 10 x 106 g/nnol, or between about 3 x 106
g/nnol
and about 6 x 106 g/nnol. "Very-high molecular weight polyethylene" refers to
polyethylene compositions with a weight average molecular weight of less than
about 3 x 106 g/nnol and more than about 1 x 106 g/nnol. In some embodiments,
the molecular weight of the very-high molecular weight polyethylene
composition is between about 2 x 106 g/nnol and less than about 3 x 106
g/nnol.
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"High molecular weight polyethylene" refers to polyethylene compositions with
weight-average molecular weight of at least about 3 x 105 g/nnol to 1 x 106
g/nnol. For purposes of the present specification, the molecular weights
referenced herein are determined in accordance with the Margolies equation
("Margolies molecular weight").
[0150] 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), Braskenn (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).
[0151] 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/nnol
to about 2,000,000 g/nnol as determined by ASTM-D 4020, an average particle
size, D50, between about 300 pm and about 1500 pm, and a bulk density
between about 0.25 g/m1 and about 0.5 g/m1 as described in International
Application No. PCT/U52011/034947 filed May 3, 2011.
[0152] 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 described herein 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.
[0153] In some embodiments, the binder particles may range from a
lower size limit in at least one dimension of about: 0.1 nanonneters, 0.5
nanonneters, 1 nanonneter, 10 nanonneters, 100 nanonneters, 500 nanonneters, 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
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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 nanonneters. Any combination of lower limits and upper limits above
may be suitable for use in the embodiments described herein, wherein the
selected maximum size is greater than the selected minimum size. In some
embodiments, the binder particles may be a mixture of particle sizes ranging
from the above lower and upper limits. In some embodiments, smaller diameter
particles may be advantageous in faster heating for binding of the binder
particles together, which may be especially useful in high-throughput
processes
for producing porous masses described herein.
[0154] While the ratio of binder particle size to active particle size can
include any iteration as dictated by the size ranges for each described
herein,
specific size ratios may be advantageous for specific applications and/or
products. By way of nonlinniting example, in smoking device filters the sizes
of
the active particles and binder particles should be such that the EPD allows
for
drawing fluids through the porous mass. In some embodiments, the ratio of
binder particle size to active particle size may range from about 10:1 to
about
1:10, or more preferably range from about 1:1.5 to about 1:4.
[0155] Additionally, the binder particles may have a bulk density in the
range of about 0.10 g/cnn3 to about 0.55 g/cnn3. In another embodiment, the
bulk density may be in the range of about 0.17 g/cnn3 to about 0.50 g/cnn3. In
yet another embodiment, the bulk density may be in the range of about 0.20
g/cnn3 to about 0.47 g/cnn3.
[0156] 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, polyannides (or nylons),
polyacrylics,
polystyrenes, polyvinyls, polytetrafluoroethylene (PTFE), polyether ether
ketone
(PEEK), any copolymer thereof, any derivative thereof, and any combination
thereof. Non-fibrous plasticized cellulose derivatives may also be suitable
for use
as binder particles described herein. Examples of suitable polyolefins
include, but
are not limited to, polyethylene,
polypropylene, polybutylene,
polynnethylpentene, 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
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thereof, and the like. Examples of suitable polyesters include polyethylene
terephthalate, polybutylene terephthalate, polycyclohexylene dinnethylene
terephthalate, polytrinnethylene terephthalate, any copolymer thereof, any
derivative thereof, any combination thereof, and the like. Examples of
suitable
polyacrylics include, but are not limited to, polynnethyl nnethacrylate, any
copolymer thereof, any derivative thereof, any combination thereof, and the
like.
Examples of suitable polystyrenes include, but are not limited to,
polystyrene,
acrylonitrile-butadiene-styrene, styrene-acrylonitrile,
styrene-butadiene,
styrene-nnaleic anhydride, any copolymer thereof, any derivative thereof, any
combination thereof, and the like. Examples of suitable polyvinyls include,
but
are not limited to, ethylene vinyl acetate, ethylene vinyl alcohol, polyvinyl
chloride, any copolymer thereof, any derivative thereof, any combination
thereof, and the like. Examples of suitable cellulosics include, but are not
limited
to, cellulose acetate, cellulose acetate butyrate, plasticized cellulosics,
cellulose
propionate, ethyl cellulose, any copolymer thereof, any derivative thereof,
any
combination thereof, and the like. In some embodiments, a binder particle may
be any copolymer, any derivative, and any combination of the above listed
binders.
[0157] In some embodiments, the binder particles described herein
may have a hydrophilic surface treatment. Hydrophilic surface treatments
(e.g.,
oxygenated functionalities like carboxy, hydroxyl, and epoxy) may be achieved
by exposure to at least one of chemical oxidizers, flames, ions, plasma,
corona
discharge, ultraviolet radiation, ozone, and combinations thereof (e.g., ozone
and ultraviolet treatments). Because many of the active particles described
herein are hydrophilic, either as a function of their composition or adsorbed
water, a hydrophilic surface treatment to the binder particles may increase
the
attraction (e.g., van der Waals, electrostatic, hydrogen bonding, and the
like)
between the binder particles and the active particles. This enhanced
attraction
may mitigate segregation of active and binder particles in the matrix
material,
thereby minimizing variability in the EPD, integrity, circumference, cross-
sectional shape, and other properties of the resultant porous masses. Further,
it
has been observed that the enhanced attraction provides for a more
homogeneous matrix material, which can increase flexibility for filter design
(e.g., lowering overall EPD, reducing the concentration of the binder
particles, or
both).
