ABSORPTION PAD

The present invention provides an (e.g. absorption) pad comprising an element, the element comprising filamentary tow.

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Description
CROSS-REFERENCE TO RELATED APPLICATION

This is a continuation of PCT/EP2020/063507, filed May 14, 2020, which claims priority from United Kingdom Application No. 1906942.6, filed May 16, 2019, the entire contents all of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to smoking articles, for example electronic cigarettes (herein referred to as “e-cigarettes”), and washers for use therewith or therein.

BACKGROUND OF THE INVENTION

An electronic or e-cigarette is a well-known type of aerosol-generating device that enables the user to simulate the act of smoking. E-cigarettes produce a vapour that when inhaled can replicate the sensation and often the flavour of tobacco smoke, but without the chemicals and odours associated with tobacco smoke. They use heat and airflow to vaporise a solution that often contains nicotine and a range of flavours for delivery to the consumer.

There are two main types of E-cigarettes, those with open systems and those with closed systems. Open systems allow the user to refill with e-liquid themselves, while closed systems require the purchase of a cartomizer or pod. The cartomizer or pod is effectively a refill once the e-liquid has been consumed.

Older e-cigarettes generally include three main sections—a battery, an atomizer and a cartridge—and are available as either disposable or re-usable devices. They can be supplied in one, two or three parts—in two-part devices, the atomizer and cartridge are combined in a single unit (also sometimes known as a cartomizer). In general, the battery compartment contains a flow sensor and an indicator light, whilst the atomiser will typically comprise a porous material in proximity to a heating element to enable liquid transferred from a reservoir to be delivered to the heating element where it is converted into vapour for delivery to the user (when the flow sensor detects that puffing has occurred). The cartridge connects to the atomizer and comprises the reservoir containing a solvent—normally glycerol, or propylene glycol or a mixture of the two—together with water, various flavours and nicotine—known as an e-liquid. The atomiser is a porous material in contact with the reservoir and is designed to present a high surface area of solution to the flow path. The heating element can either be in direct contact with the atomiser or remote from it. When the device is puffed a flow sensor activates the heating element so that the atomizer is heated or heated air is passed over the atomiser to convert some liquid into vapour for delivery to the user.

More recent pod based e-cigarettes combine the reservoir of an open system within a closed system. The e-liquid is included in a small tank within the pod.

E-cigarettes have increased rapidly in popularity in recent years, but are subject to various shortcomings in terms of consumer satisfaction. In particular, in many e-cigarettes, liquid (i.e. e-liquid) can leak from the liquid reservoir over time. This results in a number of issues for the consumer. Firstly, leakage of e-liquid onto the external surface of the of the e-cigarette can result in the user's hands and mouth becoming covered in this liquid. This is unacceptable to the consumer. Additionally, leakage will result in the e-liquid within the reservoir being depleted more rapidly which may result in the consumer having to replenish the e-liquid with greater frequently.

SUMMARY OF THE INVENTION

As a result of these issues, many e-cigarettes have begun incorporating ‘absorption washers’ into their design to prevent this leakage from the e-liquid reservoir over time. Absorption washers are made from an absorbent material and are incorporated into the structure of an e-cigarette in such a way that they absorb any e-liquid that leaks from the e-liquid reservoir.

The primary function of an absorption washer for an e-cigarette is to absorb e-liquid that has leaked from the e-liquid reservoir and so it will generally be made from a highly absorbent material. The absorption washer may additionally provide support for the e-cigarette housing while being flexible enough to be relatively easily manipulated into the e-cigarette housing during the e-cigarette manufacturing process.

High performance absorption washers for e-cigarettes are conventionally made from bicomponent fibres. These fibres can be relatively expensive to produce. Additionally, due to the presence of two components that must be separated into distinct regions, they may be complicated to manufacture. Consequently, there is a need for an absorption washer made from a highly absorbent (and optionally reasonably rigid) material that is cheaper and easier to produce than the absorption washer currently available.

According to the present invention there is provided a (e.g. absorption) pad (e.g. for a smoking article such as an e-cigarette) comprising an (e.g. substantially disc shaped) (e.g. substantially polygonal in shape) (e.g. substantially rectangular in shape) (e.g. substantially square in shape) element, the element comprising filamentary tow. Preferably the filamentary tow is cellulose acetate filamentary tow. According to the present invention there is further provided a (e.g. absorption) pad (e.g. for a smoking article such as an e-cigarette) comprising an (e.g. substantially disc shaped) (e.g. substantially polygonal in shape) (e.g. substantially rectangular in shape) (e.g. substantially square in shape) element, the element comprising cellulose acetate. Preferably the element is absorbent. Preferably the pad of the present invention is an absorption pad. It will be appreciated that the term “pad” herein means any substantially flat element to be positioned between a plurality of surfaces. The element may optionally comprise at least one opening (e.g. a bore) (e.g. a portion of the pad wherein part of the perimeter has been cut away).

