JP7685489B2 - Filter elements, mouthpieces and cooling elements - Google Patents

Description

The use of tube filter elements and tube mouthpieces in smoking articles is known in the art. Typically, a tube filter element comprises a cylindrical core of filter material that includes channels extending longitudinally from the end of the cylindrical core. Tube filter elements are usually included as part of a multi-segment filter, and tube filter elements are usually positioned at the mouth end of a smoking article to provide a distinctive end appearance. When incorporated into a smoking article, the tube filter allows smoke to leave the filter in a concentrated stream that is directed toward the user's tongue during use.

In recent years, non-combustion 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 the mouthpiece. The mouthpiece may function to mimic the sensory aspects of a traditional smoking article filter. Additionally, some non-combustion heating products include a cooling element that cools the aerosol before it reaches the mouthpiece.

According to a first aspect of the invention, there is provided a mouthpiece or filter element including a longitudinally extending core of filter material and one or more channels extending longitudinally from an end of the core, where the or each channel has a non-circular cross-section that varies longitudinally by rotation about a longitudinal axis of the mouthpiece or filter element, e.g., a longitudinal axis extending along the center of the channel.

The or each channel is configured such that its cross-section at a first point along the length of the longitudinally extending core of the filter material is rotatable relative to an adjacent point along the length of the longitudinally extending core of the filter material. It will be understood that the cross-section of the or each channel may rotate more than 360° or less than 360° along the length of the or each channel.

Applicant has discovered that, in use, smoke passing through the mouthpiece or filter element follows a non-linear, e.g., helical or spiral, path through the particular or each channel. Applicant has discovered that the mouthpiece or filter element of the present invention, in use, provides a different smoking sensation in which the smoke feels more dispersed in the mouth compared to a standard tube filter element or mouthpiece.

Without wishing to be bound by theory, it is believed that the nonlinear, e.g., helical or spiral, path taken by the smoke leads to these differences in sensory characteristics. Furthermore, applicants have found that when the filter element of the present invention is incorporated into a smoking article containing tobacco smoking material containing cloves (e.g., Kretek tobacco blend), the tobacco smoke has a spicier flavor compared to a smoking article containing a standard tube filter element or mouthpiece. Furthermore, applicants have found that when incorporated into a tobacco smoking article such as a cigarette, the filter element of the present invention leads to a reduction in the total amount of non-nicotine-containing dry particulate matter in the smoke passing through the filter compared to a standard tube filter. Applicants have also found that the filter element of the present invention increases the retention of non-nicotine-containing dry particulate matter and increases the retention of nicotine more compared to a standard tube filter.

The or each channel may have a cross-section that is a modified circle with one or more raised portions extending from the edge of the circle toward the center of the circle. The channel cross-section may be a modified circle with two diametrically opposed raised portions extending from the edge of the circle toward the center of the circle. Alternatively, the or each channel may have a cross-shaped or approximately rectangular cross-section.

The or each channel may include an inner surface that includes one or more ridges that extend helically (e.g., along the inner surface of the or each channel) about a longitudinal axis of the mouthpiece or filter element, e.g., about the longitudinal axis of the channel, e.g., about a central longitudinal axis of the channel. The one or more ridges protrude from the inner surface of the or each channel. The one or more ridges may be formed on the inner surface of the or each channel.

In the case of the or each channel having a cross-section that is a modified circle with one or more raised portions extending from an edge of the circle toward the center of the circle, the or each channel has a generally cylindrical shape, in which case the inner surface of the or each channel includes one or more ridges that extend helically around the longitudinal axis of the mouthpiece or filter element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

In the case of the or each channel having a cross-shaped cross section, the or each channel has a generally cylindrical shape, in which case the inner surface of the or each channel includes four ridges that extend helically around the longitudinal axis of the mouthpiece or filter element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

The mouthpiece or filter element may include a longitudinally extending core of filter material and one or more channels extending longitudinally from an end of the core, the or each channel having an inner surface, and the or each channel inner surface may include one or more ridges extending helically (e.g., along the or each channel inner surface) about the longitudinal axis of the mouthpiece or filter element, e.g., about the longitudinal axis of the channel, e.g., about the central longitudinal axis of the channel. The one or more ridges protrude from the or each channel inner surface. The one or more ridges may be formed on the or each channel inner surface.

The applicant has discovered that, in use, the presence of one or more ridges extending helically about the longitudinal axis of the mouthpiece or filter element provides a different and improved smoke mouthfeel compared to a standard tube mouthpiece or filter element having a constant longitudinal cross section.

Applicant has found that, in use, smoke passing through the mouthpiece or filter element follows a helical or spiral path through the particular or each channel. It has been found that the mouthpiece or filter of the present invention, in use, provides a different smoking sensation in which the smoke feels more dispersed in the mouth compared to a standard tube filter element or mouthpiece. Without wishing to be bound by theory, it is believed that the helical path taken by the smoke results in these different sensory characteristics. Furthermore, Applicant has found that when the filter element of the present invention is incorporated into a smoking article containing tobacco smoking material including cloves (e.g., kretek tobacco blend), the tobacco smoke has a spicier flavor compared to a smoking article including a standard tube filter element or mouthpiece.

Applicant has also found that the inclusion of one or more ridges extending helically around the longitudinal axis of the or each channel can lead to improved filtration compared to filter elements including channels with uniform longitudinal cross-sections. The one or more ridges can increase the surface area of the inner surface of the or each channel, which can lead to an increased surface area for adsorption. Applicant has found that when incorporated into a smoking article such as a cigarette, the filter element of the present invention can lead to a reduction in the total amount of non-nicotine-containing dry particles in the smoke passing through the filter compared to a standard tube filter.

It will be appreciated that the longitudinally extending core of filter material has an outer surface and an inner surface. The inner surface of the longitudinally extending core of filter material may define a particular channel or channels. The distance between the outer surface and the inner surface of the core is known as the wall thickness.

The longitudinally extending core of the filter material is preferably generally cylindrical. The longitudinally extending core of the filter material may have a circumference of 14 mm to 25 mm. The filter material may be any material conventionally used in the manufacture of tobacco smoke filters, such as wire, fibrous, web, or extruded material. The filter material may be natural or synthetic filament tow, such as cotton or a polymer such as polyethylene, polypropylene, or cellulose acetate tow.

The filter material may be a thermoplastic or otherwise spinnable polymer, such as polypropylene, polyethylene terephthalate or polylactic acid. The filter material may be, for example, natural or synthetic staple fibers, absorbent cotton, web materials such as paper (usually crepe paper) and synthetic nonwovens, and extrusion materials (e.g. starch, synthetic foams). Preferably, the filter material is a material that can be hardened using a plasticizer. Preferably, the filter material comprises cellulose acetate filament tow.

The total denier of the filter material may be about 20,000-100,000 g per 9000 m, for example 20,000-80,000 g per 9000 m, for example 20,000-50,000 g per 9000 m.