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[0158] In some embodiments, matrix materials and/or porous masses
may comprise active particles, binder particles, and additives. In some
embodiments, the matrix material or porous masses may comprise additives in
an amount ranging from a lower limit of about 0.01 wt%, 0.05 wt%, 0.1 wt%, 1
wt%, 5 wt%, or 10 wt% of the matrix material or porous masses to an upper
limit of about 25 wt%, 15 wt%, 10 wt%, 5 wt%, or 1 wt% of the matrix material
or porous masses, and wherein the amount of additives can range from any
lower limit to any upper limit and encompass any subset therebetween.
[0159] In some embodiments, porous masses may have a void volume
in the range of about 40% to about 90%. In some embodiments, porous masses
may have a void volume of about 60% to about 90%. In some embodiments,
porous masses may have a void volume of about 60% to about 85%. Void
volume is the free space left after accounting for the space taken by the
active
particles.
[0160] To determine void volume, although not wishing to be limited by
any particular theory, it is believed that testing indicates that the final
density of
the mixture was driven almost entirely by the active particle; thus the space
occupied by the binder particles was not considered for this calculation.
Thus,
void volume, in this context, is calculated based on the space remaining after
accounting for the active particles. To determine void volume, first the upper
and lower diameters based on the mesh size were averaged for the active
particles, and then the volume was calculated (assuming a spherical shape
based on that averaged diameter) using the density of the active material.
Then,
the percentage void volume is calculated as follows:
Void [(porous mass volume, cnn3) - (Weight of active
particles,
Volume_ gm)/(density of the active particles, gnn/cnn3)] * 100
(0/0) = porous mass volume, cnn3
[0161] In some embodiments, porous masses may have an
encapsulated pressure drop (EPD) in the range of about 0.10 to about 25 mm of
water per mm length of porous mass. In some embodiments, porous masses
may have an EPD in the range of about 0.10 to about 10 mm of water per mm
length of porous mass. In some embodiments, porous masses may have an EPD
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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).
[0162] In some embodiments, porous masses may have an active
particle loading of at least about 1 nng/nnnn, 2 nng/nnnn, 3 nng/nnnn, 4
nng/nnnn, 5
nng/nnnn, 6 nng/nnnn, 7 nng/nnnn, 8 nng/nnnn, 9 nng/nnnn, 10 nng/nnnn, 11
nng/nnnn,
12 nng/nnnn, 13 nng/nnnn, 14 nng/nnnn, 15 nng/nnnn, 16 nng/nnnn, 17 nng/nnnn,
18
nng/nnnn, 19 nng/nnnn, 20 nng/nnnn, 21 nng/nnnn, 22 nng/nnnn, 23 nng/nnnn, 24
nng/nnnn, or 25 nng/nnnn in combination with an EPD of less than about 20 mm
of
water or less per mm of length, 19 mm of water or less per mm of length, 18
mm of water or less per mm of length, 17 mm of water or less per mm of
length, 16 mm of water or less per mm of length, 15 mm of water or less per
mm of length, 14 mm of water or less per mm of length, 13 mm of water or less
per mm of length, 12 mm of water or less per mm of length, 11 mm of water or
less per mm of length, 10 mm of water or less per mm of length, 9 mm of water
or less per mm of length, 8 mm of water or less per mm of length, 7 mm of
water or less per mm of length, 6 mm of water or less per mm of length, 5 mm
of water or less per mm of length, 4 mm of water or less per mm of length, 3
mm of water or less per mm of length, 2 mm of water or less per mm of length,
or 1 mm of water or less per mm of length.
[0163] By way of example, in some embodiments, porous masses may
have an active particle loading of at least about 1 nng/nnnn and an EPD of
about
20 mm of water or less per mm of length. In other embodiments, the porous
mass may have an active particle loading of at least about 1 nng/nnnn and an
EPD
of about 20 mm of water or less per mm of length, wherein the active particle
is
not carbon. In other embodiments, the porous mass may have an active particle
comprising carbon with a loading of at least 6 nng/nnnn in combination with an
EPD of 10 mm of water or less per mm of length.
