Elements for aerosol-generating or smoking articles

Abstract

An element (100) for an aerosol-generating article or smoking article is disclosed, comprising a longitudinally extending hollow tube (101), a layer (102) containing a filler material, the layer (102) being engaged around the hollow tube (101), and a wrapper (103) engaged around the layer (102), wherein the hollow tube (101) comprises a sheet (304) of spirally wound material, the sheet (304) of spirally wound material having overlapping spiral windings.

Description

[Technical Field]

[0001] The present invention relates to an element for an aerosol-generating article, such as a heated tobacco product, or for a smoking article, such as a cigarette.

[0002] The use of tube elements in aerosol-generating articles and smoking articles is well known in the art. Typically, the tube element comprises a cylindrical core of filtration material containing channels extending longitudinally from the ends of the cylindrical core. In such articles, the tube element is usually included along with a plug of modified tobacco and other elements (e.g., a wrapped plug of filtration material).

[0003] The tube element may be positioned at the mouth end of the aerosol-generating article to provide a distinctive end appearance and concentrate the aerosol into a stream directed toward the user's tongue. Alternatively, the tube element may be used as an intermediate segment or at the tobacco end of the aerosol-generating article to facilitate the passage of the aerosol from the tobacco segment to other elements and / or to cool the aerosol before it reaches the mouthpiece. In smoking articles, the tube element may be positioned at the mouth end to provide a distinctive end appearance and reduce the appearance of stains. Alternatively, the tube element may be used as an intermediate segment or at the tobacco end of the smoking article to facilitate the passage of tobacco smoke from the tobacco segment to other elements, concentrate the tobacco smoke, and act as a reservoir to enhance nicotine delivery to the user.

[0004] In the past, cellulose acetate filamentary tow has been used as a filtration material for pipe elements because it can be manufactured into pipes exhibiting the desired hardness, structural integrity, and channel profile. The manufacture of such pipe elements can be carried out in a single, continuous process. However, cellulose acetate filamentary tow is not readily biodegradable, and as a result, aerosol-generating article elements and smoking article elements containing cellulose acetate filamentary tow can persist in the environment for many years.

[0005] Components for aerosol-generating articles and smoking articles have been manufactured from readily biodegradable materials, such as paper, but it has previously been difficult to manufacture tube components from readily biodegradable paper or other materials while retaining the stiffness and structural integrity associated with aerosol-generating article components and smoking article components made from cellulose acetate filamentary tow.

[0006] There is a need for tubing elements for aerosol-generating articles or smoking articles that have improved biodegradability compared to tubing elements comprising cellulose acetate filamentary tow, and that have desirable hardness and structural integrity, for example, similar hardness and structural integrity to existing elements for aerosol-generating articles and smoking articles formed from cellulose acetate filamentary tow, and there is also a need for methods of making such tubing elements.

[0007] In one aspect of the present invention, an element for an aerosol-generating article or smoking article is provided, comprising a longitudinally extending hollow tube, a layer comprising a filler material, the layer engaged around the hollow tube, and a wrapper engaged around the layer, wherein the hollow tube comprises a spirally wound sheet of material, the sheet of spirally wound material having overlapping spiral windings.

[0008] The aerosol-generating article may be a non-combustion heating device, a heated tobacco product such as a tobacco heating device, or an electronic cigarette.

[0009] The smoking article may be a cigarette, a cigar, a cigarillo, a hand-rolled cigarette, or the like.

[0010] The element may be a mouthpiece, such as a mouthpiece for an aerosol-generating article or a smoking article.

[0011] The element may be a cooling element, for example, an element for an aerosol-generating article that provides a cooling effect to the aerosol (eg, vapor) or tobacco smoke.

[0012] The element may be a filter element, e.g., an element for an aerosol-generating article or smoking article that provides a filtration effect for aerosols (e.g., vapor) or tobacco smoke. Alternatively, the element may not provide a filtration effect for aerosols (e.g., vapor) or tobacco smoke, e.g., the element may have zero or substantially zero aerosol (e.g., vapor) or tobacco smoke filtration effect.

[0013] The element may function as both a cooling element and a filter element for the aerosol-generating article.

[0014] The element may facilitate the passage of aerosol or tobacco smoke from the tobacco segment to other elements of the aerosol-generating article or smoking article (i.e., the aerosol or tobacco smoke may pass through the channel of the hollow tube and enter the other element). It will be understood that when an element facilitates the passage of aerosol or tobacco smoke from the tobacco segment to other elements of the aerosol-generating article or smoking article, the channel of the hollow tube may be substantially confining, e.g., may be free of any object that may confining the aerosol or tobacco smoke. In other words, the channel of the hollow tube may be empty. Thus, there may be substantially no retention of aerosol or tobacco smoke by the element, e.g., there may be no retention of aerosol or tobacco smoke by the element. It will further be understood that when assembled into a multi-segment product with additional elements, the element may contribute substantially zero, e.g., 0, to the pressure drop of the multi-segment product due to the lack of or minimal retention of aerosol or tobacco smoke by the element.

[0015] The element may act as a reservoir in which tobacco smoke from the tobacco segment is concentrated, for example, the tobacco smoke is concentrated within the channels of the hollow tube. Applicant has found that by concentrating the tobacco smoke within the element, the user receives a highly concentrated smoke, thus improving nicotine delivery.

[0016] The element may be substantially cylindrical, for example cylindrical.

[0017] The cross section of the element may be substantially circular, for example annular.

[0018] The hollow tube may be a spiral wound tube.

[0019] The hollow tube includes an outer surface and an inner surface. The inner surface of the hollow tube defines a channel extending longitudinally along the length of the hollow tube, e.g., the channel may extend longitudinally along the entire length of the hollow tube.

[0020] As used herein, the phrase "engaged around a hollow tube" means engaged around the exterior surface of the hollow tube.

[0021] The spirally wound sheet of material may be a sheet of material that extends spirally around the longitudinal axis of the element such that the spirally wound sheet of material overlaps itself at successive points along the longitudinal length of the element.

[0022] The spirally wound sheet of material may be wrapped around the longitudinal axis of the element, for example, spirally wrapped around the longitudinal axis of the element at an oblique angle to the longitudinal axis of the element.