When the filter material is formed from a single bale of tow, the total denier of the filter material may be about 20,000 to 50,000 g per 9000 m, e.g., 30,000 g to 40,000 g per 9000 m, e.g., 30,000 g to 38,000 g per 9000 m, e.g., 30,000 g, 32,000 g, 33,000 g, 37,000 g, or 40,000 g per 9000 m.

When the filter material is formed from a two-bale tow, the total denier of the filter material may be about 40,000 to 100,000 g per 9000 m, e.g., 60,000 g to 80,000 g per 9000 m, e.g., 60,000 g to 76,000 g per 9000 m, e.g., 60,000 g, 64,000 g, 66,000 g, 74,000 g, or 80,000 g per 9000 m.

The filament denier can be 5g to 9g per 9000m, for example 5g, 7.3g, 8g, or 9.0g per 9000m.

Filter materials are typically described with reference to filament denier, total denier, and fiber cross-section. For example, a filter material may include tows having the following deniers: 8.0Y40, 8.0Y32, 7.3Y33, or 9.0Y37. For example, a filter material having a denier of 8.0Y40 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.

The filter material may include a plasticizer. The filter material may include a total amount of plasticizer of about 12% to 24% by weight of the filter material and plasticizer, e.g., about 14% to 22% by weight of the filter material and plasticizer, e.g., about 16% to 20% by weight, e.g., about 17% to 19% by weight, e.g., about 18% by weight.

The total 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 general formula shown below:

Percentage of plasticizer = total amount of plasticizer (g) x 100 / (total amount of plasticizer (g) + total amount of filter material (g))

In the case of fibrous filter materials, such as filament tow, the plasticizer acts to stiffen the fibers of the filter material. Stiffening the fibers of the filter material can improve the shape definition of the filter element, particularly the definition of a particular or each channel. For example, the filter material can include plasticized fibers, such as plasticized tow, such as plasticized cellulose acetate tow. Formation of plasticized tow is known in the art. The plasticizer can be, for example, triacetin, triethylene glycol diacetate (TEGDA) or polyethylene glycol (PEG). The plasticizer can be applied to the filter material by spraying onto the surface of the filter material using methods known in the art.

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 polymeric 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 particulate hot melt water-soluble binders. The inclusion of a water-soluble binder material may further enhance the ability of the filter to be easily and quickly degraded, for example, under environmental conditions.

The filter material may include an additive. The additive may be a particulate additive. The particulate additive may be any particulate additive suitable for use in a smoke filter, such as activated carbon, zeolite, ion exchange resins (e.g., weakly basic anion exchange resins), sepiolite, silica gel, alumina, molecular sieves, carbonaceous polymer resins, and diatomaceous earth. The particulate additive may be a mixture of two or more materials. The additive may be a pigment, such as a pearlescent pigment or a thermochromic pigment.

The additive may include a smoke modifier (e.g., flavorant). The flavorant may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc. The smoke modifier (e.g., flavorant) may be applied to the filter material in liquid form. The smoke modifier (e.g., flavorant) may be liquefied before being applied to the filter material, for example, by heating above its melting point, for example, by mixing with a liquid carrier. The smoke modifier (e.g., flavorant) may be mixed with a plasticizer and applied, for example, by spraying a mixture of the smoke modifier (e.g., flavorant) and the plasticizer onto the filter material. A preferred smoke modifier (e.g., flavorant) is menthol or clove. For example, the additive may be sepiolite granules to which a menthol flavorant has been applied.

A mouthpiece or filter element of the present invention may have a non-constant wall thickness due to the presence of one or more ridges on the inner surface of a particular or each channel. The wall thickness at the narrowest point may be between 0.6 mm and 2.3 mm, e.g., between 1.8 and 2.3 mm.

The or each channel may be defined, for example, by a continuous extruded element formed from a plastic material.

The or each channel may be surrounded by filter material.

Preferably, the or each channel is defined by the filter material, e.g., such that the or each channel is surrounded by the filter material. In this configuration, a longitudinally extending core of filter material includes an outer surface and one or more inner surfaces, where the or each inner surface defines the or each channel, and the or each inner surface may include one or more ridges that extend helically around the longitudinal axis of the mouthpiece or filter element (e.g., along the inner surface of the or each channel), e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel), where the one or more ridges are defined by the filter material. The one or more ridges may protrude from the inner surface of the or each channel. The or each channel may be approximately cylindrical, although other shapes of channels are possible, e.g., channels that are approximately semi-cylindrical. It will be appreciated that while the or each channel may be approximately cylindrical, the cross-section may not be circular, for example, the cross-section may be a cross, a rectangle, or a modified circle that includes one or more raised portions extending from an edge of the circle toward the center of the circle. The non-circular cross-section and the varying cross-section along the length of the or each channel provides a unique appearance that may help combat counterfeiting.

The or each channel may extend a portion of the length of the core of filter material. Alternatively, the or each channel may extend along the entire length of the core. Preferably, the or each channel extends from the mouth end of the core of filter material, thereby causing the mouth end of the filter element or mouthpiece to have an unusual visual appearance that may be useful in combating counterfeiting, while at the same time providing an interesting visual appearance to the user.

The or each channel may have a diameter at its widest point of between 1.5 mm and 6 mm, for example between 1.5 mm and 5 mm.

For a mouthpiece or filter element having one channel, the channel may have a diameter at its widest point of 2mm to 6mm, such as 3mm to 5mm, for example 3.4mm to 4.8mm, for example 3.5mm to 4.7mm, for example 3.7mm or 4.5mm.

For mouthpieces or filter elements having two or more channels, the diameter of each channel at its widest point may be 1.5 to 3 mm, e.g., 1.8 mm to 3.0 mm, e.g., 1.9 mm to 3.0 mm, e.g., 2 mm.

The one or more ridges may extend along a portion of the length of the inner surface of the or each channel. Preferably, the ridges extend along the entire length of the inner surface of the or each channel. The ridges may have a width of 1.0 mm to 2 mm, e.g., 1.2 to 1.7 mm, e.g., 1.5 mm. The height of the ridges may be 0.2 to 1.5 mm.

The inner surface of the or each channel may include one, two, three or four ridges that extend helically around the longitudinal axis of the mouthpiece or filter element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel. Preferably, the inner surface of the or each channel includes two ridges that extend helically around the longitudinal axis of the mouthpiece or filter element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

The mouthpiece or filter element may include more than one channel, for example, two, three, or four channels extending longitudinally from the end of the core.

The circumference of the mouthpiece or filter element may be between 14 and 25 mm.

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

The mouthpiece or filter element may be for use as part of a tobacco smoke filter or a filter for smokable material other than tobacco, such as marijuana. The mouthpiece or filter element of the present invention may be incorporated into a multi-segment filter as a single segment. This may increase the number of functions that can be incorporated into the filter. For example, a mouthpiece or filter element according to any of the above statements may be combined with a further filter element comprising an additive, such as a granular additive, such as activated carbon granules. The mouthpiece or filter element of the present invention may be combined with a filter element comprising a capsule, such as a frangible capsule, such as a flavorant-containing capsule. The mouthpiece or filter element of the present invention may be combined with a filter element comprising a flavorant, such as (menthol) or a plurality of flavorants.

