Filter element, mouthpiece, and cooling element

Abstract

Disclosed is a mouthpiece, filter element or cooling element (100) for an aerosol-generating article comprising: a first section (110) comprising a longitudinally extending core of filter material (112) having an outer surface (116) and an inner surface (118), the inner surface (118) defining a channel (114) extending longitudinally from an end of the first section (110); and a second section (120) comprising a longitudinally extending core of filter material (122), the first section (110) and the second section (120) being adjacent and integral, the channel (114) having a non-circular cross-section that varies longitudinally by rotation about the longitudinal axis of the first section (110).

Description

Technical Field

[0001] The use of tube filter elements and tube mouthpieces in smoking articles is well known in the art. Typically, a tube filter element includes a cylindrical core of filter material having channels that extend longitudinally from the ends of the cylindrical core. The tube filter element is usually included as part of a multi-segment filter and is typically positioned at the mouth end of the smoking article to provide a characteristic end appearance. Thus, existing tube filters require the step of assembling the tube filter element with additional filter segments that require a complex assembly process. When incorporated into a smoking article, the tube filter allows smoke to exit the filter in a concentrated stream directed towards the user's tongue during use.

[0002] There is a need for tube filter elements that can be manufactured in a single continuous process without the need for assembly with additional filter segments. There is also a need for tube filters having different sensory characteristics.

[0003] In recent years, non-combustible smoking products have become increasingly popular. Such products include heated tobacco products, also known as tobacco heating products or non-combustion heating products. Heated tobacco products generally include tobacco, a heating element, and a power source. The heating element heats the tobacco to generate an aerosol, which is delivered to the user through a mouthpiece. The mouthpiece can act to mimic the sensory aspects of a conventional smoking article filter. Additionally, some non-combustion heating products include a cooling element that cools the aerosol before it reaches the mouthpiece. The cooling element is typically a separate element that requires assembly with other components forming the non-combustible smoking product.

[0004] In a first aspect of the present invention, a mouthpiece or filter element for an aerosol generating article is provided, comprising: a first section having a longitudinally extending core of a filter material having an outer surface and an inner surface, wherein the inner surface defines a channel extending longitudinally from the end of the first section; and a second section having a longitudinally extending core of the filter material, wherein the first and second sections are adjacent and integral, and the channel has a non-circular cross-section that varies longitudinally by rotating about the longitudinal axis of the first section.

[0005] The channel may have a cross-section that is a deformed circle, cross, or rectangle, with one or more projections extending toward the center of the circle.

[0006] The channel is configured such that its cross-section at a first location along the length of the core extending longitudinally in the filter material can be rotated relative to an adjacent location along the length of the core extending longitudinally in the filter material. It will be understood that the cross-section of the channel may be rotated by more or less than 360 degrees along the length of the channel.

[0007] The applicant has found that, during use, the aerosol in the form of smoke passing through the mouthpiece or filter element takes a nonlinear path through the channel, such as a spiral or vortex path. During use, the mouthpiece or filter element of the present invention has been found to produce a different smoking sensation, where the smoke is felt to be more dispersed in the mouth, compared to standard tube filter elements or mouthpieces. While not wishing to be bound by theory, it is thought that the nonlinear path taken by the smoke, such as a spiral or vortex path, is responsible for these differences in sensory characteristics.

[0008] The applicant has found that having a second section adjacent to and integral with the first section eliminates the need to use further individual filter segments to impart additional properties or functionality to the filter element. The mouthpiece or filter element of the present invention can be manufactured in a single continuous process, which means that the assembly of multiple filter segments is not required. However, it will be understood that the mouthpiece or filter element of the present invention is nevertheless suitable for incorporation into a multi-segment filter as needed.

[0009] The channel may be a tube or a hole. Preferably, the channel is surrounded by a filter material.

[0010] The cross-section of a non-circular transverse channel can vary in the longitudinal direction by rotating around the channel's longitudinal axis, for example, the central longitudinal axis of the channel.

[0011] The second section may comprise a core extending longitudinally in a continuous or homogeneously dispersed filter material. Preferably, the second section does not include channels such as tubes or holes.

[0012] The first section may be located, for example, at the mouthpiece end of the filter element or mouthpiece so that the channel is visible when the filter element or mouthpiece is in use.

[0013] The inner surface may have one or more ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. One or more ridges may protrude from the inner surface. One or more ridges may be formed on the inner surface. One or more ridges may be integral with the inner surface.

[0014] In the case of a channel having a cross-section that is a deformed circle having one or more protruding portions extending from the edge of the circle toward the center of the circle, the channel has a substantially cylindrical shape, and the inner surface defining the channel comprises one or more helical protrusions extending around the longitudinal axis of the first section, for example around the longitudinal axis of the channel, for example around the central longitudinal axis of the channel.

[0015] In the case of a channel having a cross-shaped cross-section, the channel has a substantially cylindrical shape, and the inner surface defining the channel comprises four ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0016] The mouthpiece or filter element comprises a first section having a core extending longitudinally in a filter material having an outer surface and an inner surface, wherein the inner surface defines a channel extending longitudinally from the end of the second section, and the second section having a core extending longitudinally in a filter material, wherein the inner surface has one or more ridges extending spirally around the longitudinal axis of the first section, and the first section and the second section are adjacent and integral.

[0017] The applicant has found that, when in use, the presence of one or more ridges extending spirally around the longitudinal axis of the first section results in a different and improved smoke mouthfeel compared to a standard tube mouthpiece or filter element having a constant cross-section in the longitudinal direction.

[0018] The applicant has found that, during use, the aerosol in the form of smoke passing through the mouthpiece or filter element takes a spiral or vortex path through the channel. During use, the mouthpiece or filter of the present invention has been found to produce a different smoking sensation, where the smoke is perceived as being more dispersed in the mouth, compared to standard tube filter elements or mouthpieces. While not wishing to be bound by theory, it is thought that the spiral path taken by the smoke contributes to these differences in sensory characteristics.

[0019] The applicant has also found that filtration can be improved compared to a filter element having channels with a uniform cross-section in the longitudinal direction by including one or more ridges that extend spirally around the channel or the longitudinal axis of each channel. The one or more ridges can increase the surface area of ​​the channel or the inner surface of each channel, thereby increasing the surface area for adsorption.

[0020] The applicant has found that having a second section adjacent to and integral with the first section eliminates the need to use further individual filter segments to impart additional properties or functionality to the filter element. The mouthpiece or filter element of the present invention can be manufactured in a single continuous process, which means that the assembly of multiple filter segments is not required. Nevertheless, it will be understood that the mouthpiece or filter element of the present invention is still suitable for incorporation into a multi-segment filter.

[0021] The channel may be a tube or a hole. Preferably, the channel is surrounded by a filter material.

[0022] The non-circular transverse channel cross-section may vary in the longitudinal direction by rotating around the channel's longitudinal axis, for example, the central longitudinal axis of the channel.

[0023] The channel may extend along the entire length of the first section.

[0024] Preferably, the core extending in each longitudinal direction of the filter material is substantially cylindrical, for example, cylindrical. The core extending in the longitudinal direction of the filter material may have a circumference of 14 mm to 25 mm.

[0025] The first section may have a non-uniform wall thickness due to the presence of one or more ridges on the inner surface of the core. The wall thickness at the narrowest point may be 0.6 mm to 2.3 mm, for example, 1.8 to 2.3 mm. The wall thickness is defined herein as the distance between the outer and inner surfaces of the longitudinally extending core.

[0026] The channel may be substantially cylindrical. It will be understood that the channel may be substantially cylindrical, but the cross-section may not be circular and may be, for example, cross-shaped, rectangular, or a deformed circle including one or more protruding portions extending from the edge of the circle towards the center of the circle.

[0027] Preferably, the channel extends from the suction end of the core of the filter material.

[0028] The channel may have a diameter of 1.5 mm to 6 mm, for example, 1.5 mm to 5 mm at its widest point.

[0029] The channel may have a diameter of 2 mm to 6 mm, for example, 3 mm to 5 mm, for example, 3.4 mm to 4.8 mm, for example, 3.5 mm to 4.7 mm, for example, 3.7 mm or 4.5 mm at its widest point.

[0030] One or more ridges may extend along a part of the length of the inner surface of the core. Preferably, the ridges extend along the entire length of the inner surface of the core. The ridges may have a width of 1.0 mm to 2 mm, for example, 1.2 to 1.7 mm, for example, 1.5 mm. The ridges may have a height of 0.2 to 1.5 mm.

[0031] The inner surface of the core may include one, two, three, or four ridges that extend spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. The inner surface of the core may include two or more ridges that extend spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. Preferably, the inner surface of the core includes two ridges that extend spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0032] The first section may include two or more channels that extend longitudinally from the end of the core, for example, two, three, or four channels.

[0033] The outer perimeter of the mouthpiece or filter element may be between 14 and 25 mm.

[0034] The length of the mouthpiece or filter element may be between 4.0 mm and 50 mm, for example, between 5 mm and 32 mm.

[0035] The second section may include a longitudinally extending core of continuous or homogeneously dispersed filter material. Preferably, the second section does not include channels such as tubes or holes.

[0036] The mouthpiece or filter element may include a third section that includes a longitudinally extending core of filter material, and the third section is adjacent to and integral with the first section such that the first section is between the third section and the second section.

