Filter element with particles distributed between segments of foam

Abstract

The present invention relates to a filter element for an aerosol-generating article. The filter element includes a filter material. The filter material includes a plurality of particles comprising an active material. The filter material includes a plurality of discrete fragments of a foam of a cellulosic material. The particles are distributed between discrete fragments of the foam.

Description

Filter elements having particles distributed between fragments of foam

[0001] This invention relates to a filter element for an aerosol generation article. This invention relates to a method for manufacturing a filter material for a filter element. This invention relates to an aerosol generation article. This invention relates to an aerosol generation system.

[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] The following are desired solutions: A filter element that provides improved sustainability. A filter element with reduced environmental impact. A filter element with reduced size. A filter element with improved filtration properties. A filter element with improved filtration efficiency. A filter element with adjustable filtration properties. A filter element that can be produced cost-effectively. A filter element with adjustable airflow properties. A filter element with improved airflow properties. A filter element that provides an improved user experience. A filter element with improved flavor delivery. An alternative to cellulose acetate filters.

[0004] According to one embodiment of the present invention, a filter element for aerosol generation articles is provided. The filter element may include a filter material. The filter material may include multiple particles. The multiple particles may contain active material. The filter material may include multiple discrete segments of a cellulosic material foam. The particles may be distributed between the discrete segments of the foam.

[0005] According to one embodiment of the present invention, a filter element for aerosol generation articles is provided. The filter element includes a filter material. The filter material includes a plurality of particles containing active material. The filter material includes a plurality of discrete segments of a cellulosic material foam. The particles are distributed between the discrete segments of the foam.

[0006] Filter elements can offer improved sustainability. Filter elements can have reduced environmental impact. Filter elements can have reduced size. Filter elements can have improved filtration properties. Filter elements can have improved filtration efficiency. Filter elements can have adjustable filtration properties. Filter elements can be manufactured cost-effectively. Filter elements can have adjustable airflow properties. Filter elements can have improved airflow properties. Filter elements can have adjustable aerosol flow properties. Filter elements can have improved aerosol flow properties. Filter elements can provide an improved user experience. Filter elements can have improved flavor delivery. Filter elements can be a replacement for cellulose acetate filters. Filter elements can be configured to replace cellulose acetate filters in aerosol-generating articles.

[0007] Particles distributed between discrete segments of foam may refer to particles arranged between discrete segments of foam.

[0008] Fragments of foam made from cellulose materials may contain virtually no particles containing active materials.

[0009] The filter material may include a bulk composed of multiple discrete segments of a foam of a cellulose-based material.

[0010] Foam can be porous. Foam can be dry foam. Foam 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 liquids by cavities of air or other gases.

[0012] Materials with closed-cell structures can refer to materials containing fluid-separating cavities of air or other gases within a solid. Materials with closed-cell structures may include cavities disposed on the surface of the material, said cavities being fluidly connected to the material's surrounding environment. Materials with open-cell 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. The dispersion can be a dispersion of regenerated cellulose. Wet foam can be generated 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.

[0014] "Pore" can refer to a cavity filled with air or other gas, the cavity being defined by walls that at least partially surround the cavity. The "diameter" of a pore can be the distance spanning the cavity between the walls that at least partially surround it. The "diameter" of a pore can also be the shortest distance spanning the cavity between the walls that at least partially surround it. Pores can be arranged on the surface of a material. Pores can be arranged within a material. Porous materials can contain pores.

[0015] "Porosity" can refer to the volume fraction of vacant space in a material or component. For example, "porosity" can refer to the volume fraction of vacant space in a foam. For instance, if 60% of the volume of a foam is not filled with solid material, then the foam will have a porosity of 0.6. "Porosity" can also refer to the volume fraction of vacant space in a filter element. Furthermore, "porosity" can refer to the volume fraction of vacant space in particles.

[0016] Foam can be biodegradable. Foam can be recycled.

[0017] Particles can be dispersed between discrete segments of foam. Particles can be arranged between discrete segments of foam. Particles can be sandwiched between discrete segments of foam. Particles can be trapped between discrete segments of foam. Particles can be fixed between discrete segments of foam.

[0018] Preferably, the particles are arranged between discrete segments of the foam.

[0019] Filter media can be cylindrical. Filter media can be solid cylindrical. Filter media can be strips. Filter media can be cuboid in shape.

[0020] The main body of a discrete foam segment can be configured as a solid cylindrical strip. Particles can be distributed within the solid cylindrical strip of the discrete foam segment. Particles can be dispersed within the solid cylindrical strip of the discrete foam segment. The main body of a discrete foam segment can also be configured as a solid cube. Particles can be distributed within the solid cube of the discrete foam segment. Particles can be dispersed within the solid cube of the discrete foam segment. The shape of the main body of the discrete foam segment can be achieved by the filter element packaging discussed below. The filter element packaging discussed below can be tightened around the discrete foam segment.

[0021] Discrete foam segments can have irregular shapes. Discrete foam segments can be irregularly packaged. Discrete foam segments can have complementary shapes. Discrete foam segments can have substantially the same size.

[0022] Discrete segments of foam can be configured to at least partially adjoin one or more other segments of foam. Discrete segments of foam can be configured to at least partially adjoin one or more adjacent segments of foam. Discrete segments of foam can be configured to contact one or more other discrete segments of foam. Discrete segments of foam can be configured to contact one or more adjacent discrete segments of foam.

[0023] The discrete segments of foam can be configured to form spaces between the discrete segments. The discrete segments of foam can be configured to form airflow channels between the discrete segments. The spaces can be filled with air. The spaces can be filled with aerosol drawn into the filter material by a user's suction. The spaces can be formed between the discrete segments of foam. The spaces can be formed between adjacent segments of foam. The spaces can be formed between the outer surfaces of adjacent discrete segments of foam. The airflow channels can be formed between the discrete segments of foam. At least some of the spaces between the discrete segments of foam can be fluidly connected to each other. At least some of the spaces between the discrete segments of foam can be fluidly interconnected. The spaces between the discrete segments of foam can form a fluidly interconnected network. The spaces between the discrete segments of foam can form a branched network. Particles can be distributed in the spaces between the discrete segments of foam. Particles can be dispersed in the spaces between the discrete segments of foam. Particles can be arranged in the spaces between the discrete segments of foam. Particles can be distributed in the airflow channels between the discrete segments of foam. In use, the aerosol drawn into the filter material by the user's suction can flow at least partially through the space between the discrete segments of the foam.

[0024] The discrete segments of a foam can have boundaries. Particles can be distributed between the boundaries of the discrete segments of the foam. The space between the discrete segments of the foam can be defined by the boundaries of the discrete segments of the foam.