[0164] In some embodiments, porous masses may be effective at the
removal of components from tobacco smoke, for example, those in the listing
herein. Porous masses may be used to reduce the delivery of certain tobacco
smoke components targeted by the World Health Organization Framework
Convention on Tobacco Control ("WHO FCTC"). By way of nonlinniting example, a
porous mass where activated carbon is used as the active particles can be used
to reduce the delivery of certain tobacco smoke components to levels below the
WHO FCTC recommendations. The components may, in some embodiments,
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include, but not be limited to, acetaldehyde, acrolein, benzene,
benzo[a]pyrene,
1,3-butadiene, and formaldehyde. Porous masses with activated carbon may
reduce acetaldehydes in a smoke stream by about 3.0% to about 6.5%/mm
length of porous mass; acrolein in a smoke stream by about 7.5% to about
12%/mm length of porous mass; benzene in a smoke stream by about 5.5% to
about 8.O%/mm length of porous mass; benzo[a]pyrene in a smoke stream by
about 9.0% to about 21.O%/mm length of porous mass; 1,3-butadiene in a
smoke stream by about 1.5% to about 3.5%/mm length of porous mass; and
formaldehyde in a smoke stream by about 9.0% to about 11.O%/mm length of
porous mass. In another example, porous masses where an ion exchange resin
is used as the active particles can be used to reduce the delivery of certain
tobacco smoke components to below the WHO recommendations. In some
embodiments, porous masses having an ion exchange resin may reduce:
acetaldehydes in a smoke stream by about 5.0% to about 7.O%/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.O%/mm length of porous mass. One of ordinary skill in the art should
understand that the values reported here relative to the concentration of
specific
smoke stream components may vary by test protocol and tobacco blend. The
reductions cited herein refer to carbonyl testing by a method similar to the
CORESTA Recommended Method No. 74, Determination of Selected Carbonyls in
Mainstream Cigarette Smoke by High Performance Liquid Chromatography, using
the Health Canada Intense Smoking Protocol. The sample cigarettes were
prepared from a US commercial brand by manually replacing the standard
cellulose acetate filter with a dual segmented filter consisting of porous
mass
segments and cellulose acetate segments. The length of the porous mass
segment varied between 5 and 15 mm.
IV. Additives
[0165] Suitable additives may include, but not be limited to, active
compounds, ionic resins, zeolites, nanoparticles, microwave enhancement
additives, ceramic particles, glass beads, softening agents, plasticizers,
pigments, dyes, flavorants, aromas, controlled release vesicles, adhesives,
tackifiers, surface modification agents, vitamins, peroxides, biocides,
antifungals, antimicrobials, antistatic agents, flame retardants, degradation
agents, and any combination thereof.
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[0166] Suitable active compounds may be compounds and/or molecules
suitable for removing components from a smoke stream including, but not
limited to, nnalic acid, potassium carbonate, citric acid, tartaric acid,
lactic acid,
ascorbic acid, polyethyleneinnine, cyclodextrin, sodium hydroxide, sulphannic
acid, sodium sulphannate, polyvinyl acetate, carboxylated acrylate, and any
combination thereof. It should be noted that an active particle may also be
considered an active compound, and vice versa. By way of nonlinniting example,
fullerenes and some carbon nanotubes may be considered to be a particulate
and a molecule.
[0167] Suitable ionic resins may include, but not be limited to, polymers
with a backbone, such as styrene-divinyl benzene (DVB) copolymer, acrylates,
nnethacrylates, phenol formaldehyde condensates, and epichlorohydrin amine
condensates; a plurality of electrically charged functional groups attached to
the
polymer backbone; and any combination thereof.
[0168] Zeolites may include crystalline aluminosilicates having pores,
e.g., channels, or cavities of uniform, molecular-sized dimensions. Zeolites
may
include natural and synthetic materials. Suitable zeolites may include, but
not be
limited to, zeolite BETA (Na7(A175i570128) tetragonal), zeolite ZSM-5
(Nan(AInSi96_
n0192) 16 H20, with n < 27), zeolite A, zeolite X, zeolite Y, zeolite K-G,
zeolite
ZK-5, zeolite ZK-4, nnesoporous silicates, SBA-15, MCM-41, MCM48 modified by
3-anninopropylsily1 groups, alunnino-phosphates, nnesoporous aluminosilicates,
other related porous materials (e.g., such as mixed oxide gels), and any
combination thereof.
[0169] Suitable nanoparticles may include, but not be limited to, nano-
scaled carbon particles like carbon nanotubes of any number of walls, carbon
nanohorns, bamboo-like carbon nanostructures, fullerenes and fullerene
aggregates, and graphene including few layer graphene and oxidized graphene;
metal nanoparticles like gold and silver; metal oxide nanoparticles like
alumina,
silica, and titania; magnetic, paramagnetic, and superparannagnetic
nanoparticles like gadolinium oxide, various crystal structures of iron oxide
like
hematite and magnetite, about 12 nnn Fe304, gado-nanotubes, and
endofullerenes like Gd C60; and core-shell and onionated nanoparticles like
gold
and silver nanoshells, onionated iron oxide, and other nanoparticles or
nnicroparticles with an outer shell of any of said materials) and any
combination
of the foregoing (including activated carbon). It should be noted that
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nanoparticles may include nanorods, nanospheres, nanorices, nanowires,
nanostars (like nanotripods and nanotetrapods), hollow nanostructures, hybrid
nanostructures that are two or more nanoparticles connected as one, and non-
nano particles with nano-coatings or nano-thick walls. It should be further
noted
that nanoparticles may include the functionalized derivatives of nanoparticles
including, but not limited to, nanoparticles that have been functionalized
covalently and/or non-covalently, e.g., pi-stacking, physisorption, ionic
association, van der Waals association, and the like. Suitable functional
groups
may include, but not be limited to, moieties comprising amines (1 , 2 , or 3
),
amides, carboxylic acids, aldehydes, ketones, ethers, esters, peroxides,
silyls,
organosilanes, hydrocarbons, aromatic hydrocarbons, and any combination
thereof; polymers; chelating agents like ethylenediannine tetraacetate,
diethylenetrianninepentaacetic acid, triglycollannic 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.
[0170] Suitable microwave enhancement additives may include, but not
be limited to, microwave responsive polymers, carbon particles, fullerenes,
carbon nanotubes, metal nanoparticles, water, and the like, and any
combination
thereof.