The pad of filamentary tow (e.g. cellulose acetate filamentary tow) may be highly absorbent. Preferably the pad has high wettability. Preferably the pad has a wettability from 50 mg/10 s to 90 mg/10 s. Herein the term “wettability” is used to indicate the extent to which the liquid maintains contact with the pad surface. A high wettability indicates the liquid has a high tendency to maintain contact with the pad surface, which indicates the pad may be highly absorbent. A method used to calculate the wettability of a pad according to the present invention has been outlined in the Examples. Preferably the pad has a high level of liquid retention. Preferably the pad has a liquid retention capability such that removal of the pad from a liquid for 1 hour leads to a percentage weight loss of the pad from 0 to 20%, e.g. 10 to 20%. A method used to calculate the liquid retention of a pad according to the present invention has been outlined in the Examples.

In one embodiment the element is disc shaped or substantially disc shaped. Herein the term “disc shaped” means an element of substantially flat and relatively thin shape that is generally circular. A disc shaped element according to the present invention does not need to be completely circular and so can have portions of the perimeter (e.g. circumference) cut away as illustrated in the attached FIG. 2. In another embodiment the element may be substantially polygonal in shape. An element according to the present invention that is polygonal in shape does not need to be completely polygonal in shape and so can have portions of the perimeter cut away. In another embodiment the element may be substantially rectangular in shape. In another embodiment the element may be substantially square in shape.

In one embodiment the pad according to the present invention may comprise no openings (e.g. contain no bores and/or no portions of the pad wherein part of the perimeter has been cut away). In such an embodiment a single pad may be incorporated into a smoking article (e.g. an e-cigarette). Further, a plurality of pads may be incorporated into a smoking article (e.g. an e-cigarette) in such an arrangement so as to fit the given e-cigarette.

According to an embodiment of the present invention there is provided a pad comprising an element, the element comprising at least one opening (e.g. a bore) (e.g. a portion of the washer wherein part of the perimeter has been cut away). Such a pad may be referred to as a washer. According to the present invention there is provided a (e.g. absorption) washer (e.g. for a smoking article such as an e-cigarette) comprising an (e.g. substantially disc shaped) (e.g. substantially polygonal in shape) (e.g. substantially rectangular in shape) (e.g. substantially square in shape) element, the element comprising filamentary tow. Preferably the filamentary tow is cellulose acetate filamentary tow. According to the present invention there is further provided a (e.g. absorption) washer (e.g. for a smoking article such as an e-cigarette) comprising an (e.g. substantially disc shaped) element, the element comprising cellulose acetate. Preferably the element is absorbent. Preferably the washer of the present invention is an absorption washer.

It will be appreciated that the term “washer” herein means any substantially flat element that is to be positioned between a plurality of surfaces, the element comprising an opening (e.g. a bore or a portion of the washer wherein part of the perimeter has been cut away, or both). The washer may include one or more bores and/or one or more portions wherein part of the perimeter has been cut away.

The washer of filamentary tow (e.g. cellulose acetate filamentary tow) may be highly absorbent. Preferably the washer has high wettability. Preferably the washer has a wettability from 50 mg/10 s to 90 mg/10 s. Herein the term “wettability” is used to indicate the extent to which the liquid maintains contact with the washer surface. A high wettability indicates the liquid has a high tendency to maintain contact with the washer surface, which indicates the washer may be highly absorbent. A method used to calculate the wettability of a washer according to the present invention has been outlined in the Examples. Preferably the washer has a high level of liquid retention. Preferably the washer has a liquid retention capability such that removal of the washer from a liquid for 1 hour leads to a percentage weight loss of the washer from 0 to 20%, e.g. 10 to 20%. A method used to calculate the liquid retention of a washer according to the present invention has been outlined in the Examples.

