Mouthpiece or filter element for an aerosol generating article

Abstract

A method of manufacturing a filter for an aerosol generating article, comprising the steps of : - supplying a filtering material, - forming and advancing a continuous gathered line of filtering material through a hollow conveying element, - cutting the continuous gathered line of filtering material so as to provide a plurality of filtering elements of a given length, wherein the method comprises a step of forming a series of conical patterns along the continuous gathered line of filtering material.

Description

Mouthpiece or filter element for an aerosol generating article

[0001] The present invention provides a mouthpiece or filter element for use with a smoking article such as a cigarette, a conventional burning cigarette, or a tobacco heating product or a heat-not-burn product, or a mouthpiece or filter element for a consumable article for use in or with an electronic or electric heating or smoking device.BACKGROUND

[0002] Mouthpieces or filter elements for smoking articles such as cigarettes, tobacco heating products or heat-not-burn (HNB) products may be manufactured from a number of different materials and methods. There is the need for conical filters, however, these filters are usually manufactured by hand or with complex manufacturing methods.

[0003] It is therefore desirable to provide reliable, and / or economic and / or simple manufacturing method to manufacture conical filters.SUMMARY OF THE INVENTION

[0004] According to the present invention, a first aspect relates to a method of manufacturing a filter for an aerosol generating article, comprising the steps of :- supplying a filtering material,- forming and advancing a continuous gathered line of filtering material through a hollow conveying element,- cutting the continuous gathered line of filtering material so as to provide a plurality of filtering elements of a given length, wherein the method comprises a step of forming a series of conical patterns along the continuous gathered line of filtering material.

[0005] The method of manufacturing can be further defined with the below features, taken alone or in combination.

[0006] According to an embodiment, the step of forming the series of conical patterns may comprise causing a cone forming element to move back and forth relatively to the hollow conveying element so as to gradually compress the supplied filtering material along the direction of advance.

[0007] According to an embodiment, the conical patterns may be tapered patterns, and / or bevelled patterns, and / or cones.

[0008] According to an embodiment, the conical patterns may have straight sides. In this embodiment, the lateral sides of the cones may be straight lines.

[0009] According to an embodiment, the conical patterns may have curved sides. In this embodiment, the lateral sides of the cones may have a curved portion, or may be curved all along the length of the cones.

[0010] According to an embodiment, the step of forming the series of conical patterns may comprise, before and / or during and / or after the back and forth move, a step of causing the cone forming element to contact and / or slide onto the supplied filtering material.[0001 1 ] According to an embodiment, the cone forming element may comprise a hollow portion at least partially surrounding the filtering material during the step of forming the series of conical patterns.

[0012] According to an embodiment, the cone forming element may comprise a needle portion at least partially surrounded by the filtering material during the step of forming the series of conical patterns.

[0013] According to an embodiment, the method of manufacturing may comprise a step of bonding fibers of the filtering material, carried out during or after the step of forming the series of conical patterns.

[0014] According to an embodiment, the method of manufacturing or the step of bonding fibers of the filtering material may comprise an exposure of the filtering material to heat and / or steam.

[0015] According to an embodiment, the cone forming element may be used to carry out the step of bonding fibers of the filtering material.

[0016] According to an embodiment, the cone forming element may comprise fluid channels to convey a fluid so as to expose the filtering material to heat and / or steam.

[0017] According to an embodiment, the method of manufacturing may comprise a step of adding a plasticizer to the filtering material, before or during the supply of the filtering material.

[0018] According to an embodiment, the method of manufacturing may comprise a step of crimping the filtering material, before or during the supply of the filtering material.

[0019] According to an embodiment, the step of cutting may be carried out to cut the filtering element at a length equal to a unitary length of the conical patterns.

[0020] According to an embodiment, the step of cutting may be carried out to cut the filtering element at a pitch defined by the succession of the conical patterns.

[0021] According to an embodiment, the step of forming a series of conical patterns along the continuous gathered line of filtering material may be carried out to generate adjacent conical parts all along the gathered line of filtering material.