[0037] Alternatively, the mouthpiece or filter element may include a third section that includes a longitudinally extending core of filter material having an outer surface and an inner surface, and the inner surface defines a channel that extends longitudinally from the end of the third section.

[0038] The channel of the third section may have a non-circular cross-section that varies in the longitudinal direction by rotating around the longitudinal axis of the third section.

[0039] The channel of the third section may have a cross-section that is a deformed circle, cross, or rectangle having one or more projections extending toward the center of the circle. The third section may be adjacent to and integral with the second section, such that the second section is between the first section and the third section.

[0040] The inner surface of the channel of the third section may have one or more ridges that extend spirally around the longitudinal axis of the third section.

[0041] The third section may be adjacent to the second section and integrated with the second section, such that the second section lies between the first section and the third section.

[0042] Preferably, the channel of the third section extends from the free end of the third section. The third section may be substantially the same as the first section. The channel of the third section is configured such that its cross-section at a first location along the length of the core extending longitudinally in the filter material can be rotated relative to an adjacent location along the length of the core extending longitudinally in the filter material. It will be understood that the cross-section of the channel may be rotated by more or less than 360 degrees along the length of the channel.

[0043] The channel in the third section may be a tube or a hole. Preferably, the channel in the third section is surrounded by a filter material.

[0044] The non-circular transverse channel cross-section may vary in the longitudinal direction by rotating around the channel's longitudinal axis, for example, the central longitudinal axis of the channel.

[0045] The inner surface of the third section may have one or more protrusions extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. One or more protrusions may project from the inner surface. One or more protrusions may be formed on the inner surface. One or more protrusions may be integral with the inner surface.

[0046] In the case of a channel of a third section having a cross-section that is a deformed circle having one or more protruding portions extending from the edge of the circle toward the center of the circle, the channel has a substantially cylindrical shape, and the inner surface defining the channel includes one or more ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0047] If the channel of the third section has a cross-sectional shape, the channel has a substantially cylindrical shape, and the inner surface defining the channel comprises four ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0048] The channel of the third section may extend along the entire length of the third section.

[0049] Preferably, the cores extending in each longitudinal direction of the filter material are substantially cylindrical, for example, cylindrical. The cores extending in the longitudinal direction of the filter material may have a circumference of 14 mm to 25 mm.

[0050] The third section may have a non-constant wall thickness due to the presence of one or more ridges on the inner surface of the core. The wall thickness at the narrowest point may be 0.6 mm to 2.3 mm, for example, 1.8 to 2.3 mm. In this specification, wall thickness is defined as the distance between the outer and inner surfaces of the core extending in the longitudinal direction.

[0051] The channel in the third section may be substantially cylindrical. Although the channel may be substantially cylindrical, it will be understood that the cross-section may not be circular, but rather a deformed circle including, for example, a cruciate, rectangular, or one or more projections extending from the edge of the circle toward the center of the circle.

[0052] The channel of the third section may have a diameter of 1.5 mm to 6 mm at its widest point, for example, 1.5 mm to 5 mm.

[0053] The channel of the third section may have a diameter of 2 mm to 6 mm at its widest point, for example, 3 mm to 5 mm, for example, 3.4 mm to 4.8 mm, for example, 3.5 mm to 4.7 mm, for example, 3.7 mm or 4.5 mm.

[0054] One or more ridges may extend along a portion of the length of the inner surface of the core. Preferably, the ridges extend along the entire length of the inner surface. The ridges may have a width of 1.0 mm to 2 mm, for example 1.2 to 1.7 mm, for example 1.5 mm. The ridges may have a height of 0.2 to 1.5 mm.

[0055] The inner surface of the core of the third section may have one, two, three, or four ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. The inner surface of the core may have two or more ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. Preferably, the inner surface of the core of the third section has two ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0056] In the case of a filter element or mouthpiece having only a first section and a second section, the first section may have a length of 5 mm to 10 mm, for example, 7 mm. The second section may have a length of 15 to 35 mm, for example, 10 mm. In the case of a filter element or mouthpiece having a first section, a second section and a third section, the lengths of the first, second, and third sections may each be independently 5 to 15 mm, for example, 11 mm.

[0057] Preferably, the first section, the second section, and the third section (if any) include the same type of filter material.

[0058] The filter material may be a material conventionally used in the manufacture of tobacco smoke filters, such as a filament material, fiber material, web material, or extruded material. The filter material may also be a natural or synthetic filamentous tow, such as cotton, or a polymer such as polyethylene or polypropylene, or a tow of cellulose acetate.

[0059] The filter material may be a thermoplastic polymer, or in other cases a spun polymer, such as polypropylene, polyethylene terephthalate, or polylactide. For example, it may be a web material such as natural or synthetic staple fiber, raw cotton, paper (usually crepe-processed), and synthetic nonwoven fabrics, as well as an extruded material (e.g., starch, synthetic foam). Preferably, the filter material is a material that can be solidified using a plasticizer. Preferably, the filter material comprises a filamentous tow of cellulose acetate.

[0060] The total denier of the filter material may be approximately 20,000 to 100,000 g per 9,000 m, for example, 20,000 to 80,000 g per 9,000 m, or for example, 20,000 to 50,000 g per 9,000 m.

[0061] If the filter material is formed from a single bale tow, the total denier of the filter material may be approximately 20,000 to 50,000 g per 9,000 m, for example 30,000 g to 40,000 g per 9,000 m, for example 30,000 g to 38,000 g per 9,000 m, for example 30,000 g, 32,000 g, 33,000 g, 37,000 g, or 40,000 g per 9,000 m.

[0062] If the filter material is formed from two bale tows, the total denier of the filter material may be approximately 40,000 to 100,000 g per 9000 m, for example 60,000 g to 80,000 g per 9000 m, for example 60,000 g to 76,000 g per 9000 m, for example 60,000 g, 64,000 g, 66,000 g, 74,000 g, or 80,000 g per 9000 m.

[0063] The filament denier may be 5g to 9g per 9000m, for example, 5g, 7.3g, 8g, or 9.0g per 9000m.

[0064] Filter materials are typically described with reference to filament denier, total denier, and fiber cross-section. For example, a filter material may include tow having deniers of 8.0Y40, 8.0Y32, 7.3Y33, or 9.0Y37. For example, a filter material having 8.0Y40 denier means that the filament denier is 8.0 g per 9000 m, the total denier is 40,000 g per 9000 m, and the filaments have a Y-shaped cross-section.

[0065] The filter material may contain a plasticizer. The filter material may contain a plasticizer in an amount of about 12% to 24% by weight of the filter material and plasticizer, for example, about 14% to 22% by weight of the filter material and plasticizer, for example, about 16% to 20% by weight, for example, about 17% to 19% by weight, for example, about 18% by weight.

[0066] The amount of plasticizer present in the mouthpiece or filter element is calculated as a percentage of the total weight of the filter material and plasticizer using the following general formula.

number

[0067] In the case of fibrous filter materials such as filamentous tow, the plasticizer acts to solidify the fibers of the filter material. Solidifying the fibers of the filter material can improve the definition of the shape of the filter element, particularly the definition of the channels. For example, the filter material may include plasticized fibers, such as plasticized tow, such as plasticized cellulose acetate tow. The formation of plasticized tow is well known in the art. The plasticizer may be, for example, triacetin, triethylene glycol diacetate (TEGDA), or polyethylene glycol (PEG). The plasticizer may be applied to the filter material by spraying it onto the surface of the filter material using methods well known in the art.

[0068] The filter material may optionally include a binder material. The filter material may optionally include a water-soluble binder material. Examples of water-soluble materials include water-soluble polymer materials such as polyvinyl alcohol, polyvinylpyrrolidone, polyvinyl ether, starch, polyethylene glycol, and polypropylene glycol; blends of water-soluble binders with plasticizers such as triacetin, triethylene glycol diacetate (TEGDA), or polyethylene glycol (PEG); and hot-melt water-soluble binders in particulate form. By including a water-soluble binder material, the ability of the filter to decompose easily and rapidly under environmental conditions can be further enhanced.

[0069] The filter material may contain additives. The additives may be particulate additives. The particulate additives may be any particulate additive suitable for use in smoke filters, such as activated carbon, zeolite, ion exchange resin (e.g., weakly basic anion exchange resin), sepiolite, silica gel, alumina, molecular sieve, carbonaceous polymer resin, and diatomaceous earth. The particulate additives may be mixtures of two or more materials. The additives may be pigments, such as pearlescent pigments or thermochromatic pigments.

[0070] The additive may include a smoke modifier (e.g., a flavoring agent). The flavoring agent may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, or vanilla. The smoke modifier (e.g., a flavoring agent) may be applied to the filter material in liquid form. The smoke modifier (e.g., a flavoring agent) may be liquefied before application to the filter material, for example by heating above its melting point or by mixing it with a liquid carrier. The smoke modifier (e.g., a flavoring agent) may be mixed with a plasticizer and applied together, for example by spraying a mixture of the smoke modifier (e.g., a flavoring agent) and a plasticizer onto the filter material. Preferred smoke modifiers (e.g., flavoring agents) are menthol or clove.

[0071] The mouthpiece or filter element may be used as part of a tobacco smoke filter or as part of a non-tobacco-smoking material, such as a marijuana filter. The mouthpiece or filter element may also be used as part of a co-combustible tobacco product, such as a tobacco heating device.