When a pad and/or washer according to the present invention is used within a smoking device such as an e-cigarette the filamentary tow may be capable of absorbing liquid (e.g. e-liquid) that has leaked from the liquid reservoir of the e-cigarette. This prevents the e-liquid from coming into contact with the users hands and mouth providing a more pleasurable smoking experience for the user. The absorption of any leaked e-liquid by the filamentary tow pad and/or washer may also reduce the rate that e-liquid is lost from the liquid reservoir. This could extend the lifetime of a given quantity of e-liquid meaning the user would have to replace the e-liquid with lower frequency, providing a more satisfactory smoking experience. Additionally, a pad and/or washer of filamentary tow (e.g. cellulose acetate filamentary tow) according to the invention may have rigidity sufficient to allow the pad and/or washer to both provide support to the housing of the e-cigarette while being flexible enough to be relatively easily manipulated into the e-cigarette housing during the e-cigarette manufacturing process.

It will be appreciated that the pad and/or washer of the present invention may be used in any type electronic smoking article to absorb liquid (e.g. e-liquid). As discussed above, the pad and/or washer of the present invention may be used in an e-cigarette containing a liquid (e.g. e-liquid) reservoir. Alternatively, the pad and/or washer of the present invention may be used in Tobacco Heated Products (THP) or heat-not-burn (HNB) products. During use of these Heated Tobacco Products, a large amount of vapour may be produced and a large amount of liquid (e.g. e-liquid) may be present in the smoking article which the pad and/or washer of the present invention is able to absorb. Further, the pad and/or washer of the present invention may be used to absorb liquid (e.g. e-liquid) in a hybrid smoking article that comprises both a liquid reservoir and a Heated Tobacco portion.

The beneficial effects of the absorption pad/washer outlined in this application (e.g. ability to absorbed leaked e-liquid and provide support for the housing of electronic smoking article) may apply to the use of the pad/washer in any electronic smoking article (e.g. an e-cigarette device e.g. a Tobacco Heated Product (THP) or heat-not-burn (HNB) device e.g. a hybrid device).

In one embodiment the element is disc shaped or substantially disc shaped. Herein the term “disc shaped” means an element of substantially flat and relatively thin shape that is generally circular. A disc shaped element according to the present invention does not need to be completely circular and so can have portions of the perimeter (e.g. circumference) cut away as illustrated in the attached FIG. 2. In another embodiment the element may be substantially polygonal in shape. An element according to the present invention that is polygonal in shape does not need to be completely polygonal in shape and so may have portions of the perimeter cut away. In another embodiment the element may be substantially rectangular in shape. In another embodiment the element may be substantially square in shape.

In one embodiment the washer according to the present invention comprises at least one bore. Preferably the bore is at the centre of the washer. It will be appreciated that a bore according to the present invention does not need to be circular in shape; the bore can be for example square or rectangular in shape. Preferably, however, the bore is circular or generally circular in shape.

In another embodiment the washer comprises at least one portion of the washer wherein part of the perimeter of the washer has been cut away. It will be appreciated that when the washer is substantially circular in shape the perimeter of the washer may be the circumference of the washer. It will be appreciated that the part of the perimeter that has been cut away from the washer can be of any shape. Preferably the cut away portion is square, rectangular, polygonal or secant in shape (i.e. forms part of a circle—see FIG. 2). Preferably the washer according to the present invention comprises at least one bore at the centre of the washer and at least one portion of the washer wherein part of the perimeter of the washer has been cut away. Preferably the washer comprises two separate portions of the washer wherein part of the perimeter has been cut away. These potions may be disposed on opposite sides of a bore positioned at the centre of the washer.

When a washer comprising at least one bore and/or at least one cutaway portion according to the prevent invention is incorporated into a (e.g. electronic) smoking article such as an e-cigarette or a THP or HNB or a hybrid device, the bore and/or cut away portion may act to facilitate the transfer of air from one region of the (e.g. electronic) smoking article to another region of the (e.g. electronic) smoking article. When a washer comprising at least one bore and/or at least one cutaway portion according to the prevent invention is incorporated into a (e.g. electronic) smoking article such as an e-cigarette or a THP or HNB or a hybrid device, the bore and/or cut away portion may serve as a conduit for e.g. wires and thus acts to facilitate the transfer of electricity from one region of the (e.g. electronic) smoking article to another region of the (e.g. electronic) smoking article. This dimensions and shape of the pad or washer may be determined by inter alia the size and shape of the (e.g. electronic) smoking article (e.g. e-cigarette) in which it may be incorporated. Preferably the pad or washer has a thickness from 1 mm to 10 mm. Preferably the pad or washer has a thickness from 2 mm to 5 mm. Preferably the pad or washer has a thickness of around 2.5 mm.