[0171] Suitable ceramic particles may include, but not be limited to,
oxides (e.g., silica, titania, alumina, beryllia, ceria, and zirconia),
nonoxides
(e.g., carbides, borides, nitrides, and silicides), composites thereof, and
any
combination thereof. Ceramic particles may be crystalline, non-crystalline, or
semi-crystalline.
[0172] As used herein, pigments refer to compounds and/or particles
that impart color and are incorporated throughout the matrix material and/or a
component thereof. Suitable pigments may include, but not be limited to,
titanium dioxide, silicon dioxide, tartrazine, E102, phthalocyanine blue,
phthalocyanine green, quinacridones, perylene tetracarboxylic acid di-innides,
dioxazines, perinones disazo pigments, anthraquinone pigments, carbon black,
titanium dioxide, metal powders, iron oxide, ultramarine, and any combination
thereof.
[0173] As used herein, dyes refer to compounds and/or particles that
impart color and are a surface treatment. Suitable dyes may include, but not
be
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limited to, CARTASOL dyes (cationic dyes, available from Clariant Services)
in
liquid and/or granular form (e.g., CARTASOL Brilliant Yellow K-6G liquid,
CARTASOL Yellow K-4GL liquid, CARTASOL Yellow K-GL liquid, CARTASOL
Orange K-3GL liquid, CARTASOL Scarlet K-2GL liquid, CARTASOL Red K-3BN
liquid, CARTASOL Blue K-5R liquid, CARTASOL Blue K-RL liquid, CARTASOL
Turquoise K-RL liquid/granules, CARTASOL Brown K-BL liquid), FASTUSOL
dyes (an auxochronne, available from BASF) (e.g., Yellow 3GL, Fastusol C Blue
74L).
[0174] Suitable flavorants may be any flavorant suitable for use in
smoking device filters including those that impart a taste and/or a flavor to
the
smoke stream. Suitable flavorants may include, but not be limited to, organic
material (or naturally flavored particles), carriers for natural flavors,
carriers for
artificial flavors, and any combination thereof. Organic materials (or
naturally
flavored particles) include, but are not limited to, tobacco, cloves (e.g.,
ground
cloves and clove flowers), cocoa, coffee, teas, and the like. Natural and
artificial
flavors may include, but are not limited to, menthol, cloves, cherry,
chocolate,
orange, mint, mango, vanilla, cinnamon, tobacco, and the like. Such flavors
may
be provided by menthol, anethole (licorice), anisole, linnonene (citrus),
eugenol
(clove), and the like, and any combination thereof. In some embodiments, more
than one flavorant may be used including any combination of the flavorants
provided herein. These flavorants may be placed in the tobacco column, in a
section of a filter, or in the porous masses described herein. The amount of
flavorant will depend on the desired level of flavor in the smoke stream
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.
[0175] Suitable aromas may include, but not be limited to, methyl
formate, methyl acetate, methyl butyrate, ethyl acetate, ethyl butyrate,
isoannyl
acetate, pentyl butyrate, pentyl pentanoate, octyl acetate, nnyrcene,
geraniol,
nerol, citral, citronella!, citronellol, linalool, nerolidol, linnonene,
camphor,
terpineol, alpha-ionone, thujone, benzaldehyde, eugenol, cinnannaldehyde,
ethyl
nnaltol, vanilla, anisole, anethole, estragole, thynnol, furaneol, methanol,
spices,
spice extracts, herb extracts, essential oils, smelling salts, volatile
organic
compounds, volatile small molecules, methyl formate, methyl acetate, methyl
butyrate, ethyl acetate, ethyl butyrate, isoannyl acetate, pentyl butyrate,
pentyl
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pentanoate, octyl acetate, nnyrcene, geraniol, nerol, citral, citronella!,
citronellol,
linalool, nerolidol, linnonene, camphor, terpineol, alpha-ionone, thujone,
benzaldehyde, eugenol, cinnannaldehyde, ethyl nnaltol, vanilla, anisole,
anethole,
estragole, thynnol, furaneol, methanol, rosemary, lavender, citrus, freesia,
apricot blossoms, greens, peach, jasmine, rosewood, pine, thyme, oaknnoss,
musk, vetiver, myrrh, blackcurrant, bergamot, grapefruit, acacia, passiflora,
sandalwood, tonka bean, mandarin, neroli, violet leaves, gardenia, red fruits,
ylang-ylang, acacia farnesiana, mimosa, tonka bean, woods, ambergris,
daffodil,
hyacinth, narcissus, black currant bud, iris, raspberry, lily of the valley,
sandalwood, vetiver, cedarwood, neroli, bergamot, strawberry, carnation,
oregano, honey, civet, heliotrope, caramel, counnarin, patchouli, dewberry,
helonial, bergamot, hyacinth, coriander, pimento berry, labdanunn, cassie,
bergamot, aldehydes, orchid, amber, benzoin, orris, tuberose, palnnarosa,
cinnamon, nutmeg, moss, styrax, pineapple, bergamot, foxglove, tulip,
wisteria,
clematis, ambergris, gums, resins, civet, peach, plum, castoreunn, myrrh,