[0072] The mouthpiece or filter element of the present invention may be incorporated into smoking articles such as cigarettes, cigarillos, and cigars. The mouthpiece or filter element of the present invention may also be incorporated into tobacco heating products or e-cigarettes. The mouthpiece or filter element may also be used independently or as part of a filter assembled by the user to form a smoking article, such as a roll-your-own smoking article.

[0073] The mouthpiece or filter element of the present invention may be incorporated into a multi-segment filter as a single segment. For example, the mouthpiece or filter element as described above may be coupled with a further filter element containing an additive, such as a granular additive, such as activated carbon granules. The mouthpiece or filter element of the present invention may be coupled with a filter element containing a capsule, such as a fragile capsule, such as a capsule containing a flavoring agent. The mouthpiece or filter element of the present invention may be coupled with a filter element containing a flavoring agent, such as (menthol) or a plurality of flavoring agents.

[0074] In further aspects of the present invention, a filter for an aerosol-generating article, such as a cigarette smoke filter, is provided, comprising a filter element as described in any of the above descriptions. The filter, such as a cigarette smoke filter, may further comprise one or more additional filter elements. Such a filter comprising two or more filter elements may be called a multi-segment filter.

[0075] One or more additional filter elements may comprise a core extending longitudinally along the filter material as defined above. One or more additional filter elements may also contain additives.

[0076] One or more additional filter elements may include one or more fully enclosed (e.g., embedded) pockets of an additive embedded inside. The additive may be a particulate additive such as activated carbon (see above), which is enclosed within the filter material, for example, as separate pockets or pods of particulate additive particles that are fully enclosed within the filter material, substantially separate from the filter material. In another example, one or more fully enclosed (e.g., embedded) pockets of an additive may be one or more fragile capsules or one or more fragile microcapsules. The capsules or microcapsules may contain various media, such as smoke modifiers such as flavoring agents (as disclosed above), and / or liquids, solids, or other materials to assist in smoke filtration, for example.

[0077] One or more additional filter elements may contain flavoring agents provided in and / or on the threads. "Flavoring thread" filter elements are well known in the art. Such filter elements typically incorporate longitudinally aligned thread or tape elements inside, which carry smoke modifiers such as flavoring agents.

[0078] The filter may include a filter element or an outer wrapper, such as a plug wrap, surrounding one or more filter elements. The wrapper may be paper, such as air-permeable paper. The wrapper may have a weight of 20 to 50 grams per square meter, for example, 27 to 35 grams per square meter. Particulate additives as described above may be applied to the wrapper or plug wrap surrounding the filter material, for example, as described in British Patent No. 2261152. Further filter elements may be wrapped by an outer wrapper, such as a plug wrap, surrounding the further filter elements. The filter elements and further filter elements as defined in any of the above descriptions may be wrapped together by an outer wrapper such as a plug wrap. The outer wrapper may function to join the filter elements and secure them in place.

[0079] In further embodiments of the present invention, an aerosol-generating article is provided comprising the filter, filter element, or mouthpiece described above. The aerosol-generating article may be a smoking article. The smoking article may include the filter described above, joined to a rod wrapped with smoking material, such as tobacco smoking material. Generally, in the case of a smoking article containing marijuana smoking material, the smoking article includes a mouthpiece as described above. The smoking article may further comprise a chipping wrapper, such as chipping paper. The chipping wrapper joins the rod wrapped with smoking material to the filter or mouthpiece by engaging around adjacent ends of the filter or mouthpiece and the rod wrapped with smoking material. The chipping wrapper may be configured to leave a portion of the outer surface of the filter / mouthpiece or filter wrapper exposed. The filter may be joined to the rod wrapped with smoking material by a full chipping wrapper that engages around the entire length of the filter or mouthpiece and adjacent ends of the rod of smoking material.

[0080] The mouthpiece, filter element, filter, or smoking article according to the present invention may not be permeable, or may be permeable by methods well known in the art, for example, by the use of a pre-perforated or air-permeable filter wrapper (plug wrap) or chipping wrapper (chipping paper), and / or laser perforation of the filter wrapper and / or chipping wrapper. The mouthpiece, filter, filter element, or smoking article according to the present invention may be permeable by laser perforation of a core (and, if present, a wrapper (one or more) (plug wrap) and chipping wrapper (chipping paper)) extending longitudinally in the filter material. A permeable full chipping wrapper (chipping paper) may also be essentially air-permeable or have vents, and in permeable products where both a filter wrapper (plug wrap) and a chipping wrapper (chipping paper) are present, the ventilation through the chipping wrapper (chipping paper) usually coincides with the ventilation through the filter wrapper (plug wrap). Vents that pass through a filter wrapper (plug wrap), a chipping wrapper (chipping paper), or both simultaneously may be created by laser perforation during the manufacture of the mouthpiece, filter, or filter element.

[0081] In a further aspect of the present invention, a multiple rod is provided comprising a plurality of mouthpieces or filter elements according to the present invention, arranged end-to-end in a mirror-image relationship.

[0082] The aerosol generating article may also be a heated aerosol generating system.

[0083] A heated aerosol generating system may include a rod of tobacco material, a heating element, a power supply, one or more cooling elements, and a mouthpiece or filter element as described above. The one or more cooling elements may be positioned downstream from the heating element and the tobacco rod. During use, the tobacco rod is heated, thereby generating a heated aerosol. The heated aerosol then passes through one or more cooling elements that act to cool the aerosol before it passes through the mouthpiece and enters the user's mouth.

[0084] In this specification, aerosol generating articles may include smoking articles such as cigarettes, cigars, cigarillos, and roll-your-own cigarettes, heated tobacco products such as non-combustion heating devices and tobacco heating devices, and e-cigarettes.

[0085] In a further aspect of the present invention, a cooling element for an aerosol-generating article is provided, comprising: a first section having a longitudinally extending core of a filter material having an outer surface and an inner surface, wherein the inner surface defines a channel extending longitudinally from the end of the first section; and a second section having a longitudinally extending core of the filter material, wherein the first and second sections are adjacent and integral, and the channel has a non-circular cross-section that varies longitudinally by rotating about the longitudinal axis of the first section.

[0086] The channel may have a cross-section that is a deformed circle, cross, or rectangle, with one or more projections extending toward the center of the circle.

[0087] The channel is configured such that its cross-section at a first location along the length of the core extending longitudinally in the filter material can be rotated relative to an adjacent location along the length of the core extending longitudinally in the filter material. It will be understood that the cross-section of the channel may be rotated by more or less than 360 degrees along the length of the channel.

[0088] The applicant found that, during use, heated aerosols passing through the cooling element take a helical or spiral path through the channel or each channel. While not wishing to be bound by theory, it is thought that the spiral path taken by the heated aerosols cools them.

[0089] The channel may be a tube or a hole. Preferably, the channel is surrounded by a filter material.

[0090] The non-circular transverse channel cross-section may vary in the longitudinal direction by rotating around the channel's longitudinal axis, for example, the central longitudinal axis of the channel.

[0091] The second section may comprise a core extending longitudinally in a continuous or homogeneously dispersed filter material. Preferably, the second section does not include channels such as tubes or holes.

[0092] The inner surface may have one or more ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. One or more ridges may protrude from the inner surface. One or more ridges may be formed on the inner surface. One or more ridges may be integral with the inner surface.

[0093] In the case of a channel having a cross-section that is a deformed circle having one or more protruding portions extending from the edge of the circle toward the center of the circle, the channel has a substantially cylindrical shape, and the inner surface defining the channel comprises one or more helical protrusions extending around the longitudinal axis of the first section, for example around the longitudinal axis of the channel, for example around the central longitudinal axis of the channel.

[0094] In the case of a channel having a cross-shaped cross-section, the channel has a substantially cylindrical shape, and the inner surface defining the channel comprises four ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0095] The cooling element comprises a first section having a core extending longitudinally in a filter material having an outer surface and an inner surface, wherein the inner surface defines a channel extending longitudinally from the end of the second section, and the second section having a core extending longitudinally in a filter material, wherein the inner surface has one or more protrusions extending spirally around the longitudinal axis of the first section, and the first section and the second section are adjacent and integral.

[0096] The channel may be a tube or a hole. Preferably, the channel is surrounded by a filter material.

[0097] The non-circular transverse channel cross-section may vary in the longitudinal direction by rotating around the channel's longitudinal axis, for example, the central longitudinal axis of the channel.

[0098] The channel may extend along the entire length of the first section.

[0099] Preferably, the cores extending in each longitudinal direction of the filter material are substantially cylindrical, for example, cylindrical. The cores extending in the longitudinal direction of the filter material may have a circumference of 14 mm to 25 mm.

[0100] The first section may have a non-constant wall thickness due to the presence of one or more ridges on the inner surface of the core. The wall thickness at the narrowest point may be 0.6 mm to 2.3 mm, for example, 1.8 to 2.3 mm. In this specification, wall thickness is defined as the distance between the outer and inner surfaces of the core extending in the longitudinal direction.

[0101] The channel may be substantially cylindrical. However, it will be understood that the cross-section may not be circular, but rather a deformed circle including, for example, a cruciate, rectangular, or one or more projections extending from the edge of the circle toward the center.

[0102] The channel may have a diameter of 1.5 mm to 6 mm at its widest point, for example, 1.5 mm to 5 mm.

[0103] The channel may have a diameter of 2 mm to 6 mm at its widest point, for example, 3 mm to 5 mm, for example, 3.4 mm to 4.8 mm, for example, 3.5 mm to 4.7 mm, for example, 3.7 mm or 4.5 mm.