[0025] Each of the discrete segments of a foam can have a boundary. Particles can be distributed between the boundaries of the discrete segments of the foam.

[0026] Discrete segments of foam can be configured as the matrix of particles. Discrete segments of foam can form the core of filter elements.

[0027] Discrete fragments of foam can originate from larger entities. Foam fragments can be obtained by fragmenting a sheet of foam. Foam fragments can be obtained by tearing pieces from a sheet of foam. The fragments can be obtained by randomly tearing pieces from a sheet of foam.

[0028] The filter material of a filter element may include at least 10 discrete segments of foam. The filter material of a filter element may include at least 25 discrete segments of foam. The filter material of a filter element may include at least 50 discrete segments of foam.

[0029] A filter element may include a proximal end. A filter element may include a distal end. Filter material may be disposed 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 material. The proximal end and the distal end of the filter element may be fluidly connected via a body of discrete segments of foam. Filter material may extend between the proximal end and the distal end of the filter element. The body of discrete segments of foam may extend between the proximal end and the distal end of the filter element.

[0030] Particles can be porous. Particles can be made of porous materials. Particles can have an open-cell structure. Particles can have a closed-cell structure. Particles can be non-porous.

[0031] Particles can originate from larger entities. Particles can be obtained by fragmenting rock material. Particles can contain solids. Particles can be made of solid materials. Particles can have regular shapes. Particles can have substantially spherical shapes. Particles can have irregular shapes. Particles can have macroscopic dimensions.

[0032] The particle size can be smaller than the size of the discrete segments of the foam. The particle volume can be smaller than the volume of the discrete segments of the foam. The particles can be configured to be arranged between the discrete segments of the foam. The particles can be enclosed between the discrete segments of the foam. The particles can be configured to be adjacent to the discrete segments of the foam. The particles can be configured to be in contact with the discrete segments of the foam. The particles can be arranged in the space between the discrete segments of the foam. The particles can be embedded between the discrete segments of the foam. The particles can be arranged in the space formed along the contact area of ​​the discrete segments of the foam. The particles can be configured to be fluidly connected to one or more of the discrete segments of the foam. The particles can be fluidly connected to one or more of the space between the discrete segments of the foam.

[0033] The discrete segments of the foam can be configured such that spaces are formed between the discrete segments. Particles can be distributed within the spaces between the discrete segments of the foam.

[0034] The particles may be composed of active materials. The particles may be made of active materials. The particles may be impregnated with active materials. The particles may be coated with active materials. Active materials may be applied to the particles. Active materials may be applied to the surface of the particles. Active materials may be arranged in the pores of the particles.

[0035] Active materials can be configured to modulate the properties of aerosols. Active materials can be activated carbon. Active materials can be configured to remove unwanted compounds from gas streams or aerosol streams. Active materials can be volatile active materials. Active materials can be flavoring materials. Active materials can be flavoring agents. Active materials can be configured to flavor aerosols drawn through filter elements.

[0036] Foam is porous. Foam can be open-cell foam. Particles can be porous. The porosity of foam can differ from that of particles. The density of foam can differ from that of particles.

[0037] The total airflow or aerosol flow can be a combination of flows through discrete segments and particles of foam, and flows surrounding discrete segments and particles of foam. Air or aerosols can flow through discrete segments of foam. Air or aerosols can flow through particles. Air or aerosols can flow through spaces formed between discrete segments of foam. Air or aerosols can flow around discrete segments of foam. Air or aerosols can flow around particles.

[0038] Airflow or aerosol flow in the filter material can be oriented primarily parallel to the longitudinal axis of the filter element. Airflow or aerosol flow through discrete segments of foam can be oriented primarily parallel to the longitudinal axis of the filter element. Airflow or aerosol flow around discrete segments of foam can be oriented primarily parallel to the longitudinal axis of the filter element. Flow oriented primarily parallel to the longitudinal axis of the filter element may be deflected by particles. Flow oriented primarily parallel to the longitudinal axis of the filter element may be deflected around particles. Particles can be configured to define turbulence. Turbulent airflow can be defined at least partially by the porosity of the particles. Turbulent airflow can be defined at least partially by the size and shape of the particles.

[0039] Turbulent airflow can cause a given volume of aerosol to remain at the particle for an increased amount of time. Turbulent airflow can cause a given volume of aerosol to interact with the particle for an increased amount of time. Turbulent airflow can cause a given volume of aerosol to flow through the particle multiple times. Turbulent airflow can lead to improved particle filtration efficiency. Turbulent airflow can lead to improved aerosol flavoring.

[0040] Filter elements provide adjustable airflow management. The properties of the airflow or aerosol flow within the filter element can be adjusted, in particular, by changing one or more of the following: foam characteristics, foam structure, foam porosity, foam density, size of discrete foam segments, shape of discrete foam segments, particle characteristics, particle structure, material from which the particles are prepared, particle porosity, particle density, volume fraction of particles in the filter material, particle distribution within the bulk of the discrete foam segments, particle size distribution, particle size, particle shape, and the spatial structure between the discrete foam segments. Flow can be primarily mediated through the discrete foam segments and the spaces formed between them. The filtration performance of the filter element can be adjusted by regulating the airflow or aerosol flow within the filter element.

[0041] The filtration performance of a filter element can be tuned by the construction of the foam and the particles. The filtration performance of foam can differ from that of particles. Foam can provide a different filtration profile than particles. For example, a first undesirable compound may be removed from the aerosol primarily by foam, while a second undesirable compound may be removed from the aerosol primarily by particles.

[0042] The suction resistance of a filter element can be adjusted, in particular, by changing one or more of the following: foam characteristics, foam structure, foam porosity, foam density, size of discrete foam segments, shape of discrete foam segments, particle characteristics, particle structure, particle porosity, particle density, volume fraction of particles in the filter material, particle distribution in the bulk of the discrete foam segments, particle size distribution, particle size, particle shape, and the spatial structure between the discrete foam segments.

[0043] 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 the foam, the porosity of the particles, and the compressive force applied to the filter material. The compressive force can be applied by the tipping paper defining the filter material or the filter element packaging, as discussed below.

[0044] 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.

[0045] 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.

[0046] Filter materials can consist of multiple discrete segments of particles and foam.

[0047] The filter material may be free of cellulose acetate.

[0048] Filter elements may be cellulose acetate-free. Foam may be cellulose acetate-free. Granules may be cellulose acetate-free.

[0049] Foam can be a porous, foamed cellulose material. Cellulose materials can be regenerated cellulose.

[0050] The foam can be a regenerated cellulose foam. The regenerated cellulose material may not contain cellulose acetate. The foam may contain regenerated cellulose material. The foam may be composed of regenerated cellulose material. The regenerated cellulose material may include regenerated cellulose fibers. The foam may contain regenerated cellulose fibers. The foam may be made from regenerated cellulose fibers. Discrete segments of the foam may be made from foamed regenerated cellulose. Discrete segments of the foam may be made from a nonwoven structure of regenerated cellulose fibers.