[0023] A portion of the spirally wound sheet of material overlaps itself on each successive spiral turn such that there are no gaps between the turns. It will be understood that when there are no gaps between successive spiral turns, the spirally wound sheet of material is substantially tubular (e.g., tubular) in shape (i.e., the spirally wound sheet of material forms a hollow tube). Thus, the spirally wound sheet of material overlaps itself at successive points along the longitudinal length of the hollow tube.

[0024] Applicant has found that a hollow tube comprising a spirally wound sheet of material having overlapping spiral windings will not buckle or deform under the weight of the layer comprising the filler material and the wrapper engaged about the layer. Applicant has also found that the hollow tube has a consistent wall thickness and uniform end appearance, which may help to prevent counterfeiting.

[0025] The hollow tube may have an average wall thickness of 0.2 to 3.0 mm, such as 0.5 to 2.5 mm, for example 1.0 to 2.0 mm, for example 1.3 to 1.5 mm. Wall thickness is defined herein as the distance between the outer surface and the inner surface of the hollow tube.

[0026] The inner diameter of the hollow tube may be 1.5 to 10 mm, such as 2.0 to 9.0 mm, for example 3.0 to 8.0 mm, for example 4.0 to 7.0 mm, for example 5.0 mm, or 6.0 mm. The inner diameter is defined herein as the distance between diametrically opposed points on the inner surface of the channel at its widest point.

[0027] The hollow tube may comprise 1 to 10 sheets of material, e.g., 1, 2, 3, 4, 5, 6, 7, 9, or 10 sheets of material. The hollow tube can comprise at least 2 sheets of material, e.g., at least 3 sheets of material, e.g., at least 4 sheets of material.

[0028] Preferably, the sheet of material for the hollow tube is paper. The paper may comprise one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper may be formed from one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper may be filter paper or a cellulose / lyocell / viscose-based paper.

[0029] Preferably, the sheet of hollow tube material is plug wrap.

[0030] The sheet of hollow tube material may have a thickness of 0.02 to 1.5mm, such as 0.1 to 1.2mm, for example 0.2 to 1.0mm, for example 0.3 to 0.8mm, for example 0.5mm or 0.6mm.

[0031] The sheet of material for the hollow tube has a density of 24 to 200 grams per square meter (g / m 2 ), e.g. 45-180g / m 2 , for example, 60 to 160 g / m 2 , for example, 100 to 120 g / m 2 The sheet may have a basis weight of

[0032] The hollow tube may be colored. The sheet of material of the hollow tube may be colored.

[0033] Preferably, the sheet of hollow tube material is a strip of material. The sheet of hollow tube material (e.g. strip of material) may have a width of 10 to 20 mm, such as 12 to 18 mm, for example 14 to 16 mm, for example 15 mm.

[0034] The applicant has developed a plug wrap with a density of 24 to 200 grams per square meter (g / m 2 It has been found that plug wrap of a basis weight of 100g can be spirally wound and manufactured into a hollow tube that will not buckle or deform under the weight of the layer containing the filler material and the wrapper engaged about the layer.

[0035] The sheet of hollow tube material may be air permeable. The air permeability of a sheet of paper hollow tube (or wrapper) material is measured in CORESTA air permeability units (CU). A CORESTA unit is the permeability of 1 cm of substrate at an applied pressure difference of 1 kPa. 2 Volumetric flow rate of air through the sample (cm 3 minutes -1 The air permeability of the sheet of material of the hollow tube may be from 20 to 6000 CORESTA, such as from 1000 to 5000 CORESTA, for example from 2000 to 4000 CORESTA.

[0036] The sheet of material for the hollow tube may include a layer of adhesive disposed on a surface of the sheet of material. The layer of adhesive may be disposed on a portion of the sheet of material that, when spirally wound, overlaps itself on each successive spiral winding. The layer of adhesive may be used to secure a first portion of the spirally wound sheet of material to a second portion of the spirally wound sheet of material in successive spiral windings. The layer of adhesive may be used to secure the hollow tube together. The layer of adhesive may include a strip of adhesive, e.g., a continuous strip of adhesive, disposed on an edge of the sheet of material. The layer of adhesive may include dots of adhesive disposed on an edge of the sheet of material. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate), as known in the art.

[0037] The hollow tube may include a layer of adhesive disposed on an exterior surface of the hollow tube. The layer of adhesive may be used to secure the layer containing the filler material to the hollow tube. The layer of adhesive may include a strip of adhesive, for example, a continuous strip of adhesive disposed along the longitudinal length of the hollow tube. Alternatively, the adhesive may include dots of adhesive disposed along the longitudinal length of the hollow tube. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate), as known in the art.

[0038] The layer comprising the filler material may be engaged around the hollow tube along the longitudinal length of the hollow tube, for example along the entire longitudinal length of the hollow tube. The layer comprising the filler material may be engaged concentrically around the hollow tube. The layer comprising the filler material may be the same length as the hollow tube.

[0039] The filler material may be gathered (eg, wrapped, eg, spirally wound) around the hollow tube.

[0040] The layer comprising the filler material may comprise 1 to 10 sheets of filler material, for example, 1, 2, 3, 4, 5, 6, 7, 9, or 10 sheets. The layer comprising the filler material can comprise at least two sheets of filler material, for example, at least three sheets of filler material, for example, at least four sheets of filler material.

[0041] The sheet of packing material may be gathered (eg, wrapped, eg, spirally wound) around the hollow tube.

[0042] In embodiments, the layer including the filler material may include a sheet of filler material concentrically engaged around the hollow tube. The sheet of filler material may be wrapped around the hollow tube around the longitudinal axis of the hollow tube. The sheet of filler material may be wrapped at a 90-degree angle relative to the longitudinal axis of the hollow tube. The sheet of filler material may be wrapped around the hollow tube once around the longitudinal axis of the hollow tube such that the sheet of filler material encircles the hollow tube once and forms a single, continuous layer of filler material around the hollow tube. In such examples, it will be understood that the width of the sheet of filler material is approximately the same as the circumference of the hollow tube, and therefore the sheet of filler material does not overlap, or does not substantially overlap, itself when wrapped around the hollow tube.

[0043] In embodiments in which the layer containing filler material includes two or more sheets of filler material, each sheet of filler material may be wrapped continuously around the hollow tube once around the longitudinal axis of the hollow tube, such that each sheet of filler material surrounds the hollow tube once, forming multiple layers of filler material around the hollow tube. Each sheet of filler material may be wrapped at a 90-degree angle relative to the longitudinal axis of the hollow tube. The multiple layers of filler material may be concentrically engaged around the hollow tube.