geranium, rose violet, jonquil, spicy carnation, galbanunn, hyacinth,
petitgrain,
iris, hyacinth, honeysuckle, pepper, raspberry, benzoin, mango, coconut,
hesperides, castoreunn, osnnanthus, mousse de chene, nectarine, mint, anise,
cinnamon, orris, apricot, plunneria, marigold, rose otto, narcissus, tolu
balsam,
frankincense, amber, orange blossom, bourbon vetiver, opopanax, white musk,
papaya, sugar candy, jackfruit, honeydew, lotus blossom, nnuguet, mulberry,
absinthe, ginger, juniper berries, spicebush, peony, violet, lemon, lime,
hibiscus,
white rum, basil, lavender, balsannics, fo-ti-tieng, osnnanthus, karo karunde,
white orchid, calla lilies, white rose, rhubrunn lily, tagetes, ambergris,
ivy, grass,
seringa, spearmint, clary sage, cottonwood, grapes, brinnbelle, lotus,
cyclamen,
orchid, glycine, tiare flower, ginger lily, green osnnanthus, passion flower,
blue
rose, bay rum, cassie, African tagetes, Anatolian rose, Auvergne narcissus,
British broom, British broom chocolate, Bulgarian rose, Chinese patchouli,
Chinese gardenia, Calabrian mandarin, Comoros Island tuberose, Ceylonese
cardamom, Caribbean passion fruit, Dannascena rose, Georgia peach, white
Madonna lily, Egyptian jasmine, Egyptian marigold, Ethiopian civet, Farnesian
cassie, Florentine iris, French jasmine, French jonquil, French hyacinth,
Guinea
oranges, Guyana wacapua, Grasse petitgrain, Grasse rose, Grasse tuberose,
Haitian vetiver, Hawaiian pineapple, Israeli basil, Indian sandalwood, Indian
Ocean vanilla, Italian bergamot, Italian iris, Jamaican pepper, May rose,
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Madagascar ylang-ylang, Madagascar vanilla, Moroccan jasmine, Moroccan rose,
Moroccan oaknnoss, Moroccan orange blossom, Mysore sandalwood, Oriental
rose, Russian leather, Russian coriander, Sicilian mandarin, South African
marigold, South American tonka bean, Singapore patchouli, Spanish orange
blossom, Sicilian lime, Reunion Island vetiver, Turkish rose, Thai benzoin,
Tunisian orange blossom, Yugoslavian oaknnoss, Virginian cedarwood, Utah
yarrow, West Indian rosewood, and the like, and any combination thereof.
[0176] Suitable tackifiers may include, but not be limited to,
nnethylcellulose, ethylcellulose, hydroxyethylcellulose, carboxy
nnethylcellulose,
carboxy ethylcellulose, water-soluble cellulose acetate, amides, diannines,
polyesters, polycarbonates, silyl-modified polyannide
compounds,
polycarbannates, urethanes, natural resins, shellacs, acrylic acid polymers, 2-
ethylhexylacrylate, acrylic acid ester polymers, acrylic acid derivative
polymers,
acrylic acid honnopolynners, anacrylic acid ester honnopolynners, poly(nnethyl
acrylate), poly(butyl acrylate), poly(2-ethylhexyl acrylate), acrylic acid
ester co-
polymers, nnethacrylic acid derivative polymers, nnethacrylic acid
honnopolynners,
nnethacrylic acid ester honnopolynners, poly(nnethyl nnethacrylate),
poly(butyl
nnethacrylate), poly(2-ethylhexyl nnethacrylate), acrylannido-methyl-propane
sulfonate polymers, acrylannido-methyl-propane sulfonate derivative polymers,
acrylannido-methyl-propane sulfonate co-polymers, acrylic acid/acrylannido-
methyl-propane sulfonate co-polymers, benzyl coco di-(hydroxyethyl)
quaternary amines, p-T-amyl-phenols condensed with formaldehyde, dialkyl
amino alkyl (nneth)acrylates, acrylannides, N-(dialkyl amino alkyl)
acrylannide,
nnethacrylannides, hydroxy alkyl (nneth)acrylates, nnethacrylic acids, acrylic
acids, hydroxyethyl acrylates, and the like, any derivative thereof, and any
combination thereof.
[0177] Suitable vitamins may include, but not be limited to, vitamin A,
vitamin B1, vitamin B2, vitamin C, vitamin D, vitamin E, and any combination
thereof.
[0178] Suitable antimicrobials may include, but not be limited to, anti-
microbial metal ions, chlorhexidine, chlorhexidine salt, triclosan,
polynnoxin,
tetracycline, amino glycoside (e.g., gentannicin), rifannpicin, bacitracin,
erythromycin, neomycin, chlorannphenicol, nniconazole, quinolone, penicillin,
nonoxynol 9, fusidic acid, cephalosporin, nnupirocin, nnetronidazolea
secropin,
protegrin, bacteriolcin, defensin, nitrofurazone, nnafenide, acyclovir,
vanocnnycin,
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clindannycin, linconnycin, sulfonamide, norfloxacin, pefloxacin, nalidizic
acid,
oxalic acid, enoxacin acid, ciprofloxacin, polyhexannethylene biguanide
(PHMB),
PHMB derivatives (e.g., biodegradable biguanides like polyethylene
hexaniethylene biguanide (PEHMB)), clilorhexidine gluconate, chlorohexidine
hydrochloride, ethylenedianninetetraacetic acid (EDTA), EDTA derivatives
(e.g.,
disodiunn EDTA or tetrasodiunn EDTA), the like, and any combination thereof.