[0051] Regenerated cellulose fibers can be obtained by dissolving pure cellulose from one or both of wood pulp and plant fibers.

[0052] 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 and regeneration techniques. The cellulose-based materials from which regenerated cellulose fibers are derived can be obtained from recycled materials.

[0053] 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.

[0054] Foam can be a tow of regenerated cellulose material. Foam can be a tow of regenerated cellulose fibers. Foam can contain bundles of regenerated cellulose fibers.

[0055] The foam 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 of the foam is determined according to ISO 845.

[0056] The foam may have a paper content between 70% and 95% by weight, preferably between 75% and 90% by weight.

[0057] The foam may contain 10% to 25% by weight, preferably 15% to 20% by weight, of a biopolymer. The biopolymer may include polyhydroxyalkanoate (PHA). The polyhydroxyalkanoate may be polyhydroxybutyrate. The foam may contain 10% to 25% by weight, preferably 15% to 20% by weight, of polyhydroxyalkanoate. The foam may contain 10% to 25% by weight, preferably 15% to 20% by weight, of polyhydroxybutyrate.

[0058] Foams can contain biodegradable thermoplastic materials. Foams can be made from biodegradable thermoplastic materials. Polyhydroxybutyrate (PHB) can be produced from sugars or carbon dioxide using cyanobacteria.

[0059] Discrete segments of foam can be obtained by segmenting foam sheets. Indentation force deflection (IFD) test values ​​can be determined according to ASTM D 3574. Characterization according to ASTM D 3574 can be performed using a 65% feed. The indentation force deflection (IFD) test values ​​of the foam 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 foam 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 foam 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.

[0060] Foam sheets can be fragmented to obtain the desired particle size. Sheets of porous foamed material can be shredded to obtain discrete fragments of foam.

[0061] The foam can be based on one or more of the following forms: wood pulp, bamboo pulp, pulp obtained from tobacco stems, and a mixture of nanocellulose and kaolin microfibrillated cellulose composites.

[0062] The foam can be a biocomposite foam. The foam can be a nanocellulose-based foam. The foam can be a mixed foam. The foam can be a mixed foam of nanocellulose and kaolin microfibrillated cellulose composites. The foam can be a polyhydroxyalkanoate-based foam. The foam can be a polyhydroxybutyrate-based foam. The foam can be a dry foam. The foam can be a solid foam.

[0063] Foams of cellulose-based materials can be foamed cellulose-based materials. Foams of cellulose-based materials can be foams of cellulose-based materials. Foams of cellulose-based materials can be manufactured according to methods for manufacturing sheets of foamed cellulose-based materials, as described in European Patent Application 23206185.3, which is incorporated herein by reference. Foams of cellulose-based materials can be filter materials used in aerosol-generating articles disclosed in European Patent Application 23206185.3, which is incorporated herein by reference. Foams of cellulose-based materials can be foamed cellulose-based materials used in aerosol-generating articles disclosed in European Patent Application 23206185.3, which is incorporated herein by reference. Sheets of foamed cellulose-based materials can be manufactured using methods including the following steps:

[0064] a) Preparing a suspension of a cellulosic material, wherein the suspension contains a foaming agent.

[0065] 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.

[0066] c) Prepare a sheet of wet foam of the cellulose material and dehydrate the sheet of wet foam of the cellulose material.

[0067] d) Dry the wet foam sheet of the cellulosic material.

[0068] e) Rewetting the foam sheet

[0069] f) Adjusting the thickness of the foam sheet, and

[0070] g) Dry the foam.

[0071] The method can produce sheets of dry foamed cellulose materials.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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. 3Up to 105 kg / m 3 between.

[0082] The particles can be evenly distributed between the discrete segments of the foam.

[0083] Particles can be evenly distributed within the main body of discrete foam segments. Particles can be evenly distributed between the discrete foam segments. Particles can be evenly dispersed between the discrete foam segments. Particles can be evenly dispersed between the discrete foam segments. Particles can be evenly distributed in the space between the discrete foam segments. Particles can be evenly dispersed in the space between the discrete foam segments. Particles can be evenly distributed in the space between the discrete foam segments. Particles can be evenly arranged in the space between the discrete foam segments.

[0084] Filter elements can be cylindrical in shape. Filter elements can be strips.

[0085] Filter elements can be solid cylindrical. Filter elements can be cuboid. Foam segments can be arranged cylindrically. Foam segments can be arranged cubically. The main body of discrete foam segments can be cylindrical. The main body of discrete foam segments can be solid cylindrical. The main body of discrete foam segments can be cuboid. Filter elements can have a substantially circular cross-section. Filter elements can have an skewed circular cross-section. Filter elements can have a rectangular cross-section. The main body of discrete foam segments can have a substantially circular cross-section. The main body of discrete foam segments can have an skewed circular cross-section. The main body of discrete foam segments can have a rectangular cross-section. Filter media can be cylindrical. Filter media can have a substantially circular cross-section. Filter media can have an skewed circular cross-section. Filter media can have a rectangular cross-section.

[0086] A filter element may include a filter element package configured to at least partially define filter material. A filter element may also include a filter element package configured to completely define filter material.

[0087] The filter element package may at least partially define discrete segments of foam. The filter element package may completely define discrete segments of foam. The filter element package may define discrete segments of foam. The filter element package may wrap around filter material. The filter element package may wrap around discrete segments of foam. The filter element package may wrap around the main body of discrete segments of foam. The filter element package may wrap around the strip-shaped main body of discrete segments of foam. The filter element package may have substantially the same length as the main body of the discrete segments of foam.

[0088] 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.

[0089] 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.

[0090] Filter element packaging can be configured to stabilize filter material. Filter element packaging can be configured to protect filter material. Filter element packaging can be configured to stabilize the body of discrete foam segments. Filter element packaging can be configured to hold discrete foam segments in a desired arrangement. Filter element packaging can be configured to stabilize the arrangement of discrete segments.

[0091] The filter media can be arranged along the longitudinal axis of the filter element. The filter element package can be arranged coaxially around the filter media.

[0092] Filter element packaging can be permanently attached to the filter media. Filter element packaging can be bonded to the filter media using starch adhesive.

[0093] Filter element packages can have permeability between 3,500 Coresta units and 12,000 Coresta units.

[0094] The filter element package may have a thickness between 0.2 micrometers and 0.4 micrometers.

[0095] 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.

[0096] Filter element packaging can be made of paper materials. Filter element packaging can be biodegradable. Filter element packaging can be recyclable.