[0104] One or more ridges may extend along a portion of the length of the inner surface of the core. Preferably, one or more ridges extend along the entire length of the inner surface of the core. The ridges may have a width of 1.0 mm to 2 mm, for example 1.2 to 1.7 mm, for example 1.5 mm. The ridges may have a height of 0.2 to 1.5 mm.

[0105] The inner surface of the core may have one, two, three, or four ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. The inner surface of the core may have two or more ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. Preferably, the inner surface of the core has two ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0106] The cooling element may have two or more channels extending longitudinally from the ends of the core, for example, two, three, or four channels.

[0107] The outer circumference of the cooling element may be 14 to 25 mm.

[0108] The length of the cooling element may be 4.0 mm to 50 mm, for example, 5 mm to 32 mm.

[0109] The second section may comprise a core extending longitudinally in a continuous or homogeneously dispersed filter material. Preferably, the second section does not include channels such as tubes or holes.

[0110] The cooling element may include a third section having a core extending longitudinally along the filter material, the third section being adjacent to and integral with the first section such that the first section is located between the third section and the second section.

[0111] Alternatively, the mouthpiece or filter element may comprise a third section having a core extending longitudinally from an outer surface and an inner surface of a filter material, the inner surface defining a channel extending longitudinally from the end of the third section.

[0112] The channel of the third section may have a non-circular cross-section that varies longitudinally by rotating around the longitudinal axis of the third section. The channel may have a cross-section that is a deformed circle, cruciform, or rectangular with one or more projections extending toward the center of the circle. The third section may be adjacent to and integral with the second section, such that the second section is between the first section and the third section.

[0113] The inner surface of the channel of the third section may have one or more ridges that extend spirally around the longitudinal axis of the third section.

[0114] The third section may be adjacent to the second section and integrated with the second section, such that the second section lies between the first section and the third section.

[0115] Preferably, the channel extends from the free end of the third section. The third section may be substantially the same as the first section. The channel of the third section is configured such that its cross-section at a first location along the length of the core extending longitudinally in the filter material can be rotated relative to an adjacent location along the length of the core extending longitudinally in the filter material. It will be understood that the cross-section of the channel may be rotated by more or less than 360 degrees along the length of the channel.

[0116] The channel in the third section may be a tube or a hole. Preferably, the channel in the third section is surrounded by a filter material.

[0117] The non-circular transverse channel cross-section may vary in the longitudinal direction by rotating around the channel's longitudinal axis, for example, the central longitudinal axis of the channel.

[0118] The inner surface of the third section may have one or more protrusions extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. One or more protrusions may project from the inner surface. One or more protrusions may be formed on the inner surface. One or more protrusions may be integral with the inner surface.

[0119] In the case of a channel of a third section having a cross-section that is a deformed circle having one or more protruding portions extending from the edge of the circle toward the center of the circle, the channel has a substantially cylindrical shape, and the inner surface defining the channel includes one or more ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0120] If the channel of the third section has a cross-sectional shape, the channel has a substantially cylindrical shape, and the inner surface defining the channel comprises four ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0121] The channel of the third section may extend along the entire length of the third section.

[0122] Preferably, the cores extending in each longitudinal direction of the filter material are substantially cylindrical, for example, cylindrical. The cores extending in the longitudinal direction of the filter material may have a circumference of 14 mm to 25 mm.

[0123] The third section may have a non-constant wall thickness due to the presence of one or more ridges on the inner surface of the core. The wall thickness at the narrowest point may be 0.6 mm to 2.3 mm, for example, 1.8 to 2.3 mm. In this specification, wall thickness is defined as the distance between the outer and inner surfaces of the core extending in the longitudinal direction.

[0124] The channel in the third section may be substantially cylindrical. Although the channel may be substantially cylindrical, it will be understood that the cross-section may not be circular, but rather a deformed circle including, for example, a cruciate, rectangular, or one or more projections extending from the edge of the circle toward the center of the circle.

[0125] The channel of the third section may have a diameter of 1.5 mm to 6 mm at its widest point, for example, 1.5 mm to 5 mm.

[0126] The channel of the third section may have a diameter of 2 mm to 6 mm at its widest point, for example, 3 mm to 5 mm, for example, 3.4 mm to 4.8 mm, for example, 3.5 mm to 4.7 mm, for example, 3.7 mm or 4.5 mm.

[0127] One or more ridges may extend along a portion of the length of the inner surface of the core. Preferably, the ridges extend along the entire length of the inner surface. The ridges may have a width of 1.0 mm to 2 mm, for example 1.2 to 1.7 mm, for example 1.5 mm. The ridges may have a height of 0.2 to 1.5 mm.

[0128] The inner surface of the core of the third section may have one, two, three, or four ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. The inner surface of the core may have two or more ridges extending spirally around the longitudinal axis of the first section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel. Preferably, the inner surface of the core of the third section has two ridges extending spirally around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel, for example, around the central longitudinal axis of the channel.

[0129] The channels in the first or third section may, for example, accommodate a heating element.

[0130] The applicant has found that a cooling element comprising a first section, a second section, and a third section as described herein can accommodate a heating element within a channel in either the first section or the third section. In such a case, the second section and the remaining sections can act to cool the aerosol formed by the heating element.

[0131] In the case of a cooling element having only a first section and a second section, the first section may have a length of 5 mm to 10 mm, for example, 7 mm. The second section may have a length of 15 to 35 mm, for example, 10 mm. In the case of a filter element or mouthpiece having a first section, a second section and a third section, the lengths of the first, second, and third sections may each be independently 5 to 15 mm, for example, 11 mm.

[0132] Preferably, the first section, the second section, and the third section (if any) include the same type of filter material.

[0133] The filter material may be a material conventionally used in the manufacture of tobacco smoke filters, such as a filament material, fiber material, web material, or extruded material. The filter material may also be a natural or synthetic filamentous tow, such as cotton, or a polymer such as polyethylene or polypropylene, or a tow of cellulose acetate.

[0134] The filter material may be a thermoplastic polymer, or in other cases a spun polymer, such as polypropylene, polyethylene terephthalate, or polylactide. For example, it may be a web material such as natural or synthetic staple fiber, raw cotton, paper (usually crepe-processed), and synthetic nonwoven fabrics, as well as an extruded material (e.g., starch, synthetic foam). Preferably, the filter material is a material that can be solidified using a plasticizer. Preferably, the filter material comprises a filamentous tow of cellulose acetate.

[0135] The total denier of the filter material may be approximately 20,000 to 100,000 g per 9,000 m, for example, 20,000 to 80,000 g per 9,000 m, or for example, 20,000 to 50,000 g per 9,000 m.

[0136] If the filter material is formed from a single bale tow, the total denier of the filter material may be approximately 20,000 to 50,000 g per 9,000 m, for example 30,000 g to 40,000 g per 9,000 m, for example 30,000 g to 38,000 g per 9,000 m, for example 30,000 g, 32,000 g, 33,000 g, 37,000 g, or 40,000 g per 9,000 m.

[0137] If the filter material is formed from two bale tows, the total denier of the filter material may be approximately 40,000 to 100,000 g per 9000 m, for example 60,000 g to 80,000 g per 9000 m, for example 60,000 g to 76,000 g per 9000 m, for example 60,000 g, 64,000 g, 66,000 g, 74,000 g, or 80,000 g per 9000 m.

[0138] The filament denier may be 5g to 9g per 9000m, for example, 5g, 7.3g, 8g, or 9.0g per 9000m.

[0139] Filter materials are typically described with reference to filament denier, total denier, and fiber cross-section. For example, a filter material may include tow having deniers of 8.0Y40, 8.0Y32, 7.3Y33, or 9.0Y37. For example, a filter material having 8.0Y40 denier means that the filament denier is 8.0 g per 9000 m, the total denier is 40,000 g per 9000 m, and the filaments have a Y-shaped cross-section.

[0140] The filter material may contain a plasticizer. The filter material may contain a plasticizer in an amount of about 12% to 24% by weight of the filter material and plasticizer, for example, about 14% to 22% by weight of the filter material and plasticizer, for example, about 16% to 20% by weight, for example, about 17% to 19% by weight, for example, about 18% by weight.

[0141] The amount of plasticizer present in the mouthpiece or filter element is calculated as a percentage of the total weight of the filter material and plasticizer using the following general formula.

number

[0142] In the case of fibrous filter materials such as filamentous tow, the plasticizer acts to solidify the fibers of the filter material. Solidifying the fibers of the filter material can improve the definition of the shape of the filter element, particularly the definition of the channels. For example, the filter material may include plasticized fibers, such as plasticized tow, such as plasticized cellulose acetate tow. The formation of plasticized tow is well known in the art. The plasticizer may be, for example, triacetin, triethylene glycol diacetate (TEGDA), or polyethylene glycol (PEG). The plasticizer may be applied to the filter material by spraying it onto the surface of the filter material using methods well known in the art.

[0143] The filter material may optionally include a binder material. The filter material may optionally include a water-soluble binder material. Examples of water-soluble materials include water-soluble polymer materials such as polyvinyl alcohol, polyvinylpyrrolidone, polyvinyl ether, starch, polyethylene glycol, and polypropylene glycol; blends of water-soluble binders with plasticizers such as triacetin, triethylene glycol diacetate (TEGDA), or polyethylene glycol (PEG); and hot-melt water-soluble binders in particulate form. By including a water-soluble binder material, the ability of the filter to decompose easily and rapidly under environmental conditions can be further enhanced.