[0179] Antistatic agents may, in some embodiments, comprise any
suitable anionic, cationic, annphoteric or nonionic antistatic agent. Anionic
antistatic agents may generally include, but not be limited to, alkali
sulfates,
alkali phosphates, phosphate esters of alcohols, phosphate esters of
ethoxylated
alcohols, and any combination thereof. Examples may include, but not be
limited
to, alkali neutralized phosphate ester (e.g., TRYFAC 5559 or TRYFRAC 5576,
available from Henkel Corporation, Mauldin, SC). Cationic antistatic agents
may
generally include, but not be limited to, quaternary ammonium salts and
innidazolines which possess a positive charge. Examples of nonionics include
the
poly(oxyalkylene) derivatives, e.g., ethoxylated fatty acids like EMEREST
2650
(an ethoxylated fatty acid, available from Henkel Corporation, Mauldin, SC),
ethoxylated fatty alcohols like TRYCOL 5964 (an ethoxylated lauryl alcohol,
available from Henkel Corporation, Mauldin, SC), ethoxylated fatty amines like
TRYMEEN 6606 (an ethoxylated tallow amine, available from Henkel
Corporation, Mauldin, SC), alkanolannides like EMID 6545 (an oleic
diethanolannine, available from Henkel Corporation, Mauldin, SC), and any
combination thereof. Anionic and cationic materials tend to be more effective
antistatic agents.
[0180] It should be noted that while porous masses, and the like, are
discussed herein primarily for smoking device filters, porous masses, and the
like, may be used as fluid filters (or parts thereof) in other applications
including,
but not limited to, liquid filtration, water purification, air filters in
motorized
vehicles, air filters in medical devices, air filters for household use, and
the like.
One skilled in the arts, with the benefit of this disclosure, should
understand the
necessary modification and/or limitations to adapt this disclosure for other
filtration applications, e.g., size, shape, size ratio of matrix material
components,
and composition of matrix material components. By way of nonlinniting example,
matrix materials could be molded to other shapes like hollow cylinders for a
concentric water filter configuration or pleated sheets for an air filter.
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[0181] In some embodiments, a system may include a material path
with a mold cavity disposed along the material path, at least one hopper
before
at least a portion of the mold cavity for feeding a matrix material to the
material
path, a heat source in thermal communication with at least a first portion of
the
material path, and a cutter disposed along the material path after the first
portion of the material path.
[0182] Some embodiments may include continuously introducing a
matrix material into a mold cavity and disposing a release wrapper as a liner
of
the mold cavity. Further, said embodiments may include heating at least a
portion of the matrix material so as to bind the matrix material at a
plurality of
contact points thereby forming a porous mass length and cutting the porous
mass length radially thereby yielding a porous mass.
[0183] Some embodiments may include continuously introducing a
matrix material into a mold cavity, heating at least a portion of the matrix
material so as to bind the matrix material at a plurality of contact points
thereby
forming a porous mass length, and extruding the porous mass length through a
die.
[0184] In some embodiments, a system may include a mold cavity
comprising at least two mold cavity parts where a first conveyer includes a
first
mold cavity part and a second conveyer include a second mold cavity part. Said
first conveyer and second conveyer may be capable of bringing together the
first
mold cavity part and the second mold cavity part to form the mold cavity and
then separating the first mold cavity part from the second mold cavity part in
a
continuous fashion. The system may further include a hopper capable for
filling
the mold cavity with a matrix material and a heat source in thermal
communication with at least a first portion of the mold cavity for
transforming
the matrix material into a porous mass.
[0185] Some embodiments may include introducing a matrix material
into a plurality of mold cavities and heating the matrix material in the mold
cavities so as to bind the matrix material at a plurality of contact points,
thereby
forming a porous mass.
[0186] Embodiments disclosed herein include:
A. a method that includes feeding via pneumatic dense phase feeding a
matrix material into a mold cavity to form a desired cross-sectional shape,
the
matrix material comprising a plurality of binder particle and a plurality of
active
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particles; heating at least a portion of the matrix material so as to bind at
least a
portion of the matrix material at a plurality of sintered contact points,
thereby
forming a porous mass length; cooling the porous mass length; and cutting the
porous mass length, thereby producing a porous mass;
B. a method that includes feeding via pneumatic dense phase feeding a
matrix material into a mold cavity to form a desired cross-sectional shape,
the
matrix material comprising a plurality of active particles and a plurality of
binder
particles having a hydrophilic surface modification; heating at least a
portion of
the matrix material so as to bind at least a portion of the matrix material at
a
plurality of sintered contact points, thereby forming a porous mass length;
reshaping the cross-sectional shape the porous mass length after heating;
cooling the porous mass length; and cutting the porous mass length, thereby
producing a porous mass; and
C. a method that includes feeding via pneumatic dense phase feeding a
matrix material into a mold cavity to form a desired cross-sectional shape,
the
matrix material comprising a plurality of active particles, a plurality of
binder
particles having a hydrophilic surface modification, and a microwave
enhancement additive; heating at least a portion of the matrix material by
irradiating the matrix material with microwave irradiation so as to bind at
least a
portion of the matrix material at a plurality of sintered contact points,
thereby
forming a porous mass length; reshaping the cross-sectional shape the porous
mass length after heating; cooling the porous mass length; and cutting the
porous mass length, thereby producing a porous mass.
