Medium dpf and total denier cellulose acetate tow

Abstract

To provide a cellulose acetate tow for forming filters with desired pressure drop, firmness, size and filtration characteristics, as well as to tow that can be processed into filter rods without issue at high speeds.SOLUTION: Disclosed are cellulose acetate tows, bales, and filter rods having from greater than 9 to less than 12.5 denier per filament and from 20,000 to 40,000 total denier, for use in smoking devices, including aerosol-generating devices such as an electrically heated cigarette.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] Priority claims This application claims priority to U.S. Provisional Patent Application No. 62 / 994,056, filed March 24, 2020, the entire contents and disclosure of which are incorporated herein by reference.

[0002] The present disclosure relates generally to cellulose acetate tow having a particular denier per filament and total denier and the use of such tow in smoking devices. Specifically, the present disclosure relates to cellulose acetate tow having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000 for use in smoking devices, including aerosol-generating devices. [Background technology]

[0003] Cellulose esters, such as cellulose acetate, are known for their use in conventional cigarette filters and other smoking articles, such as aerosol-generating devices. Aerosol-generating devices provide smokers with an aerosol similar to tobacco smoke, for example, by heating an aerosol-generating means with a fuel source, such as tobacco. The tobacco is heated or burned sufficiently to vaporize nicotine and produce a nicotine-containing aerosol stream. The smoking article may preferably have a fuel barrel with the excellent smoldering characteristics of cut tobacco or reconstituted tobacco surrounding a metal tube containing tobacco, reconstituted tobacco, or other sources of nicotine and water vapor. In other aerosol-generating devices, inhalable aerosols are generated by the transfer of heat to an aerosol-forming substrate or material that may be physically separated from, within, around, or upstream of the heat source. During consumption of an aerosol-generating article, volatile compounds are expelled by the transfer of heat from the heat source and entrained in the air inhaled through the aerosol-generating article. As the exhaled compounds cool by passing through a cooling element, they condense to form the aerosol inhaled by the user.

[0004] Similar to conventional smoking devices, filters are included in aerosol-generating devices. Furthermore, similar to conventional smoking devices, filters are typically formed from cellulose ester tow, such as cellulose acetate tow. The cellulose ester tow supplied to filter manufacturers is manufactured to meet several desired properties for cigarette filters, such as firmness, pressure drop, pressure drop variability, flyability, and openability, with the goal being to produce cigarettes with acceptable resistance to draw. Methods for manufacturing cellulose ester tow continue to be improved to improve the properties of the tow for use in cigarette filters.

[0005] Korean Patent No. 102058838 discloses a cellulose acetate tow band having a total denier of 10,000 to 40,000 and a denier per filament of 6.0 to 20.0 for use in electronic cigarette tips. Japanese Patent Publication No. 2019070217 discloses a tow band for electronic cigarettes. This application claims a cellulose acetate tow band in which multiple filaments are crimped into a bundle, the total denier is set to a value in the range of 23,000 to 40,000, and the filament denier is 7.0 or more. Summary of the Invention [Problem to be solved by the invention]

[0006] Thus, a need exists for cellulose acetate tow for forming filters having, among other things, desirable pressure drop, firmness, size and filtration characteristics, as well as tow that can be processed into filter rods at high speeds without problems. [Means for solving the problem]

[0007] In some embodiments, the present disclosure is directed to an aerosol-generating device comprising an aerosol-generating article comprising an aerosol-forming substrate; a support element; an aerosol-cooling element; and a mouthpiece comprising a cellulose acetate tow rod having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000. The cellulose acetate tow rod may have an enclosed pressure drop of 2.0 mm of water / mm length or less. The cellulose acetate tow rod may have a circumference of 18 to 26 mm. The aerosol-generating device may maintain an aerosol temperature of 250 to 350°C. The cellulose acetate tow rod may have a hardness of at least 85%. The cellulose acetate tow rod may have a total denier of 24,000 to 35,000. The cellulose acetate tow rod may have a total denier of 24,000 to 30,000. The cellulose acetate tow rod may have a denier per filament of 10 to less than 12.5. The cellulose acetate tow rod may have a denier per filament of 11.5 to 12.3. The cellulose acetate tow rod may have a denier per filament of approximately 12 and a total denier of 25,000 to 28,000. The filaments of the cellulose acetate tow rod may have a cross-sectional shape selected from the group including circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multilobal, and any combination thereof. The cellulose acetate tow may have a percent coefficient of variation of denier per filament of less than 15%, less than 12%, less than 10%, less than 8%, less than 6%, or less than 4%.

[0008] In some embodiments, the present disclosure is directed to a tow band comprising cellulose acetate tow having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000. The cellulose acetate tow rod may have a total denier of 24,000 to 35,000. The cellulose acetate tow rod may have a total denier of 24,000 to 30,000. The cellulose acetate tow rod may have a denier per filament of 10 to less than 12.5. The cellulose acetate tow rod may have a denier per filament of 11.5 to 12.3. The cellulose acetate tow rod may have a denier per filament of approximately 12 and a total denier of 25,000 to 28,000. The filaments of the cellulose acetate tow rod may have a cross-sectional shape selected from the group including circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multilobal, and any combination thereof. The cellulose acetate tow may have a percent coefficient of variation of denier per filament of less than 15%, less than 12%, less than 10%, less than 8%, less than 6%, or less than 4%.

[0009] In some aspects, the present disclosure is directed to a method for forming a mouthpiece for an aerosol generating device, the method comprising: forming a bale from a tow band having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000, the tow band comprising a plurality of cellulose acetate filaments; debaling and opening the tow band to form a filter tow; and forming a mouthpiece comprising a filter rod from the filter tow. The cellulose acetate tow rod may have an enclosed pressure drop of 2.0 mm water / mm length or less. The cellulose acetate tow rod may have a circumference of 18 to 26 mm. The aerosol generating device may maintain an aerosol temperature of 250 to 350°C. The cellulose acetate tow rod may have a hardness of at least 85%. The cellulose acetate tow rod may have a hardness of 24,000 to 35,000. The cellulose acetate tow rod may have a total denier of 24,000 to 30,000. The cellulose acetate tow rod may have a denier per filament of 10 to less than 12.5. The cellulose acetate tow rod may have a denier per filament of 11.5 to 12.3. The cellulose acetate tow rod may have a denier per filament of approximately 12 and a total denier of 25,000 to 28,000. The filaments of the cellulose acetate tow rod may have a cross-sectional shape selected from the group including circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multilobal, and any combination thereof. The cellulose acetate tow may have a percent coefficient of variation of denier per filament of less than 15%, less than 12%, less than 10%, less than 8%, less than 6%, or less than 4%.

[0010] The invention will be better understood in the light of the accompanying non-limiting figures. [Brief explanation of the drawings]

[0011] [Figure 1] 1 shows a cross-sectional view of an aerosol-generating article according to an embodiment of the present invention. [Figure 2] 1 shows a photograph of a cross section of cellulose acetate tow according to an embodiment of the present invention. [Figure 3] 1 shows a photograph of a cross section of cellulose acetate tow of a comparative example. [Figure 4] FIG. 1 shows a box plot of UCE (Process) in g-cm / cm according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0012] Introduction The present disclosure is directed to cellulose acetate tow having a medium range of denier / filament and total denier, for example, a dpf of greater than 9 to less than 12.5 and a total denier of 20,000 to 40,000. The tow can be used to form tow bands, tow bales, and filters or mouthpieces for smoking devices, such as aerosol-generating devices or devices intended for inhaling cannabis. As used herein, aerosol-generating devices do not refer to conventional cigarettes.

[0013] The aerosol-generating device described herein may include an aerosol-forming substrate, a support element, an aerosol-cooling element, and a mouthpiece. The mouthpiece may be formed from cellulose acetate tow rod having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000. The mouthpiece of the aerosol-generating device has a low containment pressure drop and a desired stiffness, aerosol release at a desired temperature, and filtration.

[0014] The present disclosure is also directed to methods for forming the mouthpiece of an aerosol-generating device, including manufacturing steps and parameters that result in a cellulose acetate tow rod having a specified denier / filament and total denier without sacrificing the quality of the cellulose acetate tow or the mouthpiece of the aerosol-generating device.