[0097] The filter element may include a tipping sheet. The tipping sheet may be configured to at least partially define the filter element package. The tipping sheet may be configured to completely define the filter element package.

[0098] The tipping paper can be configured to at least partially define the filter material. The tipping paper can be configured to completely define the filter material. The tipping paper can be configured to at least partially define discrete segments of foam. The tipping paper can be configured to completely define discrete segments of foam.

[0099] Tipping paper can be wrapped around the filter material. Tipping paper can be wrapped around discrete segments of foam. Tipping paper can be wrapped around the strip-shaped body of discrete segments of foam. Tipping paper can be arranged coaxially around the filter element package.

[0100] 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.

[0101] Tipping paper can have a permeability between 380 Coresta units and 550 Coresta units.

[0102] Tipping paper can have a thickness between 0.5 micrometers and 1.1 micrometers.

[0103] Tipping paper may have a basis weight between 25 g / m and 60 g / m, preferably between 30 g / m and 50 g / m.

[0104] The filter element may have a length between 5 mm and 21 mm, preferably between 7 mm and 11 mm.

[0105] The filter element may have an outer diameter between 3 mm and 10 mm, preferably between 4 mm and 9 mm.

[0106] The active material can be activated carbon. Granules can be made from activated carbon.

[0107] The granules can be composed of activated carbon. The activated carbon granules can be porous. The active material can be activated carbon. The granules can be made of activated carbon. Activated carbon can have an open-cell structure.

[0108] 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.

[0109] The porosity of the foam can be greater than that of the granules made of activated carbon. The ratio of the porosity of the carbon granules to the porosity of the foam can be between 1:1.10 and 1:1.40, preferably between 1:1.15 and 1:1.30.

[0110] Discrete segments of foam can have a size of 0.1 mm. 3 Up to 0.6 mm 3 Between, preferably within 0.15 mm 3 up to 0.45 mm 3 The volume between them. Each of the discrete segments of the foam may have a volume of 0.1 mm. 3 Up to 0.6 mm 3 Between, preferably within 0.15 mm 3 up to 0.45 mm 3 The volume between.

[0111] The ratio of the volume of the discrete segments of foam to the volume of the granules made of activated carbon can be between 1:0.15 and 1:0.50, preferably between 1:0.20 and 1:0.35.

[0112] The carbon particles may have a diameter between 0.1 mm and 0.75 mm, preferably between 0.15 mm and 0.55 mm.

[0113] The charcoal can be coconut activated carbon. The charcoal can be finely granulated coconut activated carbon.

[0114] Carbon has a chemically functional surface area of ​​up to 500 m². 2 / g to 3000 m 2 The BET surface area of ​​carbon can be between / g and 1350m². 2 / g to 2550 m 2 The micropore volume of carbon can be between 0.25 cm³ / g. 3 / g to 0.85 cm 3 The average pore radius of carbon can range from 2.5 Å to 15.5 Å. The total pore volume of carbon can be between 0.55 cm³ / g. 3 / g to 1.75 cm 3 Between / g.

[0115] The foam may contain plasticizers. The filter material may contain plasticizers in an amount between 3% and 10% by weight, preferably between 4% and 8% by weight. The plasticizer may be triacetin.

[0116] Filter materials may be plasticizer-free. Porous fiber materials may be plasticizer-free.

[0117] The active material can be a flavoring agent. The granules can consist of flavoring agents. The granules can contain flavoring agents. The flavoring agents can be applied to the granules. The granules can support the flavoring agents. The flavoring agents can be formulated to flavor aerosols inhaled by consumers. The flavoring agents can be liquids. The flavoring agents can be gels.

[0118] The flavoring material may contain flavoring agents. The flavoring material may contain menthol. The flavoring material may be configured to evaporate. The flavoring material may be configured to enrich the flavor of the aerosol traveling through the filter element.

[0119] The airflow or aerosol flow may be deflected by particles. The flow may be deflected around the particles. Volatile flavoring materials may be released from the particles into the flow deflected around the particles. The flow deflected around the particles may be rich in flavoring materials. Volatile flavoring materials may be released from the particles into the turbulence at the particles.

[0120] The granules can be impregnated with seasoning materials. Impregnation effectively fixes the seasoning materials to the granules. Impregnation effectively fixes the seasoning materials to the pores of the granules. The granules can be coated with seasoning materials. The seasoning materials can be adsorbed onto the granules. The seasoning materials can be adsorbed onto the surface of the granules. The seasoning materials can be adsorbed onto the inner surface of the granules. The seasoning materials can penetrate at least a portion of the granules. The seasoning materials can penetrate the granules. The seasoning materials can be disposed on the surface of the granules. The seasoning materials can be at least partially disposed inside the granules. The seasoning materials can be fixed within the granules.

[0121] The particles can be made from one or more of igneous rocks, sedimentary rocks, and ceramics. One or both of igneous rocks and sedimentary rocks may have low density.

[0122] Materials that form particles from themselves can have a higher density than foams that form discrete fragments from themselves.

[0123] The particles may contain porous materials.

[0124] Porous materials may contain pores. Particles may be made from porous materials. Flavoring materials may be applied to porous materials. Flavoring materials may be fixed within porous materials. Flavoring materials may be fixed within the pores of porous materials. Particles may be made from partially porous materials. Particles may be made from non-porous materials. Particles may be made from gels containing flavoring materials. Particles may be made from non-porous gels containing flavoring materials.

[0125] The particles may have a diameter between 0.1 mm and 2.5 mm, preferably between 0.5 mm and 1.5 mm.

[0126] Particles with a diameter between 0.1 mm and 2.5 mm, preferably between 0.5 mm and 1.5 mm, can be impregnated with seasoning materials.

[0127] Porous materials can have open-pore structures.

[0128] Open-pore porous materials can be configured to provide an airflow path through at least a portion of the porous material. Flavoring materials can be fixed within the pores of the porous material having an open-pore structure.

[0129] The granules can be configured to encapsulate flavoring materials within the granules. The granules can be configured to encapsulate liquid flavoring materials within the granules. The pore size of the porous material can be configured to encapsulate liquid flavoring materials within the granules. Volatile flavoring materials can be released from the granules. Flavoring materials can be applied to the walls defining the pores of the porous material. Flavoring materials can be applied to the inner surface of the granules. The granules can be configured to releasably encapsulate flavoring materials. Flavoring materials can be encapsulated by granule microcapsules. Flavoring materials can be fixed within the granules.

[0130] The porous material can have a pore size smaller than the droplet size of the liquid flavoring material. The porous material can have a pore size between 1.3 mm and 1 micrometer, preferably between 1.1 mm and 5 micrometers. The porous material can have a maximum pore size of about 1.3 mm, preferably about 1.1 mm. The porous material can have a minimum pore size between 1 micrometer and 100 micrometers, preferably between 5 micrometers and 30 micrometers. The porosity of the porous material can be between 0.3 and 0.7.

