Filter element comprising two porous materials for aerosol-generating articles

Abstract

The present invention relates to a filter element (100) for use in an aerosol-generating article. The filter element comprises a filter material (102). The filter material includes a porous foam material (106) dispersed in a porous fibrous material (104).

Description

[0001] This invention relates to a filter element for use in aerosol-generating articles. Specifically, it relates to an aerosol-generating article comprising a filter element.

[0002] An aerosol generating apparatus for generating inhalable vapors is known. Such an apparatus can heat an aerosol forming matrix to a temperature that causes one or more components of the aerosol forming matrix to volatilize without burning the aerosol forming matrix. The aerosol forming matrix can be provided as part of an aerosol generating article. The aerosol generating article can have a strip shape for inserting the aerosol generating article into a cavity (such as a heating chamber) of the aerosol generating apparatus. Heating elements can be arranged in or around the heating chamber for heating the aerosol forming matrix once the aerosol generating article is inserted into the heating chamber of the aerosol generating apparatus. The article may include a filter element. The filter element may include a plastic material, such as cellulose acetate tow.

[0003] It is desired to provide a filter element that offers improved sustainability. It is desired to provide a filter element with reduced environmental impact. It is desired to provide a filter element with reduced size. It is desired to provide a filter element with improved filtration properties. It is desired to provide a filter element with improved filtration efficiency. It is desired to provide a filter element with adjustable filtration properties. It is desired to provide a filter element that can be produced cost-effectively. It is desired to provide a filter element with adjustable airflow properties. It is desired to provide a filter element with improved airflow properties.

[0004] According to one embodiment of the present invention, a filter element for use in aerosol-generating articles is provided. The filter element may include a filter material. The filter material may include a porous foamed material dispersed in a porous fibrous material.

[0005] According to one embodiment of the present invention, a filter element for use in aerosol-generating articles is provided. The filter element includes a filter material. The filter material includes a porous foamed material dispersed in a porous fibrous material.

[0006] Filter elements offer improved sustainability. Filter elements can have a reduced environmental impact. Filter elements can have a smaller size. Filter elements can be compact in size. Filter elements can have improved filtration properties. Filter elements can have improved filtration efficiency. Filter elements can offer adjustable filtration properties. Filter elements can be manufactured cost-effectively. Filter elements can offer adjustable airflow properties. Filter elements can offer improved airflow properties.

[0007] The filter elements described herein can replace existing non-biodegradable filter elements with comparable performance. The filter elements described herein can replace existing plastic filter elements with comparable performance. The filter elements described herein can replace existing cellulose acetate filter elements with comparable performance.

[0008] Filter materials may be cellulose acetate-free. Porous foam materials may be cellulose acetate-free. Porous fiber materials may be cellulose acetate-free.

[0009] Filter materials can be composed of porous foamed materials dispersed within porous fibrous materials. Porous fibrous materials can be embedded within porous fibrous materials. Porous foamed materials can be dispersed throughout the porous fibrous materials.

[0010] Porous foam materials can be foam. Porous foam materials can be dry foam. Porous foam materials can be solid foam. Dry foam can refer to materials formed by filling cavities with air or other gases within a solid. Dry foam can also refer to materials formed from wet foam by drying wet foam.

[0011] Wet foam can refer to materials formed in a liquid by cavities of air or other gases.

[0012] Materials with open structures can refer to materials containing fluid interconnected cavities of air or other gases within a solid.

[0013] Foam can be generated by preparing wet foam from a dispersion and removing the liquid dispersion medium. The dispersion can be a dispersion of cellulosic materials in a liquid dispersion medium. Wet foam can be generated from the dispersion by agitating the dispersion or otherwise introducing air bubbles into the dispersion. The dispersion medium can be removed by evaporation, freeze-drying, or supercritical drying.

[0014] "Pore" can refer to a cavity filled with air or other gas, the cavity being defined by a wall that at least partially surrounds the cavity.

[0015] Porous fiber materials can be biodegradable. Porous fiber materials can be recyclable.

[0016] Porous fiber materials can be configured as solid cylindrical strips. Porous foam materials can be dispersed within solid cylindrical strips of porous fiber materials. Porous fiber materials can also be configured as solid cubes. Porous foam materials can be dispersed within solid cubes of porous fiber materials.

[0017] Porous fibrous materials can be configured as a matrix for porous foamed materials. Filter materials may include a matrix made of porous fibrous materials, wherein the porous foamed material is dispersed within the matrix of porous fibrous materials. Filter materials may consist of a matrix made of porous fibrous materials, wherein the porous foamed material is dispersed throughout the entire porous fibrous material matrix. The porous foamed material may be embedded within the porous fibrous material matrix. The porous fibrous material matrix may be cylindrical in shape. The porous fibrous material matrix may be cuboid in shape. The porous fibrous material matrix may be strips. The porous foamed material may be uniformly dispersed throughout the porous fibrous material matrix.

[0018] Filter elements may include a core made of filter material. The core may be a solid cylindrical shape. The core may be a strip. The core may be a cuboid shape.

[0019] A filter element may include a proximal end. A filter element may include a distal end. Filter media may be disposed between the proximal end and the distal end of the filter element. Filter media may extend between the proximal end and the distal end of the filter element. The proximal end and the distal end of the filter element may be fluidly connected via the filter media. The proximal end and the distal end of the filter element may be fluidly connected via a core of the filter media.

[0020] The porosity of porous foam materials can differ from that of porous fiber materials. The density of porous foam materials can also differ from that of porous fiber materials.

[0021] "Porosity" can refer to the volume fraction of vacuolar space in a material or component. For example, if 60% of the volume of a porous foam material is not filled with solid material, then the porous foam material will have a porosity of 0.6. "Porosity" can also refer to the volume fraction of vacuolar space in a filter element.

[0022] Porous fibrous materials can be configured to define an aerosol flow oriented substantially along the longitudinal axis of a filter element. Porous fibrous materials can be configured to define an airflow oriented substantially along the longitudinal axis of a filter element. Porous foam materials can be configured to define a turbulent aerosol flow. Porous foam materials can be configured to define a turbulent airflow. Segments of porous foam materials discussed below can be configured to define a turbulent aerosol flow. Segments of porous foam materials discussed below can be configured to define a turbulent airflow. Porous foam materials dispersed in porous fibrous materials can be configured to define a turbulent airflow. The turbulent airflow can be defined at least partially by the porosity of the porous foam material. The turbulent airflow can be defined at least partially by the size and shape of the segments of porous foam materials discussed below.

[0023] The properties of the airflow through the filter element can be determined by an airflow oriented substantially along the longitudinal axis of the filter element defined by the porous fibrous material and a turbulent airflow defined by the porous foam material. The properties of the aerosol flow through the filter element can also be determined by an aerosol flow oriented substantially along the longitudinal axis of the filter element defined by the porous fibrous material and a turbulent aerosol flow defined by the porous foam material. The interaction between the airflow oriented substantially along the longitudinal axis of the filter element and the turbulent airflow can improve the filtration efficiency of the filter element. Due to the interaction between the airflow oriented substantially along the longitudinal axis of the filter element and the turbulent airflow, the length of the filter element can be reduced. The size of the aerosol-generating article including the filter element can be reduced.