[0015] Advantageously, the use of cellulose acetate tow rods having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000 reduces the pressure drop value of the rod while maintaining high rod strength, thereby improving drawability while maintaining the desired hardness of the mouthpiece. Conventional cigarette filters typically use cellulose acetate tows having low dpf (e.g., 3.5 dpf or less) and medium total denier (e.g., 40,000 or less total denier), but surprisingly and unexpectedly, cellulose acetate tows having the same total denier but a higher dpf can be used in the mouthpieces of aerosol-generating devices (i.e., non-traditional cigarettes) or as filters for other types of smoking devices, such as those for smoking cannabis. It has been found that, in some embodiments, moderate dpf and total denier can be used in conventional cigarettes. When used in the mouthpiece of an aerosol-generating device or in a device for vaping cannabis, rods formed from cellulose acetate tow having a dpf of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000 can achieve a low encapsulation pressure drop that improves the drawing characteristics of the aerosol-generating device while maintaining the strength and hardness of the mouthpiece of the aerosol-generating device.

[0016] Additionally, cellulose acetate tow rods having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000 advantageously have a low coefficient of variation for pressure drop, an important cellulose acetate tow market parameter where higher values ​​are not tolerated. As used herein, pressure drop (pressure drop between rods, Cv) is measured as follows: using a Quality Test Module for Pressure Drop (QTM-6) from Cerulean of Richmond, Va., USA, using a sealed tube - latex, amber colored, 5 / 16" ID x 0.015" wall thickness, certified 1.0 g weight and a 35±5 durometer calibrated with Cerulean standard for circumferential rod and glass, the QTM is configured with air pressure - 50 psi, flow rate - target 17.7 cc / sec, sealed tube - 5 / 16" ID x 0.015" (length 157 mm (8% stretch)) and lf = on, cr = on, stop2 = off, parity = off, baud = 9600, Pd Thirty preconditioned (48 hour preconditioned at 22° C.±2° C. and 60%±2% relative humidity) rods were tested with the following settings: settle=0, inches=off, Pd=on, shape=off, roundness=off, ova=off, size-laser=on, suspend=off, wt=on, QTMld=0, auto cal=off, protocol=0 (or 1 if HOST=on), host=off (or on for LIMS or PC connection), sw2ident=2, sw1ident=1, batch size=0, cofv=on, statistics=on, results=on, language=GB, printer=on, and pressure drop and CV values ​​are reported. In some embodiments, the pressure drop CV is less than 4.0%.

[0017] Furthermore, cellulose acetate tows with a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000 produce acceptable debaling, i.e., the cellulose acetate tows can be debaled without problems and perform well on rod-making machines at speeds up to 600 m / min. "Debaling" refers to the smoothness of release from the bale surface. Typically, tows in the mid-range of denier per filament and total denier cannot meet such performance requirements at conventional tow crimp levels because they have debaling problems, including a high coefficient of variation in pressure drop and pick-up and pull-up. The coefficient of variation in pressure drop has been reduced by improving the tow crimp non-uniformity (uncurl energy, "UCE") at crimp levels much more than is used on conventional tow items with dpf less than 9.

[0018] cellulose acetate In some embodiments, the present disclosure relates to cellulose acetate tow processed into a filter rod for use as a filter in a smoking device or an aerosol-generating device, such as a mouthpiece or filter in an aerosol-generating device. In some aspects, the cellulose acetate refers to cellulose diacetate. In some aspects, the cellulose acetate has a degree of substitution of 2 to 2.6.

[0019] Cellulose acetate can be made by known methods, such as those disclosed in U.S. Pat. No. 2,740,775 and U.S. Patent Application Publication No. 2013 / 0096297, the entire contents of which are incorporated herein by reference. Typically, acetylation The cellulose is made by reacting cellulose with an acetylating agent in the presence of a suitable acid catalyst, followed by deesterification.

[0020] Tow, tow band, bale and method for manufacturing the bale In some embodiments of the present disclosure, cellulose acetate tow is formed having a dpf of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000. The tow can then be formed into a tow band containing the crimped tow and baled for subsequent use. The tow band can include multiple cellulose acetate filaments. In some embodiments, the bale can include two or more tow bands.

[0021] In some embodiments, the crimped tow band bale has a dpf of greater than 9 to less than 12.5, such as 9.5 to less than 12.5, 10 to less than 12.5, 9.5 to less than 12.3, 10 to less than 12.3, 10.5 to less than 12.3, 10.5 to less than 12.3, 11 to less than 12.3, 11 to less than 12, or approximately 12 dpf. The variability in dpf as a percent coefficient of variation (%CV) can be less than 15%, for example less than 12%, less than 10%, or less than 8%, less than 6, or less than 4, as measured by a Favimat testing device. Favimat is based on the principle of constant rate of extension (DIN 51221, 53816, ISO 5079 (Textile fibers)). - Determination of breaking force and elongation at break of individual fibers)) and equipped with an integrated measuring head for fineness measurement according to the vibrometer test principle with constant tensile force and gauge length and variable break-off frequency (ASTM D1577 (Standard Test Methods for Linear Density of Textile Fibers); BISFA 1985 / 1989, Chapter F). In terms of ranges, the variability can be in the ranges 1-15%, 1-12%, 1-10%, 1-8%, 1-6%, 1-4%, 2-15%, 2-12%, 2-10%, 2-8%, 2-6% or 2-4%.

[0022] The crimped tow band veil may have a total denier of 20,000 to 40,000, for example, 20,500 to 40,000, 21,000 to 40,000, 21,000 to 35,000, 21,000 to 30,000, 24,000 to 35,000, 24,000 to 30,000, or 25,000 to 28,000. In some embodiments, the crimped tow band comprises a plurality of cellulose acetate filaments.

[0023] Generally, the production of a tow band bale can involve spinning filaments from a dope, forming a tow band from the filaments, crimping the tow band, and baling the crimped tow band. When spinning the filaments, various temperatures for both water and air can be used. In some embodiments, the temperature and temperature profile can be varied to ensure adequate drying time and adequate removal of solvents (e.g., acetone) from within the fibers to obtain a clear, undistorted filament cross-section. Optional steps within the production process can include, but are not limited to, warming the filaments after spinning, applying a finish or additive to the filaments and / or tow band before crimping, and conditioning the crimped tow band. At least these process parameters are important for producing a bale that can be used to produce the smoking apparatus filter described herein. Note that the bale can be modified in size and shape as needed for further processing.

[0024] Filaments for use in the present invention may be round, substantially round, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X" shaped, The filaments may have any suitable cross-sectional shape, including, but not limited to, "K"-shaped, "C"-shaped, multilobal, and any combination thereof. As used herein, the term "multilobal" refers to a cross-sectional shape having a point (not necessarily the center of the cross-section) from which at least two lobes extend (not necessarily evenly spaced or evenly sized). In some embodiments, the cross-section is "Y"-shaped. The cross-section of the filaments should have low strain, e.g., less than 15%, less than 10%, less than 5%, less than 1%, or no strain, and only minimal deformation. The strain percentage can be determined by visual inspection of the cross-section of the filaments as viewed under a microscope. The cross-section of the filaments should also be uniform. Without being bound by theory, it is believed that having a strain-free cross-section allows the tow to be processed on high-speed rod-making equipment without fiber damage issues, such as broken filaments and fly. Such fiber damage issues can cause frequent rod-making machine shutdowns and require additional cleaning.

[0025] Filaments for use in the present disclosure can be produced by any method known to those skilled in the art. In some embodiments, filaments can be produced by spinning a dope through a spinneret. As used herein, the term "dope" refers to the cellulose acetate solution and / or suspension from which the filaments are produced. In some embodiments, the dope can include cellulose acetate and a solvent. In some embodiments, the dope for use in connection with the present disclosure can include cellulose acetate, a solvent, and an additive. Note that additives are described in further detail herein.

[0026] Some embodiments of the present disclosure may involve treating the filaments to achieve surface functionality on the filaments. In some embodiments, the filaments may include surface functional groups, including, but not limited to, biodegradable moieties (e.g., defect sites that increase surface area for enhanced biodegradability), chemical binding arms (e.g., carboxylic acid groups for subsequent functionalization), active particle binding sites (e.g., sulfide sites for binding gold particles or chelating groups for binding iron oxide particles), sulfur groups, or any combination thereof. Those skilled in the art will appreciate multiple methods and mechanisms for achieving surface functionality. Some embodiments may involve dipping, spraying, ionizing, functionalizing, acidifying, hydrolyzing, exposing to plasma, exposing to ionized gas, or any combination thereof, to achieve surface functionality. Suitable chemicals for imparting surface functionality can be any chemical or collection of chemicals capable of reacting with cellulose acetate, including, but not limited to, acids (e.g., sulfuric acid, nitric acid, acetic acid, hydrofluoric acid, hydrochloric acid, etc.), reducing agents (e.g., LiAlH, NaBH, H / Pt, etc.), Grignard reagents (e.g., CHMgBr, etc.), transesterification agents, amines (e.g., R-NH, such as CHNH), or any combination thereof. Exposure to plasma and / or ionized gases can react with the surface, create surface defects, or any combination thereof. The defects can increase the surface area of ​​the filaments, which can result in higher loadings and / or higher filtration efficiency in the final filter product.