[0044] Alternatively, the sheet of filler material may be wrapped around the hollow tube one or more times such that the sheet of filler material surrounds (i.e., overlaps with itself) the hollow tube one or more times, forming multiple layers of filler material around the hollow tube.

[0045] In a further embodiment, the sheet of filler material may be helically wrapped around the hollow tube, for example, helically wrapped around the longitudinal axis of the hollow tube at an oblique angle to the longitudinal axis of the hollow tube.

[0046] The spirally wound sheet of filler material may have partially overlapping spiral turns, whereby a portion of the spirally wound sheet of filler material overlaps itself on each successive spiral turn such that there are no gaps between the turns. It will be understood that with no gaps between successive spiral turns, the spirally wound sheet of filler material forms a continuous layer of filler material around the hollow tube.

[0047] The spirally wound sheet of filler material may have adjacent, non-overlapping spiral turns, whereby opposing edges of the spirally wound sheet of filler material are adjacent along the length of successive spiral turns, such that successive spiral turns are adjacent and there are no gaps between the turns.

[0048] The sheet of filler material has a density of 16 to 200 grams per square meter (g / m 2 ), e.g., 20-160g / m 2 , for example, 40 to 120 g / m 2 , e.g., 60 to 100 g / m 2 , for example, 80 to 90 g / m 2 The sheet may have a basis weight of

[0049] The sheets of packing material may each have a width of, for example, 10 to 90mm, such as 20 to 80mm, for example 50 to 60mm, such as 20 to 30mm, for example 25mm.

[0050] The sheet of filler material may include a layer of adhesive disposed on a surface thereof. The layer of adhesive may be used to secure the sheet of filler material around the hollow tube. The layer of adhesive may include a strip of adhesive, e.g., a continuous strip of adhesive, disposed on an edge of the sheet of filler material. Alternatively, the layer of adhesive may include dots of adhesive disposed on an edge of the sheet of filler material. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate), as known in the art.

[0051] The layer containing the filler material may have an average thickness of 0.2 to 3.0 mm, e.g., 0.3 to 2.5 mm, e.g., 0.4 to 2.0 mm, e.g., 0.5 to 1.5 mm, e.g., 0.8 to 1.4 mm, e.g., 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, or 1.3 mm. Thickness is defined herein as the shortest distance between a point on the outer surface of the hollow tube and a point on the wrapper engaged around the layer containing the filler material. It will be understood that the thickness of the layer containing the filler material may not be constant due to overlap of the filler material when assembled (e.g., wrapped, e.g., spirally wound) around the hollow tube, and therefore the thickness of the layer containing the filler material is an average.

[0052] The filler material may exhibit a filtering effect on aerosol (e.g., vapor) or tobacco smoke when the aerosol (e.g., vapor) or tobacco smoke is drawn through the element. The filler material may comprise a filtering material. The filler material may be a filtering material. The phrase "filtering material" herein refers to any material that has a filtering effect on aerosol (e.g., vapor) or tobacco smoke when the aerosol (e.g., vapor) or tobacco smoke is drawn through the element. In some examples, the elements of the present invention have zero or substantially zero aerosol (e.g., vapor) or tobacco smoke filtering effect. In such cases, the elements of the present invention can facilitate the passage of aerosol or tobacco smoke from the tobacco segment to other components of the aerosol-generating article or smoking article without substantially retaining the aerosol or tobacco smoke by the element. In other examples, the elements of the present invention may have an aerosol (e.g., vapor) or tobacco smoke filtering effect.

[0053] The filler material may include paper or a nonwoven material. The paper or nonwoven material may include one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper or nonwoven material may be formed from one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper or nonwoven material may be an airlaid material, filter paper, or a cellulose / lyocell / viscose-based paper.

[0054] Preferably, the layer containing the filler material does not contain cellulose acetate. Preferably, the filler material is not cellulose acetate.

[0055] Applicant has found that airlaid materials are easy to assemble into engaged layers around hollow tubes and have desirable filtering and / or cooling properties for aerosols (e.g., vapors) or tobacco smoke. Applicant has also found that airlaid materials can provide layers with consistent thickness and uniform edge appearance, which can help prevent counterfeiting.

[0056] The filler material may be embossed, or alternatively, the filler material may not be embossed.

[0057] The wrapper may be engaged around the layer including the filler material along the longitudinal length of the layer including the filler material, for example along the entire longitudinal length of the layer including the filler material. The wrapper may be engaged concentrically around the layer including the filler material. The wrapper may be the same length as the layer including the filler material, which may then be the same length as the hollow tube. Thus, the hollow tube, the layer including the filler material, and the wrapper may all be the same length.

[0058] The wrapper has a density of 24 to 200 grams per square meter (g / m 2 ), e.g. 45-180g / m 2 , for example, 60 to 160 g / m 2 , for example, 100 to 120 g / m 2 The sheet may have a basis weight of

[0059] The air permeability of the wrapper may be from 20 to 6000 CORESTA, such as from 1000 to 5000 CORESTA, for example from 2000 to 4000 CORESTA.

[0060] The wrapper may be paper, e.g., air permeable paper. Preferably, the wrapper is plug wrap. The wrapper may be coated, e.g., with starch, guar gum, and / or a hydrophobic coating. The wrapper may function to hold the layer of fill material in place around the hollow tube.

[0061] The wrapper may be secured around the layer containing the filler material with an adhesive, for example, by an overlapping adhesive seam as known in the art.

[0062] The applicant has a concentration of 100 to 160 g / m 2It has been found that a plug wrap having a basis weight of can be assembled around a layer containing a filler material and does not buckle or deform when combined with an aerosol-generating article, such as a filter element, or other element for a smoking article, or when further processed into an aerosol-generating article, such as a heated tobacco product or e-cigarette, or a smoking article, such as a cigarette.

[0063] The length of the element is between 5 and 150 mm, such as between 10 and 100 mm, for example between 50 and 90 mm, for example between 12 and 23 mm, for example between 18 mm and 22 mm.

[0064] The element may have a circumference of 14 to 30 mm, such as 16 to 25 mm, for example 17 to 24 mm, for example 18 mm to 22 mm, for example 19.8 mm, for example 24.25 mm.