[0024] The properties of the airflow or aerosol flow through the filter element can be adjusted by changing one or more of the following: the configuration of the porous fiber material, the porosity of the porous fiber material, the density of the porous fiber material, the configuration of the porous foam material, the porosity of the porous foam material, the volume fraction of the porous foam material in the filter material, the distribution of the porous foam material in the porous fiber material, the size distribution of the porous foam material segments, the size of the porous foam material segments discussed below, and the shape of the porous foam material segments. For example, increasing the volume fraction of the porous foam material in the filter material can increase the turbulent airflow.

[0025] The suction resistance of the filter element can be adjusted by changing one or more of the following: the configuration of the porous fiber material, the porosity of the porous fiber material, the density of the porous fiber material, the configuration of the porous foam material, the porosity of the porous foam material, the volume fraction of the porous foam material in the filter material, the distribution of the porous foam material in the porous fiber material, the size distribution of the porous foam material fragments, the size of the porous foam material fragments discussed below, and the shape of the porous foam material fragments.

[0026] The porosity of a filter element can affect its suction resistance. The porosity of the filter material can also affect the suction resistance of the filter element. The porosity of the filter material can be influenced by one or more of the porosity of porous fibrous materials, porous foamed materials, and the compressive force applied to the filter material. The compressive force can be applied by the tipping paper or filter element packaging that defines the filter material, as discussed below.

[0027] The properties of the filter element can be adjusted according to the characteristics of the aerosol-generating product incorporated therein. The suction resistance of the filter element can also be adjusted according to the characteristics of the aerosol-generating product incorporated therein.

[0028] Suction resistance can be determined by the porosity of the filter element. Suction resistance can be largely determined by the porosity of the filter material. The suction resistance of aerosol-generating articles, including filter elements as described herein, can be determined by the porosity of the filter element.

[0029] A filter element may include a first region and a second region. The first region may include a first filter material. The second region may include a second filter material. The first filter material may include a first porous fibrous material and a first porous foam material. The first porous foam material may be dispersed in the first porous fibrous material. The first porous foam material may be uniformly dispersed in the first fibrous material. The second filter material may include a second porous fibrous material and a second porous foam material. The second porous foam material may be dispersed in the second porous fibrous material. The second porous foam material may be uniformly dispersed in the second fibrous material. The first and second filter materials may be the filter materials described herein.

[0030] Multiple segments of the first porous foam material can be dispersed in the first porous fiber material. Multiple segments of the second porous foam material can be dispersed in the second porous fiber material. Multiple segments of the first porous foam material can be uniformly dispersed in the first porous fiber material. Multiple segments of the second porous foam material can be uniformly dispersed in the second porous fiber material.

[0031] The first porous fiber material may differ from the second porous fiber material. The first porous fiber material may be the same as the second porous fiber material. The first porous foam material may differ from the second porous foam material. The first porous foam material may be the same as the second porous foam material. The porosity of the first porous fiber material may differ from the porosity of the second porous fiber material. The porosity of the first porous foam material may differ from the porosity of the second porous foam material.

[0032] The first filter material may be arranged near the second filter material. The first filter material in the second filter material may be configured to have a matching shape. The first filter material may be configured as a strip. The second filter material may be configured as a strip.

[0033] A filter element may include multiple regions. Each region may include a filter material. Each filter material may include a porous fibrous material and a porous foam material. For each region, the porous foam material may be dispersed within the porous fibrous material. For each region, multiple segments of the porous foam material may be dispersed within the porous fibrous material. At least some of the filter materials in the regions may be configured to be different from each other. All filter materials in the regions may be configured to be different from each other. The porous fibrous material may differ between regions. The porous foam material may differ between regions. For each region, the porous foam material may be dispersed within the porous fibrous material. The filter material in each region may be the filter material described herein.

[0034] The aerosol flow characteristics of a filter element can be adjustable by providing two or more filter materials. Similarly, the airflow characteristics of a filter element can be adjustable by providing two or more filter materials. For example, by combining a first filter material having a first aerosol flow characteristic and a second filter material having a second aerosol flow characteristic in a filter element, the aerosol flow or airflow characteristics of the filter element can be adjusted.

[0035] Porous foam materials can be uniformly dispersed in porous fiber materials. Porous foam materials can be substantially uniformly dispersed in porous fiber materials.

[0036] Porous foam materials can be uniformly dispersed throughout a porous fibrous material. Filter materials may include porous foam materials uniformly distributed within a porous fibrous material. Porous foam materials can be uniformly distributed throughout a porous fibrous material. Porous foam materials can be uniformly dispersed within a porous fibrous material.

[0037] Filter materials can be configured to remove or at least reduce unwanted components of aerosols.

[0038] A filter element may include a filter element package. The filter element package may be configured to at least partially define the filter material. The filter element package may be configured to completely define the filter material.

[0039] The filter element package may be configured to at least partially surround the filter material. The filter element package may be configured to completely surround the filter material. The filter element package may wrap around the filter material.

[0040] Filter element packaging may at least partially define a porous fiber material. Filter element packaging may completely define a porous fiber material. Filter element packaging may wrap around a porous fiber material. Filter element packaging may wrap around a core of filter material. A fifth element packaging may be configured to wrap around a strip of filter material. Filter element packaging may wrap around a strip of porous fiber material. Filter element packaging may wrap around a cube of porous fiber material.

[0041] A filter element may consist of a filter element package and filter media. A filter element may consist of filter media enclosed in a filter element package.

[0042] Porous fiber materials can be configured to be compressible. Filter element packages can be configured to compress filter media. Filter element packages can be configured to compress porous fiber materials. Filter element packages can be configured to compress porous foam materials. Filter element packages can be configured to extruded filter media. Filter element packages can be configured to extruded porous fiber materials. Filter element packages can be configured to extruded foam materials. Filter element packages can be configured to compress porous fiber materials. Filter element packages can be tightened around the filter media. Filter element packages can apply compressive force to the filter media. Compression can change the porosity of the filter media. Compression can be adjusted to adjust the porosity of the filter media. The suction resistance of the filter element can be adjusted by compression. The flow characteristics of the filter element can be adjusted by compression.

[0043] The filter element package can be configured to stabilize the filter material. The filter element package can also be configured to protect the filter material.

[0044] The filter element package may be configured to at least partially define the first filter material and the second filter material. The filter element package may be configured to completely define the first filter material and the second filter material. The filter element package may be configured to fix the relative positions of the first filter material and the second filter material.

[0045] Filter element packaging can be permanently attached to the filter media. Filter element packaging can be bonded to the filter media using starch adhesive.

[0046] The filter element can be stabilized by permanently attaching the filter material to the filter element packaging.

[0047] Filter element packages can have permeability between 3,500 Coresta units and 12,000 Coresta units.

[0048] The filter element package may have a thickness between 0.2 micrometers and 0.4 micrometers.

[0049] The filter element package may have a basis weight between 10 g / m and 30 g / m, preferably between 17 g / m and 21 g / m.

[0050] The filter element may include a tipping paper. The tipping paper may be configured to at least partially define the filter material. The tipping paper may be configured to completely define the filter material. The tipping paper may be configured to at least partially define the filter element package. The tipping paper may be configured to completely define the filter element package.

[0051] Tipping paper may at least partially wrap around the filter material. Tipping paper may completely wrap around the filter material. Tipping paper may at least partially define the porous fibrous material. Tipping paper may completely define the porous fibrous material. Tipping paper may at least partially wrap around the porous fibrous material. Tipping paper may completely wrap around the porous fibrous material. Tipping paper may wrap around the filter material. Tipping paper may wrap around the porous fibrous material. Tipping paper may wrap around strips of porous fibrous material.