[0027] In some embodiments, the present disclosure may include forming a tow band from a plurality of filaments, such as cellulose acetate filaments. In some embodiments, the tow band may include any of the dpf and total denier values ​​described herein, such as a dpf of greater than 9 to less than 12.5 and a total denier of 20,000 to 40,000.

[0028] In some embodiments of the present disclosure, the tow band may include two or more types of filaments. In some embodiments, the two or more types of filaments may vary based on dpf, cross-sectional shape, composition, treatment prior to forming the tow band, or any combination thereof. Examples of suitable additional filaments include carbon filaments, activated carbon, etc. These may include, but are not limited to, filaments, natural fibers, synthetic filaments, cellulose acetate filaments having a denier per filament of less than about 9, or any combination thereof.

[0029] Some embodiments of the present disclosure may include a step of crimping the tow band to form a crimped tow band. The step of crimping the tow band may involve using any suitable crimping technique known to those skilled in the art. These techniques may include various devices, including, but not limited to, stuffer boxes or gears. Non-limiting examples of crimping devices and their operating mechanisms can be found in U.S. Patent Nos. 7,610,852 and 7,585,441, the relevant disclosures of which are incorporated herein by reference. A suitable stuffer box crimper may have smooth crimper nip rolls, threaded or grooved crimper nip rolls, textured crimper nip rolls, upper flaps, lower flaps, or any combination thereof.

[0030] In some embodiments, crimp can also be characterized by uncurmp energy (UCE) and breaking strength (BS). As used herein, "UCE" is the amount of work required to uncurl a tow band. UCE is the area under the load-elongation curve between specified load limits per unit length of the stretched sample (at the upper load limit). BS is calculated by considering the double thickness of the tow at the highest load point of the stress-strain curve. The tow must meet minimum strength requirements so that it can be processed by a rod making machine without breaking. UCE can be measured either in process ("process UCE" is measured when the tow is laid or braided before baling) or from the tow bale ("bale UCE"). Generally, UCE and BS are: Preconditioning the tow band sample (for bale testing at 22°C ± 2°C and 60% ± 2% relative humidity for 24 hours, and for process testing at 22°C ± 2°C and 60% ± 2% relative humidity for 2 hours); Pre-cutting the tow band sample; Warming up (for approximately 20 minutes prior to normal calibration) an Instron tensile testing machine (Model 1130, crosshead gear - gear numbers R1940-1 and R940-2, Instron Series IX - Version 6 data acquisition and analysis software, Instron 50Kg maximum capacity load cell, Instron top roller assembly, 1 inch x 4 inch x 1 / 8 inch thick high-grade non-slip grip surfaces); Loading the pre-conditioned tow band sample (looping a length of approximately 76 cm over the center of the top roller and spreading it evenly across it); Pre-tensioning the tow band (gently pulling to 100g ± 2g per reading display); Mounting each end of the sample at the bottom of the no-slip grips to provide a gauge length of 50 cm (the gauge length is measured from the top of the no-slip grips) with the highest allowable pressure (but not higher than the manufacturer's recommended pressure); and Test at a crosshead speed of 30 cm / min (Instron Model 1130) until the tow band breaks. It can be measured by

[0031] The average of at least three data points is calculated according to Formula I: Formula I: UCE(g-cm / cm)=(E * 1000) / ((D * 2)+500) where (E) is the energy (g-cm) between the 0.220 kg and 6 kg or 10 kg load limits required to fall below the tow breaking strength, (D) is the displacement in mm at the preset point (6 kg or 10 kg), (2) is a multiplier to adjust for duplicate specimens, and (500) is the original gauge length (mm). In some embodiments, the process UCE is measured using an upper load and displacement of 10 kg, and the bale UCE is measured using an upper load and displacement of 6 kg.

[0032] The breaking strength (BS) is calculated using Equation II: Formula II: BS=L (where (L) is the load (kg) measured at maximum load) It can be calculated according to:

[0033] Bale UCE can range from a lower limit of about 200 g-cm / cm, 225 g-cm / cm, 250 g-cm / cm, or 260 g-cm / cm to an upper limit of about 400 g-cm / cm, 350 g-cm / cm, 325 g-cm / cm, or 300 g-cm / cm, where the UCE can range from any lower limit to any upper limit and encompass any subset therebetween. Process-to-bale UCE, tested at the same upper load and displacement, can be calculated by applying a bias to the process UCE value because UCE is known to increase from process to bale. The process-to-bale bias is approximately 20 UCE units. Typically, process UCE is measured as the tow bale is formed to control for crimp during which the bale UCE is measured. The process-to-bale UCE is approximately -50 units when the process is tested at a 10 kg process upper load and displacement and the bale is tested at a 6 kg upper load and displacement. In some embodiments, the process UCE can be in the range of 270-350 g-cm / cm, 280-340 g-cm / cm, or 290-330 g-cm / cm. The bale UCE can be in the range of 200-370 g-cm / cm, 200-360 g-cm / cm, 200-350 g-cm / cm, or any range or value therebetween.

[0034] A typical UCE (process) specification for a 12 dpf, 40,000 total denier is in the range of 290-350 g-cm / cm, with a target of 320 g-cm / cm. A typical UCE (process) specification for a 12 dpf, 25,000 total denier is in the range of 270-350 g-cm / cm, with a target of 300 g-cm / cm. A typical UCE (process) specification for a 12 dpf, 28,000 total denier is in the range of 260-310 g-cm / cm, with a target of 290 g-cm / cm. Bale UCE specifications can be determined by adding 20 to each value. A typical UCE (bale) specification for a 12 dpf, 40,000 total denier is in the range of 310-370 g-cm / cm, with a target of 340 g-cm / cm. Typical UCE (bale) specifications for 12 dpf, 25,000 total denier are in the range of 290-370 g-cm / cm, with a target of 320 g-cm / cm. Typical UCE (bale) specifications for 12 dpf, 28,000 total denier are in the range of 280-330 g-cm / cm, with a target of 310 g-cm / cm.

[0035] Surprisingly, it has been found that cellulose acetate tows of medium total denier exhibit similar breaking strengths and UCEs to conventional tows, such as tows having lower dpf.

[0036] The crimp structure can play a role in the processability of the final bale. Examples of crimp structures can include, but are not limited to, cross-direction, machine direction, some angle between the cross-direction and machine direction, random, or any combination thereof. As used herein, the term "cross-direction" when describing crimp orientation refers to crimps or fiber bending within the plane of the tow band. As used herein, the term "machine direction" when describing crimp orientation refers to crimps that protrude outside the plane of the tow band and are perpendicular to the plane of the tow band. The terms cross-direction and machine direction generally refer to the overall crimp orientation and may have a deviation of up to ±30 degrees from the structure. Please note.

[0037] In some embodiments of the present disclosure, the crimped tow band may include filaments having a first crimp structure and filaments having a second crimp structure.

[0038] In some embodiments of the present disclosure, the crimped tow band can include filaments having at least a longitudinal crimp structure near the edges and at least a transverse crimp structure near the center. In some embodiments, the crimped tow band can include filaments having a transverse crimp structure near the edges and filaments having a longitudinal crimp structure near the center.

[0039] The crimp structure can be important for the processability of the final bale in subsequent processing steps; for example, a crosswise crimp structure can provide better filament cohesion than a longitudinal crimp structure unless additional steps are taken to increase cohesion. To achieve crosswise crimp, at least one of three processing parameters can be manipulated: the moisture content of the tow band before crimping, the thickness of the tow band during crimping, and the nip / flap force ratio during crimping.