[0065] The element may have a hardness of between 90% and 97%, such as between 91% and 97%, for example between 92% and 97%, such as 94%, 95% or 96%.

[0066] As used herein, hardness is a measurement of the degree to which an element deforms following the application of a given pressure for a given time. Hardness is measured using a Cerulean QTM Module 7 instrument. A preload is applied to the element and the contact point diameter (DP) is measured. A higher load is then applied and the depressed diameter (DL) is measured after a given time or when a slope threshold is reached. Hardness is calculated as %H = (DL / DP) x 100. The load cell used with the QTM Module 7 instrument is 290 grams.

[0067] Applicant has found that the elements of the present invention do not buckle or deform when combined with other elements (such as filter elements) for an aerosol-generating article or smoking article, or when further processed into an aerosol-generating article (such as a heated tobacco product or e-cigarette) or smoking article (such as a cigarette). Applicant has also found that the structural integrity of the elements can be comparable to that of other elements of an aerosol-generating article or smoking article formed, for example, from cellulose acetate filamentous tow. Thus, the elements of the present invention can be easily assembled with additional elements into a multi-segment product, such as a multi-segment filter.

[0068] The element may comprise biodegradable materials. Preferably, the element comprises only biodegradable materials. The element may be biodegradable. Preferably, the element does not contain cellulose acetate.

[0069] As used herein, biodegradable means capable of being broken down by living organisms such as bacteria and fungi.

[0070] The element or material of the element may be at least 90% biodegradable after 6 months under controlled composting conditions as determined in accordance with ISO 14855 Determination of the ultimate aerobic biodegradability of plastic materials under controlled composting conditions - Method by analysis of evolved carbon dioxide.

[0071] An element or material of an element may be readily biodegradable. As used herein, the phrase readily biodegradable means that the element has a "Ready Biodegradability" level of biodegradability as measured according to OECD Test No. 301B: Ready Biodegradability (CO2 Evolution (Modified Storm Test)).

[0072] Applicant has discovered that by fabricating the element from readily biodegradable paper or other material, the element can provide desirable cooling and / or filtering properties for aerosols (e.g., vapor) or tobacco smoke, while at the same time being readily biodegradable.

[0073] In a further aspect of the present invention, there is provided a multi-segment product for an aerosol-generating article or smoking article, such as a multi-segment filter, which comprises an element as described above and one or more separate further elements.

[0074] In a further aspect of the present invention, there is provided an aerosol-generating or smoking article comprising the elements described above or comprising a multi-segment product comprising the elements described above.

[0075] As used herein, aerosol-generating articles may include non-combustion heated devices, heated tobacco products such as tobacco heating devices, and electronic cigarettes. As used herein, smoking articles may include cigarettes, cigars, cigarillos, cigarettes, and the like.

[0076] An aerosol-generating article or smoking article may include the multi-segment product or element described above joined to a wrapped rod of smoking material, such as tobacco smoking material. The aerosol-generating article or smoking article may further comprise a tipping wrapper, e.g., tipping paper. The tipping wrapper joins the wrapped rod of smoking material to the multi-segment product or element by engaging around adjacent ends of the multi-segment product or element and the wrapped rod of smoking material. The tipping wrapper may be configured to leave a portion of the outer surface of the multi-segment product or element exposed. The multi-segment product or element may be joined to the wrapped rod of smoking material by a complete tipping wrapper that engages around the entire length of the multi-segment product or element and the adjacent end of the rod of smoking material.

[0077] Applicant has found that an aerosol-generating article or smoking article comprising an element according to the present invention can exhibit reduced appearance of stains at the mouth end (i.e., the user's mouth end) compared to conventional (e.g., non-annular) elements or mouthpieces. Elements according to the present invention can also condense aerosols, such as vapor, or tobacco smoke into a stream directed toward the user's tongue. Applicant has also found that elements according to the present invention can provide cooling of the aerosol (e.g., vapor) or tobacco smoke. Applicant has also found that elements according to the present invention can facilitate the passage of aerosols (e.g., vapor) or tobacco smoke from a tobacco segment to other elements of the aerosol-generating article without substantial retention of the aerosol (e.g., vapor) or tobacco smoke by the element. Applicant has also found that elements according to the present invention can function as a reservoir in which aerosols or tobacco smoke from a tobacco segment are condensed, for example, within the channels of a hollow tube. Applicant has also found that elements according to the present invention can improve nicotine delivery to the user. Applicant has also found that elements according to the present invention may provide a filtering effect against aerosols (eg, vapors) or tobacco smoke.

[0078] A multi-segment product, element, aerosol-generating article, or smoking article according to the present invention may be unventilated or may be ventilated by methods known in the art, for example, by using a pre-perforated or breathable wrapper or tip wrapper (tipping paper), and / or laser perforation of the wrapper and / or tip wrapper. Breathable full tip wrappers (tipping papers) may likewise be inherently air-permeable or may be provided with ventilation holes; in breathable products where both a wrapper and a tip wrapper (tipping paper) are present, ventilation through the tip wrapper (tipping paper) typically coincides with ventilation through the wrapper. Ventilation holes through the wrapper, through the tip wrapper (tipping paper), or both simultaneously may be created by laser drilling during element manufacturing.

[0079] In a further aspect of the invention, there is provided a multiple rod comprising a plurality of cooling elements according to the invention, arranged end-to-end, for example in a mirror image relationship.

[0080] In a further aspect of the present invention, there is provided a method for making elements for an aerosol-generating article or a smoking article, the method comprising the steps of advancing a sheet of material in a longitudinal direction, spirally winding the sheet of material around a forming rod so that the sheet of material partially overlaps itself on successive spiral windings, thereby forming a longitudinally extending hollow tube, advancing filler material in a longitudinal direction, gathering (e.g., wrapping, e.g., spirally winding) the filler material around the hollow tube to form a layer comprising engaged filler material around the hollow tube, gathering (e.g., wrapping) and securing a wrapper around the layer comprising filler material to form a continuous rod, and cutting the continuous rod to form individual elements.

[0081] The sheet of material may be continuously advanced.

[0082] The sheet of material may be drawn from a source (eg, a roll of material) before being advanced towards the forming rod.