[0131] Particles of flavoring materials encapsulated and fixed in microcapsules are stable over a wide range of ambient temperatures and humidity. The risk of contamination of surrounding foam fragments by the flavoring materials can be reduced or avoided under a wide range of environmental conditions. Deterioration of filter elements due to unintended release of flavoring materials during storage can be reduced. Deterioration of filter elements due to unintended release of flavoring materials caused by external forces acting on the filter elements can also be reduced.

[0132] Porous materials can be selected from ceramics, sedimentary rocks, and expanded clay.

[0133] Ceramic materials, sedimentary rocks, and expanded clays can have open-pore structures. Particles made of ceramics offer improved chemical stability. Particles made of ceramics offer improved thermal stability. One or both of the pore size and porosity of particles made of ceramics can be easily tuned.

[0134] Expanded clay can contain pores arranged in a honeycomb structure. Particles made from expanded clay can have a substantially spherical shape. Expanded clay can be produced by heating natural clay in a rotary kiln at a temperature above approximately 1200 degrees Celsius.

[0135] Sedimentary rocks can be selected from either limestone or sandstone.

[0136] The particles of expanded clay may have a diameter between 0.1 mm and 2.5 mm, preferably between 0.15 mm and 1.5 mm.

[0137] The porosity of sedimentary rocks can be between 0.3 and 0.5.

[0138] The porosity of the ceramic can be between 0.3 and 0.8, preferably between 0.4 and 0.7.

[0139] The amount of flavoring material in ceramic particles can be controlled by adjusting the porosity of the ceramic.

[0140] Porous materials can be impregnated with flavorings. Impregnation effectively binds the flavorings to the particles.

[0141] Porous materials can have closed-cell structures.

[0142] The surface area to volume ratio of the particles can be maximized. The surface area to volume ratio of particles coated with flavoring material can be maximized to maximize the surface area of ​​the flavoring material. The particles can have a substantially spherical shape. For a given particle volume in the bulk of discrete segments of foam per unit volume, the number of particles can be maximized.

[0143] Porous materials with closed-cell structures can be advantageously used with flavor-enhancing ingredients. Porous materials with closed-cell structures can be advantageously used with menthol.

[0144] The surface of the granules may have pores. These pores can be coated with seasoning materials. The surface of the granules may have indentations. These indentations can be coated with seasoning materials.

[0145] The porous material can be igneous rock, preferably selected from pumice, volcanic cinder and vesicular basalt.

[0146] Igneous rocks can have closed-cell structures. Pumice can have a porosity of 0.85.

[0147] Igneous rock particles can have pores on their outer surfaces, allowing the adsorption of flavoring materials into the particles to coat the inner surfaces of the pores as well. This arrangement protects the fluid from interaction with external components, including flavoring materials that cannot enter the pores due to air being trapped within them. This configuration is suitable when the flavoring material is to be used in relatively small quantities, such as in the case of menthol or other flavor enhancers, because the fluid transported to the particles during adsorption is less than that delivered by capillary action.

[0148] Porous materials can be coated with flavoring agents.

[0149] The filter element may include a first filter material as described herein. The filter element may include a second filter material as described herein. The first filter material may be disposed upstream of the second filter material.

[0150] The first filter material may include granules containing activated carbon. The second filter material may include granules containing flavoring material. A filter element may include the first filter material and the second filter material, the first filter material comprising granules made of activated carbon, and the second filter material comprising granules containing flavoring material. A 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.

[0151] Alternatively, the first filter material may be wrapped in a first filter element package. The second filter material may be wrapped in a second filter element package.

[0152] The first and second filter materials may be wrapped with tipping paper. The first and second filter materials may be at least partially defined by tipping paper. The first and second filter materials may be completely defined by tipping paper. The filter element package may be defined by tipping paper. The first and second filter element packages may be defined by tipping paper.

[0153] Due to the presence of charcoal particles, the first filter material provides efficient filtration of aerosols. Due to the presence of particles containing flavoring ingredients, the second filter material provides flavoring of the aerosols. Flavoring efficiency is improved by placing the first filter material upstream of the second filter material. Furthermore, placing the first filter material upstream of the second filter material prevents flavoring ingredients evaporating from the second filter material from being removed by the first filter material. The suction resistance of the first filter material can be the same as that of the second filter material.

[0154] The length of the filter element can be between 9 mm and 30 mm, preferably between 10 mm and 20 mm.

[0155] The length of the filter element having first and second filter materials can be between 9 mm and 30 mm, preferably between 10 mm and 20 mm.

[0156] The length of the first filter material can be between 5 mm and 17 mm, preferably between 6 mm and 10 mm.

[0157] The length of the second filter material can be between 4 mm and 12 mm, preferably between 5 mm and 9 mm. The length of the main body of the discrete segments of the foam of the first filter material can be between 5 mm and 17 mm, preferably between 6 mm and 10 mm.

[0158] The length of the second filter material can be between 4 mm and 12 mm, preferably between 5 mm and 9 mm. The length of the main body of the discrete segments of the foam of the second filter material can be between 4 mm and 12 mm, preferably between 5 mm and 9 mm.

[0159] The filter element of this invention can be manufactured using standard equipment.

[0160] In a preferred embodiment of the invention, the filter material may include granules made of activated carbon. The granules made of activated carbon may be sandwiched between segments of foam. The granules made of activated carbon may be uniformly distributed between the discrete segments of foam. The foam may be a regenerated cellulose foam. The foam may be cellulose acetate-free. The filter material may be a strip. The filter material may be entirely defined by a filter element package. The filter element package may be entirely defined by a tipping paper. The filter element provides efficient and adjustable filtration due to the combination of the foam segments and carbon particles, and the aerosol flow surrounding the foam segments and carbon particles. The foam segments and carbon particles can efficiently remove unwanted compounds from the aerosol flow. The filtration efficiency provided by the carbon particles is improved due to the turbulence caused by and located at the carbon particles.