[0040] In some embodiments of the present disclosure, filaments can be bonded to one another to provide better processability for the final bale. While adhesive additives can be used with any crimp structure, it can be advantageous to use adhesive additives with longitudinal crimp structures. In some embodiments, adhesion can involve adhesive additives on and / or within the filaments. Examples of such adhesive additives can include, but are not limited to, binders, adhesives, resins, tackifiers, or any combination thereof. It should be noted that any additive described herein or any additive capable of bonding two filaments together in any other form can be used, including, but not limited to, active particles, active compounds, ionic resins, zeolites, nanoparticles, ceramic particles, softeners, plasticizers, pigments, dyes, fragrances, fragrances, controlled-release vesicles, surface modifiers, lubricants, emulsifiers, vitamins, peroxides, biocides, antifungals, antibacterial agents, antistatic agents, flame retardants, antifoaming agents, decomposition agents, conductivity modifiers, stabilizers, or any combination thereof. Some embodiments of the present disclosure may involve adding an adhesion additive to the filaments (in the filaments, on the filaments, or both) by incorporating the adhesion additive into the dope, incorporating the adhesion additive into the finish, applying the adhesion additive to the filaments (before, after, and / or during formation of the tow band), applying the adhesion additive to the tow band (before, after, and / or during crimping), or any combination thereof. In some aspects, titanium dioxide is present in an amount greater than 0.01 wt%, such as, for example, from 0.01 wt% to 1 wt%. In other aspects, titanium dioxide is present in an amount equal to or less than 0.01 wt%, such as, for example, from 0 to 0.01 wt%.

[0041] Additionally, some embodiments of the present disclosure may involve heating the filaments before, after, and / or during crimping. While the heating can be used in conjunction with any crimping configuration, it may be advantageous to use the heating in conjunction with longitudinal crimping. The heating may involve exposing the filaments of the tow band to steam, an aerosolized compound (e.g., a plasticizer), a liquid, a heated fluid, a direct heat source, an indirect heat source, an irradiation source that causes additives (e.g., nanoparticles) in the filaments to generate heat, or any combination thereof.

[0042] Some embodiments of the present disclosure may include conditioning the crimped tow band. The conditioning step can be used to achieve a crimped tow band with a residual acetone content of 0.5% w / w or less of the crimped tow band. The conditioning step can be used to achieve a residual acetone content of 8% w / w or less of the crimped tow band. It can be used to achieve a crimped tow band with a residual moisture content. The conditioning process can involve exposing the filaments of the crimped tow band to water vapor, an aerosolized compound (e.g., a plasticizer), a liquid, a heated fluid, a direct heat source, an indirect heat source, an irradiation source that causes additives (e.g., nanoparticles) in the filaments to generate heat, or any combination thereof.

[0043] Some embodiments of the present disclosure may include baling the crimped tow band to produce a bale. In some embodiments, baling may involve placing, for example, placing, stacking, or arranging the crimped tow band in a pattern within a can. Note that can is used generically to refer to a container that may be of any shape, preferably square or rectangular, and of any material. As used herein, the term "pattern" refers to any design that may or may not change during placement. In some embodiments of the present disclosure, the pattern may be substantially zigzag with a periodicity of about 0.5 cycles / ft to about 6 cycles / ft. In some embodiments, the placement may involve puddling the crimped tow band at a puddling index of about 10 mm / m to about 40 mm / m. As used herein, the term "puddling" refers to at least partially placing the tow band on itself to place the tow band with an actual length that is longer than the linear distance along which the tow band is placed. As used herein, the term "puddling index" refers to the length of the tow band per linear distance the tow band is laid.

[0044] In some embodiments of the present disclosure, the baling process may involve compressing the crimped tow band placed in a suitable container.

[0045] In some embodiments, the bale comprises a crimped tow band having a dpf of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000, the crimped tow band comprising a plurality of cellulose acetate filaments. Some embodiments of the present disclosure may involve placing the crimped tow band from the bale into an apparatus to form a filter rod.

[0046] filter rod In some embodiments of the present disclosure, a bale of crimped tow bands having a medium dpf and total denier (as described above) can be used to form a filter rod suitable for use with smoking devices such as conventional cigarettes, devices for inhaling cannabis, or aerosol generating devices. Examples of suitable tow bands having a medium dpf and total denier can be those according to the various embodiments disclosed herein.

[0047] The cellulose acetate filter rod can be unwrapped cellulose acetate. The filter rod can have a cross-sectional shape selected from the group including circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multi-lobed, and any combination thereof. In some aspects, the cross section of the filter rod is "Y" shaped.

[0048] The cellulose acetate tow described herein can be made into a filter rod for use as a cellulose acetate tow filter in a smoking device. The method for forming the filter can include feeding a tow band (crimped or uncrimped) having a medium dpf and total denier into an apparatus capable of producing a filter rod from a bale. In some embodiments, the process for producing a filter rod includes opening the crimped tow band to form an opened tow band; optionally treating the opened tow band with an additive; channeling the opened tow band to form a continuous tow cable; wrapping the continuous tow cable in paper and wrapping it. The manufacturing method may include at least one of the following steps: producing a wrapped tow rod; or alternatively, omitting the wrapping step to produce an unwrapped tow rod; gluing the paper of the wrapped tow rod to produce a filter rod; cutting the filter rod into filter rods, filters, and / or filter sections; or any combination thereof. In some embodiments, producing the filters and / or filter sections may involve cutting the filter rod or filter rod. In some embodiments, producing the filter sections may involve cutting the filter rod, filter rod, or filter. The filter rod, filter rod, and / or filter section may have any cross-sectional shape, including, but not limited to, circular, substantially circular, oval, substantially oval, polygonal (including those with rounded corners), or any combination thereof.

[0049] Some embodiments of the present disclosure may involve treating the opened tow band with an additive at least once. In some embodiments, the treating step can be performed while the opened tow band has a large end-to-end width and / or while the opened tow band is being channeled. If the additive is in particulate form, the treating step may be advantageously performed during channeling, but is not necessarily required. It should be noted that the treating step can be performed by any method, including, but not limited to, spreading, dipping, submerging, immersing, rinsing, washing, painting, coating, sprinkling, dripping, spraying, placing, sprinkling, scattering, applying, or any combination thereof.

[0050] Suitable additives may be those described above, including, but not limited to, active particles, active compounds, ion exchange resins, zeolites, nanoparticles, ceramic particles, softeners, plasticizers, pigments, dyes, perfumes, fragrances, controlled release vesicles, binders, adhesives, tackifiers, surface modifiers, lubricants, emulsifiers, vitamins, peroxides, biocides, antifungals, antibacterial agents, antistatic agents, flame retardants, antifoaming agents, decomposition agents, conductivity modifiers, stabilizers, and any combination thereof.

[0051] In some embodiments of the present disclosure, the additives, e.g., active particles and / or active compounds, can reduce and / or remove smoke stream constituents from the smoke stream. Those skilled in the art having the benefit of this disclosure will understand that the smoke stream can be replaced with a fluid stream for other filter applications. Examples of smoke components include acetaldehyde, acetamide, acetone, acrolein, acrylamide, acrylonitrile, aflatoxin B-1,4-aminobiphenyl, 1-aminonaphthalene, 2-aminonaphthalene, ammonia, ammonium salts, anabasine, anatabine, O-anisidine, arsenic, A-α-C, benz[a]anthracene, benz[b]fluoroanthene, benz[j]aceanthrylene, benz[k]fluoroanthene, benzene, benzo[b]furan, benzo[a]pyrene, benzo[c]phenanthrene, beryllium, 1,3-butadiene, butyraldehyde, cadmium, caffeic acid, carbon monoxide, catechol, chlorinated dioxins / furans, chromium, chrysene, cobalt, coumarin, cresol, crotonaldehyde, cyclopenta[c,d]pyrene, dibenz(a,h)acridine, dibenz(a,j)a Clidine, dibenz[a,h]anthracene, dibenzo(c,g)carbazole, dibenzo[a,e]pyrene, dibenzo[a,h]pyrene, dibenzo[a,i]pyrene, dibenzo[a,l]pyrene, 2,6-dimethylaniline, ethyl carbamate (urethane), ethylbenzene, ethylene oxide, eugenol, formaldehyde, furan, glu-P-1, glu-P-2, hydrazine, hydrogen cyanide, hydroquinone , indeno[1,2,3-cd]pyrene, IQ, isoprene, lead, MeA-α-C, mercury, methyl ethyl ketone, 5-methylchrysene, 4-(methylnitrosamino)-1-(3-pyridyl)-1-butanone (NNK), 4-(methylnitrosamino)-1-(3-pyridyl)-1-butanol (NNAL), naphthalene, nickel, nicotine, nitrate, nitric oxide, nitrogen oxides, nitrite, nitrobenzene, nitro Examples of suitable amines include, but are not limited to, methane, 2-nitropropane, N-nitrosoanabasine (NAB), N-nitrosodiethanolamine (NDELA), N-nitrosodiethylamine, N-nitrosodimethylamine (NDMA), N-nitrosoethylmethylamine, N-nitrosomorpholine (NMOR), N-nitrosonornicotine (NNN), N-nitrosopiperidine (NPIP), N-nitrosopyrrolidine (NPYR), N-nitrososarcosine (NSAR), phenol, PhIP, polonium-210 (radioactive isotope), propionaldehyde, propylene oxide, pyridine, quinoline, resorcinol, selenium, styrene, tar, 2-toluidine, toluene, Trp-P-1, Trp-P-2, uranium-235 (radioactive isotope), uranium-238 (radioactive isotope), vinyl acetate, vinyl chloride, or any combination thereof. In some embodiments of the present disclosure, the additive may reduce and / or remove components from the fluid stream, suitable components may include, but are not limited to, dust particles, pollen, mold, bacteria, ozone, etc., or any combination thereof.