[0022] According to an embodiment, the conical parts are presenting an identical unitary length or pitch.

[0023] A second aspect of the disclosure may relate to a filtering element manufactured with the method of manufacturing according to the first aspect and comprising:- a body,- a first end, arranged at a first extremity of the body and arranged to form a mouth end to be held by user lips,- a second end, arranged at a second extremity of the body and arranged to be adjacent to an aerosol generating substrate of the aerosol generating article, wherein the first end presents a first diameter, the second end presents a second diameter being greater than the first diameter.

[0024] According to an embodiment:- the first diameter may be comprised between 4.0 mm and 7.5 mm, preferably between 4.5 mm and 7.0 mm, preferably between 5.0 mm and 6.0 mm, preferably between 5.2 mm and 5.8 mm, and / or- the second diameter may be comprised between 5.5 mm and 8.5 mm, preferably between 6.0 mm and 8.0 mm, preferably between 6.5 mm and 7.5 mm, preferably between 6.85 mm and 7.35 mm.

[0025] According to an embodiment, the body may present a conical shape.

[0026] According to an embodiment, the body may comprise filtering material comprising:- cellulose acetate, and / or- biodegradable material, and / or- cellulose,- cellulose paper.

[0027] According to an embodiment, the filtering element:- may have a length comprised in a range of 20 mm to 160 mm, and / or- when having a length of 120 mm, may have a pressure drop comprised in the range of 20 mmWg to 1200 mmWg, preferably in the range of 280 mmWg to 320 mmWg, preferably in the range of 290 mmWg to 310 mmWg, preferably in the range of 295 mmWg to 305 mmWg preferably when measured according to the CORESTA recommended method N° 41 .

[0028] A third aspect of the disclosure relates to a filter for an aerosol generating article (such as a conventional cigarette, a burning cigarette, a heatnot burn article, a tobacco heated article), comprising a filtering element according to the second aspect and a conical wrapper.

[0029] A fourth aspect of disclosure relates to an aerosol generating article, comprising a filter according to third aspect, and / or a filtering element according to second aspect.

[0030] According to an embodiment, the aerosol generating article may comprise an aerosol generating medium comprising:- a tobacco substrate, and / or- an aerosol former, such as glycerin, and / or- reconstituted tobacco, and / or- porous or fibrous material, containing an aerosol former, and / or- nicotine.

[0031] According to an embodiment, the aerosol generating article may be arranged to generate :- aerosol or smoke during a burning step, or- aerosol during a heat-not- burn stepDESCRIPTION OF FIGURES

[0032] Other features and advantages of the present invention will appear more clearly from the following detailed description of particular non- limitative examples of the invention, illustrated by the appended drawings where:- figure 1 represents a simplified sketch of an aerosol generating article with a filter comprising a filtering element manufactured by a manufacturing method of the present disclosure ;- figure 2 represents a simplified method for manufacturing the filtering element of figure 1 ;- figure 3 represents another simplified method for manufacturing the filtering element of figure 1 .DETAILLED DESCRIPTION OF EMBODIMENTS

[0033] Figure 1 shows a simplified sketch an aerosol generating article with a filter 10 comprising a filtering element 1 1 manufactured by a manufacturing method of the present disclosure. In particular, the aerosol generating article comprising a filter 10 adjacent to an aerosol generating part 20.

[0034] The aerosol generating part 20 may comprise an aerosol generating medium 21 wrapped in a wrapper 22. The aerosol generating medium 21 can be a burning substrate capable of delivering an aerosol containing for example nicotine. In an example, the aerosol generating medium 21 can be tobacco, shredded tobacco, cut filler. The aerosol generating medium 21 can be a non burning substrate (a heat-not-burn substrate) capable of delivering an aerosol containing for example nicotine when heated or subjected to any specific action. In an example, the aerosol generating medium 21 can be reconstituted tobacco, porous material, fibres or the like to be heated by an electronic or electric device.