[0144] The filter material may contain additives. The additives may be pigments, such as pearlescent pigments or thermochromatic pigments.

[0145] The additive may include an aerosol modifier (e.g., a flavoring agent). The flavoring agent may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, or vanilla. The aerosol modifier (e.g., a flavoring agent) may be applied to the filter material in liquid form. The aerosol modifier (e.g., a flavoring agent) may be liquefied before application to the filter material, for example by heating above its melting point or by mixing it with a liquid carrier. The aerosol modifier (e.g., a flavoring agent) may be mixed with a plasticizer and applied together, for example by spraying a mixture of a smoke modifier (e.g., a flavoring agent) and a plasticizer onto the filter material. Preferred aerosol modifiers (e.g., flavoring agents) are menthol or clove.

[0146] The cooling element of the present invention may be used as part of an aerosol generating article, or it may form part of a heated tobacco product, for example.

[0147] In a further aspect of the present invention, an aerosol-generating article comprising a cooling element as described herein is provided.

[0148] The aerosol generating article may also be a heated aerosol generating system. The heated aerosol generating system may include a rod of tobacco material, a heating element, a power supply, one or more cooling elements as described in any of the above descriptions, and a mouthpiece or filter element as described in any of the herein descriptions. The one or more cooling elements may be positioned downstream from the heating element and the tobacco rod. During use, the tobacco rod is heated, thereby generating a heated aerosol. The heated aerosol then passes through one or more cooling elements that act to cool the aerosol before it passes through the mouthpiece and enters the user's mouth.

[0149] In the case of a cooling element comprising a first section, a second section, and a third section, the heating element may be housed within a channel in either the first section or the third section. The second section and the remaining sections act to cool the heated aerosol during use.

[0150] In a further aspect of the present invention, a multiple rod is provided comprising a plurality of cooling elements according to the present invention, arranged end-to-end in a mirror-image relationship.

[0151] In a further aspect of the present invention, an apparatus is provided for manufacturing a mouthpiece, filter element, or cooling element for an aerosol generating article, the apparatus comprising a molding chamber having an inlet for receiving filter material and an outlet for discharging a rod of filter material, and a molding rod, the molding rod being configured to rotate, the molding chamber comprising a curing zone extending longitudinally along at least a portion of the length of the molding chamber, and the molding rod being configured to move longitudinally (e.g., reciprocating) between a first position in which the end of the molding rod is positioned at the end of the curing zone and the molding rod extends along the entire length of the curing zone, and a second position in which the end of the molding rod is longitudinally separated from the first position and the molding rod does not extend along the entire length of the curing zone.

[0152] The curing zone extends laterally along the width of the molding chamber.

[0153] The molding rod may be configured to rotate around its central longitudinal axis.

[0154] In the second position, the molding rod may be configured not to extend into the curing zone.

[0155] The molding chamber may comprise a substantially cylindrical hollow element, for example, a cylindrical hollow element, the inner surface of which is configured to mold the filter material to form a cylindrical rod of the filter material. The molding chamber inlet may be spaced longitudinally apart from the molding chamber outlet.

[0156] The curing zone may extend along the entire width and length of the molding chamber, or it may extend along a portion of the entire width and length of the molding chamber.

[0157] The molding rod may be configured to extend at least partially into the molding chamber. For example, the molding rod may be configured to protrude from the molding chamber. The molding rod may be configured to extend along the entire length of the molding chamber. For example, in a first position, the molding rod may be configured to extend along the entire length of the molding chamber, and in a second position, the molding rod may be configured to extend along a portion of the length of the molding chamber. In the second position, the molding rod may be configured not to extend into the molding chamber.

[0158] In the second position, the molding rod may be configured to extend along a portion of the length of the curing zone. Alternatively, in the second position, the molding rod may be configured to extend to the curing zone but not into the curing zone.

[0159] The applicant has found that an apparatus including a molding rod configured to rotate around the longitudinal axis of a molding chamber, and also configured to reciprocate longitudinally as described herein, enables the manufacture of a filter element or mouthpiece as described herein. It will be understood that the speed at which the filter material is advanced into the molding chamber and the frequency of the reciprocating motion of the molding rod can control the relative lengths of the first section, second section, and third section (if any) that form the filter element or mouthpiece of the present invention.

[0160] The molding rod may be coupled to a first motor for rotating the molding rod. The motor may be configured to rotate the molding rod.

[0161] The molding rod may be coupled to a second motor for moving the molding rod between a first position and a second position. The motor may be configured to move the molding rod between the first position and the second position. The molding rod may be coupled to the second motor via a cam.

[0162] Preferably, the molded rod has a non-circular cross-section. The non-circular cross-section may be a deformed circle, cross-shaped, or rectangular with one or more depressions.

[0163] Preferably, the apparatus includes a heating element for applying heat to the filter material, thereby curing the filter material. Preferably, the molding chamber includes a heating element so as to apply heat to the filter material in the curing zone. The heating element may apply heat in the form of hot air, infrared radiation, or a steam jet. Preferably, the heating element includes a steam element for applying steam to (or configured to apply steam to) the filter material. The molding chamber may include a steam element for applying steam to (or configured to apply steam to) the filter material in the curing zone. The steam element may be for applying steam directly to (or configured to apply steam to) the filter material in the curing zone. The molding chamber may include a steam inlet for applying steam to (or configured to apply steam to) the filter material within the molding chamber, for example, in the curing zone.

[0164] The apparatus may include a further heating element (e.g., in the form of a steam element) for applying heat (e.g., in the form of steam) to the rod of filter material. The further heating element or steam element may be spaced longitudinally away from the outlet of the molding chamber.

[0165] The apparatus may include a stuffer jet for collecting (or being configured to collect) the filter material before it enters the molding chamber. The stuffer jet may have an inlet for applying fast-moving air, such as compressed air, to the filter material.

[0166] The apparatus may include a filter material expansion element for expanding the filter material before it enters the molding chamber, or configured to expand the filter material. For example, the filter material expansion element is for blooming the filter material, or configured to bloom the filter material. The molding rod may extend through the filter material expansion element. The applicant has found that including the filter material expansion element allows the filter material to twist as the molding rod rotates, thereby initiating flow channel formation before the filter material enters the molding chamber, which helps to improve the definition of the flow channel.

[0167] The filter material expansion element may be located between the stuffer jet and the molding chamber. The stuffer jet and the molding chamber may be spaced longitudinally apart so that the filter material expands into the space between the stuffer jet and the molding chamber. The apparatus may also include one or more air jet elements for applying (or configured to apply) high-speed moving air, such as compressed air, to the filter material after it has left the molding chamber.

[0168] The apparatus may include a plasticizing element that applies (or is configured to apply) a plasticizer to the filter material before the filter material enters the molding chamber. The plasticizing element may be positioned longitudinally away from the entrance of the molding chamber.

[0169] The device may include a wrapping element for (or configured to) wrap a longitudinally extending rod with a wrapper, such as a plug wrap.

[0170] The apparatus may include a cutting element for cutting (or configured to cut) rods of filter material.

[0171] A further aspect of the present invention provides a method for manufacturing a mouthpiece, filter element, or cooling element for an aerosol generating article, the method comprising advancing a filter material longitudinally and drawing the filter material through into a molding chamber having an inlet for receiving the filter material and an outlet through which a rod of the filter material exits, wherein the molding chamber comprises a curing zone extending longitudinally along at least a portion of the length of the chamber, and moving the molding rod longitudinally between a first position in which the end of the molding rod is positioned at the end of the curing zone and the molding rod extends along the entire length of the curing zone and a second position in which the end of the molding rod is longitudinally separated from the first position and the molding rod does not extend along the entire length of the curing zone (for example) The process includes, for example, reciprocating motion and rotating the molding rod, wherein in the first position, the advancing filter material moves forward through a space defined by the inner surface of the molding chamber and the molding rod to form a first section comprising a longitudinally extending core of the filter material having an outer surface and an inner surface, the inner surface defining a longitudinally extending channel having a non-circular cross-section that varies longitudinally by rotating around the longitudinal axis of the first section, and in the second position, the filter material moves forward into a space defined by the end of the molding rod, the inner surface of the chamber and the end of the curing zone to form a second section comprising a longitudinally extending core of the filter material, thereby forming a longitudinally extending rod of the filter material having alternating first and second sections.

[0172] The filter material may advance continuously.

[0173] Preferably, the curing zone extends along the width of the molding chamber.

[0174] The molding chamber may comprise a substantially cylindrical (e.g., cylindrical) hollow element, the inner surface of which is configured to mold the filter material to form a cylindrical rod of the filter material. The substantially cylindrical hollow element includes a curing zone that extends laterally along the substantially cylindrical width of the element and longitudinally along at least a portion of the substantially cylindrical hollow element.

[0175] The outlet of the molding chamber may be spaced longitudinally apart from the inlet of the molding chamber.

[0176] The curing zone may extend along the entire length of the molding chamber, or it may extend along a portion of the length of the molding chamber.

[0177] The molding rod may extend at least partially into the molding chamber. For example, the molding rod may protrude from the molding chamber. The molding rod may extend along the entire length of the molding chamber. For example, in the first position, the molding rod may extend along the entire length of the molding chamber, and in the second position, the molding rod may extend along a portion of the length of the molding chamber. In the second position, the molding rod does not have to extend into the molding chamber.