[0052] In some embodiments, when packaging, suitable papers may include, but are not limited to, chip paper, plug wrap paper, chip-based paper, wood-based paper, flax-containing paper, flax paper, functional paper, specially marked paper, colored paper, highly porous paper, corrugated paper, high surface strength paper, or any combination thereof. Those skilled in the art, given the benefit of this disclosure, will recognize that the paper can be replaced with any known sheet material. In some embodiments, the paper may include additives, sizing agents, printability enhancers, or any combination thereof. In some embodiments, the filter is an unwrapped cellulose acetate filter. Some embodiments of the present disclosure may involve gluing the paper of a wrapped tow rod to produce a filter rod length. The gluing step may be accomplished using any known adhesive capable of adhesively securing the paper wrapped around the tow rod.

[0053] Some embodiments of the present disclosure may involve cutting a length of filter rod into filter rods and / or filter sections. The cutting step may involve any known cutting method and / or cutting device. The length of the filter rod may range from a lower limit of about 50 mm, 75 mm, or 100 mm to an upper limit of about 150 mm, 140 mm, 130 mm, 120 mm, 110 mm, or 100 mm, and the length may range from any lower limit to any upper limit, including any subset therebetween. The length of the filter may range from a lower limit of about 20 mm, 25 mm, or 30 mm to an upper limit of about 50 mm, 45 mm, or 40 mm, and the length may range from any lower limit to any upper limit, including any subset therebetween. The length of the filter section can range from a lower limit of about 3 mm, 4 mm, or 5 mm to an upper limit of about 15 mm, 14 mm, 13 mm, 12 mm, 11 mm, or 10 mm, and the length can range from any lower limit to any upper limit, including any subset therebetween.

[0054] Some embodiments of the present disclosure may involve connecting at least two filter sections. Some embodiments may involve connecting at least two filter sections in fluid communication with one another. Connecting may include, but is not limited to, bonding, adhering, joining, associating, interlocking, etc. In some embodiments, connecting may be end-to-end along the longitudinal axis of the filter sections. In some embodiments, connecting at least two filter sections may form a segmented filter and / or a segmented filter rod. Some embodiments may involve providing at least two filter sections in respective containers, such as hoppers, crates, boxes, drums, bags, or cartons, prior to the connecting step. Some embodiments may include providing at least two filter sections in an alternating row. Some embodiments may involve providing at least two filter sections in a row. To form a segmented filter and / or a segmented filter rod, , may involve wrapping the at least two filter sections in paper. Some embodiments may involve transporting the segmented filter and / or segmented filter rod for storage or use.

[0055] In some embodiments, the filter may be a segmented filter. Some embodiments may involve a segmented filter in which at least one first section is a filter section described herein and at least one second filter section may include, but is not limited to, a cavity, a porous mass, polypropylene, polyethylene, polyolefin tow, polypropylene tow, polyethylene terephthalate, polybutylene terephthalate, randomly oriented acetate, paper, corrugated paper, a concentric filter, a carbon-filled tow, silica, magnesium silicate, zeolite, a molecular sieve, salt, a catalyst, sodium chloride, nylon, a flavoring, tobacco, a capsule, cellulose, a cellulose derivative, cellulose acetate, a catalytic converter, iodine pentoxide, a coarse powder, carbon particles, carbon fibers, fibers, glass beads, nanoparticles, a void chamber, a baffled void chamber, or any combination thereof. Note that first and second are used for clarity of description and do not imply any order or positional relationship. In some embodiments, the second filter section can be a cellulose acetate filter section having a different encapsulated pressure drop (EPD) than the first filter section. In some embodiments, the first filter section and the second filter section can be different filter sections as described herein, such as different additives, different additive concentrations, different EPDs, different total denier, different dpf, or any combination thereof.

[0056] In some embodiments of the present disclosure, the filter rod, filter, filter section, segmented filter, and / or segmented filter rod may include at least one cavity. In some embodiments, the cavity may be between two filter sections. The cavity may be filled with various substances, including, but not limited to, additives, granular carbon, flavorings, catalysts, molecular sieves, zeolites, or any combination thereof. The cavity may contain capsules, e.g., polymer capsules, that themselves contain flavorings or catalysts. In some embodiments, the cavity may also contain molecular sieves that react with selected components in smoke to remove or reduce the concentration of the components without adversely affecting the smoke's desired flavor components. In some embodiments, the cavity may contain tobacco as an additional flavoring. Note that a cavity that is not fully filled with the selected substance may lack sufficient interaction between mainstream smoke components and the substance within the cavity.

[0057] Some embodiments of the present disclosure may involve operatively connecting a filter rod, filter, filter section, segmented filter, and / or segmented filter rod to smokable material. Some embodiments may involve connecting a filter rod, filter, filter section, segmented filter, and / or segmented filter rod to smokable material such that the filter rod, filter, filter section, segmented filter, and / or segmented filter rod is in fluid communication with the smokable material.

[0058] In some embodiments of the present disclosure, the filter rod, filter, filter section, segmented filter, and / or segmented filter rod can be in fluid communication with the smokable material. In some embodiments, a smoking apparatus can include a filter rod, filter, filter section, segmented filter, and / or segmented filter rod in fluid communication with the smokable material. In some embodiments of the present disclosure, a smoking apparatus can include a housing capable of functionally maintaining the filter rod, filter, filter section, segmented filter, and / or segmented filter rod in fluid communication with the smokable material. In some embodiments, the filter rod, filter, filter section, segmented filter, and / or segmented filter rod can be in fluid communication with the smokable material. The filter rod may be removable from the housing, replaceable and / or disposable.

[0059] In some embodiments, the filter can include a tow including a plurality of cellulose acetate filaments having a dpf of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000. The filter can have a trapped pressure drop of about 2.0 mmH2O / mm of filter length, e.g., 1.75 mmH2O / mm of filter length or less, 1.60 mmH2O / mm of filter length or less, or 1.50 mmH2O / mm of filter length or less, and can have a circumference of about 26 mm or less, e.g., 18 mm to 26 mm. In some embodiments, the filter can have a circumference in the range of 18 mm to 26 mm, e.g., 21 mm to 25 mm, or 22 mm to 24 mm. In other embodiments, the filter can further include an additive.

[0060] smoking equipment In some embodiments of the present disclosure, a smoking article can include any of the filter rods, filters, filter sections, segmented filters, and / or segmented filter rods (collectively "filter components") described above, comprising cellulose acetate of medium dpf and total denier. The medium dpf and total denier filter components can be in fluid communication with the smokable material. In some embodiments, the smoking article can include a housing capable of operably maintaining the filter rods, filters, filter sections, segmented filters, and / or segmented filter rods in fluid communication with the smokable material. In some embodiments, the filter rods, filters, filter sections, segmented filters, and / or segmented filter rods can be removable, replaceable, and / or disposable from the housing.

[0061] As used herein, the term "smokable material" refers to a material that can produce smoke when burned or heated. Suitable smokable materials include, but are not limited to, tobacco, such as bright leaf tobacco, Orient tobacco, Turkish tobacco, Cavendish tobacco, Corojo tobacco, Criollo tobacco, Parikh tobacco, shade tobacco, white burley tobacco, flue-cured tobacco, burley tobacco, Maryland tobacco, Virginia tobacco; tea; herbs; carbonized or pyrolyzed components; inorganic filler components; or any combination thereof. Tobacco can be in the form of cut filler tobacco lamina, processed tobacco stem, reconstituted tobacco filler, or volume-expanded tobacco filler. Tobacco and other cultivated smokable materials can be grown in the United States or in areas outside the United States.