When the pad or washer is substantially circular in shape, preferably the pad or washer has a diameter from 3 mm to 10 mm. Preferably the pad or washer has a diameter of around 7 mm. This diameter may allow the pad or washer to both provide support to the housing of the e-cigarette or a THP or HNB or a hybrid device while also forming a seal with the housing of the e-cigarette or a THP or HNB or a hybrid device such that it prevents any leaked e-liquid from escaping from the e-cigarette or a THP or HNB or a hybrid device housing. When the pad or washer comprises an opening (e.g. a bore) (e.g. a portion of the pad or washer wherein part of the perimeter has been cut away), a wall thickness of the pad or washer may be from 0.1 mm to 5 mm. Preferably a wall thickness from 4 mm to 0.6 mm, preferably from 3 mm to 2 mm, preferably from 2 mm to 1 mm.

When the pad or washer is substantially rectangular in shape, preferably the pad or washer has a length from 3 mm to 10 mm, preferably the pad or washer has a length from 5 mm to 8 mm, preferably the pad or washer has a length of around 7 mm. Preferably the pad or washer has a width from 0.5 mm to 5 mm, preferably the pad or washer has a width from 1 mm to 4 mm, preferably the pad or washer has a width of about 3 mm.

According to the present invention there is further provided a (e.g. absorption) pad (e.g. for a smoking article such as an e-cigarette) comprising filamentary tow. Preferably the filamentary tow is cellulose acetate filamentary tow. According to the present invention there is further provided a (e.g. absorption) pad (e.g. for a smoking article such as an e-cigarette) comprising cellulose acetate. Preferably the pad is absorbent. Preferably the pad of the present invention is an absorption pad.

The pad of filamentary tow (e.g. cellulose acetate filamentary tow) may be highly absorbent. Preferably the pad has high wettability. Preferably the pad has a wettability from 50 mg/10 s to 90 mg/10 s. Herein the term “wettability” is used to indicate the extent to which the liquid maintains contact with the pad surface. A high wettability indicates the liquid has a high tendency to maintain contact with the pad surface, which indicates the pad may be highly absorbent. A method used to calculate the wettability of a pad according to the present invention has been outlined in the Examples. Preferably the pad has a high level of liquid retention. Preferably the pad has a liquid retention capability such that removal of the pad from a liquid for 1 hour leads to a percentage weight loss of the pad from 0 to 20%, e.g. 10 to 20%. A method used to calculate the liquid retention of a pad according to the present invention has been outlined in the Examples.

According to an embodiment of the present invention there is provided a pad comprising at least one opening (e.g. a bore) (e.g. a portion of the washer wherein part of the perimeter has been cut away). Such a pad may be referred to as a washer.

According to the present invention there is further provided a (e.g. absorption) washer (e.g. for a smoking article such as an e-cigarette) comprising filamentary tow. Preferably the filamentary tow is cellulose acetate filamentary tow. According to the present invention there is further provided a (e.g. absorption) washer (e.g. for a smoking article such as an e-cigarette) comprising cellulose acetate. Preferably the washer is absorbent. Preferably the washer of the present invention is an absorption washer.

The washer of filamentary tow (e.g. cellulose acetate filamentary tow) may be highly absorbent. Preferably the washer has high wettability. Preferably the washer has a wettability from 50 mg/10 s to 90 mg/10 s. Herein the term “wettability” is used to indicate the extent to which the liquid maintains contact with the washer surface. A high wettability indicates the liquid has a high tendency to maintain contact with the washer surface, which indicates the washer may be highly absorbent. A method used to calculate the wettability of a washer according to the present invention has been outlined in the Examples. Preferably the washer has a high level of liquid retention. Preferably the washer has a liquid retention capability such that removal of the washer from a liquid for 1 hour leads to a percentage weight loss of the washer from 0 to 20%, e.g. 10 to 20%. A method used to calculate the liquid retention of a washer according to the present invention has been outlined in the Examples.

Preferably the washer according to the present invention comprises at least one bore. Preferably the bore is at the centre of the washer. It will be appreciated that a bore according to the present invention does not need to be circular in shape; the bore can be for example square or rectangular in shape. Preferably, however, the bore is circular or generally circular in shape.