[0083] The method may include advancing 1 to 10 sheets of material, e.g., 1, 2, 3, 4, 5, 6, 7, 9, or 10 sheets of material. The method may include advancing at least two sheets of material, e.g., at least three sheets of material, at least four sheets of material. If more than one sheet of filler material is present, it may be drawn from two or more sources, such as two rolls of material.

[0084] The method may include applying an adhesive to the advancing sheet of material. The adhesive may be applied to a surface of the advancing sheet of material. The adhesive may be applied to the advancing sheet of material before the advancing sheet of material is spirally wound around a forming rod. For example, the adhesive may be applied to the advancing sheet of material at a gluing station before the advancing sheet of material is spirally wound around a forming rod. The adhesive may be sprayed onto the sheet of material, for example, sprayed onto a surface of the sheet of material, for example along a longitudinal edge of the sheet of material. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate), as known in the art.

[0085] The adhesive may be applied to the portion of the sheet of material that overlaps itself as it is spirally wrapped around the forming rod (eg, in successive spiral wraps).

[0086] The forming rod is sometimes called a mandrel.

[0087] The shaped rod may be substantially cylindrical, for example cylindrical.

[0088] The forming rod may have an outer surface that defines the inner diameter of the hollow tube.

[0089] The shaped rod may have a diameter of 1.5 to 10 mm, such as 2.0 to 9.0 mm, for example 3.0 to 8.0 mm, for example 4.0 to 7.0 mm, for example 5.0 mm or 6.0 mm.

[0090] The inner diameter of the hollow tube may be 1.5 to 10 mm, for example, 2.0 to 9.0 mm, for example, 3.0 to 8.0 mm, for example, 4.0 to 7.0 mm, for example, 5.0 mm or 6.0 mm.

[0091] The sheet of material may have a width of 10 to 20mm, such as 12 to 18mm, for example 14 to 16mm, for example 15mm.

[0092] The sheet of material is spirally wound around the outer surface of the forming rod, for example, spirally wound around the longitudinal axis of the forming rod at an oblique angle to the longitudinal axis of the forming rod. In each successive spiral winding around the forming rod, a first portion of the sheet of material partially overlaps a second portion of the sheet of material, such that no gaps exist between successive windings of the sheet of material. The overlapping portions of the sheet of material may be secured to one another by an adhesive.

[0093] Preferably, the sheet of material is paper. The paper may comprise one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper may be formed from one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper may be filter paper or a cellulose / lyocell / viscose-based paper.

[0094] Preferably, the sheet of material is plug wrap.

[0095] The filler material may be advanced continuously.

[0096] The filler material may be drawn from a supply before being advanced towards the longitudinally extending hollow tube.

[0097] The filler material is gathered (eg, wrapped, eg, spirally wound) around the hollow tube along the longitudinal length of the hollow tube, eg, along the entire longitudinal length of the hollow tube.

[0098] The filler material may be a sheet of filler material.

[0099] The method can include advancing 1 to 10 sheets of filler material, e.g., 1, 2, 3, 4, 5, 6, 7, 9, or 10 sheets of filler material. The method may include advancing at least two sheets of filler material, e.g., at least three sheets of filler material, at least four sheets of filler material. When more than one sheet of filler material is present, it may be drawn from two or more sources, such as two rolls of filler material.

[0100] The sheet of packing material may have a width of 10 to 90mm, such as 20 to 80mm, for example 50 to 60mm, for example 20 to 30mm, for example 25mm. The sheet of packing material may be cut to a width of 60 to 90mm.

[0101] The method may include longitudinally cutting a sheet of filler material to form two or more longitudinally extending sheets of filler material. For example, cutting may occur at a cutting station before the sheet of filler material is advanced longitudinally and then gathered around the hollow tube. Two or more longitudinally extending sheets of filler material may be stacked on top of each other following cutting. Two or more longitudinally extending sheets of filler material may continue to advance longitudinally after cutting. The sheet of filler material may be cut to form two, three, four, or more longitudinally extending sheets of filler material. Alternatively, the filler material may be cut by a separate process and wound onto a reel for use in the method of the present invention.

[0102] In embodiments, the sheet of filler material may be wrapped around the hollow tube about its longitudinal axis. The sheet of filler material may be wrapped at a 90-degree angle relative to the longitudinal axis of the hollow tube. The sheet of filler material may be wrapped around the hollow tube about its longitudinal axis once, such that the sheet of filler material surrounds the hollow tube once and forms a single continuous layer of filler material around the hollow tube. Alternatively, the sheet of filler material may be wrapped around the hollow tube about its longitudinal axis more than once, such that the sheet of filler material surrounds (i.e., overlaps with itself) the hollow tube more than once and forms multiple layers around the hollow tube.

[0103] The sheet of filler material may be wrapped around the hollow tube in a collection chamber for collecting (or configured to collect) the sheet of filler material around the hollow tube. The sheet of filler material may be drawn into the collection chamber having an inlet for receiving the sheet of filler material and the hollow tube and an outlet through which the hollow tube (and the layer of filler material engaged around the hollow tube) exits the collection chamber. The collection chamber may be a tapered chamber having a diameter at the inlet that is larger than a diameter at the outlet.

[0104] In embodiments where the method includes advancing two or more sheets of packing material, the sheets of packing material may be stacked on top of each other to form a stack of two or more sheets of packing material. The stack of two or more sheets of packing material may be wrapped continuously around the hollow tube once around the longitudinal axis of the hollow tube, such that each sheet of packing material surrounds the hollow tube once, forming multiple layers of packing material around the hollow tube. Each sheet of packing material may be wrapped at a 90-degree angle relative to the longitudinal axis of the hollow tube. The multiple layers of packing material may be concentrically engaged around the hollow tube. The sheets of packing material may be wrapped around the hollow tube in a collection chamber for (or configured to) collect the sheets of packing material around the hollow tube.

[0105] In a further embodiment, the sheet of filler material may be helically wrapped around the hollow tube, for example, helically wrapped around the longitudinal axis of the hollow tube at an oblique angle to the longitudinal axis of the hollow tube.

[0106] Here, "wrapped around a hollow tube" means wrapped around the outer surface of a hollow tube.