[0161] In another preferred embodiment of the invention, the filter element may include granules provided with a flavoring material. The granules provided with the flavoring material may be sandwiched between segments of foam. The granules provided with the flavoring material may be uniformly distributed between the discrete segments of foam. The foam may be a regenerated cellulose foam. The foam may be cellulose acetate-free. The filter material may be a strip. The filter material may be entirely defined by a filter element package. The filter element package may be entirely defined by a tipping paper. The granules may have an open-cell structure and may be impregnated with a flavoring material. For example, the granules may be made of one of ceramics, sedimentary rocks, and expanded clay, and such granules may be impregnated with a flavoring material. The flavoring material may be at least partially disposed within the pores of the granules. Alternatively, the granules may have a closed-cell structure and may be coated with a flavoring material. For example, the granules may be made of an igneous rock preferably selected from pumice, volcanic slag, and vesicular basalt, and may be coated with a flavoring material. Alternatively, the granules may be made of a gel loaded with a flavoring material. The filter element provides efficient filtration while also flavoring the aerosol with volatile flavoring materials. The turbulence caused by the particles containing the flavoring material and located at the particles containing the flavoring material can improve the flavoring efficiency of aerosols.

[0162] In another preferred embodiment of the invention, the filter element may include a first filter material and a second filter material. The first filter material includes particles made of activated carbon, and the second filter material includes particles provided with a flavoring material. The foams of the first and second filter materials may be regenerated cellulose foam. The foams of the first and second filter materials may be free of cellulose acetate. The particles made of activated carbon may be sandwiched between discrete segments of the foam of the first filter material. The particles made of activated carbon may be uniformly distributed between the discrete segments of the foam of the first filter material. The particles provided with a flavoring material may be sandwiched between discrete segments of the foam of the second filter material. The particles with the flavoring material may be uniformly distributed between the discrete segments of the foam of the second filter material. The first filter material may be a strip. The second filter material may be a strip. The first filter material may be wrapped by a first filter element package. The second filter material may be wrapped by a second filter element package. The first filter element may be arranged upstream of the second filter material. The first filter material wrapped by the first filter element package and the second filter material wrapped by the second filter element package may be defined by tipping paper to form a filter element. The filter element provides efficient filtration and also flavors aerosols. By placing the first filter material upstream of the second filter material, the unwanted removal of volatile flavoring materials can be reduced or avoided.

[0163] The present invention also relates to an aerosol generating article comprising a filter element as described herein.

[0164] Aerosol-generating articles may include aerosol-forming matrices.

[0165] The present invention also relates to an aerosol generation system, which includes an aerosol generation article and an aerosol generation device as described herein.

[0166] The present invention also relates to a method for manufacturing a filter material for use in filter elements as described herein, which may include the following steps:

[0167] (a) Providing multiple discrete segments of foam made of cellulosic materials

[0168] (b) Provide multiple particles containing active materials,

[0169] (c) Distribute the particles between the discrete segments of the foam.

[0170] The present invention also relates to a method for manufacturing a filter material for use in filter elements as described herein, comprising the following steps:

[0171] (a) Providing multiple discrete segments of foam made of cellulosic materials

[0172] (b) Provide multiple particles containing active materials,

[0173] (c) Distribute the particles between the discrete segments of the foam.

[0174] As used herein, the terms “proximal,” “distal,” “upstream,” and “downstream” 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.

[0175] 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.

[0176] An aerosol generating device may include an opening through which aerosol exits the device and is delivered to the user during use. The opening may also be referred to as a proximal end. During use, the user inhales through the proximal end or opening of the aerosol generating device to inhale the aerosol generated by the device. The opening may include a mouthpiece. Alternatively, the user may inhale directly from 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 opening. The proximal end or opening of the aerosol generating device may also be referred to as a downstream end, and 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 opening of the aerosol generating device and the distal end or upstream end.

[0177] Aerosol generating articles may include an opening through which aerosols exit the article and are delivered to the user during use. The opening may also be referred to as a proximal end. A filter element, as described herein, may be disposed at the opening of the article. Aerosol generating articles may include a distal end opposite the proximal end or the opening. The proximal end or the opening 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.

[0178] 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.

[0179] As used herein, "aerosol generating device" can refer to an apparatus that interacts with an aerosol-forming matrix to generate aerosols. An aerosol generating article may include a mouthpiece. The aerosol-forming matrix may be part of the aerosol generating article. An aerosol generating device may be a smoking device that interacts with the aerosol-forming matrix of the aerosol generating article to generate aerosols that can be directly inhaled into the user's lungs through the user's mouth. An aerosol generating device may be a holder. 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.

[0180] 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.

[0181] 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.

[0182] 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 orifices 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.

[0183] 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.

[0184] 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.

[0185] 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.

[0186] 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.

[0187] 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.

[0188] As an alternative to resistance heating elements, heating elements can be configured as induction heating elements. Induction heating elements can include induction coils and sensors. 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 domains within the sensor, as the magnetic orientation of these domains aligns with the alternating magnetic field. Another effect contributing to hysteresis loss is when magnetic domains grow or shrink within the sensor. Typically, all these changes occurring in sensors 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.

[0189] 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.

[0190] 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.

[0191] 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.

[0192] 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.

[0193] 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.

[0194] 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.

[0195] Example 1: A filter element for aerosol generation articles, wherein the filter element includes a filter material, wherein the filter material includes a plurality of particles containing active material, wherein the filter material includes a plurality of discrete segments of a cellulosic foam, and wherein the particles are distributed between the discrete segments of the foam.

[0196] Example 2: The filter element according to Example 1, wherein the filter material is composed of the plurality of particles and the plurality of discrete segments of the foam.

[0197] Example 3: The filter element according to Example 1 or Example 2, wherein the filter material does not contain cellulose acetate.

[0198] Example 4: The filter element according to any one of the preceding examples, wherein the cellulose material is regenerated cellulose.

[0199] Example 5: A filter element according to any one of the preceding examples, wherein the foam is based on one or more of wood pulp, bamboo pulp, pulp obtained from tobacco stems, and a mixture of nanocellulose and kaolin microfibrillated cellulose composite materials.

[0200] Example 6: A filter element according to any one of the preceding examples, wherein the particles are uniformly distributed between the discrete segments of the foam.

[0201] Example 7: A filter element according to any one of the preceding examples, wherein the filter element is cylindrical in shape, and preferably wherein the filter element is a strip.

[0202] Example 8: A filter element according to any one of the preceding examples, wherein the filter element includes a filter element package configured to at least partially, preferably completely, define the filter material.

[0203] Example 9: The filter element according to Example 8, wherein the filter element package is made of paper material.

[0204] Example 10: A filter element according to Example 8 or Example 9, wherein the filter element includes a tipping paper, wherein the tipping paper is configured to at least partially, preferably completely, define the filter element package.

[0205] Example 11: 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.

[0206] Example 12: A filter element according to any one of the preceding examples, wherein the filter element has an outer diameter between 3 mm and 10 mm, preferably between 4 mm and 9 mm.

[0207] Example 13: A filter element according to any one of the preceding examples, wherein the active material is activated carbon, and wherein the particles are made of activated carbon.

[0208] Example 14: The filter element according to Example 13, 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.