[0178] In the second position, the molding rod may extend along a portion of the length of the curing zone. Alternatively, in the second position, the molding rod may extend to the curing zone but not into the curing zone.

[0179] It will be understood that controlling the speed at which the filter material is advanced into the molding chamber and the frequency of the reciprocating motion of the molding rod can control the relative lengths of the first, second, and third sections forming the filter element, mouthpiece, or cooling element of the present invention. The relative speed at which the filter material advances and the frequency of the reciprocating motion of the molding rod can be controlled by a controller using techniques known in the art.

[0180] The molding rod may be rotated by a first motor coupled to the molding rod.

[0181] The molding rod may be moved longitudinally (reciprocating) between a first position and a second position by a second motor coupled to the molding rod.

[0182] Preferably, the molded rod has a non-circular cross-section. The non-circular cross-section may be a deformed circle, cross-shaped, or rectangular with one or more depressions.

[0183] Preferably, heat is applied to the filter material within the curing zone. The heat may be applied in the form of steam, hot air, or infrared radiation. Preferably, steam is applied directly to the filter material within the curing zone.

[0184] The heat acts to harden the filter material within the hardening zone, thereby forming a longitudinally extending rod of the filter material, for example, a longitudinally extending cylindrical rod of the filter material including a longitudinally extending channel as described herein.

[0185] The method may include the step of applying a plasticizer to the filter material before the filter material is drawn into the molding chamber. The plasticizer may be applied to the filter material at a plasticizing station. The plasticizer can be sprayed onto the filter material using techniques known in the art. Alternatively, the filter material may be pre-plasticized by a separate plasticizing process.

[0186] The plasticizer may be applied such that the filter material contains the plasticizer in an amount of about 12% to 24% by weight of the filter material and the plasticizer, for example, about 14% to 22% by weight of the filter material and the plasticizer, for example, about 16% to 20% by weight, for example, about 17% to 19% by weight, for example, about 18% by weight.

[0187] The amount of plasticizer present in the filter material is calculated as a percentage of the total weight of the filter material and plasticizer using the following general formula.

number

[0188] The filter material used in the method of the present invention may be defined by any description herein.

[0189] The method may include a step of expanding the filter material before it enters the molding chamber. The filter material may be expanded into space before it enters the molding chamber. The filter material may be expanded from a narrow flow of filter material to a wider (more dispersed) flow of filter material. The molding chamber may condense the expanded filter material, thereby forming a rod of filter material as described above.

[0190] The molding rod may extend through the expanded filter material.

[0191] The method may include a step of drawing the filter material into a stuffer jet before it enters the molding chamber. The filter material may be drawn into the stuffer jet before the step of expanding the filter material. In such a configuration, the step of expanding the filter material may include expanding the filter material into the space between the stuffer jet and the molding chamber. The stuffer jet can condense the filter material into a narrow flow of the filter material. Once it leaves the stuffer jet, the filter material can expand to form a wider (more dispersed) flow of the filter material.

[0192] The applicant has found that the step of expanding the filter material before it enters the molding chamber helps the filter material twist as the molding rod rotates, initiating channel formation before the filter material enters the molding chamber and improving channel definition.

[0193] The method may include the step of cutting a longitudinally extending rod of filter material to form one or more filter elements, cooling elements, or mouthpieces. It will be understood that the longitudinally extending rod of filter material may be cut at regular intervals to form the filter elements, mouthpieces, or cooling elements according to the present invention. The cutting frequency may be determined depending on the type of filter. The cutter can be controlled by a controller using techniques known in the art.

[0194] The cutting step may form a filter element, mouthpiece, or cooling element having two or three sections as described herein. It will be understood that the timing of the cutting step, combined with the speed at which the filter material advances, will determine whether the formed filter element, mouthpiece, or cooling element includes two or three sections, and also the configuration of those sections.

[0195] This method may include, for example, a step of wrapping a longitudinally extending rod around a wrapper before the cutting step.

[0196] The method may include a step of applying high-speed moving air, such as compressed air, to the rod of filter material after it has exited the molding chamber. The applicant has found that applying high-speed moving air to the rod of filter material helps to further harden and solidify the rod of filter material. [Brief explanation of the drawing]

[0197] Hereinafter, preferred embodiments of the present invention will be described only as examples, with reference to the attached drawings.

[0198] [Figure 1] This is a perspective view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 2] This is an end view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 3] This is a perspective view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 4] This is a side view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 5] Figure 3 is a cross-sectional view of the mouthpiece, filter element, or cooling element shown. [Figure 6] This is a cross-sectional view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 7] This is a cross-sectional view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 8] This is an end view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 9] This is a cross-sectional view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 10] This is an end view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 11] This is a cross-sectional view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 12] This is a perspective view of a mouthpiece, filter element, or cooling element according to the present invention. [Figure 13] This is a schematic diagram of an apparatus for manufacturing mouthpieces, filter elements, or cooling elements for use. [Figure 14a] This is a cross-sectional view of a part of an apparatus for manufacturing a mouthpiece, filter element, or cooling element for use. [Figure 14b] This is a cross-sectional view of a part of an apparatus for manufacturing a mouthpiece, filter element, or cooling element for use.

[0199] Figure 1 shows a perspective view of a mouthpiece, filter element, or cooling element 100 for an aerosol generating device according to one embodiment of the present invention. The mouthpiece, filter element, or cooling element 100 comprises a first section 110 and a second section 120. The first section 110 comprises a core 112 extending longitudinally in the form of a cylindrical core of filter material. The filter material may be cellulose acetate, but other filter materials are also preferred. The cylindrical core 112 of the filter material forming the first section comprises an outer surface 116 and an inner surface (shown as 118 in Figure 2). The outer surface 116 defines the cylindrical core, and the inner surface 118 defines a channel 114. The channel 114 extends from the free end of the first section 110 and extends along the entire length of the first section 110. In the case of a filter element or mouthpiece, the channel 114 extends from the mouthpiece end. The channel 114 has a non-circular cross-section, which, as shown in Figure 1, is a deformed circle with two protrusions 119. The cross-section varies longitudinally by rotating around the longitudinal axis of the first section 110, for example, around the longitudinal axis of the channel 114. The protrusions 119 are formed as helical ridges (as shown in Figure 2) extending around the longitudinal axis L. The ridges 119 extend along the inner surface 118 that defines the channel 114, and the ridges protrude from the inner surface. The two ridges 119 are integral with the inner surface 118 and are defined by the filter material that constitutes the core. As shown in Figure 1, the channel is centrally located relative to the core 112.

[0200] The second section 120 is integral with the first section 110. The second section 120 comprises a core 122 extending longitudinally in the form of a cylindrical core of the filter material. The filter material may be cellulose acetate, but other filter materials are also suitable. The filter material forming the second section 120 is continuous and homogeneous. The filter material forming the second section 120 is of the same type as the filter material forming the first section. The second section does not contain a channel. The cylindrical core 122 of the filter material is defined by an outer surface 126.

[0201] Figure 2 shows an end view of the mouthpiece, filter element, or cooling element shown in Figure 1, which is also an end view of the first section 110. Figure 2 shows the raised portion 119 in more detail.

[0202] Figure 3 shows a perspective cross-sectional view of the first section shown in Figure 1. As shown in Figure 3, the core 112 extends along the longitudinal axis (L), and the channel 114 extends along the longitudinal axis L of the core 112.

[0203] Figure 4 shows a side view of the first section along the plane defined by the y-axis and L-axis shown in Figure 3.

[0204] Figure 5 shows a cross-sectional view of the first section along line AA, as shown in Figure 4. The channel cross-section shown in Figure 5 includes a deformed circle having two diametrically opposed projections extending from the edge of the circle toward the center of the circle. The diametrically opposed projections correspond to a raised portion 119 that extends spirally around the longitudinal axis of the first section 110. As shown in Figure 5, the cross-section of channel 114 is rotated relative to the channel cross-section shown at the end of the first section, as shown in Figure 3.

[0205] The raised portion 119 extends spirally with respect to the longitudinal axis (L) of the first section 110, and therefore the position of the raised portion 119 with respect to the circumference of the channel 114 varies along the length of the first section 110.

[0206] Figure 6 shows a further cross-sectional view of the first section 110 along line BB, as shown in Figure 4. As shown in Figure 6, the cross-section of channel 114 is rotated relative to both the cross-section shown in Figure 5 and the end section shown in Figure 3.

[0207] Figure 7 shows a cross-sectional view of a first section of a further filter element, mouthpiece, or cooling element 200 according to the present invention. The filter element or mouthpiece 200 shown in Figure 7 is similar to those shown in Figures 5 and 6, but includes four ridges 219 that extend spirally along the inner surface of the core 214 around the longitudinal axis of the first section.

[0208] Figure 8 shows an end view, and Figure 9 shows a cross-sectional view of a first section of a further filter element, mouthpiece, or cooling element 300 according to the present invention. The first section shown in Figures 7 and 8 is similar to those shown in Figures 1 to 6, except that the first section shown in Figures 7 and 8 has a channel 314 having a rectangular cross-section. The cross-section of the channel varies in the longitudinal direction of the core by rotating around the longitudinal axis of the first section.