[0062] In some embodiments, the smokable material may be in the form of a column, such as a tobacco column. As used herein, the term "tobacco column" refers to a blend of tobacco and, optionally, other ingredients and flavorings that can be combined to produce a tobacco-based smokable article, such as a cigarette or cigar. In some embodiments, the tobacco column may include ingredients selected from the group consisting of tobacco, sugar (e.g., sucrose, brown sugar, invert sugar, or high fructose corn syrup), propylene glycol, glycerol, cocoa, cocoa products, carob bean gum, carob bean extract, and any combination thereof. In still other embodiments, the tobacco column may further include flavors, fragrances, menthol, licorice extract, diammonium phosphate, ammonium hydroxide, and any combination thereof. In some embodiments, the tobacco column may include additives. In some embodiments, the tobacco column may include at least one bendable element.

[0063] Suitable housings include cigarettes, cigarette holders, cigars, cigar holders, pipes, water pipes, hookahs, electronic smoking devices, hand-rolled cigarettes, hand-rolled cigars, paper or any of their This may include, but is not limited to, any combination.

[0064] In some embodiments of the present disclosure, the filter rod, filter, filter section, segmented filter, and / or segmented filter rod may be degradable over time, either naturally or in the presence of a catalyst, such as a catalyst pill, coating, or portion of the rod. As used herein, the term "degradable" refers to the ability to decompose when exposed to an outdoor environment (i.e., exposure to rain, dew, or other water sources). The degree of degradation is at least sufficient to convert cellulose acetate to cellulose and at most sufficient to convert cellulose acetate to glucose. In some embodiments, degradation may occur over a period of at least one month, up to about six months, up to about two years, or up to about five years. Those skilled in the art, having the benefit of this disclosure, will understand that environmental conditions, such as exposure to light and relative humidity, and additives, such as catalysts, in the filter rod, filter, filter section, segmented filter, and / or segmented filter rod affect the rate of degradation. In some embodiments of the present disclosure, the filter rod, filter, filter section, segmented filter, and / or segmented filter rod may be recyclable.

[0065] Because consumers are expected to smoke smoking devices including a filter rod, filter, filter section, segmented filter, and / or segmented filter rod according to any of the embodiments described herein, the present disclosure also provides methods for smoking such smoking devices. For example, in one embodiment, the present disclosure provides a method for smoking a smoking device, comprising: heating or igniting a smoking device including a filter rod, filter, filter section, segmented filter, and / or segmented filter rod according to any of the embodiments described herein to form smoke; and drawing the smoke through the smoking device, wherein the filter rod, filter, filter section, segmented filter, and / or segmented filter rod reduces the presence of at least one component in the smoke stream. In some embodiments, the smoking device is a cigarette. In other embodiments, the smoking device is a cigar, pipe, water pipe, hookah, electronic smoking device, smokeless smoking device, hand-rolled cigarette, hand-rolled cigar, or other smoking device.

[0066] Some embodiments of the present disclosure may include a smoking device including a filter comprising a smokable material and a tow having a dpf of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000, the tow comprising a plurality of cellulose acetate filaments. The filter generally has an enclosed pressure drop of 2.0 mmH2O / mm-filter length or less and may have a circumference of about 26 mm or less, for example, 18 mm to 26 mm.

[0067] Aerosol generating devices Referring to Figure 1, an aerosol-generating device is illustrated. In some embodiments, the aerosol-generating device can include, but is not limited to, an electronic smoking device, an aerosol-generating device having a combustion source, a smokeless smoking device, etc. References hereafter will be made to aerosol-generating devices (unless otherwise specified).

[0068] In some embodiments, the present disclosure is directed to an aerosol-generating device comprising a hollow filter, an unwrapped filter, or a combination thereof. The aerosol-generating device may include an outer casing, a reservoir having an aerosol-forming material, a mouthpiece in fluid communication with the reservoir, and a power source / heating means surrounding the reservoir. In some embodiments, the mouthpiece and / or reservoir may comprise a cellulose acetate filter comprising cellulose acetate tow as described herein.

[0069] In one embodiment, the present disclosure relates to an aerosol-generating article that uses electrical energy to form an inhalable substance. The aerosol-generating article can include one or more substances (e.g., fragrances, and / or tobacco) in an inhalable form or state. For example, the inhalable substance may be in the form of a substantial vapor (i.e., a substance in the gas phase at a temperature below its critical point). Alternatively, the inhalable substance may be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For purposes of this disclosure, the following embodiments are considered as examples of aerosol-generating devices incorporating a medium total denier cellulose acetate filter. A medium dpf and total denier cellulose acetate filter may be provided in any configuration within the aerosol-generating device and is not limited to the embodiments discussed below. In some aspects, the use of a medium dpf and total denier tow enables the aerosol-generating device to maintain an aerosol temperature of 250-350°C, e.g., 275-325°C, 285-315°C, or 295-305°C.

[0070] Aerosol generating devices are described in more detail in U.S. Pat. Nos. 4,819,665; 5,499,636; 6,026,820; 8,881,737; 8,910,640; and 9,597,466; and U.S. Patent Application Publication Nos. 2005 / 0172976; 2015 / 0027474; 2016 / 0309782; and 2017 / 0055580, all of which are incorporated by reference in their entireties.

[0071] 1 shows a typical aerosol-generating article 10 according to some embodiments. The aerosol-generating article 10 may include an outer casing 20, an air passageway 30, a mouthpiece 40, a power / heat source 50, and a reservoir 70 containing an aerosol-forming material 80. During use, when a user inserts the mouthpiece 40 into their mouth, air flows through the air passageway 30 and out the distal end of the aerosol-generating article 10. The aerosol-generating article 10 can generate an aerosol from the aerosol-forming material 80, which may be derived from tobacco and other additives.

[0072] In some embodiments, the mouthpiece 40 and / or reservoir 70 containing the aerosol-forming material 80 includes a cellulose acetate filter. In some embodiments, the mouthpiece 40 and / or reservoir 70 of the aerosol-generating device includes a cellulose acetate filter containing cellulose acetate of a medium dpf and total denier. The cellulose acetate filter may include cellulose acetate tow having a dpf of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000. In some embodiments, the mouthpiece 40 and / or reservoir 70 includes a cellulose acetate filter. In some aspects, the cellulose acetate filter includes a hollow cellulose acetate tube having a dpf of at least 3 and a total denier of at least 50,000, or a dpf of at least 6 and a total denier of at least 40,000. In some embodiments, the cellulose acetate filter is unwrapped cellulose acetate.

[0073] In some embodiments, aerosol-forming material 80 is disposed within reservoir 70. In the embodiment shown in Figure 1, aerosol-forming material 80 comprises a gathered sheet of crimped, homogenized tobacco material. The crimped sheet of homogenized tobacco material may include an aerosol-forming agent, such as glycerin.

[0074] The aerosol-generating article 10 shown in Figure 1 is designed to require a power / heat source 50 to form an inhalable aerosol. During use, the power / heat source 50 of the aerosol-generating article 10 heats the aerosol-forming material 80 to a temperature sufficient to volatilize compounds capable of forming an aerosol, which is drawn through the air passageway 30 and inhaled by the user. During use, the volatile material expelled from the aerosol-forming substrate 80 can optionally be directed along an aerosol cooling element toward the mouthpiece of the aerosol-generating article 10. The volatile material forms an aerosol that is inhaled by the user. The aerosol cooling element may be cooled within the aerosol cooling element to achieve this. In some aspects, the aerosol cooling element may comprise cellulose acetate tow having a denier per filament of at least 3 and a total denier of at least 50,000, or a denier per filament of at least 6 and a total denier of at least 40,000. In some embodiments, the aerosol cooling element may comprise a hollow cellulose acetate filter, an unwrapped cellulose acetate filter, or a combination thereof.

[0075] As the aerosol passes downstream through the aerosol cooling element, the temperature of the aerosol can be reduced by the transfer of thermal energy from the aerosol to the aerosol cooling element. When the aerosol is introduced into the aerosol cooling element, its temperature is about 60° C. Due to cooling within the aerosol cooling element, the temperature of the aerosol is about 40° C. when it exits the aerosol cooling element.