Preferably the washer comprises at least one portion of the washer wherein part of the perimeter of the washer has been cut away. It will be appreciated that when the washer is substantially circular in shape the perimeter of the washer may be the circumference of the washer. It will be appreciated that the part of the perimeter that has been cut away from the washer can be of any shape. Preferably the cut away portion is square, rectangular, polygonal or secant in shape (i.e. forms part of a circle—see FIG. 2). Preferably the washer according to the present invention comprises at least one bore at the centre of the washer and at least one portion of the washer wherein part of the perimeter of the washer has been cut away. Preferably the washer comprises two separate portions of the washer wherein part of the perimeter has been cut away. These potions may be disposed on opposite sides of a bore positioned at the centre of the washer.

This dimensions and shape of the pad or washer may be determined by inter alia the size and shape of the smoking article (e.g. e-cigarette) in which it may be incorporated. Preferably the pad or washer has a thickness from 1 mm to 10 mm. Preferably the pad or washer has a thickness from 2 mm to 5 mm. Preferably the pad or washer has a thickness of around 2.5 mm. When the pad or washer is substantially circular in shape, preferably the pad or washer has a diameter from 3 mm to 10 mm. Preferably the pad or washer has a diameter of around 7 mm. This diameter may allow the pad or washer to both provide support to the housing of the e-cigarette or a THP or HNB or a hybrid device while also forming a seal with the housing of the e-cigarette or a THP or HNB or a hybrid device such that it prevents any leaked e-liquid from escaping from the e-cigarette housing or a THP or HNB or a hybrid device. When the pad or washer comprises an opening (e.g. a bore) (e.g. a portion of the pad or washer wherein part of the perimeter has been cut away), a wall thickness of the pad or washer may be from 0.1 mm to 5 mm. Preferably a wall thickness from 4 mm to 0.6 mm, preferably from 3 mm to 2 mm, preferably from 2 mm to 1 mm. Herein, the term smoking article includes e-cigarettes, nicotine delivery devices etc.

According to the present invention in another aspect there is provided a (e.g. electronic smoking) device comprising an (e.g. absorption) pad and/or washer comprising a (e.g. substantially disc shaped) element, the element comprising filamentary tow (e.g. cellulose acetate filamentary tow). Preferably the pad and/or washer engages with at least one surface of the (e.g. electronic smoking) device. Preferably the device comprises a fluid (e.g. a liquid) containing reservoir. Preferably the device is a smoking article (e.g. an e-cigarette). A filamentary tow pad and/or washer used within a device (e.g. a smoking article e.g. an e-cigarette) according to this aspect of the present invention may absorb fluid (e.g. e-liquid) that has leaked from the fluid reservoir, therefore reducing mess and providing a more pleasurable smoking experience for the user. In another embodiment, the device is a THP or HNB electronic smoking device. A filamentary tow pad and/or washer used within a device according to this aspect of the present invention may absorb fluid (e.g. e-liquid) that has leaked from the device, therefore reducing mess and providing a more pleasurable smoking experience for the user. In another embodiment, the device is a hybrid smoking device. A filamentary tow pad and/or washer used within a device according to this aspect of the present invention may absorb fluid (e.g. e-liquid) that has leaked from the device, therefore reducing mess and providing a more pleasurable smoking experience for the user.

According to the present invention in a further aspect there is provided a smoking article (e.g. an e-cigarette) comprising; a housing; a heating element (e.g. located within the housing); a power source for at least the heating element (e.g. located within the housing) and a pad and/or washer. The (e.g. absorption) pad and/or washer comprises a (e.g. substantially disc shaped) element, the element comprising filamentary tow (e.g. cellulose acetate filamentary tow). Preferably the pad and/or washer engages with at least one surface of the smoking article. Preferably the smoking article comprises a fluid (e.g. a liquid) containing reservoir. Preferably the smoking article is an e-cigarette.

According to the present invention in another aspect there is provided the use of a (e.g. absorption) pad and/or washer comprising an (e.g. substantially disc shaped) element, the element comprising filamentary tow (e.g. cellulose acetate filamentary tow) in a device comprising a fluid (e.g. liquid) containing reservoir. Preferably the device the pad and/or washer is used in is a smoking article (e.g. an e-cigarette). Preferably the pad and/or washer used in the device (e.g. an e-cigarette) is an absorption pad and/or washer. Preferably the pad and/or washer used in the device (e.g. an e-cigarette) is an absorption pad and/or washer wherein the absorption pad and/or washer absorbs fluid (e.g. a liquid) that has escaped (e.g. leaked) from the fluid containing reservoir. Preferably the pad and/or washer engages with at least one surface of the device. In one embodiment the pad and/or washer is used within an e-cigarette wherein the pad and/or washer is position in between a battery and a fluid reservoir. In another embodiment the pad and/or washer is used within an e-cigarette wherein the pad and/or washer is positioned at the mouth end of the e-cigarette to prevent e-liquid from entering the consumer's mouth.