[0107] The sheet of filler material may be spirally wound around the hollow tube in a forming chamber, the forming chamber being for (or configured to) spirally wind the sheet of filler material around the hollow tube. In some examples, the forming chamber may include a forming rod, and the sheet of hollow tube material may be spirally wound around the forming rod before the sheet of filler material is spirally wound around the hollow tube, thereby forming a longitudinally extending hollow tube. The sheet of filler material (and the sheet of hollow tube material) may be drawn into a forming chamber having an inlet for receiving the sheet of filler material (and the sheet of hollow tube material) and an outlet through which the hollow tube (and the layer of filler material engaged around the hollow tube) exits the forming chamber.

[0108] The sheet of packing material may be spirally wound such that the sheet has partially overlapping spiral turns, whereby a portion of the spirally wound sheet of packing material overlaps itself on each successive spiral turn with no gaps between the turns, thereby forming a continuous layer of packing material around the hollow tube. Alternatively, the sheet of packing material may be spirally wound such that the sheet has adjacent, non-overlapping spiral turns with opposite edges of the spirally wound sheet of packing material adjacent along the length of successive spiral turns, such that successive spiral turns are adjacent with no gaps between the turns, thereby forming a continuous layer of packing material around the hollow tube.

[0109] Applicant has found that spirally winding the filler material around the hollow tube provides a uniform layer of filler material having a substantially consistent wall thickness.

[0110] The method may further include applying an adhesive to the advancing sheet of filler material before it is spirally wrapped around the longitudinally extending hollow tube. The adhesive may be applied to the advancing sheet of filler material at a bonding station before it is spirally wrapped around the hollow tube. The adhesive may be sprayed onto the sheet of filler material, for example, onto a surface of the sheet of filler material, for example, onto an edge of the sheet of filler material. The adhesive may be used to secure the sheet of filler material around the hollow tube. The adhesive may be a hot melt or water-based adhesive (e.g., ethyl vinyl acetate) as known in the art.

[0111] The filler material may include paper or a nonwoven material. The paper or nonwoven material may include one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper or nonwoven material may be formed from one or more plant-based fibers, such as flax, hemp, jute, sisal, abaca, cotton, coconut, bamboo, starch, or wood pulp. The paper or nonwoven material may be an airlaid material, filter paper, or a cellulose / lyocell / viscose-based paper.

[0112] A wrapper is wrapped around the layer containing the filler material. The wrapper may be wrapped using standard methods known in the art, such as a garniture unit. The wrapper may be secured around the layer containing the filler material with an adhesive, for example, by an overlapping adhesive seam as known in the art.

[0113] The continuous rod may be cut through the cross section to form the individual elements. The continuously extending rod may be cut using standard cutting methods known in the art, such as a rotary drum cutter. The continuous rod may be cut at a further cutting station.

[0114] In a further aspect of the present invention, there is provided an element for an aerosol-generating article formed by a method according to any of the above descriptions.

[0115] In a further aspect of the present invention, there is provided an element of a smoking article formed by a method according to any of the above statements. [Brief explanation of the drawings]

[0116] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 is a perspective view of an element for an aerosol-generating article or smoking article according to the present invention. [Figure 2] FIG. 2 is a cross-sectional view of the element shown in FIG. 1. [Figure 3] 1 is a perspective view of an element for an aerosol-generating article or smoking article according to the present invention. [Figure 4] 1 is a schematic diagram of the method of the present invention. [Figure 5] 1 is a perspective view of an element for an aerosol-generating article or smoking article according to the present invention. [Figure 6] 1 is a schematic diagram of the method of the present invention.

[0117] FIG. 1 shows a perspective view of an element 100 for an aerosol-generating article, such as a heated tobacco product or an e-cigarette, or for a smoking article, such as a cigarette, according to an embodiment of the present invention.

[0118] The element 100 comprises a longitudinally extending hollow tube 101, a layer containing a filler material 102 engaged around the hollow tube 101, and a wrapper 103 engaged around the layer 102. The hollow tube 101 has a width of 15 mm and a basis weight of 120 g / m 2The filler material may comprise a spirally wound strip of sheet material, which may be a strip of plug wrap, although it will be understood that other materials are suitable. The spirally wound sheet of material has overlapping spiral wraps (not shown) to form the hollow tube 101. The spirally wound sheet of material extends helically around the longitudinal axis of the element 100 such that the sheet of material overlaps itself at successive points along the longitudinal length of the hollow tube 101. Successive wraps of the spirally wound sheet of material may be secured to one another by a layer of adhesive disposed on the surface of the spirally wound sheet of material (not shown), thereby securing the hollow tube 101 together. The layer containing the filler material may comprise a 15 mm wide sheet of airlaid nonwoven material, although it will be understood that other filler materials are suitable. The sheet of filler material is wrapped once around the hollow tube 101 and secured to the hollow tube 101 and wrapper 103 by lines of adhesive (not shown) on the hollow tube 101 and wrapper 103. The filler material may be embossed. The wrapper 103 has a basis weight of 100 g / m 2 and has an air permeability of 20-6000 CORESTA. Element 100 is 108 mm long and 24.5 mm in circumference.

[0119] Figure 2 shows a cross-sectional view of the cross-sectional profile of element 100 along line AA, as shown in Figure 1. The cross-section of element 100 is annular. The inner diameter of hollow tube 101 is designated d, and the average thickness of the layer including filler material 102 is designated t. The layer of filler material 102 has an average thickness of 1.3 mm. The inner diameter of hollow tube 101 is 6 mm, and the average wall thickness of hollow tube 101 is 0.6 mm.

[0120] 3 shows a perspective view of an element 300 for an aerosol-generating or smoking article according to an embodiment of the present invention. Element 300 comprises a longitudinally extending hollow tube 301, a layer 302 containing a filler material engaged around hollow tube 301, and a wrapper 303 engaged around layer 302. Hollow tube 301 has a width of 15 mm and a basis weight of 100 g / m 2The layer comprising the filler material 302 may comprise a spirally wound sheet of material 304, which may be a strip of plug wrap, although it will be understood that other materials are suitable. A portion of the spirally wound sheet of material 304 overlaps itself in each successive wrap such that there are no gaps between the wraps. The spirally wound sheet of material 304 forms a hollow tube 301. Successive wraps of the spirally wound sheet of material 304 may be secured to one another using a layer of adhesive (not shown) disposed on the surface of the sheet of material 304. The adhesive is applied to the portion of the sheet of material 304 that overlaps itself (e.g., in successive spiral wraps), thereby securing the hollow tube 301 together. The layer comprising the filler material 302 may comprise a 15 mm wide sheet of airlaid nonwoven material 305, although it will be understood that other filler materials are suitable. The sheet of filler material 305 is spirally wrapped around hollow tube 301 in adjacent, non-overlapping spiral wraps, whereby opposing edges of the spirally wrapped sheet of filler material 305 abut along the length of successive wraps with no gaps between the wraps. The spirally wrapped sheet of filler material 305 thus forms a continuous layer of filler material 302 around hollow tube 301. The spirally wrapped sheet of filler material 305 is secured to hollow tube 301 and wrapper 303 by a line of adhesive (not shown) on hollow tube 301 and a line of adhesive (not shown) on wrapper 303. Wrapper 303 has a basis weight of 100 g / m 2 plug wrap, secured around the layer containing the filler material 302 with a line of adhesive (not shown).