The mouthpiece or filter element of the present invention can be incorporated into a smoking article, such as a cigarette, cigarillo, or cigar. The mouthpiece or filter element of the present invention can be incorporated into a tobacco heating product or an electronic cigarette. The mouthpiece or filter element can also be used alone or as part of a filter that is assembled by a user to form a smoking article, such as a roll-your-own smoking article.

In a further aspect of the invention, there is provided a filter, e.g. a tobacco smoke filter, comprising a filter element according to any of the above statements. The filter, e.g. a tobacco smoke filter, may further comprise one or more further filter elements. Such a filter comprising more than one filter element may be referred to as a multi-segment filter.

The one or more further filter elements may include a longitudinally extending core of filter material, as defined above. The one or more further filter elements may include an additive.

One or more of the further filter elements may include pockets of fully encapsulated (e.g., embedded) additive embedded therein. The additive may be, for example, a particulate additive such as activated carbon (see above) that is substantially separate from the filter material and encapsulated within the filter material as separate pockets or pods of particulate additive particles fully encapsulated within the filter material. In another example, the fully encapsulated (e.g., embedded) pockets of additive may be a frangible capsule(s) or one or more frangible microcapsules. The capsules or microcapsules may contain various media, for example, flavorants (such as those described above) and/or smoke modifiers, such as liquids, solids, or other materials that aid in the filtration of smoke. The use of capsules or microcapsules is known in the art.

One or more additional filter elements may include a flavorant provided in and/or on the thread. "Flavour Thread" filter elements are known in the art. Such filter elements typically incorporate longitudinally aligned thread or tape elements therein, which carry a smoke modifier such as a flavorant.

The filter may include an external wrapper, such as a plug wrap, surrounding the filter element or one or more filter elements. The wrapper may be paper, such as a breathable paper. The wrapper may have a weight of 20 to 50 grams per square meter, such as 27 to 35 grams per square meter. The particulate additive as described above may be applied to the wrapper or plug wrap surrounding the filter material, for example as described in GB 2261152. The further filter element may be wrapped by an external wrapper, such as a plug wrap, surrounding the further filter element. The filter element and the further filter element as defined according to any of the above statements may be wrapped together by an external wrapper, such as a plug wrap. The external wrapper may function to bind and secure the filter elements in place.

The filter may include a first filter element and a second filter element, the first filter element including a longitudinally extending core of filter material and one or more longitudinally extending channels from the ends of the core, where the or each channel has a cruciform cross-section that varies longitudinally by rotation about the longitudinal axis of the mouthpiece or filter element. The second filter element may include a longitudinally extending core of filter material (e.g., as defined above) and a capsule (e.g., a frangible capsule) that is fully encapsulated within the core of filter material. The capsule may include a smoke modifier such as a flavorant, e.g., menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, and the like. The filter may include a plug wrap surrounding the first and second filter elements. The second filter element may be individually surrounded by an additional plug wrap.

In a further aspect of the invention, there is provided a smoking article comprising a filter, filter element or mouthpiece as described above. The smoking article may comprise a filter as described above joined to a rolled rod of smoking material, such as tobacco smoking material. Generally, for smoking articles comprising marijuana smoking material, the smoking article comprises a mouthpiece according to any of the above statements. The smoking article may further comprise a tipping wrapper, e.g., tipping paper. The tipping wrapper joins the rolled rod of smoking material to the filter or mouthpiece by engaging around the adjacent ends of the filter or mouthpiece and the rolled rod of smoking material. The tipping wrapper may be configured to leave a portion of the exterior surface of the filter/mouthpiece or filter wrapper exposed. The filter may be joined to the rolled rod of smoking material by a complete tipping wrapper that engages around the entire length of the filter or mouthpiece and the adjacent ends of the rod of smoking material.

The mouthpiece, filter element, filter or smoking article according to the invention may be unventilated or may be ventilated by methods known in the art, for example by using a pre-perforated or breathable filter wrapper (plug wrap) or tipping wrapper (tipping paper) and/or by laser perforation of the filter wrapper and/or tipping wrapper. The mouthpiece, filter, filter element or smoking article according to the invention may be ventilated by laser perforation of the longitudinally extending core of the filter material (and the wrapper (plug wrap) and tipping wrapper (tipping paper), if present). The complete tipping wrapper (tipping paper), which is breathable, may likewise be inherently breathable or may be provided with vents, and in the case of breathable products in which both a filter wrapper (plug wrap) and a tipping wrapper (tipping paper) are present, ventilation through the tipping wrapper (tipping paper) is usually consistent with ventilation through the filter wrapper (plug wrap). Vents through the filter wrapper (plug wrap), or the tipping wrapper (tipping paper), or both simultaneously, can be created by laser drilling during manufacture of the mouthpiece, filter, or filter element.

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

In a further aspect of the invention, a cooling element is provided that includes a longitudinally extending core of filter material and one or more channels extending longitudinally from an end of the core, where the or each channel has a non-circular cross-section that varies longitudinally by rotation about a longitudinal axis of the cooling element, e.g., a longitudinal axis extending along the center of the channel.

The or each channel is configured such that its cross-section at a first point along the length of the longitudinally extending core of the filter material is rotatable relative to an adjacent point along the length of the longitudinally extending core of the filter material. It will be understood that the cross-section of the or each channel may rotate more than 360° or less than 360° along the length of the or each channel.

Applicant has discovered that, in use, the aerosol generated by heating the tobacco is cooled as the aerosol passes through the particular channel or channels. Applicant has discovered that the particular channel or channels cause the aerosol to follow a non-linear, e.g. helical or spiral, path through the particular channel or channels, which has the effect of cooling the aerosol.

The or each channel may have a cross-section that is a modified circle with one or more raised portions extending from the edge of the circle toward the center of the circle. The or each channel may have a cross-section that is a modified circle with two diametrically opposed raised portions extending from the edge of the circle toward the center of the circle. Alternatively, the or each channel may have a cross-shaped or approximately rectangular cross-section.

The or each channel may include an inner surface that includes one or more ridges that extend helically (e.g., along the inner surface of the or each channel) about the longitudinal axis of the cooling element, e.g., about the longitudinal axis of the channel, e.g., about the central longitudinal axis of the channel. The one or more ridges protrude from the inner surface of the or each channel. The one or more ridges may be formed on the inner surface of the or each channel.

In the case of the or each channel having a cross-section that is a modified circle with one or more raised portions extending from an edge of the circle toward the center of the circle, the or each channel has a generally cylindrical shape, in which case the inner surface of the or each channel includes one or more ridges that extend helically around the longitudinal axis of the cooling element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

In the case of the or each channel having a cruciform cross section, the or each channel has a generally cylindrical shape, in which case the inner surface of the or each channel includes four ridges that extend helically around the longitudinal axis of the cooling element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

The cooling element may include a longitudinally extending core of filter material and one or more channels extending longitudinally from an end of the core, the or each channel having an inner surface, and the inner surface of the or each channel may include one or more ridges extending helically (e.g., along the inner surface of the or each channel) about the longitudinal axis of the cooling element, e.g., about the longitudinal axis of the channel, e.g., about the central longitudinal axis of the channel. The one or more ridges protrude from the inner surface of the or each channel. The one or more ridges may be formed on the inner surface of the or each channel.