Preferably the pad and/or washer is used within an e-cigarette wherein the pad and/or washer facilitates the transfer of air from one region of the e-cigarette to another region of the e-cigarette. The pad and/or washer may be permeable to air but impermeable to liquid (e.g. e-liquid) hence providing a liquid seal in the e-cigarette.

Preferably the pad and/or washer is used within an e-cigarette wherein the pad and/or washer facilitates the transfer of electricity from one region from the e-cigarette to another region of the e-cigarette (e.g. serve as a conduit for e.g. wires).

A pad or washer according to the present invention may be made from natural or synthetic filamentary tow, e.g. of cotton or plastics such as polyethylene or polypropylene, or cellulose acetate filamentary tow. The filamentary tow may be a thermoplastic or otherwise spinnable polymer, for example polypropylene, polyethylene terephthalate or polyacetide. Preferably the filamentary tow is cellulose acetate filamentary tow.

The fibres (e.g. cellulose acetate filamentary tow) may be plasticised. In other words, the pad or washer may optionally include a plasticiser. The formation of plasticised tow is well known in the art. The plasticiser (which plasticises the fibres) may be, for example, triacetin, triethyleneglycol diacetate (TEGDA) or polyethylene glycol (PEG). The fibres may be fibres of plasticised cellulose acetate tow. The fibres may be cellulose acetate tow which has been plasticised with e.g. triacetin.

The filamentary tow (e.g. cellulose acetate filamentary tow) may optionally include a binder material. The filamentary tow (e.g. cellulose acetate filamentary tow) may optionally include a water soluble binder material. Examples of water soluble materials include water soluble polymer materials such as polyvinyl alcohol, polyvinyl pyrrolidone, polyvinyl ether, starches, polyethylene glycols and polypropylene glycols; blends of water soluble binders with plasticisers such as triacetin, triethyleneglycol diacetate (TEGDA), or polyethylene glycol (PEG); and hot melt water soluble binders in particulate form. The inclusion of a water soluble binder material may further enhance the ability of the pad or washer to be readily and swiftly degraded when required e.g. under environmental conditions.

A pad or washer according to the present invention may be manufactured by pulling a continuous bundle of filamentary tow (e.g. cellulose acetate filamentary tow), optionally with triacetin already applied thereto, through a fix die having an external perimeter equal to that of the desired perimeter of the pad or washer to be produced. Heated steam may be applied to the filamentary tow whilst the filamentary tow is in the die. The heated steam may be applied via a duct in the die. The heated steam may be for curing plasticizer applied to the filamentary tow (if present), allowing the pad or washer to maintain the shape of the die after exiting the die. Once the filamentary tow has exited the die it may be cut in order to form a pad or washer with the desired thickness.

When the pad or washer comprises an opening (e.g. a bore) the fix die may additionally include a protruding inner rod (or mandrel) extending through the die having a cross-sectional profile equal to that of the desired cross-section of the opening (e.g. bore) of the washer. When the filamentary tow is pulled through the die, it passes around the inner rod such that on exiting the die, a washer is formed having an opening (e.g. bore) having a cross-sectional profile equivalent to the of the inner rod. Heated steam may be applied to the filamentary tow whilst the filamentary tow is in the die. The heated steam may be applied via a duct in the die. The heated steam may be for curing plasticizer applied to the filamentary tow (if present), allowing the washer to maintain the shape of the die after exiting the die. Once the filamentary tow has exited the die it may be cut in order to form a washer with the desired thickness comprising a bore at the centre of the washer. Such a washer may be disc shaped or substantially disc shaped. It will be appreciated that the skilled person would be capable of modifying this manufacturing procedure in order to produce a washer comprising at least one portion of the washer wherein part of the circumference of the washer has been cut away. In particular the skilled person would be capable of modifying the shape of the fix die allowing for the production of a washer comprising at least one portion of the washer wherein part of the circumference has been cut away. Further, the skilled person would be capable of modifying the manufacturing procedure (e.g. the shape of the fix die) to produce a washer comprising at least one bore at the centre of the washer and at least one portion of the washer wherein part of the circumference of the washer has been cut away.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be illustrated with reference to the following Examples and the attached Figures.

FIG. 1 illustrates a washer according to one embodiment of the present invention.

FIG. 2 illustrates a washer according to another embodiment of the invention.