[0035] The filter 10 may comprise the filtering element 1 1 typically consisting or comprising a filtering material, such as a porous material, or air permeable material. As an example, the filtering material can be or can comprise cellulose acetate, and / or biodegradable material, and / or cellulose, cellulose paper. The filtering element 1 1 is arranged or surrounded by a filter wrapper 12. The filter wrapper 12 and the wrapper 22 can be joined by a tipping paper.

[0036] One can notice figure 1 that the filter 10 and the aerosol generating part 20 have a conical shape. In particular, the filter 10 can have :- a first diameter at the mouth end side comprised between 4.0 mm and 7.5 mm, preferably between 4.5 mm and 7.0 mm, preferably between 5.0 mm and 6.0 mm, preferably between 5.2 mm and 5.8 mm, preferably the first diameter is 5.5 mm and / or- a second diameter at the aerosol generating part side comprised between 5.5 mm and 8.5 mm, preferably between 6.0 mm and 8.0 mm, preferably between 6.5 mm and 7.5 mm, preferably between 6.85 mm and 7.35 mm, preferably thesecond diameter is 7.14 mm. In other words, at least the filter 10 is tapered, beveled or conical. The aerosol generating part 20 may be conical or may be cylindrical.

[0037] The figure 2 represents a simplified method for manufacturing the filtering element 1 1 of figure 1 . In an automatic manufacturing method, figure 2 shows form the right to the left:- 1 10: supply of 2 bands of cellulose acetate from two different bales,- 120: crimping each of the 2 bands of cellulose acetate, by two pairs or crimping rollers,-130: application of a plasticizer, for example triacetin,- 140: joining the two bands of tow by a supply roller to deliver filtering material,- 150: passing the filtering material through a hollow conveying tube, i.e. gathering the filtering material to provide a continuous band or line of filtering material,- 150-160: with a back and forth movement of a mandril M or needle, forming conical patterns along the continuous gathered line of filtering material,- 160: applying steam or heat to the conical patterns of the continuous gathered line of filtering material,- 170: conveying the conical patterns of the continuous gathered line of filtering material to a garniture 175, at a speed of 55-60 mpm, in this particular example, there is no wrapper,- 180, cutting rods with a knife according to the pitch of the conical patterns of the continuous gathered line of filtering material to a garniture to provide filtering elements 11 .

[0038] Figure 3 represents another simplified method for manufacturing the filtering element 1 1 of figure 1 . Each acetate tow 1 10 is going into TPP (Pressure and plasticizer application) then continues to delivery roll DR. The tow 1 10 then goes to stuffer jet SJ on mandrill house and insert to bobbin BB that has shaft B&F-M for move back and forth. The bobbin BB is for forming the filter with steam process, the filtering material continues to shoe long folderLSF and cradle CR before going to knife head KH to be cut into filter rod, and then goes to packaging line PJ.

[0039] It is of course understood that obvious improvements and / or modifications for one skilled in the art may be implemented, still being under the scope of the invention as it is defined by the appended claims.

Claims

CLAIMS1 . A method of manufacturing a filter for an aerosol generating article, comprising the steps of :- supplying a filtering material,- forming and advancing a continuous gathered line of filtering material through a hollow conveying element,- cutting the continuous gathered line of filtering material so as to provide a plurality of filtering elements of a given length, wherein the method comprises a step of forming a series of conical patterns along the continuous gathered line of filtering material.

2. The method of manufacturing a filter according to claim 1 , wherein the step of forming the series of conical patterns comprises causing a cone forming element to move back and forth relatively to the hollow conveying element so as to gradually compress the supplied filtering material along the direction of advance.

3. The method of manufacturing according to claim 2, wherein the step of forming the series of conical patterns comprises, before and / or during and / or after the back and forth move, causing the cone forming element to contact and / or slide onto the supplied filtering material.