Applicant has discovered that, in use, heated aerosol passing through the cooling element follows a helical or spiral-like path through the particular channel or channels. Without wishing to be bound by theory, it is believed that the helical path followed by the heated aerosol cools the aerosol.

It will be appreciated that the longitudinally extending core of filter material has an outer surface and an inner surface. The inner surface of the longitudinally extending core of filter material may define a particular channel or channels. The distance between the outer surface and the inner surface of the core is known as the wall thickness.

The longitudinally extending core of the filter material is preferably substantially cylindrical. The longitudinally extending core of the filter material may have a circumference of 14 mm to 25 mm. The filter material may be any material conventionally used in the manufacture of tobacco smoke filters, for example, linear, fibrous, web, or extruded material. The filter material may be natural or synthetic filament tow, for example cotton or a polymer such as polyethylene, polypropylene, or cellulose acetate tow.

The filter material may be a thermoplastic or otherwise spinnable polymer, such as polypropylene, polyethylene terephthalate or polylactic acid. The filter material may be, for example, natural or synthetic staple fibers, absorbent cotton, web materials such as paper (usually crepe paper) and synthetic nonwovens, and extrusion materials (e.g. starch, synthetic foams). Preferably, the filter material is a material that can be hardened using a plasticizer. Preferably, the filter material comprises cellulose acetate filament tow.

The total denier of the filter material may be about 20,000-100,000 g per 9000 m, for example 20,000-80,000 g per 9000 m, for example 20,000-50,000 g per 9000 m.

When the filter material is formed from a single bale of tow, the total denier of the filter material may be about 20,000 to 50,000 g per 9000 m, e.g., 30,000 g to 40,000 g per 9000 m, e.g., 30,000 g to 38,000 g per 9000 m, e.g., 30,000 g, 32,000 g, 33,000 g, 37,000 g, or 40,000 g per 9000 m.

When the filter material is formed from a two-bale tow, the total denier of the filter material may be about 40,000 to 100,000 g per 9000 m, e.g., 60,000 g to 80,000 g per 9000 m, e.g., 60,000 g to 76,000 g per 9000 m, e.g., 60,000 g, 64,000 g, 66,000 g, 74,000 g, or 80,000 g per 9000 m.

The filament denier can be 5g to 9g per 9000m, for example 5g, 7.3g, 8g, or 9.0g per 9000m.

Filter materials are typically described with reference to filament denier, total denier, and fiber cross-section. For example, a filter material may include tows having the following deniers: 8.0Y40, 8.0Y32, 7.3Y33, or 9.0Y37. For example, a filter material having a denier of 8.0Y40 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.

The filter material may include a plasticizer. The filter material may include a total amount of plasticizer of about 12% to 24% by weight of the filter material and plasticizer, e.g., about 14% to 22% by weight of the filter material and plasticizer, e.g., about 16% to 20% by weight, e.g., about 17% to 19% by weight, e.g., about 18% by weight.

The total amount of plasticizer present in the cooling element is calculated as a percentage of the total weight of the filter material and plasticizer using the general formula shown below:

Percentage of plasticizer = total amount of plasticizer (g) x 100 / (total amount of plasticizer (g) + total amount of filter material (g))

In the case of fibrous filter materials, such as filament tow, the plasticizer acts to stiffen the fibers of the filter material. Stiffening the fibers of the filter material can improve the definition of the shape of the cooling element, particularly the definition of the particular or each channel. For example, the filter material can include plasticized fibers, such as plasticized tow, such as plasticized cellulose acetate tow. The formation of plasticized tow is known in the art. The plasticizer can be, for example, triacetin, triethylene glycol diacetate (TEGDA) or polyethylene glycol (PEG). The plasticizer can be applied to the filter material by spraying onto the surface of the filter material using methods known in the art.

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 polymeric 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 particulate hot melt water-soluble binders. The inclusion of a water-soluble binder material may further enhance the ability of the cooling element to be easily and quickly degraded, for example, under environmental conditions.

The cooling element of the present invention may have a non-constant wall thickness due to the presence of one or more ridges on the inner surface of a particular channel or each channel. The wall thickness at the narrowest point may be between 0.6 mm and 2.3 mm, for example, between 1.0 and 2.3 mm.

The or each channel may be defined by a continuous extruded element formed, for example, from a plastic material.

The or each channel may be surrounded by a filter material.

Preferably, the or each channel is defined by the filter material, e.g., such that the or each channel is surrounded by the filter material. In this configuration, a longitudinally extending core of filter material includes an outer surface and an inner surface, where the inner surface defines the or each channel, and the inner surface may include one or more ridges that extend helically (e.g., along the inner surface of the or each channel) about the longitudinal axis of the cooling element (e.g., about the longitudinal axis of the channel, e.g., about the central longitudinal axis of the channel), where the one or more ridges are defined by the filter material. The one or more ridges may protrude from the inner surface of the or each channel. The or each channel may be substantially cylindrical, although other shapes of channels are possible, e.g., channels that are substantially semi-cylindrical. It will be understood that while the or each channel may be substantially cylindrical, the cross section is not circular, e.g., the cross section may be a cross, a rectangle, or a modified circle that includes one or more ridges extending from an edge of the circle toward the center of the circle.

The or each channel may extend a portion of the length of the core of filter material. Alternatively, the or each channel may extend along the entire length of the core. Preferably, the or each channel extends from the mouth end of the core of filter material.

The or each channel may have a diameter at its widest point of between 1.5 mm and 6 mm, for example between 1.5 mm and 5 mm.

For cooling elements with one channel, the channel may have a diameter at its widest point of 2mm to 6mm, such as 3mm to 5mm, for example 3.4mm to 4.8mm, for example 3.5mm to 4.7mm, for example 3.7mm or 4.5mm.

For cooling elements having two or more channels, the diameter of each channel at its widest point may be 1.5 to 3 mm, e.g., 1.8 mm to 3.0 mm, e.g., 1.9 mm to 3.0 mm, e.g., 2 mm.

The one or more ridges may extend along a portion of the length of the inner surface of the or each channel. Preferably, the ridges extend along the entire length of the inner surface of the or each channel. The ridges may have a width of 1.0 mm to 2 mm, e.g., 1.2 to 1.7 mm, e.g., 1.5 mm. The height of the ridges may be 0.2 to 1.5 mm.

The inner surface of the or each channel may include one, two, three or four ridges that extend helically around the longitudinal axis of the cooling element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel. Preferably, the inner surface of the or each channel includes two ridges that extend helically around the longitudinal axis of the cooling element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

The cooling element may include more than one channel, for example, two, three, or four channels extending longitudinally from the end of the core.

The length of the cooling element may be 5-50 mm, for example 10-30 mm, for example 8-24 mm, for example 15-20 mm, for example 18 mm.

The circumference of the cooling element may be 12-30 mm, such as 15-28 mm, for example 17-25 mm, for example 18-25 mm, for example 20-24 mm, for example 22-24 mm, for example 23 mm, for example 22 mm. The length of the cooling element may be 4.0 mm-50 mm, for example 5 mm-32 mm.