[0187] Each of embodiments A, B, and C may have one or more of the
following additional elements in any combination: Element 1: wherein pneumatic
dense phase feeding occurs at a feeding rate of about 1 nninnin to about 800
nninnin; Element 2: wherein pneumatic dense phase feeding occurs at a feeding
rate of about 1 nninnin to about 800 nninnin and the mold cavity has a
diameter
of about 3 mm to about 10 mm; Element 3: wherein heating involves irradiating
with microwave radiation the at least a portion of the matrix material;
Element
4: wherein the matrix material further comprises a microwave enhancement
additive; Element 5: wherein the mold cavity is at least partially formed by a
paper wrapper; Element 6: wherein the binder particle has a hydrophilic
surface
treatment; Element 7: the method further including reshaping the cross-
sectional shape the porous mass length after heating; Element 8: the method
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further including reheating the porous mass length before cutting, thereby
forming a second plurality of sintered contact point; Element 9: the method
further including reheating the porous mass, thereby forming a second
plurality
of sintered contact point; Element 10: wherein the porous mass is a sheet
suitable for use in an air filter; Element 11: wherein the porous mass is a
sheet
with a thickness of about 5 mm to about 50 mm; Element 12: wherein the
porous mass is suitable for use in a smoking article filter; Element 13:
wherein
the porous mass is suitable for use in a water filter; and Element 14: wherein
the porous mass is a hollow cylinder.
[0188] By way of non-limiting example, exemplary combinations
applicable to A, B, C include: Element 1 in combination with Element 3;
Element
2 in combination with Element 3; Element 4 in combination with any of the
foregoing; Element 3 in combination with Element 4; at least one of Elements 7-
9 in combination with any of the foregoing; Element 7 in combination with
Element 8; Element 7 in combination with Element 9; Element 7 in combination
with Element 3; Element 5 in combination with any of the foregoing; one of
Elements 10-14 in combination with any of the foregoing; Element 6 in
combination with any of the foregoing; and Element 6 in combination with one
of
Elements 1-4.
[0189] To facilitate a better understanding of the embodiments
described herein, the following examples of representative embodiments are
given. In no way should the following examples be read to limit, or to define,
the
scope of the invention.
EXAMPLES
[0190] Example 1. To measure integrity, samples are placed in a French
square glass bottle and shaken vigorously using a wrist action shaker for 5
minutes. Upon completion, the weight of the samples before and after shaking
are compared. The difference is converted to a percent loss value. This test
simulates deterioration under extreme circumstances. Less than 2% weight loss
is assumed to be acceptable quality.
[0191] Porous mass samples were produced with GUR 2105 with carbon
additive and GUR X192 with carbon additive were produced both with and
without paper wrappings. Said samples were cylinders measuring 8 mm x 20
mm. The results of the integrity test are given below in Table 1.
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Table 1
Carbon:GUR Percent Loss Percent Loss
GU R
Ratio (with paper) (no paper)
2105 85:15 0.94% 2.64%
2105 80:20 0.59% 3.45%
2105 75:25 0.23% 0.57%
2105 70:30 0.14% 1.00%
X192 80:20 34.51% 60.89%
X192 75:25 13.88% 43.78%
X192 70:30 8.99% 14.33%
plasticized carbon- 4.01 nng/nnnn
0.98% n/a
on-tow filter carbon
[0192] This example demonstrates that increasing the percent of binder
(GUR) in the porous mass and including a wrapper (paper) enhances the
integrity of the porous mass. Further, porous masses can be designed to have
comparable integrity to a Dalmatian filter (plasticized carbon-on-tow filter),
which is used for increased removal of smoke components.
[0193] Example 2. To measure the amount of particles released when a
fluid is drawn through a filter (or porous mass), samples are dry puffed and
the
particles released are collected on a Cambridge pad.
[0194] The particle release characteristics of porous masses were
compared to a Dalmatian filter (plasticized carbon-on-tow filter). Samples
were
cylinders measuring 8 mm x 20 mm of (1) a porous mass with 333 mg of
carbon, (2) a porous mass with 338 mg of carbon having been water washed,
and (3) a Dalmatian filter with 74 mg of carbon. Table 2 below shows the
results
of the particle release test.
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Table 2
Initial mg Carbon/ Carbon mg Carbon Loss/
Carbon
Sample Loading mm filter Loss g Initial Carbon
(mg) length (mg) Loading
porous mass 333 16.65 0.18 0.53
washed
338 16.9 0.073 0.22
porous mass
Dalmatian
74 3.7 0.15 2.07
filter
[0195] This example demonstrates that porous masses have
comparable particle amounts that are released upon drawing as compared to
Dalmatian filters even with many times more carbon loading, 4.5 times more in
this example. Further, particle release can be mitigated with porous masses
with
treatments like washing. Other mitigating steps could be increasing the binder
concentration in the porous mass, increasing the degree of mechanical binding
in
the porous mass (e.g., by increasing the time at binding temperatures),
optimizing the size and shape of the additive (e.g., carbon), and the like.
[0196] Example 3. A matrix material of 80 wt% carbon (PICATIF, 60%
active carbon available from Jacobi) and 20 wt% GUR 2105 were mixed and
poured into paper tubes plugged at one end. The filled tubes were placed in a
microwave oven and irradiated for 75 seconds (about 300 W and about 2.45
GHz). A significant portion of the matrix material had bonded together and was
cut into two sections, 17 mm and 21 mm. The sections of porous mass were
analyzed and demonstrated EPDs of 8.4 mm of water/mm of length and 2.7 mm
of water/mm of length, respectively.