[0076] The cellulose acetate tow described herein can be used as an aerosol cooling element. The aerosol cooling element refers to a component that cools the aerosol formed by volatile compounds expelled from an aerosol-forming substrate. The aerosol cooling element is a separate element from the mouthpiece containing the cellulose acetate filter, but in some embodiments, cellulose acetate tow having a dpf of at least 3 and a total denier of at least 50,000 can be used in both the filter and the aerosol cooling element. The aerosol cooling element has a relatively large surface area, for example, 300 mm per mm of length, while still achieving a low pressure drop. 2 ~1000mm 2 It can have:

[0077] The aerosol cooling element can be formed from a sheet having a thickness of 5 to 500 micrometers, e.g., 10 to 250 micrometers, which can then be pleated. The aerosol cooling element can include an outer tube or wrapper containing or disposing longitudinally extending channels. For example, to form the aerosol cooling element, a pleated, gathered, or folded sheet material can be packaged in a wrapper material, e.g., a plug wrapper. In some embodiments, the aerosol cooling element comprises a sheet of crimped material gathered into a rod shape and bound by a wrapper, e.g., a filter paper wrapper. The aerosol cooling element can be made during the production of filters, as described above.

[0078] In some embodiments, the aerosol cooling element is formed in the shape of a rod having a length of 7 to 28 mm. For example, the aerosol cooling element may have a length of 18 mm. In some embodiments, the aerosol cooling element may have a substantially circular cross-section and a diameter of 5 mm to 10 mm. For example, the aerosol cooling element may have a diameter of 7 mm.

[0079] The cellulose acetate tow can be the only component of the aerosol cooling element or can be combined with a polylactic acid layer. In some embodiments, the weight ratio of polylactic acid to cellulose acetate tow is 10:1 to 1:10, e.g., 5:1 to 1:5, 3:1 to 1:3, 1:2 to 2:1, or 1:1.

[0080] The present disclosure may be better understood in view of the following non-limiting examples. [Example]

[0081] Example 1: Cross section of tow Cellulose acetate tows with dpf values ​​greater than 9 and less than 12.5 and total deniers of 20,000 to 40,000 were extruded using an optimized extrusion process with optimized spinning machine temperatures and temperature profiles. Cross sections of the tows were captured using a Leica RM 2255 microtome, a Leitz Orthoplan compound microscope equipped with a 160 / 0.17 objective, and Clemex Vision PE (Professional Edition) software. ) version: 8.0.153. The "Y" shaped cross section was crisp and well-defined, as shown in Figure 2. This tow had an acceptable cross section, with 0% distortion and only minimal deformation based on visual inspection of the cross section in Figure 2. Furthermore, the specific surface area index ("SSAI" = (perimeter / area) x 0.5 x (area / 3.14156) square root was 1.64. The tow had a dpf coefficient of variation (%) of 1.38% as measured by a Favimat (with an integrated measuring head for fineness measurement according to the vibrometer testing principle).

[0082] Comparative Example A: Cross Section of Tow Cellulose acetate tow having the same dpf and total denier as in Example 1 was formed and photographed without adjusting the extrusion process described in Example 1. As shown in Figure 3, the "Y" shaped cross section was not as sharp or well-defined as that shown in Figure 2. This tow had an unacceptable cross section and, based on visual inspection of the cross section shown in Figure 3, had a distortion of greater than 15%. The cross section also had deformation. A typical distorted cross section is shown circled in Figure 3.

[0083] Example 2: EPD and Hardness Cellulose acetate tow formed as in Example 1 had a dpf of 12 and a total denier of 40,000. Thirty rods were formed from the tow. The rods had an average circumference of 23.67 mm. The encapsulation pressure drop and hardness of the rods were measured according to the methods described herein. The average encapsulation pressure drop per mm of length was 1.12 mmH2O / mm-filter length, and the average hardness was 89.35%. Thus, the rods had acceptable encapsulation pressure drop and hardness compared to conventional tows made from lower dpf tows.

[0084] Comparative Example B: EPD and Hardness Conventional cellulose acetate tow was formed having a dpf of 8 and a total denier of 25,000. Thirty rods were formed from the tow, with an average circumference of 23.91 mm. Pressure drop and hardness were tested as in Example 2. The average encapsulation pressure drop was 0.94 mmH2O / mm-filter length, and the average hardness was 84.36%.

[0085] Example 3: Comparison of Process UCE vs. Bale UCE at the same upper load and displacement To ensure that the process-to-bale bias was approximately 20 UCE units, the UCE of a tow having 12 dpf and 28,000 total denier was measured both during the tow laying process and from the bale. The upper load was 6 kg. The UCE was measured as follows: I. Precondition the tow band sample (for bales at 22°C ± 2°C and 60% ± 2% relative humidity for 24 hours, and for process tests at 22°C ± 2°C and 60% ± 2% relative humidity for 2 hours); II. Warm up (approximately 20 minutes prior to normal calibration) an Instron tensile testing machine (Model 1130, crosshead gear - gear numbers R1940-1 and R940-2, Instron Series IX - Version 6 data acquisition and analysis software, Instron 50Kg maximum capacity load cell, Instron top roller assembly, 1 inch x 4 inch x 1 / 8 inch thick high grade Buna-N 70 Shore A durometer rubber grip faces); III. Load the pre-conditioned tow band sample (approximately 76 cm length looped over the center of the top roller and spread evenly across it); IV. Pre-tension the tow band (gently pull to 100g ± 2g per reading display); V. Mount each end of the specimen in the lower grips to obtain a gauge length of 50 cm ( The gauge length is measured from the top of the rubber grip (attached at the highest allowable (but not higher than the manufacturer's recommended) pressure); and VI. Test at a crosshead speed of 30 cm / min until the tow band breaks.

[0086] When UCE is measured in-process, it is measured after the tow is placed in the bin, thus making the sample accessible. The results, shown in Table 1 below, confirm that a bias of approximately 20 units is appropriate for calculating bale UCE from process UCE.

[0087] [Table 1]

[0088] Example 4: Comparison of Process UCE vs. Bale UCE at Different Upper Loads and Displacements To establish a -50 unit bias for converting from the process UCE measured at 10 kg to the bale UCE measured using a 6 kg upper load and displacement, the UCE of a tow having 12 dpf and 28,000 total denier was measured both during the tow laying process and from the bale. Other than the changes in the upper load and variation of the bale UCE, the process was identical to Example 3. The results are shown in Table 2.

[0089] [Table 2]

[0090] Example 5 Tow deformation was produced at significantly higher process UCE levels within the average target range of 280-330. The upper load was 10 kg, and the tows were run on a KDF6 (filter rod making machine) at a rod making speed of 600 m / min. Above 280 UCE (process), the coefficient of variation of pressure drop ranged from 2.8% to 3.8%. Tow unbaling performance improved significantly. Other rod making parameters remained acceptable. All other process parameters used to make the woven fabric remained the same (extrusion settings, speed, crimper sizing, tow placement parameters, bale settings, etc.). The results are shown in Table 4, which reports the process UCE measured using an upper load and displacement at 10 kg.

[0091] Comparative example C: A 12 dpf, 28,000 total denier tow was produced within the conventional UCE range of 230-270 UCE (process measured using a 10 kg upper load and displacement). The tow was run on a KDF6 (filter rod making machine) at a rod making rate of 600 m / min. The tow had a high coefficient of variation in pressure drop, averaging 5.4% (process) at 240 UCE and 4.0% (process) at 260 UCE. Furthermore, the tow unbaled poorly using picking and pull-up.

[0092] Specific examples Example 1: An aerosol-generating device comprising an aerosol-generating article comprising an aerosol-forming substrate; a support element; an aerosol-cooling element; and a mouthpiece comprising a cellulose acetate tow rod having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000.

[0093] Example 2: The aerosol generating device of Example 1, wherein the cellulose acetate tow rod has a containment pressure drop of less than or equal to 2.0 mm of water / mm of length.

[0094] Example 3: The aerosol generating device of either Example 1 or 2, wherein the cellulose acetate tow rod has a circumference of 18 to 26 mm.

[0095] Example 4: An aerosol generating device according to any one of Examples 1 to 3, which maintains an aerosol temperature of 250 to 350°C.

[0096] Example 5: The aerosol generating device of any one of Examples 1 to 4, wherein the cellulose acetate tow rod has a hardness of at least 85%.