[0209] Example 15: The filter element according to Example 13 or Example 14, wherein the porosity of the foam is greater than the porosity of the particles made of activated carbon, preferably wherein the ratio of the porosity of the carbon particles to the porosity of the foam is between 1:1.10 and 1:1.40, preferably between 1:1.15 and 1:1.30.

[0210] Example 16: A filter element according to any one of Examples 13 to 15, wherein the discrete segments of the foam have a diameter of 0.1 mm. 3 Up to 0.6 mm 3 Between, preferably within 0.15 mm 3 up to 0.45 mm 3 The volume between.

[0211] Example 17: A filter element according to any one of Examples 13 to 16, wherein the ratio of the volume of the discrete fragments of foam to the volume of the particles made of activated carbon is between 1:0.15 and 1:0.50, preferably between 1:0.20 and 1:0.35.

[0212] Example 18: A filter element according to any one of Examples 13 to 17, wherein the carbon particles have a diameter between 0.1 mm and 0.75 mm, preferably between 0.15 mm and 0.55 mm.

[0213] Example 19: A filter element according to any one of Examples 13 to 18, wherein the foam comprises a plasticizer, preferably triacetin, and wherein the filter preferably comprises the plasticizer in an amount between 3% and 10% by weight, preferably between 4% and 8% by weight.

[0214] Example 20: A filter element according to any one of Examples 1 to 12, wherein the active material is a flavoring material, optionally wherein the particles are composed of the flavoring material.

[0215] Example 21: The filter element according to Example 20, wherein the particles comprise a porous material.

[0216] Example 22: The filter element according to Examples 20 and 21, wherein the particles have a diameter between 0.1 mm and 2.5 mm, preferably between 0.5 mm and 1.5 mm.

[0217] Example 23: A filter element according to any one of Examples 20 to 22, wherein the porous material has an open-pore structure.

[0218] Example 24: The filter element according to Example 23, wherein the porous material has a pore size between 1.3 mm and 1 micrometer, preferably between 1.1 mm and 5 micrometers.

[0219] Example 25: A filter element according to Example 23 or Example 24, wherein the porous material is selected from ceramics, sedimentary rocks and expanded clay.

[0220] Example 26: The filter element according to Example 25, wherein the sedimentary rock is selected from limestone and sandstone.

[0221] Example 27: The filter element according to Example 25, wherein the expanded clay particles have a diameter between 0.1 mm and 2.5 mm, preferably between 0.15 mm and 1.5 mm.

[0222] Example 28: A filter element according to Example 25 or Example 26, wherein the porosity of the sedimentary rock is between 0.3 and 0.5.

[0223] Example 29: The filter element according to Example 25, wherein the porosity of the ceramic is between 0.3 and 0.8, preferably between 0.4 and 0.7.

[0224] Example 30: A filter element according to any one of Examples 23 to 29, wherein the porous material is impregnated with the flavoring material.

[0225] Example 31: A filter element according to Example 21 or Example 22, wherein the porous material has a closed-cell structure.

[0226] Example 32: The filter element according to Example 31, wherein the porous material is igneous rock, preferably wherein the igneous rock is selected from pumice, volcanic cinder and vesicular basalt.

[0227] Example 33: A filter element according to Example 31 or Example 32, wherein the porous material is coated with the flavoring material.

[0228] Example 34: A filter element according to any one of the preceding examples, wherein the filter element comprises a first filter material according to any one of Examples 13 to 19 and a second filter material according to any one of Examples 20 to 33, wherein the first filter material is disposed upstream of the second filter material.

[0229] Example 35: The filter element according to Example 34, wherein the length of the filter element is between 9 mm and 30 mm, preferably between 10 mm and 20 mm.

[0230] Example 36: The filter element according to Example 34 or Example 35, wherein the length of the first filter material is between 5 mm and 17 mm, preferably between 6 mm and 10 mm.

[0231] Example 37: A filter element according to any one of Examples 34 to 36, wherein the length of the second filter material is between 4 mm and 12 mm, preferably between 5 mm and 9 mm.

[0232] Example 38: An aerosol generating article comprising a filter element according to any one of Examples 1 to 37.

[0233] Example 39: An aerosol generating article according to Example 38, comprising an aerosol forming matrix.

[0234] Example 40: An aerosol generation system comprising an aerosol generation article and an aerosol generation apparatus according to any one of Examples 38 and 39.

[0235] Example 41: A method for manufacturing a filter material for a filter element according to any one of Examples 1 to 37, comprising the following steps:

[0236] (a) Providing multiple discrete segments of foam made of cellulosic materials

[0237] (b) Provide multiple particles containing active materials,

[0238] (c) Distribute the particles between the discrete segments of the foam.

[0239] The features described with respect to one embodiment can also be applied to other embodiments of the invention.

[0240] The invention will be further described by way of example only with reference to the accompanying drawings, in which:

[0241] Figure 1 illustrates a filter element according to the present invention comprising particles made of activated carbon;

[0242] Figure 2 shows the filter element of Figure 1, with the filter element packaging and sputtering paper partially removed;

[0243] Figure 3 shows a filter element including a filter element package and a filter material containing carbon particles;

[0244] Figure 4 shows the filter element and splice paper of Figure 3;

[0245] Figure 5 shows a filter element including granules provided with flavoring material;

[0246] Figure 6 shows the filter element of Figure 5, with the filter element packaging and sputtering paper partially removed;

[0247] Figure 7 shows a filter element including flavoring material granules and filter element packaging;

[0248] Figure 8 shows the filter element and splice paper of Figure 7;

[0249] Figure 9 shows a filter element including a first filter material and a second filter material.

[0250] Figure 1 shows a filter element 10 comprising filter material 12, which includes a plurality of particles 14. Figure 1A shows a three-dimensional view of the filter element 10. Figure 1B shows a longitudinal section of the filter element 10. The particles 14 are made of activated carbon. The filter material comprises a plurality of discrete segments 16 of foam. The foam is a regenerated cellulose foam. The discrete segments 16 of foam are arranged cylindrically. The carbon particles 14 are uniformly distributed between the discrete segments 16 of foam. The carbon particles 14 are sandwiched between the discrete segments 16 of foam. The carbon particles 14 are arranged in spaces 17 formed between the discrete segments 16 of foam. The discrete segments 16 of foam form the matrix of the carbon particles 14. The discrete segments 16 of foam may be adjacent to each other. The discrete segments 16 of foam are defined by a filter element package 18. The filter element package 18 is defined by a tipping paper 20. Figure 1A shows the longitudinal axis 22 of the filter element. Figure 1B indicates the length 24 and width 26 of the filter element. The filter material 12 extends along the length 24 of the filter element. The filter element has a cylindrical strip shape.