FIG. 3 illustrates a washer according to another embodiment of the invention.

FIG. 4 is a graph indicating the liquid retention over time of washer A according to the present invention and washer B, a conventional absorption washer.

FIG. 5 illustrates a schematic illustration of a smoking article according to the present invention.

 DETAILED DESCRIPTION EXAMPLE 1

FIG. 1 illustrates an absorption washer 1 for a smoking article such as an e-cigarette of diameter 7 mm and thickness 2.5 mm comprising a substantially disc shaped element 2 made from plasticised cellulose acetate filamentary tow. The absorption washer 1 further has a circular bore 3 or hole at the centre of the washer of diameter 2 mm. When the absorption washer 1 is incorporated into an e-cigarette the cellulose acetate filamentary tow may be capable of absorbing e-liquid that has leaked from the liquid reservoir of the electronic cigarette.

Absorption washer 1 may be manufactured by pulling a continuous bundle of cellulose acetate filamentary tow, optionally with triacetin already applied thereto, through a fix die having an external diameter approximately equal to that of the desired diameter of the absorption washer 1, the fix die including a protruding inner rod (or mandrel) extending through the die having a cross-sectional profile equal to that of the desired cross-section of the circular bore 3 of absorption washer 1. When the filamentary tow is pulled through the die, it passes around the inner rod such that on exiting the die, an absorption washer 1 is formed having a circular bore 3 having a cross-sectional profile equivalent to the of the inner rod. Heated steam may be applied to the filamentary tow whilst the filamentary tow is in the die. The heated steam may be applied via a duct in the die. The heated steam may be for curing plasticizer applied to the filamentary tow (if present), allowing the absorption washer 1 to maintain the shape of the die after exiting the die. Once the filamentary tow has exited the die it may be cut in order to form a substantially disc shaped element 2 of thickness 2.5 mm comprising a circular bore 3 at the centre of the washer.

EXAMPLE 2

FIG. 2 illustrates an absorption washer 101 for a smoking article such as an e-cigarette of diameter 7 mm and thickness 2.5 mm comprising a substantially disc shaped element 102 made from plasticised cellulose acetate filamentary tow. The absorption washer 101 further has a circular bore 103 or hole at the centre of the washer of diameter 2 mm. The washer 101 is substantially circular but with two separate portions wherein part of the circumference has been cut away. The two cut away regions 104A and 104B are disposed on opposite sides of the circular bore 103. The two cutaway regions 104A and 104B are indicated by the dotted line in FIG. 2 indicating the region which has been cut away is a secant (i.e. forms part of a circle). When the absorption washer 101 is incorporated into an e-cigarette the cellulose acetate filamentary tow may be capable of absorbing e-liquid that has leaked from the liquid reservoir of the electronic cigarette. Absorption washer 101 may be manufactured using a similar method to that used to manufacture absorption washer 1 where the shape of the fix die used is changed to allow for the two cutaway regions 104A and 104B to be produced.

EXAMPLE 3

FIG. 3 illustrates an absorption pad 201 for a smoking article such as an e-cigarette of length 7 mm, width 3 mm and thickness 2.5 mm comprising an element 202 substantially rectangular in shape made from plasticised cellulose acetate filamentary tow. When absorption pad 201 is incorporated into an e-cigarette the cellulose acetate filamentary tow may be capable of absorbing e-liquid that has leaked from the liquid reservoir of the electronic cigarette. A plurality of absorption pads 201 may be incorporated into confined spaces for specific designs of e-cigarettes.

Absorption pad 201 may be manufactured by pulling a continuous bundle of cellulose acetate filamentary tow, optionally with triacetin already applied thereto, through a fix die having an external perimeter approximately equal to that of the desired perimeter of the absorption pad 201. Heated steam may be applied to the filamentary tow whilst the filamentary tow is in the die. The heated steam may be applied via a duct in the die. The heated steam may be for curing plasticizer applied to the filamentary tow (if present), allowing the absorption pad 201 to maintain the shape of the die after exiting the die. Once the filamentary tow has exited the die it may be cut in order to form a substantially rectangular in shape element 201 of thickness 2.5 mm.