[0209] Figure 10 shows an end view, and Figure 11 shows a cross-sectional view of a first section of a further filter element, mouthpiece, or cooling element 400 according to the present invention. The first section shown in Figure 10 is similar to those shown in Figures 1 to 8, except that the first section shown in Figures 10 and 11 has a channel 414 having a cruciate cross-section. The cross-section of the channel varies in the longitudinal direction of the core by rotating about the longitudinal axis of the first section.

[0210] Figure 12 shows a further filter element, mouthpiece, or cooling element 500 according to the present invention. The filter element, mouthpiece, or cooling element 500 is similar to that shown in Figure 1, but includes a third section 130 which is integrated with the second section. The first section 110 and the second section 120 are the same as those described above with respect to Figures 1 to 6. The third section 130 is similar to the first section 110 and includes a core extending longitudinally in the form of a cylindrical core 132 of the filter material. The cylindrical core 132 of the filter material forming the third section includes an outer surface 136 and an inner surface. The outer surface 136 defines the cylindrical core 132, and the inner surface defines a channel 134. The channel 134 extends from the free end of the third section 130 and extends along the entire length of the third section 130. In the case of a filter element or mouthpiece, the channel 114 of the first section extends from the mouthpiece end. The channel 134 has a non-circular cross-section, which, as shown in Figure 1, is a deformed circle with two protrusions 139. The cross-section is longitudinally varied by rotating around the longitudinal axis of the third section, for example, around the longitudinal axis of the channel 134. The protrusions 139 are formed as helical ridges extending around the longitudinal axis. The ridges 139 extend along the inner surface defining the channel 134, and the ridges 139 protrude from that inner surface. The two ridges 139 are integral with the inner surface and are defined by the filter material that constitutes the core. As shown in Figure 12, the channel is centrally located relative to the core 132.

[0211] The applicant found that the filter element shown in Figure 12 may be particularly suitable for use in heated tobacco products, since the channel in the first or third section can accommodate a heating element, and the second section and the remaining section not accommodating a heating element can provide aerosol filtration and act as a cooling element for cooling the aerosol.

[0212] Any of the mouthpieces or filter elements illustrated in Figures 1 to 12 may form part of the filter contained in a smoking article such as a cigarette. Some smoking articles, such as those containing marijuana, include the mouthpieces described herein.

[0213] During use, the smoke travels through the mouthpiece or filter element, taking a spiral path within the channel, meaning that the smoke exiting the mouthpiece or filter element continues to follow a spiral path, for example, in the user's mouth. The spiral path taken by the smoke affects the mouthfeel of the smoke. A second section provides additional filtration of the smoke, and the second section may include additives to modify the properties of the smoke.

[0214] Any of the mouthpieces or filter elements shown in Figures 1 to 12 may form part of a heated tobacco product or an e-cigarette.

[0215] The cooling elements illustrated in Figures 1 to 12 may form part of a heated aerosol generating system, which can form part of a non-combustible product such as a heated tobacco product. A heated aerosol generating system typically includes a heating element, a power supply, a tobacco rod, one or more cooling elements, and a mouthpiece. The cooling elements described herein may be incorporated into a heated aerosol generating system between the mouthpiece and the tobacco rod. During use, the heating element heats the tobacco rod to form an aerosol. The aerosol then enters the cooling element and is cooled by the cooling element. Due to the channel configuration, the aerosol takes a spiral path through the cooling element, which lowers the temperature of the aerosol. In the case of the cooling element illustrated in Figure 12, either the first or third section may house the heating element, thereby allowing the heating and cooling elements to be contained within a single element.

[0216] Figure 13 is a schematic diagram of a method and apparatus for manufacturing a filter element, mouthpiece, or cooling element as described in Figures 1 to 12.

[0217] Referring to Figure 13, the apparatus comprises a stuffer jet 20 configured to receive filter material 10. A forming chamber 30 is longitudinally spaced from the stuffer jet. The space between the stuffer jet and the forming chamber defines a filter material expansion element in the form of a tow-blooming section 25, into which the filter material expands as it exits the stuffer jet 20. A forming rod in the form of a mandrel 60 extends longitudinally through the center of the stuffer jet 20 and the tow-blooming section 25 into the forming chamber 30. The mandrel 60 is coupled to a first motor 70, which is configured to rotate the mandrel around its central longitudinal axis. A second motor 80 is coupled to the mandrel and is configured to reciprocate the mandrel 60 longitudinally. It will be understood that the second motor 80 is coupled to the first motor 70 so that the second motor 80 reciprocates and simultaneously rotates the mandrel 60, and the second motor 80 reciprocates together with the first motor 70. An air jet element 40 is longitudinally spaced from the molding chamber 30 and is configured to apply a high-speed moving airflow, such as compressed air, to the rod 50 of filter material after it has left the molding chamber 30. A cutter 90 is longitudinally spaced from the air jet element 40 and is configured to cut the rod 50 of filter material into one or more filter elements, mouthpieces, or cooling elements 100. The mandrel 60, stuffer jet 20, tow blooming section 25, and molding chamber 30 are described in more detail below with respect to Figures 14a and 14b.

[0218] Next, with reference to Figure 13, a method for fabricating a filter element, mouthpiece, or cooling element 100 will be described. The tow 10 is advanced continuously in the longitudinal direction L. The tow may be made of cellulose acetate or another suitable filter material. The tow may be drawn from the bale and may be pre-treated. For example, a plasticizer may be sprayed directly onto the tow in a plasticizing station (not shown) using a method well known in the art. Alternatively, the plasticizer may be applied to the tow bale using a separate process before the tow bale is formed.

[0219] The tow 10 is advanced and flattened before entering the stuffer jet 20. The jet of the stuffer 20 is configured to pull and collect the tow. As the tow exits the stuffer jet 20 through the stuffer jet outlet, the tow expands into the gap between the outlet of the stuffer jet 20 and the inlet of the forming chamber 30. The tow 10 continues to advance into the forming chamber 30, which forms the tow into a cylindrical rod 50 that extends longitudinally along the filter material. The mandrel 60 extends longitudinally into the forming chamber 30 through the center of the stuffer jet 20 and the tow expansion section 25. The tow 10 advances around the mandrel 60, as a result of the mandrel 60 forming a longitudinally extending channel within the forming rod of the tow.

[0220] As the tow 10 passes through the molding chamber 30, the rotation of the mandrel 60 forms a longitudinally extending channel, and the channel cross-section varies longitudinally by rotating around the central longitudinal axis of the channel.

[0221] The reciprocating motion of the mandrel 60 forms alternating first and second sections on the rod of filter material. The first section comprises a core extending longitudinally in the filter material, including an outer surface defining the core and an inner surface defining the channel, as described with reference to Figures 1 to 12. The second section comprises a continuous and homogeneous core extending longitudinally in the filter material, without a channel.

[0222] The wedge 10 is cured by steam inside the molding chamber 30.

[0223] After the rod of filter material exits the molding chamber 30, the rod of filter material 50 is subjected to a high-speed airflow by an air jet element 40 to further harden it. The rod of filter material is then cut by a cutter 90 into individual filter elements, mouthpieces, or cooling elements.

[0224] Next, the process and apparatus for forming the rod of filter material, forming the channel, and forming alternating first and second sections will be described in more detail with reference to Figures 14a and 14b.

[0225] Figures 14a and 14b show the configuration of the stuffer jet, tow expansion element, and molding chamber in use and in the first and second configurations.

[0226] Figure 14a shows the mandrel 60 in a first position. Figure 14a shows a stuffer jet 20, which is a funnel-shaped element having an inlet 24 and an outlet 26 for filter material such as a tow 10, and an air inlet 22 for applying high-speed moving air to the tow 10. The inlet 24 of the stuffer jet 20 has a larger diameter than the outlet 26 so that the stuffer jet 20 tapers. The high-speed moving air enters the stuffer jet 20 through the air inlet 22, propelling the tow into the stuffer jet 20, through which it advances longitudinally, and in the stuffer jet 20 the tow is condensed into a cylindrical shape. After the tow exits the stuffer jet through the outlet 26, the tow 10 expands into the gap 25 between the outlet 26 of the stuffer jet and the inlet of the molding chamber, which is longitudinally spaced away from the outlet 26 of the stuffer jet 20. The expanded tow continues to advance longitudinally and enters the molding chamber 30. The molding chamber includes an inlet into which the expanded tow enters and an outlet into which a rod 50 extending longitudinally along the filter material exits the molding chamber 30. The molding chamber 30 includes a steam inlet 32 ​​through which steam enters the molding chamber. As shown in Figure 13a, the molding chamber includes a curing zone 35 that extends along the longitudinal length of the molding chamber and across the width of the molding chamber 30. The mandrel 60 extends longitudinally along the entire length of the curing zone 35 in the molding chamber 30, passing through the center of the stuffer jet 20 and the tow expansion element 25, so that the end of the mandrel 60 aligns with the end of the curing zone 35.

[0227] In this first configuration, the tow 10 passes through the annular space between the mandrel 60 and the inner surface of the molding chamber 30, thereby forming a channel that extends along the length of the curing zone 35. Steam is applied to the filter material in the molding chamber 30, thereby curing the filter material by solidifying it, thereby forming a first section of the filter material having a longitudinally extending core having an outer surface defining a longitudinally extending core and an inner surface defining a longitudinally extending channel.