[0052] Tipping paper may have a textured surface. Tipping paper may have a textured outer surface. Tipping paper may have an embossed surface. Tipping paper may have an embossed outer surface. Tipping paper may have a smooth surface. Tipping paper may have a smooth outer surface.

[0053] Tipping paper can attach filter elements to other parts of the aerosol-generated product into which the filter elements will be incorporated.

[0054] Tipping paper can have a permeability between 380 Coresta units and 550 Coresta units.

[0055] Tipping paper can have a thickness between 0.5 micrometers and 1.1 micrometers.

[0056] Tipping paper may have a basis weight between 25 g / m and 60 g / m, preferably between 30 g / m and 50 g / m.

[0057] Porous fibrous materials may include multiple fibers. The fibers may be arranged substantially parallel to the longitudinal axis of the filter material. The fibers may be regenerated cellulose fibers. The longitudinal axis of the fibers may be arranged substantially parallel to the longitudinal axis of the filter material. The fibers may be arranged substantially parallel to the longitudinal axis of the filter element. The longitudinal axis of the fibers may be arranged substantially parallel to the longitudinal axis of the filter element.

[0058] Airflow through porous fiber materials can be oriented along the longitudinal axis of the fibers. Aerosol flow through porous fiber materials can also be oriented along the longitudinal axis of the fibers.

[0059] Porous fiber materials can be regenerated cellulose materials. Porous fiber materials can include regenerated cellulose materials. Regenerated cellulose materials can include regenerated cellulose fibers.

[0060] Regenerated cellulose materials may not contain cellulose acetate. Porous fiber materials may include regenerated cellulose fibers. Porous fiber materials may be made of regenerated cellulose fibers. Regenerated cellulose fibers may be arranged substantially parallel to the longitudinal axis of the filter material. The longitudinal axis of the regenerated cellulose fibers may be arranged substantially parallel to the longitudinal axis of the filter material.

[0061] Regenerated cellulose fibers can be derived from tobacco. Specifically, they can be derived from tobacco plant stems. Since tobacco plant stems are largely used as waste from tobacco processing, regenerated cellulose fibers derived from tobacco plant stems can be a sustainable source of fiber. Regenerated cellulose fibers can also be obtained from bamboo. Bamboo stalks can be obtained from bamboo. Due to the large-scale existence of sustainable bamboo agriculture, bamboo can be a sustainable source of fiber. Since waste from bamboo processing materials can be used to obtain regenerated cellulose fibers, bamboo can be a sustainable source of regenerated cellulose fibers. Regenerated cellulose materials can be derived from one or more of tobacco plant stems and bamboo stalks.

[0062] Regenerated cellulose fibers can have a uniform length. The length of regenerated cellulose fibers can be homogenized. The length of regenerated cellulose fibers can be homogenized using continuous spinning in regeneration technology. The cellulose-based materials from which regenerated cellulose fibers are derived can be obtained from recycled materials.

[0063] The uniformity of regenerated cellulose fiber length can be achieved through the preparation and dissolution of intermediate compounds such as sodium xanthate or acetate derivatives, as well as fiber regeneration. Derivatization of cellulose fibers can improve their solubility in solvents. Solvents can be aqueous or non-aqueous. The cellulose structure can be transformed depending on the type of solvent, processing conditions, and the type of fiber to be obtained.

[0064] Porous fiber materials can be tows of regenerated cellulose fibers. Porous fiber materials can include bundles of regenerated cellulose fibers.

[0065] The fiber can be one or more regenerated cellulose fibers selected from viscose fiber, rayon fiber, modal fiber, Tencel fiber, and lyocell fiber, and any combination thereof. The fiber is preferably selected from Tencel fiber and lyocell fiber. Tencel fiber and lyocell fiber can be biodegradable.

[0066] Regenerated cellulose materials can have a crystallinity between 4.7 cN / dtex and 5.5 cN / dtex.

[0067] Regenerated cellulose materials can have tensile strength between 3.4% and 4.1%.

[0068] Regenerated cellulose materials can have a density of 150 kg / m³. 3 Up to 750 kg / m 3 Between, preferably between 250 kg / m 3 Up to 500kg / m 3 The packing density between them.

[0069] Regenerated cellulose materials may have a glass transition temperature between 150°C and 190°C, preferably between 160°C and 180°C.

[0070] Regenerated cellulose materials may have a melting point between 220°C and 300°C, preferably between 230°C and 280°C.

[0071] The regenerated cellulose material may have a specific gravity between 1.2 and 1.5, preferably between 1.3 and 1.4 (25 / 4 degrees Celsius). The regenerated cellulose material may have an elongation at break between 45% and 55%.

[0072] Filter elements can be solid cylindrical. Filter elements can be strip-shaped. Filter elements can be cuboid-shaped. The shape of the filter element can match the shape of the aerosol-generating article to which the filter element will be bonded. The shape of the filter element can match the shape of porous fibrous materials.

[0073] Filter elements may have a circular cross-section. Filter elements may have a rectangular cross-section. Filter elements may have a substantially circular cross-section. Filter elements may have an skewed circular cross-section.

[0074] Porous fiber materials can be configured into cylindrical shapes. Porous fiber materials can be configured into solid cylindrical shapes. Porous fiber materials can be strips. Porous fiber materials can be cuboid in shape. Porous fiber materials can have circular cross-sections. Porous fiber materials can have substantially circular cross-sections. Porous fiber materials can have oblique circular cross-sections. Porous fiber materials can have rectangular cross-sections.

[0075] The filter element of this invention can be manufactured using standard filter manufacturing equipment. The filament can be produced using Korber Hauni KDFLEAD NWT equipment.

[0076] Porous foam materials may include open-cell foam. Porous foam materials may be composed of open-cell foam. Porous foam materials may be open-cell foam.

[0077] Porous foam materials can be foamed cellulose materials. Porous foam materials can be foams of cellulose materials. Porous foam materials can be manufactured according to methods for producing sheets of foamed cellulose materials, as described in European Patent Application 23206185.3, which is incorporated herein by reference. Porous foam materials can be filter materials used in aerosol-generating articles disclosed in European Patent Application 23206185.3, which is incorporated herein by reference. Porous foam materials can be foamed cellulose materials used in aerosol-generating articles disclosed in European Patent Application 23206185.3, which is incorporated herein by reference. Sheets of foamed cellulose materials can be manufactured using methods including the following steps:

[0078] a) Preparing a suspension of a cellulosic material, wherein the suspension contains a foaming agent.

[0079] b) Stir the suspension of the cellulosic material and optionally add a hydrophobic agent to the suspension of the cellulosic material to obtain a wet foam of the cellulosic material.

[0080] c) Prepare a sheet of wet foam of the cellulose material and dehydrate the sheet of wet foam of the cellulose material.

[0081] d) Dry the wet foam sheet of the cellulosic material.

[0082] e) Rewetting the foam sheet

[0083] f) Adjusting the thickness of the foam sheet, and

[0084] g) Dry the foam.

[0085] The method can produce sheets of dry foamed cellulose materials.

[0086] Suspensions of cellulosic materials can be suspensions of pulp. Suspensions of cellulosic materials can be suspensions of wood pulp. Suspensions of cellulosic materials can be suspensions of cellulose. Suspensions of cellulosic materials can be suspensions of refined cellulose. Suspensions of cellulosic materials can be suspensions of cellulosic fibers. Suspensions of cellulosic materials can be suspensions of cellulose fibers.