[0197] This example demonstrates the applicability of microwave
irradiation in the production of porous masses and the like. As discussed
above,
microwave irradiation may, in some embodiments, be used in addition to other
heating techniques in the formation of porous masses and the like described
herein.
[0198] Example 4. Five porous masses were prepared for each of a first
matrix material of 80 wt% carbon (PICATIF, 60% active carbon available from
Jacobi) and 20% GUR 2105 and a second matrix material 80 wt% carbon
(PICATIF, 60% active carbon available from Jacobi) and 20 wt% plasma treated
GUR 2105 (i.e., an example of a binder with a hydrophilic surface
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modification). The properties of the resultant porous masses were measured
(Table 3). The ovality of the porous mass is measured with a method similar to
that used to measure the ovality of traditional cigarette filters where a
circumference/ovality tester optically scans the sample to measure the
circumference, maximum diameter (a), and minimum diameter (b). Ovality is
calculated as a-b and indicates the degree of deformation from circular to
ovular
of the cross-sectional shape.
Table 3
plasma
GUR 2105 treated GUR
2105
Average 2.123 0.033 1.946
0.028
Weight (g)
Coeff. of Var. 1.6 1.4
Circumference Average 23.70 0.09 23.67
0.07
(mm) Coeff. of Var. 0.4 0.3
Average 0.24 0.05 0.27 0.05
Ovality (mm)
Coeff. of Var. 21.4 20.0
EPD (mm of Average 340 24 221 11
water/120 mm
of length) Coeff. of Var. 7.1 4.8
[0199] For each of these measurements, especially EPD, the standard
deviation in the porous masses comprising plasma treated GUR 2105 is equal
to or less than the non-treated GUR 2105. Further, in comparing the values of
the EPD between the samples, for the same concentration of binder particles,
the plasma treated GUR 2105 yields a lower EPD than the non-treated GUR
2105. This example demonstrates that binder particles with hydrophilic
surfaces
minimize variability in porous mass properties (indicated by the coefficient
of
variability reported) and reduce the overall EPD of the porous mass.
[0200] Example 5. Two matrix material samples were used for
preparing porous masses: (1) control - 10 wt% GUR 2105, 10 wt% GUR
2122, 80 wt% activated carbon and (2) graphite - 10 wt% GUR 2105, 10 wt%
GUR 2122, 79 wt% activated carbon, 1 wt% powdered graphite (available
from McMaster-Carr) (i.e., an example of a microwave enhancement additive).
The matrix material was fed via pneumatic dense phase feeding at 60 psi into a
mold cavity formed by paper rolled into a tube/cylinder shape. The mold cavity
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with matrix material therein was passed through a single mode 2.45 GHz
microwave
chamber at 2 m/min. The microwave input energy was varied. The resultant
porous
masses were analyzed for EPD, circumference, and rod integrity (as measured
above) (Table 4).
Table 4
Absorbed EPD (mm Rod
Sample Microwave water/120 Circ. (mm) Integrity
Power mm length) (0/0 wt loss)
control 155 914.2 23.7 4.0
control 191 965.4 24.2 2.7
control 240 972.0 24.1 1.5
control 290 278.2 23.9 3.3
control 345 152.2 23.7 7.3
graphite 131 200.8 24.2 5.1
graphite 193 143.4 24.0 2.7
graphite 272 142.4 23.9 1.2
graphite 341 100.6 23.7 1.2
graphite 389 52.4 23.9 3.0
[0201] This example demonstrates that the inclusion of microwave
enhancement additives improve the microwave sintering process as evidenced by
the
decrease in EPD and comparable to improved rod integrity for similar microwave
power.
[0202] Therefore, the present invention is well adapted to attain the ends and
advantages mentioned as well as those that are inherent therein. The
particular
embodiments disclosed above are illustrative only, as the present invention
may be
modified and practiced in different but equivalent manners apparent to those
skilled in
the art having the benefit of the teachings herein. Furthermore, no
limitations are
intended to the details of construction or design herein shown, other than as
described in the claims below. It is therefore evident that the particular
illustrative
embodiments disclosed above may be altered, combined, or modified and all such
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variations are considered within the scope of the present invention. The
invention
illustratively disclosed herein suitably may be practiced in the absence of
any element
that is not specifically disclosed herein and/or any optional element
disclosed herein.
While compositions and methods are described in terms of "comprising,"
"containing,"
or "including" various components or steps, the compositions and methods can
also
"consist essentially of" or "consist of" the various components and steps. All
numbers
and ranges disclosed above may vary by some amount. Whenever a numerical range
with a lower limit and an upper limit is disclosed, any number and any
included range
falling within the range is specifically disclosed. In particular, every range
of values (of
the form, "from about a to about b," or, equivalently, "from approximately a
to b," or,
equivalently, "from approximately a-b") disclosed herein is to be understood
to set
forth every number and range encompassed within the broader range of values.
Also,
the terms in the claims have their plain, ordinary meaning unless otherwise
explicitly
and clearly defined by the patentee. Moreover, the indefinite articles "a" or
"an," as
used in the claims, are defined herein to mean one or more than one of the
element
that it introduces.
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