The cooling element of the present invention can be used as part of a heated aerosol generating system, which can, for example, form part of a heated tobacco product.

In a further aspect of the present invention, there is provided a heated aerosol generating system including a cooling element as described by any of the above statements.

The heated aerosol generating system may include a rod of tobacco material, a heating element, a power source, one or more cooling elements according to any of the statements above, and a mouthpiece. The one or more cooling elements may be disposed downstream of the heating element and the tobacco rod. In use, the tobacco rod is heated, thereby generating a heated aerosol. The heated aerosol then passes through one or more cooling elements, which act to cool the aerosol before it passes through the mouthpiece and into the user's mouth.

In a further aspect of the present invention, there is provided a plurality of rods including a plurality of cooling elements according to the present invention arranged end-to-end in a mirror image relationship.

In a further aspect of the invention, there is provided a method of making a mouthpiece, filter element or cooling element comprising drawing filter material through a shaping element to form a longitudinally extending core of filter material, wherein the shaping element comprises a rotating rod having a non-circular cross-section, the or each rotating rod forming one or more longitudinally extending channels within the core of filter material, the or each channel having a cross-section that varies longitudinally upon rotation about the longitudinal axis of the mouthpiece, filter element or cooling element.

The or each rod may be generally cylindrical and include one or more grooves that form one or more ridges on the inner surface of the or each channel, the one or more ridges extending helically around the longitudinal axis of the mouthpiece, filter element or cooling element, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

The or each rod may have a cruciform cross-section, or the or each rod may have a rectangular cross-section.

The shaping element may include a chamber from which the or each rotating rod projects. The chamber may be cylindrical. As the filter material enters the chamber, the walls of the chamber shape the filter material into a longitudinally extending core of the filter material, e.g., into a cylindrical rod. As the filter material passes through the chamber, it passes around the or each protruding rotating rod, thereby forming one or more channels in the filter material. Rotation of the or each rod causes the cross-section of the or each channel to change longitudinally by rotating about the longitudinal axis of the longitudinally extending core.

In the case of a rod containing one or more grooves, the one or more grooves lead to the formation of one or more ridges on the inner surface of the channel. As the rod rotates and the filter material passes around the rod and into one or more grooves in the rod, one or more ridges are formed on the inner surface of the channel that extends helically around the longitudinal axis of the longitudinally extending core of the filter material.

In the case of a rod having a cruciform cross section, the channel formed has a cruciform cross section. Rotation of the rod defines a substantially cylindrical channel, the inner surface of which is formed with four ridges that extend helically around the longitudinal axis of the core of filter material, e.g., around the longitudinal axis of the channel, e.g., around the central longitudinal axis of the channel.

It will be understood that the diameter of the or each channel at its widest point is determined by the diameter of the or each rod at its widest point. The size and shape of any grooves in one or more rods may determine the size and shape of the ridges formed on the inner surface of the or each channel. Additionally, the number of grooves present in the or each rod may determine the number of ridges formed on the inner surface of the channel. The helical pitch of the ridges may be determined by the rotational speed at which the rods rotate and the speed at which the filter material is drawn through the forming element.

The filter material may include a plasticizer. The filter material may include a total amount of plasticizer 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. The plasticizer may be, for example, triacetin, triethylene glycol diacetate (TEGDA) or polyethylene glycol (PEG). The plasticizer may be applied to the filter material before it enters the molding element, for example, the plasticizer may be sprayed onto the filter material before it enters the molding element.

The filter material may be a thermoplastic or otherwise spinnable polymer, such as polypropylene, polyethylene terephthalate or polylactic acid. The filter material may be, for example, natural or synthetic staple fibers, absorbent cotton, web materials such as paper (usually crepe paper) and synthetic nonwovens, and extrusion materials (e.g. starch, synthetic foams). Preferably, the filter material is a material that can be hardened using a plasticizer. Preferably, the filter material comprises cellulose acetate filament tow.

The total denier of the filter material may be about 20,000-100,000 g per 9000 m, for example 20,000-80,000 g per 9000 m, for example 20,000-50,000 g per 9000 m.

When the filter material is formed from a single bale of tow, the total denier of the filter material may be about 20,000 to 50,000 g per 9000 m, e.g., 30,000 g to 40,000 g per 9000 m, e.g., 30,000 g to 38,000 g per 9000 m, e.g., 30,000 g, 32,000 g, 33,000 g, 37,000 g, or 40,000 g per 9000 m.

When the filter material is formed from a two-bale tow, the total denier of the filter material may be about 40,000 to 100,000 g per 9000 m, e.g., 60,000 g to 80,000 g per 9000 m, e.g., 60,000 g to 76,000 g per 9000 m, e.g., 60,000 g, 64,000 g, 66,000 g, 74,000 g, or 80,000 g per 9000 m.

The filament denier can be 5g to 9g per 9000m, for example 5g, 7.3g, 8g, or 9.0g per 9000m.

Filter materials are typically described with reference to filament denier, total denier, and fiber cross-section. For example, a filter material may include tows having the following deniers: 8.0Y40, 8.0Y32, 7.3Y33, or 9.0Y37. For example, a filter material having a denier of 8.0Y40 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.

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 polymeric 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 particulate hot melt water-soluble binders. The inclusion of a water-soluble binder material may further enhance the ability of the filter to be easily and quickly degraded, for example, under environmental conditions.

Depending on the method of making the mouthpiece or filter element, the filter material may include an additive. The additive may be a particulate additive. The particulate additive may be any particulate additive suitable for use in smoke filters, such as activated carbon, zeolite, ion exchange resins (e.g., weakly basic anion exchange resins), sepiolite, silica gel, alumina, molecular sieves, carbonaceous polymer resins, and diatomaceous earth. The particulate additive may be a mixture of two or more materials. The additive may be a pigment, such as a pearlescent pigment or a thermochromic pigment.

The additive may include a smoke modifier (e.g., flavorant). The flavorant may be, for example, menthol, spearmint, peppermint, nutmeg, cinnamon, clove, lemon, chocolate, peach, strawberry, vanilla, etc. The smoke modifier (e.g., flavorant) may be applied to the filter material in liquid form. The smoke modifier (e.g., flavorant) may be liquefied before being applied to the filter material, for example, by heating above its melting point, for example, by mixing with a liquid carrier. The smoke modifier (e.g., flavorant) may be mixed with a plasticizer and applied, for example, by spraying a mixture of the smoke modifier (e.g., flavorant) and the plasticizer onto the filter material. A preferred smoke modifier (e.g., flavorant) is menthol or clove. For example, the additive may be sepiolite granules to which a menthol flavorant has been applied.

The method may include heating the filter material as it passes through the molding element. The heating causes the plasticized filter material to harden, thereby solidifying the filter material and thereby maintaining the shape formed by the molding element. Heat may be applied to the filter material by applying steam, for example superheated steam. The steam may be applied through an inlet in the molding element such that the filter material is heated as it passes through the molding element.