[0087] Cellulose-based materials can be cellulose. Cellulose-based materials can be cellulose fibers. Cellulose-based materials can be cellulose fibers. Cellulose-based materials may include cellulose. Cellulose-based materials may include cellulose fibers. Cellulose-based materials may not contain cellulose acetate.

[0088] Cellulose materials may be based on bleached softwood pulp, unbleached softwood pulp, bleached eucalyptus pulp, and bleached cotton pulp, or any combination thereof. Cellulose materials may be derived from bleached softwood pulp, unbleached softwood pulp, bleached eucalyptus pulp, and bleached cotton pulp, or any combination thereof.

[0089] The foaming agent may contain one or more surfactants. Preferably, the foaming agent may be a mixture containing about 80 mol% sodium dodecyl sulfate (SDS) and about 20 mol% polyoxyethylene (20) dehydrated sorbitan monolaurate.

[0090] Preferably, the hydrophobic agent can be an alkyl ketene dimer (AKD). The hydrophobic agent can be added to the suspension of the cellulosic material at an amount of about 1% by weight.

[0091] In step a), the cellulose material can be refined to between 2% and 3%. In step a), the conductivity of the cellulose material suspension can be adjusted to 1000 μS / cm by adding sodium chloride. In step a), the pH of the cellulose material suspension can be adjusted to approximately 8 by adding sodium hydroxide. In step a), a strength additive can be added to the cellulose material suspension. The strength additive can be selected from one or more of sodium carboxymethyl cellulose (CMC), microfibrillated cellulose, and cellulose nanofibrils.

[0092] In step c), the wet foam of the cellulose material can be poured onto a manually operated sheet mold. In step c), the sheet of wet foam of the cellulose material can be dehydrated by gravity. In step c), dehydration can be performed without vacuum. In step c), a fabric can be placed on top of the foam to stabilize it. In step d), drying can be carried out in an oven at 70 degrees Celsius.

[0093] In step e), the foam can be rewetted to a moisture content of 50%. In step e), the foam sheet can be rewetted by exposing the sheet to an atmosphere with a moisture content of 50% for up to 4 hours.

[0094] In step g), the foam may be dried in an oven at 70 degrees Celsius. In step g), the foam may be cured at approximately 80 degrees Celsius for 2 hours to ensure complete reaction of AKD.

[0095] Foamed cellulose materials can be cellulose foams. Foamed cellulose materials can be dry cellulose foams. Foamed cellulose materials can be solid cellulose foams. Foamed cellulose materials can be open-cell foams. Foamed cellulose materials may not contain cellulose acetate. Foamed cellulose materials can be porous. The density of cellulose foam can be up to 45 kg / m³. 3 Up to 105 kg / m3 between.

[0096] Porous foam materials can be prepared from plant-based pulps. Porous foam materials can be prepared from one or more of wood pulp, bamboo pulp, tobacco stalk pulp, nanocellulose, and kaolin microfibrillated cellulose composites.

[0097] Porous foam materials can be biodegradable.

[0098] Porous foam materials can be derived from one or more of wood pulp, bamboo pulp, and tobacco stalk pulp, or any combination thereof.

[0099] Porous foam materials can be biocomposite foams. Porous foam materials can be nanocellulose-based foams. Porous foam materials can be mixed foams. Porous foam materials can be mixed foams of nanocellulose and kaolin microfibrillated cellulose composites. Porous foam materials can be polyhydroxyalkanoate-based foams. Porous foam materials can be polyhydroxybutyrate-based foams. Porous foam materials can be dry foams. Porous foam materials can be solid foams.

[0100] Porous foam materials can be produced by preparing wet foam from a dispersion and removing the dispersion medium. The dispersion can be a dispersion of cellulosic materials. Wet foam can be produced from the dispersion by agitation or by otherwise introducing air bubbles into the dispersion. The dispersion medium can be removed by evaporation, freeze-drying, or supercritical drying.

[0101] Porous foam materials can have a density of 15 kg / m³. 3 Up to 45 kg / m 3 Between, preferably between 20 kg / m 3 Up to 40 kg / m 3 The density between.

[0102] The density of porous foam materials can be measured according to ISO 845.

[0103] The porous foam material may have a paper content between 70% and 95% by weight, preferably between 75% and 90% by weight.

[0104] The porous foam material may contain a biopolymer in an amount between 10% and 25% by weight, preferably between 15% and 20% by weight. The biopolymer may include polyhydroxyalkanoate (PHA). The polyhydroxyalkanoate may be polyhydroxybutyrate. The porous foam material may contain a polyhydroxyalkanoate in an amount between 10% and 25% by weight, preferably between 15% and 20% by weight. The porous foam material may contain a polyhydroxybutyrate in an amount between 10% and 25% by weight, preferably between 15% and 20% by weight.

[0105] Porous foam materials can include biodegradable thermoplastic materials. Porous foam materials can be made from biodegradable thermoplastic materials. Polyhydroxybutyrate (PHB) can be produced from sugars or carbon dioxide using cyanobacteria.

[0106] The filter material may include multiple segments of porous foam material dispersed in a porous fibrous material.

[0107] Fragments can be particles of porous foamed materials. Fragments can also be fragments of sheets of porous foamed materials. Fragments of porous foamed materials can originate from sheets of porous foamed materials. Fragments can be obtained by tearing fragments from sheets of porous foamed materials. Fragments of porous foamed materials can originate from the fragmentation of sheets of porous foamed materials.

[0108] Fragments can have various shapes. Fragments can have various sizes.

[0109] Filter materials can consist of segments of porous foamed material dispersed within porous fibrous materials. These segments can be embedded within the porous fibrous material. Alternatively, the segments of porous foamed material can be dispersed throughout the porous fibrous material. Or, the porous fibrous material can surround these segments of porous foamed material.

[0110] Fragments of porous foam material can be uniformly dispersed within porous fiber material. Fragments of porous foam material can be substantially uniformly dispersed within porous fiber material.

[0111] Fragments of porous foam material can be uniformly dispersed throughout the porous fibrous material. Filter material may include multiple fragments of porous foam material uniformly distributed within the porous fibrous material. Fragments of porous foam material can be uniformly distributed throughout the porous fibrous material. Fragments of porous foam material can be uniformly dispersed within the porous fibrous material. Fragments of porous foam material can be dispersed within solid cylindrical strips of porous fibrous material.

[0112] Porous fibrous materials can be configured as a matrix of segments of porous foamed materials. Filter materials may include a matrix made of porous fibrous materials, wherein segments of porous foamed materials are dispersed within the matrix of porous fibrous materials. Filter materials may consist of a matrix made of porous fibrous materials, wherein segments of porous foamed materials are dispersed throughout the matrix of porous fibrous materials. Segments of porous foamed materials may be embedded within the matrix of porous fibrous materials. The matrix of porous fibrous materials may be cylindrical in shape. The matrix of porous fibrous materials may be strips. Segments of porous foamed materials may be uniformly dispersed throughout the matrix of porous fibrous materials.

[0113] Fragments of porous foam materials can have a diameter of 0.1 mm. 3 up to 0.5 mm 3 Between, preferably within 0.15 mm3 Up to 0.35mm 3 The volume between. Each segment of the porous foam material can have a volume of 0.1 mm. 3 up to 0.5 mm 3 Between, preferably within 0.15 mm 3 up to 0.35 mm 3 The volume between. The fragment can be approximately 0.25 mm. 3 The median volume.

[0114] The porosity of the filter material can be between 0.3 and 0.8, preferably between 0.4 and 0.7, and more preferably between 0.5 and 0.6. Porosity can be the ratio of the pore volume of the filter material to the total volume of the filter material.