[0121] 4 shows a schematic diagram of the process of the present invention. Element 300 can be made by the process shown in FIG.

[0122] Width 15mm and basis weight 100g / m 2A sheet of plug wrap 306 is unwound from roll 307 and continuously advanced in the longitudinal direction L. At bonding station 308, adhesive is sprayed onto the surface of the advancing plug wrap 306 along its longitudinal edges. The plug wrap 306 continues to advance toward a forming chamber 309, which includes a 5.0 mm diameter cylindrical forming rod (mandrel) (not shown). The plug wrap 306 sheet is drawn into the forming chamber 309 through an inlet and spirally wrapped around the forming rod, causing the plug wrap 306 sheet to partially overlap itself on successive spiral wraps, with the overlapping portions of the plug wrap sheet secured together by the adhesive, thereby forming a longitudinally extending hollow tube having an inner diameter of approximately 5.0 mm. A 15 mm wide sheet of airlaid nonwoven filler material 310 is unwound from roll 311 and continuously advanced in the longitudinal direction L. A sheet of filler material 310 is drawn into the forming chamber 309 through an inlet and is spirally wrapped around the hollow tube in adjacent, non-overlapping spiral wraps, whereby opposing edges of the spirally wrapped sheet of filler material are adjacent along the length of successive wraps to form a continuous layer around the hollow tube. The hollow tube (and layer of filler material engaged around the hollow tube) 312 exits the forming chamber 309 through an outlet. At the garniture unit 313, a sheet of filler material 310 having a basis weight of 100 g / m 2 The plug wrap 315 is unwrapped from the roll 311 and wrapped around the layer (and hollow tube) 312 containing the filler material and secured using an adhesive to form a continuous rod 316. The continuous rod 316 is cut at a cutting station 317 to form the individual elements 300.

[0123] 5 shows a perspective view of an element 400 for an aerosol-generating or smoking article according to an embodiment of the present invention. Element 400 comprises a longitudinally extending hollow tube 401, a layer 402 containing a filler material engaged around hollow tube 401, and a wrapper 403 engaged around layer 402. Hollow tube 401 has a width of 15 mm and a basis weight of 100 g / m 24. The layer including the filler material 402 comprises a spirally wound sheet of material 404, which may be a strip of plug wrap, although it will be understood that other materials are suitable. A portion of the spirally wound sheet of material 404 overlaps itself in each successive wrap such that there are no gaps between the wraps. The spirally wound sheet of material 404 forms a hollow tube 401. Successive wraps of the spirally wound sheet of material 404 may be secured to one another using a layer of adhesive (not shown) disposed on the surface of the sheet of material 404. The adhesive is applied to the portion of the sheet of material 404 that overlaps itself (e.g., in successive spiral wraps), thereby securing the hollow tube 401 together. The layer including the filler material 402 comprises four sheets of airlaid nonwoven material, although it will be understood that other filler materials are suitable. Each sheet of filler material is wrapped once around hollow tube 401 at a 90 degree angle relative to the longitudinal axis of the hollow tube, thereby forming multiple layers of filler material concentrically engaged around hollow tube 401. The layers including filler material 402 are secured to hollow tube 401 and wrapper 403 by lines of adhesive (not shown) on hollow tube 401 and wrapper 403. Wrapper 403 has a basis weight of 100 g / m 2 plug wrap, secured around the layer containing filler material 402 with a line of adhesive (not shown).

[0124] 6 shows a schematic diagram of the process of the present invention. The element 400 according to FIG. 5 may be made by the process shown in FIG.

[0125] Width 15mm and basis weight 100g / m 2A sheet of plug wrap 406 is unwound from roll 405 and advanced in a longitudinal direction L. At bonding station 407, adhesive is sprayed onto the surface of the advancing plug wrap 406 along its longitudinal edges. The sheet of plug wrap 406 continues to advance toward a 5.0 mm diameter cylindrical forming rod (mandrel) 408. The sheet of plug wrap 406 is spirally wound around forming rod 408, overlapping itself on successive spiral wraps, with the overlapping portions of the plug wrap 406 secured together by adhesive, thereby forming a longitudinally extending hollow tube 409 having an inner diameter of approximately 5.0 mm. The hollow tube 409 is advanced toward collection chamber 410 and drawn into collection chamber 410 through an inlet. A 60 mm wide sheet of airlaid nonwoven filler material 411 is unwound from roll 412. At the cutting station 413, the sheet of airlaid nonwoven filler material 411 is cut longitudinally to form four 15 mm wide, longitudinally extending sheets 415 of filler material. The four sheets of filler material 415 are stacked on top of each other and advanced in the longitudinal direction L toward the collection chamber 410. The stack of four sheets of filler material 415 is drawn into the collection chamber 410 through the inlet and wrapped once around the hollow tube 409 at a 90 degree angle relative to the longitudinal axis of the hollow tube, so that each sheet of filler material surrounds the hollow tube 409 once, forming multiple layers of filler material concentrically engaged around the hollow tube 409. The hollow tube (and the layers of filler material engaged around the hollow tube) 416 exits the collection chamber 410 through the outlet. The collection chamber 410 is a tapered chamber with an inlet diameter larger than the outlet diameter. The tapered chamber aids in condensing the filler material around the hollow tube. In the garniture unit 419, the basis weight is 100 g / m 2 The plug wrap 418 is unwrapped from a roll 417 and wrapped around the layer (and hollow tube) 416 containing the filler material and secured using an adhesive to form a continuous rod 420. The continuous rod 420 is cut at a cutting station 421 to form the individual elements 400.