4. The method of manufacturing according to any one of claims 2 to 3, wherein the cone forming element comprises a hollow portion at least partially surrounding the filtering material during the step of forming the series of conical patterns.

5. The method of manufacturing according to any one of claims 2 to 3, wherein the cone forming element comprises a needle portion at least partially surrounded by the filtering material during the step of forming the series of conical patterns.

6. The method of manufacturing according to any one of claims 1 to 5, comprising a step of bonding fibers of the filtering material, carried out during or after the step of forming the series of conical patterns.

7. The method of manufacturing according to claim 6, wherein the step of bonding fibers of the filtering material comprises an exposure of the filtering material to heat and / or steam.

8. The method of manufacturing according to any one of claims 6 or 7, wherein the cone forming element comprises is used to carry out the step of bonding fibers of the filtering material.

9. The method of manufacturing according to any one of claims 6 to 8, wherein the cone forming element comprises fluid channels to convey a fluid so as to expose the filtering material to heat and / or steam.

10. The method of manufacturing according to any one of claims 6 to 9, comprising a step of adding a plasticizer to the filtering material, before or during the supply of the filtering material.11 . The method of manufacturing according to any one of claims 1 to 10, comprising a step of crimping the filtering material, before or during the supply of the filtering material.

12. The method of manufacturing according to any one of claims 1 to 11 , wherein the step of cutting is carried out to cut the filtering element at a length equal to a unitary length of the conical patterns13. The method of manufacturing according to any one of claims 1 to 12, wherein the step of forming a series of conical patterns along the continuous gathered line of filtering material is carried out to generate adjacent conical parts all along the gathered line of filtering material.

14. The method of manufacturing according to claim 14, wherein the conical parts are presenting an identical unitary length.

15. A filtering element manufactured with the method of manufacturing according to any one of claims 1 to 14, comprising:- a body,- a first end, arranged at a first extremity of the body and arranged to form a mouth end to be held by user lips,- a second end, arranged at a second extremity of the body and arranged to be adjacent to an aerosol generating substrate of the aerosol generating article, wherein the first end presents a first diameter, the second end presents a second diameter being greater than the first diameter.

16. The filtering element according to claim 15, wherein:- the first diameter is comprised between 4.0 mm and 7.5 mm, preferably between 4.5 mm and 7.0 mm, preferably between 5.0 mm and 6.0 mm, preferably between 5.2 mm and 5.8 mm, and / or- the second diameter is comprised between 5.5 mm and 8.5 mm, preferably between 6.0 mm and 8.0 mm, preferably between 6.5 mm and 7.5 mm, preferably between 6.85 mm and 7.35 mm.

17. The filtering element according to any one of claims 15 or 16, wherein the body presents a conical shape.

18. The filtering element according to any one of claims 15 to 17, wherein the body comprises filtering material comprising:- cellulose acetate, and / or- biodegradable material, and / or- cellulose,- cellulose paper.

19. The filtering element according to any one of claims 15 to 18:- having a length comprised in a range of 20 mm to 160 mm, and / or- when having a length of 120 mm, having a pressure drop comprised in the range of 20 mmWg to 1200 mmWg, preferably in the range of 280 mmWg to320 mmWg, preferably in the range of 290 mmWg to 310 mmWg, preferably in the range of 295 mmWg to 305 mmWg preferably when measured according to the CORESTA recommended method N° 41 .

20. A filter for an aerosol generating article, comprising a filtering element according to any one of claims 15 to 19 and a conical wrapper.21 . An aerosol generating article, comprising a filter according to claim 20, and / or a filtering element according to any one of claims 15 to 19.

22. The aerosol generating article of claim 21 , comprising an aerosol generating medium comprising:- a tobacco substrate, and / or- an aerosol former, such as glycerin, and / or- reconstituted tobacco, and / or- porous or fibrous material, containing an aerosol former, and / or- nicotine.

23. The aerosol generating article of claim 21 or 22, arranged to generate :- aerosol or smoke during a burning step, or- aerosol during a heat-not- bum step.

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