[0097] Example 6: The aerosol generating device of any of Examples 1 to 5, wherein the cellulose acetate tow rod has a total denier of 24,000 to 35,000.

[0098] Example 7: The aerosol generating device of any of Examples 1 to 6, wherein the cellulose acetate tow rod has a total denier of 24,000 to 30,000.

[0099] Example 8: The aerosol-generating device of any of Examples 1 to 7, wherein the cellulose acetate tow rod has a denier per filament of 10 to less than 12.5.

[0100] Example 9: The aerosol generating device of any of Examples 1 to 8, wherein the cellulose acetate tow rod has a denier per filament of 11.5 to 12.3.

[0101] Example 10: The aerosol-generating device of any of Examples 1 to 9, wherein the cellulose acetate tow rod has a denier per filament of approximately 12 and a total denier of 25,000 to 28,000.

[0102] Example 11: The filaments of the cellulose acetate tow rod may be round, substantially round, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multilobal, and any combination thereof. Specific examples 1 to 10 of the aerosol generating device, which has a cross-sectional shape selected from the group including:

[0103] Example 12: The aerosol-generating device of any of Examples 1 to 11, wherein the cellulose acetate tow has a coefficient of variation percent of denier / filament of less than 15%, less than 12%, less than 10%, less than 8%, less than 6%, or less than 4%.

[0104] Example 13: A tow band comprising cellulose acetate tow having a denier per filament of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000.

[0105] Example 14: The tow band of Example 13, wherein the cellulose acetate tow rod has a total denier of 24,000 to 35,000.

[0106] Example 15: The tow band of any of Examples 13-14, wherein the cellulose acetate tow rod has a total denier of 24,000 to 30,000.

[0107] Example 16: The tow band of any of Examples 13 to 15, wherein the cellulose acetate tow rod has a total denier of 10 to less than 12.5.

[0108] Example 17: The tow band of any of Examples 13-16, wherein the cellulose acetate tow rod has a denier per filament of 11.5 to 12.3.

[0109] Example 18: The tow band of any of Examples 13-17, wherein the cellulose acetate tow rod has a denier per filament of approximately 12 and a total denier of 25,000 to 28,000.

[0110] Example 19: The tow band of any of Examples 13 to 18, wherein the filaments of the cellulose acetate tow rod have a cross-sectional shape selected from the group consisting of circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multilobal, and any combination thereof.

[0111] Example 20: The tow band of any of Examples 13-19, wherein the cellulose acetate tow has a denier / filament coefficient of variation percent of less than 15%, less than 12%, less than 10%, less than 8%, less than 6%, or less than 4%.

[0112] Example 21: A tow bale including a tow band according to any one of Examples 13 to 20.

[0113] Example 22: A method for forming a mouthpiece for an aerosol generating device, comprising the steps of: forming a bale from a tow band having a denier per filament greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000, wherein the tow band comprises a plurality of cellulose acetate filaments; unbaling and opening the tow band to form a filter tow; and forming a mouthpiece comprising a filter rod from the filter tow.

[0114] Example 23: The method of Example 22, wherein the cellulose acetate tow rod has an encapsulation pressure drop of less than or equal to 2.0 mm of water / mm of length.

[0115] Example 24: The method of any of Examples 22-23, wherein the cellulose acetate tow rod has a circumference of 18-26 mm.

[0116] Example 25: The method of any of Examples 22-24, wherein the aerosol generating device maintains an aerosol temperature of 250-350°C.

[0117] Example 26: The method of any of Examples 22-25, wherein the cellulose acetate tow rod has a hardness of at least 85%.

[0118] Example 27: The aerosol generating device of any of Examples 1 to 26, wherein the cellulose acetate tow rod has a total denier of 24,000 to 35,000.

[0119] Example 28: The method of any of Examples 22-27, wherein the cellulose acetate tow rod has a total denier of 24,000 to 30,000.

[0120] Example 29: The method of any of Examples 22-28, wherein the cellulose acetate tow rod has a denier per filament of 10 to less than 12.5.

[0121] Example 30: The method of any of Examples 22-29, wherein the cellulose acetate tow rod has a denier per filament of 11.5 to 12.3.

[0122] Example 31: The method of any of Examples 22-30, wherein the cellulose acetate tow rod has a denier per filament of approximately 12 and a total denier of 25,000 to 28,000.

[0123] Example 32: The method of any of Examples 22-31, wherein the filaments of the cellulose acetate tow rod have a cross-sectional shape selected from the group consisting of circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multilobal, and any combination thereof.

[0124] Example 33: The method of any of Examples 22-32, wherein the cellulose acetate tow has a percent coefficient of variation of denier per filament of less than 15%, less than 12%, less than 10%, less than 8%, less than 6%, or less than 4%.

[0125] Example 34: The aerosol-generating device of any of Examples 1 to 12, wherein the cellulose acetate tow has a veil UCE of 200 g-cm / cm to 370 g-cm / cm.

[0126] Example 35: The tow band of any of Examples 13-20, wherein the cellulose acetate tow has a bale UCE of 200 g-cm / cm to 370 g-cm / cm.

[0127] While the present invention has been described in detail, modifications within the spirit and scope of the present invention will be readily apparent to those skilled in the art. It should be understood that aspects of the present invention and parts of various embodiments, as well as various features set forth above and / or in the appended claims, may be combined or interchanged in whole or in part. In the above description of various embodiments, embodiments that refer to other embodiments may be appropriately combined with other embodiments, as understood by those skilled in the art. Furthermore, those skilled in the art will appreciate that the above description is for illustrative purposes only and is not intended to limit the present invention. All U.S. patents and publications cited herein are incorporated by reference in their entirety.

Claims

1. an aerosol-forming substrate; Support element; aerosol cooling elements; and A mouthpiece comprising a cellulose acetate tow rod having a denier per filament of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000. aerosol-generating articles, including An aerosol generating device comprising:

2. 2. The aerosol generating device of claim 1, wherein the cellulose acetate tow rod has a containment pressure drop of 2.0 mm of water / mm of length or less.

3. 2. The aerosol generating device according to claim 1, wherein the cellulose acetate tow rod has a circumference of 18 to 26 mm.

4. 2. The aerosol generating device according to claim 1, which maintains an aerosol temperature of 250 to 350°C.

5. 10. The aerosol generating device of claim 1, wherein the cellulose acetate tow rod has a hardness of at least 85%.

6. 2. The aerosol generating device of claim 1, wherein the cellulose acetate tow rod has a total denier of 24,000 to 35,000.

7. 2. The aerosol generating device of claim 1, wherein the cellulose acetate tow rod has a total denier of 24,000 to 30,000.

8. 2. The aerosol generating device of claim 1, wherein the cellulose acetate tow rod has a denier per filament of 10 to less than 12.

5.

9. 9. The aerosol generating device according to claim 1, wherein the cellulose acetate tow has a bale UCE of 200 g-cm / cm to 370 g-cm / cm.

10. 10. The aerosol generating device according to claim 1, wherein the filaments of the cellulose acetate tow rod have a cross-sectional shape selected from the group consisting of circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multi-lobed, and any combination thereof.

11. 2. The aerosol generating device of claim 1, wherein the cellulose acetate tow has a denier / filament percent coefficient of variation of less than 10%.

12. A tow band comprising cellulose acetate tow having a denier per filament of greater than 9 and less than 12.5 and a total denier of 20,000 to 40,000.

13. The tow band of claim 12, wherein the cellulose acetate tow rod has a total denier of 24,000 to 35,000.

14. The tow band of claim 12, wherein the cellulose acetate tow rod has a total denier of 24,000 to 30,000.

15. The tow band of claim 12, wherein the cellulose acetate tow rod has a denier per filament of 10 to less than 12.

5.

16. The tow band of claim 12, wherein the cellulose acetate tow rod has a bale UCE of 200 g-cm / cm to 370 g-cm / cm.

17. The filaments of the cellulose acetate tow rod have a cross-sectional shape selected from the group consisting of circular, substantially circular, crenulated, oval, substantially oval, polygonal, substantially polygonal, dogbone, "Y", "X", "K", "C", multi-lobal, and any combination thereof.

18. The tow band of claim 13, wherein the cellulose acetate tow has a denier / filament coefficient of variation percent of less than 10%.

19. A tow bale comprising the tow band of claim 12.

20. 20. The tow bale of claim 19, wherein the cellulose acetate tow has a bale UCE of 200 g-cm / cm to 370 g-cm / cm.

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