[0126] Any of the elements shown in Figures 1-3 and 5 may form part of an aerosol-generating article, such as a heated tobacco product or an e-cigarette, or a multi-segment product included in a smoking article, such as a cigarette. Elements according to Figures 1-3 and 5 may be assembled into a multi-segment product, aerosol-generating article, or smoking article according to methods known in the art.

[0127] An aerosol-generating article, such as a heated tobacco product, includes a rod of tobacco material, a heating element, a power source, one or more additional filter segments, and any of the elements shown above in Figures 1-3 and 5. The elements may be located at the mouth end of the aerosol-generating article (i.e., function as a mouthpiece), and the one or more additional filter segments may be located downstream from the heating element and tobacco rod.

[0128] During use, the heating element of a heated tobacco product heats the tobacco rod to form an aerosol. The aerosol then passes through one or more elements, which may function to cool or filter the aerosol, before passing through any of the elements shown in Figures 1-3 and 5 above and into the user's mouth. The aerosol may also be filtered by the element so that the levels of certain compounds in the aerosol are reduced. The aerosol may also be cooled by the element, i.e., the temperature of the aerosol decreases as it passes along the length of the element.

Claims

1. 1. An element for an aerosol-generating or smoking article comprising a longitudinally extending hollow tube, a layer including a filler material, the layer being engaged around the hollow tube; and a wrapper engaged about said layer, said hollow tube comprising a spirally wound sheet of material, said spirally wound sheet of material having overlapping spiral windings.

2. 10. An element for an aerosol-generating or smoking article according to claim 1, wherein the layer comprises a sheet of filler material wrapped around the hollow tube.

3. 3. An element for an aerosol-generating or smoking article according to claim 2, wherein the sheet of filler material is wrapped at a 90 degree angle relative to the longitudinal axis of the hollow tube.

4. 4. An element for an aerosol-generating or smoking article according to claim 3, wherein the sheet of filler material is wrapped once around the hollow tube.

5. 10. An element for an aerosol-generating or smoking article according to claim 1, wherein the layer comprises a sheet of filler material spirally wrapped around the hollow tube.

6. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 5, wherein the layer comprises 1 to 10 sheets of filler material.

7. The sheet of filler material has a density of 16 to 200 grams per square meter (g / m ２ 7. An element for an aerosol-generating article or smoking article according to any one of claims 2 to 6, having a basis weight of 10 ...

8. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 7, wherein the layer comprising the filler material is of an average thickness of 0.2 to 3.0 mm.

9. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 8, wherein the filling material is a filtering material.

10. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 9, wherein the filler material is paper or a nonwoven material.

11. 11. An element for an aerosol-generating article or smoking article according to claim 10, wherein the paper or nonwoven material comprises plant-based fibers.

12. 12. An element for an aerosol-generating article or a smoking article according to claim 10 or 11, wherein the paper or nonwoven material is an airlaid material, a filter paper, or a cellulose / lyocell / viscose-based paper.

13. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 12, wherein the filler material is embossed.

14. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 13, wherein the average wall thickness of the hollow tube is from 0.2 to 3.0 mm.

15. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 14, wherein the hollow tube has an inner diameter of 1.5 to 10 mm.

16. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 15, wherein the sheet of material of the hollow tube is paper.

17. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 16, wherein the sheet of hollow tube material has a thickness of 0.02 to 1.5 mm.

18. The sheet of material of the hollow tube has a density of 24 to 200 grams per square meter (g / m ２ 18. An element for an aerosol-generating article or smoking article according to any one of claims 1 to 17, having a basis weight of 10 ...

19. An element for an aerosol-generating article or smoking article according to any one of claims 1 to 18, wherein the sheet of material of the hollow tube is plug wrap.

20. 20. An element for an aerosol-generating article or smoking article according to any one of claims 1 to 19, wherein the sheet of hollow tube material comprises a layer of adhesive disposed on a surface of the sheet of material.

21. The wrapper has a viscosity of 24 to 200 grams per square meter (g / m ２ 21. An element for an aerosol-generating article or smoking article according to any one of claims 1 to 20, which is a plug wrap with a basis weight of 1000 psi or less.

22. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 21, wherein the length of the element is from 5 to 150 mm.

23. An element for an aerosol-generating article or a smoking article according to any one of claims 1 to 22, wherein the circumference of the element is between 14 and 30 mm.

24. A multi-segment product for an aerosol-generating article or a smoking article, comprising an element according to any one of claims 1 to 23 and one or more separate further segments.

25. An aerosol-generating or smoking article comprising an element according to any one of claims 1 to 24, or comprising a multi-segment product according to claim 24.

26. 1. A method of making an element for an aerosol-generating article or a smoking article, comprising: advancing a sheet of material longitudinally; helically winding said sheet of material around a forming rod so that said sheet of material partially overlaps itself on successive helical windings, thereby forming a longitudinally extending hollow tube; longitudinally advancing the filler material; gathering the filler material around the hollow tube to form a layer including the filler material engaged around the hollow tube; gathering and securing a wrapper around the layer containing the filler material to form a continuous rod; and cutting the continuous rod to form individual mouthpieces or filter elements.

27. 27. The method of claim 26, including applying an adhesive to the advancing sheet of material.

28. 28. The method of claim 27, wherein the overlapping portions of the sheets of material are secured together by an adhesive.

29. A method according to any one of claims 26 to 28, wherein the packing material is a sheet of packing material.

30. 27. The method of claim 26, including the step of longitudinally cutting the sheet of filler material, thereby forming two or more sheets of longitudinally extending filler material.

31. 31. The method of claim 29 or 30, wherein the sheet of packing material is wrapped around the hollow tube.

32. 32. The method of claim 31 , wherein the sheet of filler material is wrapped at a 90 degree angle relative to the longitudinal axis of the hollow tube.

33. A method according to any one of claims 26 to 30, wherein the sheet of packing material is wrapped helically around the outer surface of the hollow tube.

34. 34. The method of claim 33, wherein the spirally wound sheet of filler material overlaps itself in successive spiral wraps.

35. 35. The method of claim 34, wherein the spirally wound sheet of filler material has adjacent, non-overlapping spiral turns.

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