[0115] The porosity of porous fiber materials can be greater than that of porous foam materials. The ratio of the porosity of porous foam materials to that of porous fiber materials can be between 1:1.08 and 1:1.31, preferably between 1:1.12 and 1:1.23.

[0116] The volume ratio of porous fiber material to porous foam material can be between 1:0.1 and 1:0.4, preferably between 1:0.15 and 1:0.25.

[0117] A filter element may include multiple segments of porous foam material dispersed in a porous fibrous material. Alternatively, a filter element may include multiple discrete segments of porous foam material dispersed in a porous fibrous material. Or, a filter element may include multiple discrete segments of porous foam material uniformly dispersed in a porous fibrous material.

[0118] Fragments of porous foam materials can be obtained by fragmenting porous foam material sheets. Indentation force deflection (IFD) test values ​​can be determined according to ASTM D3574. Characterization according to ASTM D 3574 can be performed using a 65% feed. The indentation force deflection (IFD) test values ​​of the porous foam material sheets are between 380 N and 570 N, preferably between 410 N and 500 N. Hardness can be determined according to ISO 2439 Method B. The hardness of the porous foam material sheets is between 75 N and 105 N, preferably between 80 N and 100 N. Compression set value can be determined according to ISO 1856 Method C1. The compression set value can be determined after 2.5 hours. The compression set value of the porous foam material sheets is between 20% and 40%, preferably between 25% and 35%. Thermal conductivity can be determined according to ISO 8302. The thermal conductivity of the foamed porous material sheet can be between 0.025 W / mK and 0.05 W / mK, preferably between 0.03 W / mK and 0.04 W / mK.

[0119] Porous foam sheets can be fragmented to obtain the desired particle size. Porous foam sheets can also be shredded to obtain porous foam fragments.

[0120] Filter elements may include porous fibrous material in the form of strips. The porous fibrous material may include fibers having a longitudinal axis arranged parallel to the longitudinal axis of the filter element. Strips of porous foam material may include segments of porous foam material. These segments of porous foam material may be uniformly dispersed within the strips of porous fibrous material. A filter element package may wrap around the strips of porous fibrous material. The filter element package may compress the strips of porous fibrous material. Tipping paper may wrap around the filter element package. The flow characteristics of the filter element can be adjusted, in particular, by varying the porosity of the porous fibrous material, the porosity of the porous foam material, the relative amounts of porous fibrous material and porous foam material, the arrangement of the porous foam material within the porous fibrous material, and the compression of the porous fibrous material by the filter element package.

[0121] The filter material may contain a plasticizer. The plasticizer may be triacetin. The filter material may contain triacetin in an amount between 4% and 7% by weight.

[0122] Filter materials may be plasticizer-free. Porous fiber materials may be plasticizer-free.

[0123] The filter material may contain between 4% and 7% by weight of triacetin in the total weight of the filter material in the filter element.

[0124] The filter element may have a length between 5 mm and 21 mm, preferably between 7 mm and 11 mm.

[0125] The filter element may have a diameter between 3 mm and 10 mm, preferably between 4 mm and 9 mm.

[0126] In a preferred embodiment of the invention, the filter material may comprise multiple discrete segments of a porous foam material uniformly dispersed in a porous fibrous material. The porous fibrous material may comprise multiple regenerated cellulose fibers. The longitudinal axis of the fibers may be arranged substantially parallel to the longitudinal axis of the filter material. The filter material may be free of cellulose acetate.

[0127] The present invention also relates to an aerosol generating article comprising a filter element and an aerosol forming matrix as described herein.

[0128] Aerosol-generating articles can be strips. Aerosol-generating articles can be cylindrical. Aerosol-generating articles can be cuboid in shape. Aerosol-generating articles can have a circular cross-section. Aerosol-generating articles can have a substantially circular cross-section. Aerosol-generating articles can have an oblique circular cross-section. Aerosol-generating articles can have a rectangular cross-section.

[0129] The present invention also relates to an aerosol generation system, comprising an aerosol generation apparatus as described herein and an aerosol generation article as described herein.

[0130] The present invention also relates to a method for manufacturing a filter material for a filter element of an aerosol generating apparatus, comprising the following steps:

[0131] a) Provide porous foam materials

[0132] b) Disperse the porous foam material in the porous fiber material.

[0133] The filter material can be the filter material of the filter element described in this article.

[0134] As used herein, the terms “proximal,” “distal,” “downstream,” and “upstream” can be used to describe the relative position of a component or part of a component of an aerosol generating device with respect to the direction in which it is drawn by a user during use of the aerosol generating device.

[0135] As used herein, the terms “proximal,” “distal,” “downstream,” and “upstream” can be used to describe the relative position of a component or part of an aerosol-generating article with respect to the direction in which it is aspirated by a user during use of the aerosol-generating article.

[0136] An aerosol generating device may include an orifice through which aerosol exits the device and is delivered to the user during use. The orifice may also be referred to as a proximal end. During use, the user inhales through the proximal end or orifice of the aerosol generating device to inhale the aerosol generated by the device. Alternatively, the user may inhale directly through an aerosol-generating article inserted into an opening at the proximal end of the aerosol generating device. The opening at the proximal end may be an opening of a cavity. The cavity may be configured to receive the aerosol-generating article. The aerosol generating device may include a distal end opposite the proximal end or orifice. The proximal end or orifice of the aerosol generating device may also be referred to as a downstream end, while the distal end of the aerosol generating device may also be referred to as an upstream end. Components or portions of components of the aerosol generating device may be described as upstream or downstream of each other based on their relative position between the proximal end, downstream end, or orifice and the distal end or upstream end of the aerosol generating device.

[0137] Aerosol generating articles may include an orifice through which aerosols exit the aerosol generating article and are delivered to the user during use. The orifice may also be referred to as a proximal end. A filter element, as described herein, may be disposed at the orifice of the article. Aerosol generating articles may include a distal end opposite the proximal end or orifice. The proximal end or orifice of the aerosol generating article may also be referred to as a downstream end, and the distal end of the aerosol generating article may also be referred to as an upstream end. A filter element, as described herein, may be disposed near the aerosol forming matrix.

[0138] The longitudinal axis of a component may extend between its proximal and distal ends. The longitudinal axis of a filter element may extend between its proximal and distal ends. The longitudinal axis of an aerosol-generating article may extend between its proximal and distal ends. The longitudinal axis of an aerosol-generating apparatus may extend between its proximal and distal ends.

[0139] As used herein, "aerosol generating device" can refer to an apparatus that interacts with an aerosol-forming matrix to generate aerosols. The aerosol-forming matrix may be part of an aerosol-generating article. An aerosol generating device may be a smoking device that interacts with the aerosol-forming matrix of an aerosol-generating article to generate aerosols that can be directly inhaled into the lungs of a user through their mouth. An aerosol generating device may be a retainer. The device may be an electrically heated smoking device. An aerosol generating device may include a housing, a circuit system, a power supply, a heating chamber, and a heating element.

[0140] The aerosol generating device may include a circuit system. The circuit system may include a microprocessor, which may be a programmable microprocessor. The microprocessor may be part of a controller. The circuit system may include additional electronic components. The circuit system may be configured to regulate the power supply to a heating element. Power may be continuously supplied to the heating element after the aerosol generating device is activated, or it may be supplied intermittently, such as based on puff-by-puff suction. Power may be supplied to the heating element in the form of current pulses. The circuit system may be configured to monitor the resistance of the heating element and preferably control the power supply to the heating element based on the resistance of the heating element.