[0228] Figure 14b shows the mandrel 60 in a second position, where it is positioned behind the mandrel shown in Figure 14a. In the second position, the end of the mandrel 60 is longitudinally separated from the first position taken by the mandrel as shown in Figure 14a, and the mandrel 60 does not extend along the entire length of the curing zone 35. As shown in Figure 14b, the mandrel 60 is pulled out to the outside of the curing zone 35. In the second position, the tow 10 enters the space defined by the end of the mandrel 60 and the inner surface of the molding chamber 30, forming a second section with a longitudinally extending core of the channelless filter material.

[0229] As shown in Figure 14b, the first section advances forward due to the vapor applied to the filter material in the hardening zone 35, and maintains its shape, including the channel. Thus, the method forms alternating first and second sections. It will be understood that the filter material is advanced at a speed correlated with the speed at which the mandrel reciprocates, so that alternating first and second sections are formed. The relative speed between the advancing filter material and the mandrel can be controlled by a controller (not shown).

[0230] The shape of the mandrel determines the cross-sectional shape of the channel. For example, the rod used to fabricate the mouthpiece, filter element, or cooling element shown in Figures 1 to 6 is a cylinder containing two diametrically opposed grooves that extend along the length of the mandrel. The mandrel used to fabricate the mouthpiece, filter element, or cooling element shown in Figure 7 is a cylinder with two pairs of diametrically opposed grooves. The mandrels used to fabricate the mouthpiece, filter element, or cooling element shown in Figures 8 and 9 have a rectangular cross-section, and the mandrels used to form the mouthpiece, filter element, or cooling element shown in Figures 10 and 11 have a cruciate cross-section.

[0231] The channel shape is defined by the mandrel as described above. The mandrel is constantly rotating during this method. The rotation of the mandrel as the filter material passes through the forming chamber forms a longitudinally extending channel, and the channel cross-section varies longitudinally by rotating around the central longitudinal axis of the channel. In the case of a mandrel containing grooves, such as those used to produce mouthpieces, filter elements, or cooling elements shown in Figures 1 to 6, the grooves within the mandrel define ridges on the inner surface of the core defining the channel. The rotation of the mandrel, and therefore the rotation of the grooves, forms ridges on the inner surface of the core defining the channel. The ridges extend along the inner surface and follow a helical path around the longitudinal axis of the channel. The helical pitch of the ridges can be varied by controlling the rotational speed of the mandrel and the speed at which the tow is drawn out through the forming chamber. The depth and width of each ridge may be changed by changing the depth and width of each groove in the mandrel. If additional protrusions are desired, the mandrel may include additional grooves. For example, the mouthpiece, filter element, or cooling element shown in Figure 7 utilizes a mandrel having four grooves.

[0232] The diameter of the channel at its widest point can be varied by changing the diameter of the rod at its widest point. Similarly, the diameter and shape of the core of the filter material can be varied by changing the diameter and shape of the molding chamber.

[0233] The applicant has found that by including a tow expansion element, the expanded tow can be twisted before entering the molding chamber, which helps in the formation of the channel as described above, thus improving the definition of the channel.

[0234] It will be understood that while the mandrel extends through the stuffer jet and tow blooming sections, channel formation may begin in these sections, but since no heating occurs, the filter material will not harden. This means that when the mandrel is drawn out to the second position, a second section without channels may still be formed.

[0235] The cutting step is timed according to the desired type of filter element, mouthpiece, or cooling element. For example, the cutting step may be timed to form a filter element, mouthpiece, or cooling element having a first section and sections as shown in Figure 1. A rod of filter material can be cut through the center of each first section to form a filter element, mouthpiece, or cooling element having first, second, and third sections, where the first and third sections are shorter than the second section. The rod can be cut such that each filter element, mouthpiece, or cooling element has first, second, and third sections of equal length.

Claims

1. A mouthpiece, filter element, or cooling element (100) for an aerosol generating article, comprising: a first section (110) having a core (112) extending longitudinally from a filter material having an outer surface (116) and an inner surface (118), wherein the inner surface defines a channel (114) extending longitudinally from the end of the first section; and a second section (120) having a core extending longitudinally from a filter material, wherein the first section and the second section are adjacent and integral, and the channel has a non-circular cross-section that varies longitudinally by rotating about the longitudinal axis of the first section, and the cross-section is a deformable circle, cross-shaped, or rectangular with two or more protruding portions (119) extending toward the center of the deformable circle, the protruding portions (119) being integrally formed with the inner surface.

2. The mouthpiece, filter element, or cooling element (100) according to claim 1, wherein the inner surface (118) comprises two or more ridges extending spirally around the longitudinal axis of the first section (110), and the ridges are integrally formed with the inner surface.

3. A third section (130) comprises a core (132) extending longitudinally from an outer surface (136) and an inner surface of the filter material, wherein the inner surface defines a channel (134) extending longitudinally from the end of the third section, and / or The channel of the third section has a non-circular cross-section that varies in the longitudinal direction by rotating around the longitudinal axis of the third section, and / or The channel of the third section has a cross-section that is a deformed circle, cross-shaped, or rectangular, having one or more protruding portions (139) extending toward the center of the deformed circle. The mouthpiece, filter element, or cooling element (500) according to claim 1.

4. The mouthpiece, filter element, or cooling element (500) according to claim 3, wherein the third section (130) is adjacent to and integral with the second section, such that the second section (120) is located between the first section (110) and the third section.

5. The aforementioned raised portion or each raised portion (119) extends along the entire length of the inner surface (118), and / or the filter material contains a plasticizer. The mouthpiece, filter element, or cooling element according to claim 2.

6. A filter for an aerosol-generating article comprising the filter element described in any one of claims 1 to 5.

7. A multiple rod comprising a plurality of mouthpieces, filter elements, or cooling elements according to any one of claims 1 to 5, joined end-to-end in a mirror-image relationship.

8. An aerosol generating article comprising a mouthpiece, filter element, or cooling element as described in any one of claims 1 to 5.

9. Apparatus for manufacturing mouthpieces, filter elements, or cooling elements for aerosol generating articles, The device comprises a molding chamber (30) having an inlet for receiving filter material and an outlet for discharging a rod of filter material, and a molding rod (60), The molding rod is configured to rotate, The molding chamber includes a curing zone (35) that extends longitudinally along at least a portion of the length of the molding chamber, The molding rod is configured to move longitudinally between a first position in which the end of the molding rod is positioned at the end of the hardening zone and the molding rod extends along the entire length of the hardening zone, and a second position in which the end of the molding rod is moved longitudinally away from the first position and the molding rod does not extend along the entire length of the hardening zone. Device.

10. The molding rod is coupled to a first motor (70) for rotating the molding rod, and / or The molding rod is coupled to a second motor (80) for moving the molding rod between the first position and the second position, and / or The molding chamber comprises a hollow, substantially cylindrical element for molding the filter material, and / or the molding rod has a non-circular cross-section, and / or The non-circular cross-section is a deformed circle, cross, or rectangle having one or more depressions. The apparatus according to claim 9.

11. The filter material is provided with a heating element for applying heat to the filter material, and / or The filter material is provided with a steam element for applying steam, and / or The molding chamber (30) includes a steam element for applying steam to the filter material in the curing zone (35). The apparatus according to claim 9.

12. The system includes a cutting element for cutting the rod of the filter material, and / or The system includes a plasticizing element for applying a plasticizer to the filter material before the filter material enters the molding chamber (30), The apparatus according to claim 9.

13. A method for manufacturing a mouthpiece, filter element, or cooling element for an aerosol generating article, The filter material (10) is advanced in the longitudinal direction, The filter material is drawn into the molding chamber (30) through the molding chamber, The molding chamber includes an inlet for receiving the filter material and an outlet through which the rod of the filter material passes when it leaves the molding chamber. The molding chamber includes a curing zone (35) that extends longitudinally along at least a portion of the length of the molding chamber, The molding rod (60) is moved longitudinally between a first position in which the end of the molding rod is positioned at the end of the hardening zone and the molding rod extends along the entire length of the hardening zone, and a second position in which the end of the molding rod is moved longitudinally away from the first position and the molding rod does not extend along the entire length of the hardening zone. This includes rotating the molding rod, In the first position, the advancing filter material moves through the space defined by the inner surface of the chamber and the molding rod to form a first section comprising a core extending longitudinally of the filter material having an outer surface and an inner surface, the inner surface defining a longitudinally extending channel having a non-circular cross-section that varies longitudinally by rotating around the longitudinal axis of the first section. At the second position, the filter material advances into the space defined by the end of the molding rod, the inner surface of the chamber, and the end of the curing zone to form a second section comprising a core extending longitudinally in the filter material, thereby forming a longitudinally extending rod of the filter material having alternating first and second sections. method.

14. Heat is applied to the filter material within the curing zone (35), and / or Steam is applied to the filter material within the curing zone, and / or the molding chamber (30) comprises a substantially cylindrical hollow element having an inlet for receiving the filter material and an outlet for discharging the rod of filter material, and / or The molded rod has a non-circular cross-section, and / or The non-circular cross-section is a deformed circle, cross, or rectangle having one or more depressions. The method according to claim 13.

15. This includes applying a plasticizer to the filter material before the filter material is drawn into the molding chamber (30), and / or The process includes the step of expanding the filter material before it enters the molding chamber, and / or The filter material is drawn into a stuffer jet (20) before entering the molding chamber, and / or the longitudinal rods of the filter material are cut to form one or more filter elements, mouthpieces, or cooling elements (90). The method according to either claim 13 or 14.

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