The method may include applying cooling air to the filter material after it has passed through the forming element. The cooling air may have a temperature of 20°C to 26°C, for example 22°C to 25°C, for example 22°C to 24.5°C.

Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIG. 2 is an end view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 1 is a perspective view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 2 is a side view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 4 is a cross-sectional view of the mouthpiece, filter element, or cooling element shown in FIG. FIG. 4 is a cross-sectional view of the mouthpiece, filter element, or cooling element shown in FIG. FIG. 2 is a cross-sectional end view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 2 is an end view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 2 is a cross-sectional view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 2 is an end view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 2 is a cross-sectional view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 2 is a cross-sectional view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 2 is a cross-sectional view of a mouthpiece, filter element or cooling element according to the present invention. FIG. 1 is a perspective view of a multi-segment filter according to the present invention.

FIG. 1 shows an end view of a mouthpiece, filter element, or cooling element according to an embodiment of the present invention. The mouthpiece, filter element, or cooling element 100 includes a longitudinally extending core of filter material 102. The core of filter material is generally cylindrical (see FIG. 2). The core of filter material includes cellulose acetate tow, including triacetin as a plasticizer in an amount of 18% by weight of the filter material and plasticizer. The filament denier of the cellulose acetate tow is 7.3 g per 1000 m, with a total denier of 36000 g (7.3Y36) per 1000 m. The mouthpiece, filter element, or cooling element 100 also includes a channel 104 extending longitudinally through the core 102 from an end of the core 102. The channel 104 is defined by the filter material forming the core 102. The channel is surrounded by the filter material. As shown in FIGS. 1 and 2, the channel 104 is centrally located relative to the core 102 and is generally cylindrical. The circumference of the mouthpiece or filter element is 23.4 mm.

As shown in FIG. 2, the mouthpiece, filter element, or cooling element includes an outer surface 106 that defines a longitudinally extending core 102. As shown in FIG. 2, the core 102 extends along a longitudinal axis (l). The longitudinally extending core 102 includes an inner surface 108 that defines a channel 104. The channel 104 extends along the longitudinal axis l of the core 102. The distance between the outer surface 106 and the inner surface 108 is known as the wall thickness and is 1.2 mm. As shown in FIG. 1, the inner surface 108 includes two ridges 110 that extend helically around the longitudinal axis (l) of the mouthpiece, filter element, or cooling element. The ridges 110 extend along the inner surface 108 of the channel 104, and the ridges 110 protrude from the inner surface 108 of the channel 104. The two ridges 110 are integral with the inner surface 108 and are defined by the filter material that constitutes the core 102.

Figure 3 shows a side view of a filter element, mouthpiece, or cooling element along the plane defined by the y-axis and l-axis shown in Figure 2.

Figure 4 shows a cross-section of a mouthpiece, filter element, or cooling element along line A-A as shown in Figure 2. The channel cross-section shown in Figure 4 includes a modified circle having two diametrically opposed raised portions extending from the edge of the circle toward the center of the circle. The diametrically opposed raised portions correspond to ridges 110 that extend helically about the longitudinal axis of the mouthpiece, filter element, or cooling element. It will be appreciated that the irregular cross-sections of the mouthpieces and filter elements of the present invention may be useful in combating counterfeiting. As shown in Figure 4, the cross-section of the channel 104 is rotated relative to the channel cross-section shown at the end of the filter element 100 as shown in Figure 2.

The ridges 110 extend helically relative to the longitudinal axis (l) of the mouthpiece, filter element, or cooling element, such that the position of the ridges relative to the circumference of the channel varies along the length of the filter element, mouthpiece, or cooling element. Such a non-uniform cross-section along the length of the filter element or mouthpiece provides an additional anti-counterfeiting feature.

FIG. 5 shows a further cross-sectional view of the mouthpiece, filter element or cooling element along line B-B as shown in FIG. 3. As shown in FIG. 5, the cross-section of the channel 104 is rotated with respect to both the cross-section shown in FIG. 4 and the end cross-section shown in FIG. 2.

Figure 6 shows a cross-sectional view of a further filter element or mouthpiece 200 according to the present invention. The filter element or mouthpiece 200 shown in Figure 6 is similar to that shown in Figures 4 and 5, but includes four ridges 210 that extend along the inner surface of the channel 204 in a spiral manner around the longitudinal axis of the mouthpiece, filter element or cooling element.

Figure 7 shows an end view and Figure 8 shows a cross-sectional view of a further filter element, mouthpiece or cooling element 300 according to the invention. The filter element, mouthpiece or cooling element 300 shown in Figures 7 and 8 is similar to that shown in Figures 1 to 6, but the filter element, mouthpiece or cooling element 300 shown in Figures 7 and 8 has a channel 304 with a rectangular cross-section. The cross-section of the channel varies longitudinally of the core by rotating the mouthpiece, filter element or cooling element about its longitudinal axis.

Figure 9 shows an end view and Figure 10 shows a cross-sectional view of a further filter element, mouthpiece or cooling element 400 according to the invention. The filter element, mouthpiece or cooling element 400 shown in Figure 10 is similar to that shown in Figures 1 to 8, but the filter element, mouthpiece or cooling element 400 shown in Figures 9 and 10 has a channel 404 with a cross-shaped cross section. The cross section of the channel varies longitudinally of the core by rotating the mouthpiece, filter element or cooling element about its longitudinal axis.

Figure 11 shows a cross-sectional view of a further filter element, mouthpiece or cooling element 500 according to the present invention. The filter element, mouthpiece or cooling element 500 shown in Figure 11 is similar to that shown in Figures 1-5, but includes two channels 504a and 504b. Each channel 504a, 504b includes a ridge 510a and 510b that extends helically around the longitudinal axis of the mouthpiece, filter element or cooling element.

Figure 12 shows a cross-sectional view of a further filter element, mouthpiece, or cooling element 600 according to the present invention. The filter element, mouthpiece, or cooling element 600 shown in Figure 12 is similar to that shown in Figures 1-5, but includes three channels 604a, 604b, and 604c. Each channel 604a, 604b, 604c includes a ridge 610a, 610b, and 610c that extends helically around the longitudinal axis of the mouthpiece, filter element, or cooling element.

Any of the mouthpieces or filter elements shown in Figures 1-12 can form part of a multi-segment filter included in a smoking article, such as a cigarette. Some smoking articles, such as marijuana-containing smoking articles, include a mouthpiece as described herein and do not include an additional filter element, such as a filter element included in a multi-segment filter.

In use, as the smoke travels through the mouthpiece or filter element, it follows a helical path within the channel, meaning that the smoke exiting the mouthpiece or filter element continues to follow a helical path, for example, within the user's mouth. As explained in more detail in the examples below, the helical path that the smoke follows affects the mouthfeel of the smoke.

The cooling element may form part of a heated aerosol generating system, which may form part of a non-combustible product such as a heated cigarette. A heated aerosol generating system generally includes a heating element, a power source, a tobacco rod, one or more cooling elements, and a mouthpiece. The cooling element described herein may be incorporated into the heated aerosol generating system between the mouthpiece and the tobacco rod. In 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. The configuration of the channels causes the aerosol to follow a helical path through the cooling element, thereby reducing the temperature of the aerosol.