[0141] The aerosol generating device may include a power source, typically a battery, within the body of the device. In one embodiment, the power source is a lithium-ion battery. Alternatively, the power source may be a nickel-metal hydride battery, a nickel-cadmium battery, or a lithium-based battery such as a lithium-cobalt, lithium-iron-phosphate, lithium titanate, or lithium-polymer battery. Alternatively, the power source may be another form of charge storage device, such as a capacitor. The power source may require recharging and may have a capacity sufficient to store enough energy for one or more uses; for example, the power source may have sufficient capacity to continuously generate aerosols for periods of approximately six minutes or multiples of six minutes. In another instance, the power source may have sufficient capacity to provide a predetermined number of discontinuous activations of the suction or heating element.

[0142] The cavity of the aerosol generating apparatus may have an open end into which the aerosol-generating article is inserted. The open end may be a proximal end. The cavity may have a closed end opposite the open end. The closed end may be the base of the cavity. The closed end may be closed except for providing air vents disposed in the base. The base of the cavity may be flat. The base of the cavity may be circular. The base of the cavity may be disposed upstream of the cavity. The open end may be disposed downstream of the cavity. The cavity may have an elongated extension. The cavity may have a longitudinal central axis. The longitudinal direction may be the direction extending along the longitudinal central axis between the open end and the closed end. The longitudinal central axis of the cavity may be parallel to the longitudinal axis of the aerosol generating apparatus.

[0143] The cavity can be configured as a heating chamber. The cavity can have a cylindrical shape. The cavity can have a hollow cylindrical shape. The cavity can have a shape corresponding to the shape of the aerosol-generating article to be received in the cavity. The cavity can have a circular cross-section. The cavity can have an elliptical or rectangular cross-section. The cavity can have an inner diameter corresponding to the outer diameter of the aerosol-generating article.

[0144] An airflow channel can pass through the cavity. Ambient air can be drawn into the aerosol generating device through the airflow channel, enter the cavity, and be drawn towards the user. A mouthpiece can be positioned downstream of the cavity, or the user can inhale directly from the aerosol generating article. The airflow channel can extend through the mouthpiece.

[0145] In any aspect of this disclosure, the heating element may include a resistive material. Suitable resistive materials include, but are not limited to: semiconductors (such as doped ceramics), electrically “conductive” ceramics (such as, for example, molybdenum disilicide), carbon, graphite, metals, metal alloys, and composite materials made of ceramic and metallic materials. Such composite materials may include doped or undoped ceramics. Examples of suitable doped ceramics include doped silicon carbide. Examples of suitable metals include titanium, zirconium, tantalum, platinum, gold, and silver. Examples of suitable metal alloys include stainless steel, nickel-containing alloys, cobalt-containing alloys, chromium-containing alloys, aluminum-containing alloys, titanium-containing alloys, zirconium-containing alloys, hafnium-containing alloys, niobium-containing alloys, molybdenum-containing alloys, tantalum-containing alloys, tungsten-containing alloys, tin-containing alloys, gallium-containing alloys, manganese-containing alloys, gold-containing alloys, iron-containing alloys, and superalloys based on nickel, iron, cobalt, stainless steel, Timetal®, and iron-manganese-aluminum based alloys. In composite materials, the resistive material may optionally be embedded in, encapsulated in, or coated with an insulating material, or vice versa, depending on the energy transfer kinetics and desired external physicochemical properties.

[0146] As described, in any of the aspects of this disclosure, the heating element may be part of an aerosol generating apparatus. The aerosol generating apparatus may include an internal heating element, an external heating element, or both, wherein “internal” and “external” refer to the aerosol forming matrix. The internal heating element may take any suitable form. For example, the internal heating element may take the form of a heating blade. Alternatively, the internal heater may take the form of a sleeve or substrate with different conductive portions, or a resistance metal tube. Alternatively, the internal heating element may be one or more heating needles or rods extending through the center of the aerosol forming matrix. Other alternatives include heating wires or filaments, such as Ni-Cr (nickel-chromium), platinum, tungsten, or alloy wires, or heating plates. Optionally, the internal heating element may be deposited in or on a rigid carrier material. In one such embodiment, the resistance heating element may be formed using a metal having a defined relationship between temperature and resistivity. In such an exemplary apparatus, the metal may be formed as a rail on a suitable insulating material (such as a ceramic material) and then sandwiched in another insulating material (such as glass). Heaters formed in this way can be used to both heat and monitor the temperature of the heating element during operation.

[0147] The external heating element can take any suitable form. For example, it can take the form of one or more flexible heating foils on a dielectric substrate (such as polyimide). The flexible heating foil can be shaped to conform to the periphery of the matrix receiving cavity. Alternatively, the external heating element can take the form of a metal mesh or multiple metal meshes, a flexible printed circuit board, a molded interconnect device (MID), a ceramic heater, a flexible carbon fiber heater, or can be formed on a suitable shaped substrate using coating techniques (such as plasma vapor deposition). The external heating element can also be formed using a metal with a defined relationship between temperature and resistivity. In such an exemplary device, the metal can be formed as a rail between two layers of suitable insulating material. An external heating element formed in this way can be used to both heat and monitor the temperature of the external heating element during operation.

[0148] As an alternative to resistance heating elements, heating elements can be configured as induction heating elements. Induction heating elements can include an induction coil and a sensor. Generally, the sensor is a material capable of generating heat when penetrated by an alternating magnetic field. When located in an alternating magnetic field, if the sensor is conductive, eddy currents are typically induced by the alternating magnetic field. If the sensor is magnetic, another effect that typically contributes to heating is often referred to as hysteresis loss. Hysteresis loss occurs primarily due to the movement of magnetic domain blocks within the sensor, as the magnetic orientation of these domain blocks aligns with the alternating magnetic induction field. Another effect contributing to hysteresis loss is when magnetic domains will grow or shrink within the sensor. Typically, all these changes occurring in the sensor at the nanoscale or below are referred to as "hysteresis loss" because they generate heat within the sensor. Therefore, if the sensor is both magnetic and conductive, both hysteresis loss and eddy current generation contribute to heating the sensor. If the sensor is magnetic but non-conductive, hysteresis loss will be the only means of heating the sensor when penetrated by an alternating magnetic field. According to the invention, the sensor can be conductive or magnetic, or both. An alternating magnetic field generated by one or more induction coils heats the sensor, which then transfers the heat to the aerosol-forming matrix, causing aerosol formation. Heat transfer can be primarily via thermal conduction. This heat transfer is optimal if the sensor is in close thermal contact with the aerosol-forming matrix.

[0149] As used herein, the term "aerosol-generating article" can refer to an article comprising an aerosol-forming matrix capable of releasing volatile compounds that can form aerosols. For example, an aerosol-generating article can be a smoking article that generates aerosols that can be directly inhaled into the lungs of a user through their mouth. Aerosol-generating articles can be disposable.

[0150] Aerosol-generating articles can be combustible cigarettes. Aerosol-generating articles may include tobacco sticks and filter elements described herein. Tobacco can be burned. A user can light a cigarette to burn the tobacco.

[0151] As used herein, the term "aerosol-forming matrix" can refer to a matrix capable of releasing one or more volatile compounds that can form aerosols. Such volatile compounds can be released by heating the aerosol-forming matrix. The aerosol-forming matrix can suitably be part of an aerosol-generating article or a smoking article. In combustible cigarettes, the matrix can be burned. The matrix may contain tobacco.