[0251] In use, the filter element can be part of the aerosol-generating article. The user can draw air or aerosol through the filter element 10. This flow can be oriented by foam fragments, carbon particles, and the space between the foam fragments. Turbulence induced by and located at the carbon particles 14 can cause the flow to be exposed to the activated carbon particles 14 for an extended period. The activated carbon particles 14 can more efficiently remove unwanted components from the flow. The components removed by the activated carbon can be complementary to the components removed from the flow by the foam fragments 16.

[0252] Figure 2 shows the filter element 10 of Figure 1, with the filter element packaging 18 and spigot 20 partially removed. The filter element packaging 18 and spigot 20 are shown partially removed to more clearly illustrate the structure of the filter element 10 to the reader. The descriptions associated with Figure 1 apply correspondingly to Figure 2.

[0253] Figure 3 shows a filter element comprising a filter element package 18 and a filter material 12 containing carbon particles. Figure 3A shows the filter element package 18 partially removed from the filter material 12 to illustrate the structure of the filter element 10 more clearly to the reader. In Figure 3B, the filter element package 18 completely defines the filter material 12.

[0254] Figure 4 shows the filter element 10 and the spigot 20 of Figure 3. Figure 4A shows the spigot 20 partially removed from the filter element package 18 to illustrate the structure of the filter element 10 more clearly to the reader. In Figure 3A, the spigot 20 completely defines the filter element package 18.

[0255] Figure 5 illustrates a filter element comprising filter material 12 having particles 14 provided with flavoring material. The description associated with Figure 1 applies correspondingly to the filter element 10 of Figure 5. However, the filter element of Figure 5 comprises particles provided with flavoring material, rather than charcoal particles. The particles 14 may be formed from a porous material having an open-cell or closed-cell structure. Particles 14 with an open-cell structure may be impregnated with flavoring material. Particles 14 with a closed-cell structure may be coated with flavoring material. The flavoring material may be fixed to the particles.

[0256] In use, the filter element 10 can be incorporated into the aerosol generating product. The user can draw air or aerosol through the filter element 10. Flavoring materials can evaporate to enrich the flavor of the stream passing through the filter element 10.

[0257] Figure 6 shows the filter element of Figure 5, with the filter element packaging 18 and spigot 20 partially removed. The filter element packaging 18 and spigot 20 are shown partially removed to more clearly illustrate the structure of the filter element 10 to the reader. The descriptions associated with Figure 5 apply correspondingly to Figure 6.

[0258] Figure 7 shows a filter element 10 comprising granules 14 provided with flavoring material and a filter element package 18. Figure 7A shows the filter element package 18 partially removed from the filter material 12 to illustrate the structure of the filter element 10 more clearly to the reader. In Figure 7B, the filter element package 18 completely defines the filter material.

[0259] Figure 8 shows the filter element 10 and the spigot 20 of Figure 7. Figure 8A shows the spigot 20 partially removed from the filter element package 18 to illustrate the structure of the filter element 10 more clearly to the reader. In Figure 8A, the spigot 20 completely defines the filter element package 10.

[0260] Figure 9 illustrates a filter element comprising a first filter material 12A and a second filter material 12B. The first filter material is filter material 14A comprising charcoal particles as described in Figures 1 to 4. The second filter material is filter material comprising flavoring material particles 14B as described in Figures 5 to 8. The first filter material 12A and the second filter material 12B comprise discrete fragments 16 of regenerated cellulose foam. The first filter material 12A is defined by a first filter element package 18A. The second filter material 12B is defined by a second filter element package 18B. The first filter element package 18A and the second filter element package 18B are wrapped by a single sprinkling paper 20.

[0261] A first filter material 12A is disposed upstream of a second filter material 12B. An upstream airflow or aerosol flow 28 may enter the upstream end of the first filter material 12A. This flow may initially travel through the first filter material 12A. The first filter material may remove unwanted compounds from this flow. This flow may subsequently enter the upstream end of the second filter material 12B. Flavoring material may be released from the particles 14B on which flavoring material is provided to enrich the flow passing through the second filter material 12B with flavor. This flow may exit the filter element 10 downstream of the airflow or aerosol flow 30. By positioning the first filter material 12A upstream of the second filter material 12B, unwanted removal of flavor released from the particles 14B on which flavoring material is provided can be reduced or avoided.

Claims

1. A filter element for an aerosol-generating article, wherein the filter element comprises a filter material, wherein the filter material comprises a plurality of particles containing an active material, wherein the filter material comprises a plurality of discrete segments of a cellulosic foam, and wherein the particles are distributed between the discrete segments of the foam.

2. The filter element of claim 1, wherein the filter material is free of cellulose acetate.

3. The filter element according to claim 1 or claim 2, wherein the cellulose material is regenerated cellulose.

4. The filter element according to any one of the preceding claims, wherein the particles are uniformly distributed between the discrete segments of the foam.

5. The filter element according to any one of the preceding claims, wherein the filter element comprises a filter element package configured to at least partially, preferably completely, define the filter material.

6. The filter element according to any one of the preceding claims, wherein the discrete segments of the foam have a diameter of 0.1 mm. 3 Up to 0.6 mm 3 Between, preferably within 0.15 mm 3 up to 0.45 mm 3 The volume between.

7. The filter element according to any one of the preceding claims, wherein the active material is activated carbon, and wherein the particles are made of activated carbon.

8. The filter element according to claim 7, wherein the volume ratio of the discrete segments of foam to the volume of the particles made of activated carbon is between 1:0.15 and 1:0.50, preferably between 1:0.20 and 1:0.

35.

9. The filter element according to any one of claims 1 to 6, wherein the active material is a flavoring material, and optionally wherein the particles are composed of the flavoring material.

10. The filter element of claim 9, wherein the particles comprise a porous material having an open-pore structure, wherein the porous material is impregnated with the flavoring material, preferably wherein the porous material is selected from ceramics, sedimentary rocks, and expanded clay.

11. The filter element of claim 9, wherein the particles comprise a porous material having a closed-cell structure, wherein the porous material is coated with the flavoring material, and preferably wherein the porous material is igneous rock.

12. The filter element according to any one of the preceding claims, wherein the filter element comprises a first filter material according to claim 7 or claim 8 and a second filter material according to any one of claims 9 to 11, wherein the first filter material is disposed upstream of the second filter material.

13. An aerosol generating article comprising a filter element according to any one of claims 1 to 12.

14. An aerosol generation system comprising the aerosol generation article and aerosol generation apparatus according to claim 13.

15. A method for manufacturing a filter material for a filter element according to any one of claims 1 to 12, comprising the following steps: (a) providing a plurality of discrete segments of a cellulosic material foam; (b) providing a plurality of particles containing an active material; and (c) distributing the particles among the discrete segments of the foam.

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