The filter element, mouthpiece and cooling element shown in Figures 1 to 12 can be manufactured by the following process.

The continually advancing plasticized tow is drawn into a forming element, which includes a generally cylindrical chamber with a rod (mandrel) protruding from it.

The shape of the rod determines the cross-sectional shape of the channel. For example, the rods used to make the mouthpieces, filter elements, or cooling elements shown in Figures 1-5 are cylinders that include two diametrically opposed grooves that run along the length of the cylindrical rod. The rods used to make the mouthpieces, filter elements, or cooling elements shown in Figure 6 are cylinders with two pairs of diametrically opposed grooves. The rods used to make the mouthpieces, filter elements, or cooling elements shown in Figures 7 and 8 have a rectangular cross-section, and the rods used to form the mouthpieces, filter elements, or cooling elements shown in Figures 9 and 10 have a cross-shaped cross-section.

For a mouthpiece, filter element, or cooling element as shown in FIG. 11, the molding element includes two protruding mandrels. For a mouthpiece, filter element, or cooling element as shown in FIG. 12, the molding element includes three protruding mandrels.

The chamber also includes a steam inlet to allow superheated steam to enter the chamber. The rod is connected to an external motor, which rotates the rod.

As the plasticized tow advances into the chamber, it is shaped into a longitudinally extending cylindrical core by the inner walls of the chamber. The chamber acts as a die. While the tow is being shaped by the inner walls of the chamber, it is forced around the rod, thereby forming channels in the core, the channels being defined by the filter material. The channel shape is defined by the rod as described above. As the filter material passes through the chamber, rotation of the rod forms longitudinally extending channels, and rotation around the longitudinal central axis of the channel changes the channel cross section longitudinally. In the case of a grooved rod, such as that used to make the mouthpiece, filter element, or cooling element shown in Figures 1-6, the grooves of the rod define ridges on the inner surface of the channel. Rotation of the rod and the resulting rotation of the grooves form ridges on the inner surface of the channel, which extend along the inner surface of the channel and follow a helical path around the longitudinal axis of the channel. By controlling the speed at which the rod rotates and the rate at which the tow is drawn through the chamber, the helical pitch of the ridges can be changed. The depth and width of each ridge can be modified by changing the depth and width of each groove in the rod. If more ridges are desired, the rod can include additional grooves. For example, the mouthpiece, filter element, or cooling element shown in FIG. 6 uses a rod with four grooves.

In the case of a cruciform rod, the rod forms a channel with a cruciform cross section. As the rod rotates, a roughly cylindrical channel is formed within the core, with the triangular gaps between adjacent prongs of the cruciform rod forming ridges on the inner surface of the channel.

For a rod with a rectangular cross section, rotation of the rod means that the cross section of the channel changes longitudinally by rotating along the longitudinal length of the core.

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 of the core of filter material can be varied by modifying the diameter of the cylindrical chamber. If a channel is desired that does not include a ridge extending along its entire length, the rod can be modified to include a groove that does not extend along the entire length of the rod.

Superheated steam enters the chamber through the inlet and heats the plasticized tow. The action of the heat acts to stiffen the plasticized tow, thereby hardening the filter material so that it retains its shape after leaving the forming element.

The filter material leaves the molding element in the shape of a generally cylindrical, longitudinally extending core that includes a longitudinally extending channel within the core. In the case of a rod that includes two grooves, the channel includes two ridges that extend helically around the longitudinal axis of the channel and along the inner surface of the channel.

The tow may be plasticized as part of the above process before the tow enters the forming elements; for example, the continuously advancing tow may be sprayed with a plasticizer at a plasticization station located before the forming elements. Alternatively, the plasticizer may be pre-applied to the tow in a separate process.

The generally cylindrical, longitudinally extending core may be further treated with steam and then cooled by a series of air jets to cut the generally cylindrical, longitudinally extending core into a series of individual filter elements, mouthpieces or cooling elements.

13 shows a multi-segment filter 700 including a filter element 400 similar to that shown in FIGS. 9 and 10. The filter element 400 includes a longitudinally extending core of filter material 402. The core is generally cylindrical as shown in FIG. 13. The filter element 400 also includes a channel 404 extending longitudinally from an end of the core 402 along the entire length of the core 402. The channel 404 is defined by the filter material forming the core 402, and the channel is surrounded by the filter material. The channel 404 is centrally located with respect to the core 402. The channel 404 has a generally cruciform cross-section. As shown in the cross-sectional portion of FIG. 13, the cross-section of the channel 404 varies longitudinally by rotating the filter element 400 about its longitudinal axis.

As shown in the cross-sectional portion of FIG. 13, the channel includes four ridges 410 that extend helically around the longitudinal axis of the filter element 400.

The multi-segment filter 700 also includes a second filter element 710. The second filter element 710 includes a longitudinally extending core of filter material 720. As shown in the second cross-sectional portion of FIG. 13, the second filter element 710 includes a capsule 740 that is completely encapsulated within the core of filter material 720. The capsule may be a frangible capsule that includes a smoke modifier, such as a flavorant. It will be understood that other additives may be included in the core. The second filter element 710 is wrapped with a first plug wrap 750, and the first filter element 400 and the second filter element 710 are wrapped together with a second plug wrap 760 that functions to hold the first filter element and the wrapped second filter element together.

The second filter element can be fabricated according to standard methods known in the art. The first filter element and the second filter element can be bonded and rolled using standard manufacturing methods known in the art.

Four filtered cigarettes containing a filter element according to the invention were prepared along with four control filtered cigarettes. The filtered cigarettes according to the invention were prepared based on a standard commercially available kretek (clove flavored) tobacco cigarette. The standard 27 mm monocellulose acetate filter was removed from the cigarette and replaced with a multi-segment filter according to the invention. The multi-segment filter of the invention included a 20 mm removed section of the standard monocellulose acetate filter joined to a filter element of the invention having a length of 7 mm.

The control cigarette contained a multi-segment filter comprising a 20 mm monocellulose acetate filter bonded to a 7 mm standard tube filter.

Four users smoked the filtered cigarettes. The users reported that, compared to the control cigarettes, the filtered cigarettes containing the filter elements of the present invention produced tobacco smoke that had a spicier taste and was more evenly distributed in the mouth. The users reported that the control cigarettes containing the standard tube filter elements produced smoke that was concentrated on the tongue.

A filtered cigarette was constructed including a single filter element as shown in Figure 1. Further filtered cigarettes were constructed including a single filter element as shown in Figures 7 and 8.

A filtered cigarette was assembled containing a single standard tube filter element containing channels with a continuous cross-section.

Each type of filtered cigarette was tested by smoking under standard conditions and the total amount of non-nicotine dry particulate matter (NFDPM) gained was measured (in accordance with standards ISO ISO 17025, ISO 3308, ISO 4387).

Applicant has discovered that cigarettes containing the filter element of the present invention have lower NFDPM acquisition than cigarettes containing a single standard tube filter element.