[0152] The aerosol forming matrix can be a solid aerosol forming matrix. It can include both solid and liquid components. The aerosol forming matrix can include tobacco-containing materials containing volatile tobacco flavor compounds released from the matrix upon heating. The aerosol forming matrix can also include non-tobacco materials. The aerosol forming matrix can contain aerosol forming agents that facilitate the formation of dense and stable aerosols. Examples of suitable aerosol forming agents are glycerol and propylene glycol.

[0153] The aerosol-generating matrix may comprise homogenized tobacco material, an aerosol-forming agent, and water. Providing homogenized tobacco material can improve aerosol generation, nicotine content, and aroma characteristics of aerosols generated during the heating of aerosol-generating articles. Specifically, the process of manufacturing homogenized tobacco involves grinding tobacco leaves, which more effectively releases nicotine and aroma upon heating.

[0154] The following is a non-exhaustive list of non-limiting examples. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0155] Example 1: A filter element for use in an aerosol-generating article, wherein the filter element comprises a filter material, wherein the filter material comprises a porous foam material dispersed in a porous fibrous material.

[0156] Example 2: The filter element according to Example 1, wherein the porous foam material is uniformly dispersed in the porous fiber material.

[0157] Example 3: A filter element according to Example 1 or Example 2, wherein the filter element includes a filter element package, wherein the filter element package is configured to at least partially, preferably completely, define the filter material.

[0158] Example 4: The filter element according to Example 3, wherein the filter element package is permanently attached to the filter material, preferably wherein the filter element package is bonded to the filter material by starch adhesive.

[0159] Example 5: A filter element according to Example 3 or Example 4, wherein the filter element package has a permeability between 3,500 Coresta units and 12,000 Coresta units.

[0160] Example 6: A filter element according to any one of Examples 3 to 5, wherein the filter element package has a thickness between 0.2 micrometers and 0.4 micrometers.

[0161] Example 7: A filter element according to any one of Examples 3 to 6, wherein the filter element package has a basis weight between 10 g / m and 30 g / m, preferably between 17 g / m and 21 g / m.

[0162] Example 8: A filter element according to any one of the preceding examples, wherein the filter element includes a tipping paper, wherein the tipping paper is configured to at least partially, preferably completely, define the filter material, and preferably wherein the tipping paper is configured to at least partially define the filter element package according to any one of Examples 3 to 7.

[0163] Example 9: The filter element according to Example 8, wherein the tipping paper has a permeability between 380 Coresta units and 550 Coresta units.

[0164] Example 10: The filter element according to Example 8 or Example 9, wherein the splice paper has a thickness between 0.5 micrometers and 1.1 micrometers.

[0165] Example 11: A filter element according to any one of Examples 8 to 10, wherein the tipping paper has a basis weight between 25 g / m and 60 g / m, preferably between 30 g / m and 50 g / m.

[0166] Example 12: A filter element according to any one of the preceding examples, wherein the porous fiber material comprises a plurality of fibers, wherein the longitudinal axis of the fibers is arranged substantially parallel to the longitudinal axis of the filter material, preferably wherein the fibers are regenerated cellulose fibers.

[0167] Example 13: The filter element according to Example 12, wherein the porous fiber material is a regenerated cellulose material, and the regenerated cellulose material preferably includes the regenerated cellulose fibers.

[0168] Example 14: The filter element according to Example 13, wherein the regenerated cellulose material is derived from one or more of tobacco plant stems and bamboo stalks.

[0169] Example 15: A filter element according to any one of Examples 12 to 14, wherein the fiber is one or more regenerated cellulose fibers selected from viscose fiber, rayon fiber, modal fiber, Tencel fiber and lyocell fiber and any combination thereof.

[0170] Example 16: A filter element according to any one of Examples 13 to 15, wherein the regenerated cellulose material has a crystallinity between 4.7 cN / dtex and 5.5 cN / dtex.

[0171] Example 17: A filter element according to any one of Examples 13 to 16, wherein the regenerated cellulose material has a tensile strength between 3.4% and 4.1%.

[0172] Example 18: A filter element according to any one of Examples 13 to 17, wherein the regenerated cellulose material has a density of 150 kg / m³. 3 Up to 750 kg / m 3 Between, preferably between 250 kg / m 3 Up to 500 kg / m 3 The packing density between them.

[0173] Example 19: A filter element according to any one of Examples 13 to 18, wherein the regenerated cellulose material has a glass transition temperature between 150°C and 190°C, preferably between 160°C and 180°C.

[0174] Example 20: A filter element according to any one of Examples 13 to 19, wherein the regenerated cellulose material has a melting point between 220°C and 300°C, preferably between 230°C and 280°C.

[0175] Example 21: A filter element according to any one of the preceding examples, wherein the filter element has a solid cylindrical shape, preferably wherein the filter element has a strip shape.

[0176] Example 22: The filter element according to any one of the preceding examples, wherein the porous foam material comprises open-cell foam, preferably composed of open-cell foam.

[0177] Example 23: The filter element according to any one of the preceding examples, wherein the porous foam material is derived from one or more of wood pulp, bamboo pulp and tobacco stalk pulp or any combination thereof.

[0178] Example 24: A filter element according to any one of the foregoing examples, wherein the porous foam material has a density of 15 kg / m³. 3 Up to 45 kg / m 3Between, preferably between 20 kg / m 3 Up to 40 kg / m 3 The density between.

[0179] Example 25: The filter element according to any one of the preceding examples, wherein the porous foam material has a paper content between 70% and 95% by weight, preferably between 75% and 90% by weight.

[0180] Example 26: The filter element according to any one of the preceding examples, wherein the porous foam material comprises a biopolymer in an amount between 10% by weight and 25% by weight, preferably between 15% by weight and 20% by weight, wherein the biopolymer preferably comprises polyhydroxyalkanoate (PHA) or, more preferably, polyhydroxybutyrate.

[0181] Example 27: A filter element according to any one of the preceding examples, wherein the filter material comprises a plurality of segments of the porous foam material dispersed in the porous fiber material.

[0182] Example 28: The filter element according to Example 27, wherein the segment of the porous foam material has a diameter of 0.1 mm. 3 up to 0.5 mm 3 Between, preferably within 0.15 mm 3 up to 0.35 mm 3 The volume between.

[0183] Example 29: A filter element according to any one of the preceding examples, wherein the porosity of the filter material is between 0.3 and 0.8, preferably between 0.4 and 0.7, more preferably between 0.5 and 0.6, wherein the porosity is the ratio of the pore volume of the filter material to the total volume of the filter material.

[0184] Example 30: The filter element according to any one of the preceding examples, wherein the porosity of the porous fiber material is greater than the porosity of the porous foam material, preferably wherein the ratio of the porosity of the porous foam material to the porosity of the porous fiber material is between 1:1.08 and 1:1.31, and preferably between 1:1.12 and 1:1.23.

[0185] Example 31: The filter element according to any one of the preceding examples, wherein the volume ratio of the porous fiber material to the porous foam material is between 1:0.1 and 1:0.4, preferably between 1:0.15 and 1:0.25.

[0186] Example 32: A filter element according to any one of the preceding examples, wherein the filter material comprises a plasticizer, preferably wherein the plasticizer is triacetin, and preferably wherein the filter material comprises triacetin in an amount between 4% and 7% by weight.

[0187] Example 33: A filter element according to any one of the preceding examples, wherein the filter element has a length between 5 mm and 21 mm, preferably between 7 mm and 11 mm.

[0188] Example 34: A filter element according to any one of the preceding examples, wherein the filter element has a diameter between 3 mm and 10 mm, preferably between 4 mm and 9 mm.

[0189] Example 36: A filter element according to any one of the preceding examples, wherein the filter material is free of cellulose acetate.

[0190] Example 36: An aerosol generating article comprising a filter element and an aerosol forming matrix according to any one of Examples 1 to 35.

[0191] Example 37: An aerosol generation system comprising an aerosol generation apparatus and an aerosol generation article according to Example 36.

[0192] Example 38: A method for manufacturing a filter material for a filter element of an aerosol generating apparatus, comprising the following steps:

[0193] a) Provide porous foam materials

[0194] b) Disperse the porous foam material in the porous fiber material.

[0195] The features described with respect to one embodiment can also be applied to other embodiments of the invention.

[0196] The invention will be further described by way of example only with reference to the accompanying drawings, in which:

[0197] Figure 1 A three-dimensional view of the filter element of the present invention is shown;

[0198] Figure 2 Another three-dimensional view of the filter element of the present invention is shown; and

[0199] Figure 3 A longitudinal cross-section of the filter element of the present invention is shown.

[0200] Figure 1A three-dimensional view of a filter element 100 of the present invention is shown. The filter element includes a filter material 102. The filter material includes a porous fiber material 104. The filter material includes a porous foam material 106. The porous foam material 106 is uniformly dispersed throughout the porous fiber material 104. The porous fiber material 104 is configured as a solid cylindrical strip. The porous fiber material 104 is configured as a matrix in which segments of the porous foam material 106 are dispersed. The filter material 102 includes a filter element package 108. The porous fiber material 104 is wrapped by the filter element package 108. The filter element package 108 is adjacent to the porous fiber material 104. The filter element package 108 is in contact with the porous fiber material 104. The filter element package 108 is arranged radially outward from the porous fiber material 104 in a direction orthogonal to the longitudinal axis of the filter element. To provide a better view of the porous fiber material 104 and the porous foam material 106, the filter element package 108 is shown partially removed from the filter material 102. The filter element package 108 is wrapped with splice paper 110. The splice paper 110 is adjacent to the filter element package 108. The splice paper 110 is arranged radially outward from the filter element package 108 in a direction orthogonal to the longitudinal axis of the filter element. To provide a better view of the porous fiber material 104, the porous foam material 106, and the filter element package 108, the splice paper 110 is shown partially removed from the filter material 102.

[0201] The porous fiber material 104 is made of regenerated cellulose fibers. They are arranged substantially parallel to the longitudinal axis of the filter material (see below). Figure 2 ).

[0202] The filter element 100 may be part of an aerosol-generating article comprising an aerosol-forming matrix. Aerosols may be generated from the aerosol-forming matrix. The aerosols can be drawn through the filter element by a consumer inhaling the article.

[0203] The flow characteristics of the product can be adjusted by changing the properties of the porous fiber material 104, the porous foam material 106, and the radial compressive force applied to the porous fiber material 104 by one or both of the filter element packaging 108 and the tipping paper 110.

[0204] The porous fiber material 104 is configured to promote flow oriented substantially parallel to the longitudinal axis of the filter element (longitudinal flow). The fibers constituting the porous fiber material 104 are arranged such that the longitudinal axis of the fibers is substantially parallel to the longitudinal axis of the filter element 100. The porous foam material 106 is configured to promote turbulent flow. The longitudinal flow promoted by the porous fiber material 104 can be redirected by segments of the porous foam material 106. The longitudinal flow promoted by the porous fiber material 104 can enter the porous foam material 106 and can be redirected due to the porous structure of the porous foam material. The longitudinal flow promoted by the porous fiber material 104 can bypass segments of the porous foam material 106.

[0205] The porosity of the filter material can be adjusted by adjusting the compression force of one or both of the filter element packaging 18 and the tipping paper 110.

[0206] Figure 2 Another three-dimensional view of the filter element 100 of the present invention is shown. Figure 1 The relevant instructions apply accordingly. Figure 2 The filter element 100. The filter element package 108 and the sputtering paper 110 are shown as fully defining the filter material 102. Figure 2 The longitudinal axis 112 of the filter element 100 is also shown.

[0207] Figure 3 A longitudinal cross-section of the filter element 100 of the present invention is shown. (Compared to...) Figure 1 and Figure 2 The relevant instructions apply accordingly. Figure 3 The filter element. Additionally... Figure 3 The length 114 and width 116 of the filter element 100 are indicated. Segments of porous foam material 106 are uniformly arranged along the length of the filter element 100. Segments of porous foam material 106 are uniformly arranged along the width of the filter element 100.

Claims

1. A filter element for use in an aerosol-generating article, wherein the filter element comprises a filter material, wherein the filter material comprises a porous foam material dispersed in a porous fibrous material, wherein the volume ratio of the porous fibrous material to the porous foam material is between 1:0.1 and 1:0.

4.

2. The filter element according to claim 1, wherein the porous foam material is uniformly dispersed in the porous fiber material.

3. The filter element according to claim 1 or claim 2, wherein the filter element includes a filter element package, wherein the filter element package is configured to at least partially, preferably completely, define the filter material.

4. The filter element according to any one of the preceding claims, wherein the filter element includes a tipping paper, wherein the tipping paper is configured to at least partially, preferably completely, define the filter material, and preferably wherein the tipping paper is configured to at least partially define the filter element packaging according to claim 3.

5. The filter element according to any one of the preceding claims, wherein the porous fiber material comprises a plurality of fibers, wherein the longitudinal axis of the fibers is arranged substantially parallel to the longitudinal axis of the filter material, preferably wherein the fibers are regenerated cellulose fibers.

6. The filter element according to claim 5, wherein the porous fiber material is a regenerated cellulose material, and the regenerated cellulose material preferably includes the regenerated cellulose fibers.

7. The filter element according to any one of the preceding claims, wherein the filter element has a solid cylindrical shape, preferably wherein the filter element has a strip shape.

8. The filter element according to any one of the preceding claims, wherein the filter material comprises a plurality of segments of the porous foamed material dispersed in the porous fibrous material.

9. The filter element of claim 8, wherein the segment of the porous foam material has a diameter of 0.1 mm. 3 up to 0.5 mm 3 Between, preferably within 0.15 mm 3 up to 0.35 mm 3 The volume between.

10. The filter element according to any one of the preceding claims, wherein the porosity of the filter material is between 0.3 and 0.8, preferably between 0.4 and 0.7, more preferably between 0.5 and 0.6, wherein the porosity is the ratio of the pore volume of the filter material to the total volume of the filter material.

11. The filter element according to any one of the preceding claims, wherein the porosity of the porous fiber material is greater than the porosity of the porous foam material, preferably wherein the ratio of the porosity of the porous foam material to the porosity of the porous fiber material is between 1:1.08 and 1:1.31, and more preferably between 1:1.12 and 1:1.

23.

12. The filter element according to any one of the preceding claims, wherein the volume ratio of the porous fiber material to the porous foam material is between 1:0.15 and 1:0.

25.

13. The filter element according to any one of the preceding claims, wherein the filter element has a length between 5 mm and 21 mm, preferably between 7 mm and 11 mm.

14. The filter element according to any one of the preceding claims, wherein the filter element has a diameter between 3 mm and 10 mm, preferably between 4 mm and 9 mm.

15. An aerosol generating article comprising a filter element and an aerosol forming matrix according to any one of claims 1 to 14.

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