Filtered cigarettes were assembled. The filtered cigarettes included a multi-segment filter comprising a single standard 7 mm tube filter element bonded to a 20 mm monoacetate filter. The standard tube filter included channels having a continuous cross-section. The multi-segment filter was bonded to a tobacco rod. Additional filtered cigarettes were assembled and included a multi-segment filter comprising either filter element A, B, or C. Each of filter elements A, B, or C was 7 mm in length.

Filter element A is a single filter element as shown in Figures 1 to 5.

Filter element B is a single filter element as shown in Figures 7 and 8.

Filter element C is a single filter element as shown in Figures 9 and 10.

Total particulate matter (TPM) was measured for each tested filter element. Total particulate matter in the mainstream smoke emitted from the filter was measured by performing smoking tests under standard conditions using a method according to ISO 4387. Total particulate matter collected by the filter was measured using gravimetric analysis. The filters were also extracted using isopropanol and the extracted mixture was analyzed using gas chromatography coupled to a flame ionization detector (GC-FID) to determine the total amount of nicotine. This analysis was performed according to standard ISO 10315. The extracted mixture was analyzed using gas chromatography coupled to a thermal conductivity detector (GC-TCD) to determine the total amount of water. This analysis was performed according to standard ISO 10362.

The total amount of non-nicotine-containing dry particulate matter (NFDPM) (tar) is calculated using the following formula:

NFDPM = TPM - nicotine - water (mg/cig)

Tar and nicotine retention rates were calculated according to the following formula:

Nicotine retention rate (%) = Nicotine in filter (mg) x 100% / (Nicotine in mainstream smoke + Nicotine in filter (mg))

NFDPM retention rate (%) = NFDPM (mg) in filter x 100% / (NFDPM in mainstream smoke + NFDPM (mg) in filter)

The total amount of nicotine in the filter after smoking was measured according to the method described above. The total amount of NFDPM in the filter after smoking was calculated as described above.

The NFDPM retention and nicotine retention results are summarized in Table 1 below.

As shown in Table 1 above, the filters of the present invention (including filter elements A, B, and C) exhibited much higher NFDPM retention rates compared to the standard tube filters. Furthermore, with the exception of filter element A, the filter elements of the present invention exhibited equal or higher nicotine retention rates compared to the standard tube filters.

A cooling element according to the present invention was prepared. The cooling element was constructed as shown in Figures 1-5 and as described above. The cooling element had a length of 18 mm and a circumference of 22.53 mm.

A comparative cooling element, 18 mm in length, was also made from crimped polylactic acid (PLA) filter material.

The cooling element according to the invention and the comparative cooling element were each incorporated into separate tobacco heating product devices, which were then smoked using a linear smoking machine under conditions conforming to standard ISO 20778.

The total amount of hydroquinone, resorcinol, and catechol in the vapor emitted from the device was measured using high performance liquid chromatography (HPLC) with fluorescence detection (FLD).

The results of these tests are shown in Table 2 below.

As shown in Table 2, the cooling element of the present invention significantly reduced the amount of hydroquinone, resorcinol, and catechol present in the vapor exhausted from the device.

Claims (18)

a longitudinally extending core of filter material;
one or more channels extending longitudinally from an end of the core;
A mouthpiece or filter element comprising:
the or each channel has a non-circular cross-section that varies in the longitudinal direction by rotation about the longitudinal axis of said mouthpiece or filter element;
A mouthpiece or filter element in which the or each channel has a cross-section that is a modified circle having two or more ridges extending toward the center of the circle, or in which the or each channel has a cross-shaped or rectangular cross-section. 2. The mouthpiece or filter element of claim 1, wherein the or each channel has a cruciform or rectangular cross-section. The mouthpiece or filter element of claim 1, wherein the inner surface of the or each channel includes one or more ridges that extend helically about the longitudinal axis of the mouthpiece or filter element. A mouthpiece or filter element comprising a longitudinally extending core of filter material and one or more channels extending longitudinally from an end of said core, wherein the or each channel has an inner surface, and the inner surface of the or each channel includes two or more ridges that extend helically around the longitudinal axis of the mouthpiece or filter element. A mouthpiece or filter element according to any preceding claim, wherein the or each channel is defined by the filter material and/or the or each channel extends along the entire length of the core. 6. A mouthpiece or filter element according to claim 2 , wherein the one or more ridges extend along the entire length of the inner surface of the channel and/or the one or more ridges are integrally formed with the inner surface of the channel. 7. The mouthpiece or filter element of claim 1 , comprising two, three or four channels, and/or the longitudinally extending core of said filter material has a circumference of between 14mm and 25mm, and/or the longitudinally extending core of said filter material has a total denier of between 20,000 and 100,000g per 9000m , and/or the filter material comprises cellulose acetate, and/or the filter material comprises a plasticiser. A filter comprising a filter element according to any one of claims 1 to 7 . 10. The filter of claim 8 , comprising an additional filter element coupled to the first filter element. The filter of claim 9 , wherein the further filter element comprises an additive. 11. A filter according to any one of claims 8, 9 and 10, comprising a first filter element according to any one of claims 1 to 7 and a second filter element coupled to the first filter element, the second filter element comprising a longitudinally extending core of smoke filtering material and a capsule completely encapsulated within the core of smoke filtering material, the capsule comprising a smoke modifier. A plurality of rods comprising a plurality of mouthpieces or filter elements according to any one of claims 1 to 7 joined end-to-end in a mirror image relationship. 12. A smoking article comprising a mouthpiece or filter element according to any one of claims 1 to 6, or a filter according to any one of claims 8 to 11 , wherein the mouthpiece, filter element or filter is joined to a rod of smokable material. a longitudinally extending core of filter material;
one or more channels extending longitudinally from an end of the core;
A cooling element comprising:
the or each channel has a non-circular cross-section which varies in the longitudinal direction by rotation about the longitudinal axis of the cooling element;
A cooling element wherein the or each channel has a cross-section that is a modified circle having two or more ridges extending toward the center of the circle, or the or each channel has a cross-shaped or rectangular cross-section. a longitudinally extending core of filter material;
one or more channels extending longitudinally from an end of the core;
A cooling element comprising:
A cooling element, wherein the or each channel has an inner surface, the inner surface of the or each channel including two or more ridges extending helically about a longitudinal axis of the cooling element. A heated aerosol generating system comprising a cooling element according to claim 14 or 15 . 1. A method of making a mouthpiece, filter element or cooling element comprising drawing a filter material through a molding element to form a longitudinally extending core of filter material,
wherein the shaping element comprises one or more rotating rods having a non-circular cross-section, the or each rotating rod forming one or more channels in a core of the filter material, the or each channel having a cross-section that varies in the longitudinal direction by rotation about a longitudinal axis of the mouthpiece, filter element, or cooling element. 18. The method of claim 17, wherein the or each rod comprises one or more grooves forming one or more ridges on the inner surface of the or each channel, the one or more ridges extending helically around a longitudinal axis of the mouthpiece, filter element or cooling element, and/or the filter material comprises a plasticizer, and/or the filter material is heated as it passes through the molding element .

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