EXAMPLE 4

An experiment was performed to calculate the wettability of a washer according to the present invention and a conventional absorption washer made from bicomponent fibres. Washer A is a washer according to the present invention made from cellulose acetate filamentary tow. Washer B is a conventional absorption washer made from bicomponent fibres of polypropylene and polyethylene. Both washers are of approximately the same shape and dimensions. A propylene glycol solution was prepared containing a dye. Washer A and washer B were then fully immersed in this solution for 10 seconds. The washers were then removed from the solution with any solvent excess removed. The weight of the washers was then measured (W0). The wettability of washer A and washer B was then calculated by determining the change in weight of the washers after being immersed in the propylene glycol solution for seconds. As can be seen by the results in Table 1 the wettability of the cellulose acetate washer A is around the same value as the wettability of the bicomponent fibres washer B. In fact, the wettability value for washer A is higher than that for washer B. Consequently, it is clear that a washer according to the present invention made from cellulose acetate filamentary tow is capable of providing similar or better absorption characteristics compared to convention bicomponent fibre washers while being cheaper and easier to produce.

TABLE 1 Wettability Washer (mg/10 s) Washer A 79.12 Washer B 75.06

EXAMPLE 5

An experiment was performed to calculate the liquid retention over time of a washer according to the present invention and a conventional absorption washer made from bicomponent fibres. Washer A is a washer according to the present invention made from cellulose acetate filamentary tow. Washer B is a conventional absorption washer made from bicomponent fibres of polypropylene and polyethylene. Both washers are of approximately the same shape and dimensions. A propylene glycol solution was prepared containing a dye. Washer A and washer B were then fully immersed in this solution for 10 seconds. The washers were then removed from the solution with any solvent excess removed. The weight of the washers was then measured (W0). The washers were then left in room temperature conditions and the weights of the washers measured every hour and recorded. The liquid retention of each washer was then calculated by determining the percentage of weight lost by each washer with time by the following calculation:

Liquid ⁢ ⁢ retention ⁢ ⁢ is ⁢ ⁢ expressed ⁢ ⁢ as ⁢ ⁢ % ⁢ ⁢ lost ⁢ ⁢ weight = ( W 0 - W 1 ) W 0

Where W0 is the weight of the washer after it has been immersed in and removed from the propylene glycol solution after t=0 seconds and Wt is the weight of the washer after it has been immersed in and removed from the propylene glycol solution after time t. FIG. 4 indicates the liquid retention of washers A and B after removal from the propylene glycol solution as a function of time. As can be seen from FIG. 4, the liquid retention profile for washer A is around the same as that for washer B. In fact, washer A has slightly lower % weight loss values than washer B indicating that washer A may have greater liquid retention. Consequently, it is clear from FIG. 4 that a washer according to the present invention made from cellulose acetate filamentary tow is capable of providing similar or better liquid retention (i.e. absorption) characteristics compared to conventional bicomponent fibre washers while being cheaper and easier to produce.

FIG. 5 illustrates a schematic illustration of a smoking article 300 according to the present invention. The smoking article 300 (e.g. an e-cigarette) comprises a housing 302; a heating element 304 (e.g. located within the housing); a power source 306 for at least the heating element 304 (e.g. located within the housing) and a pad and/or washer 308. The (e.g. absorption) pad and/or washer 308 comprises a (e.g. substantially disc shaped) element, the element comprising filamentary tow (e.g. cellulose acetate filamentary tow). Preferably the pad and/or washer 308 engages with at least one surface of the smoking article 300. Preferably the smoking article 300 comprises a fluid (e.g. a liquid) containing reservoir 310. Preferably the smoking article is an e-cigarette.

There have been disclosed hereinbefore the washers, pads, uses, devices and smoking articles defined by the following numbered paragraphs:

  • 1.) A washer comprising an element, the element comprising filamentary tow.
  • 2.) A washer comprising an element, the element comprising cellulose acetate.
  • 3.) A washer according to paragraph 1 wherein the filamentary tow is cellulose acetate filamentary tow.
  • 4.) A washer according to any preceding paragraph wherein the element is absorbent.
  • 5.) A washer according to any preceding paragraph wherein the washer is an absorption washer.
  • 6.) A washer according to any preceding paragraph wherein the washer has high wettability.
  • 7.) A washer according to paragraph 6 wherein the washer has a wettability from 50 mg/10 s to 90 mg/10 s.
  • 8.) A washer according to any preceding paragraph wherein the washer has a high level of liquid retention.
  • 9.) A washer according to any preceding paragraph having a liquid retention capability such that removal of the washer from a liquid for 1 hour leads to a percentage weight loss of the washer from 0 to 20%, e.g. 10 to 20%.
  • 10.) A washer according to any preceding paragraph wherein the element is disc shaped or substantially disc shaped.
  • 11.) A washer according to any preceding paragraph wherein the element is substantially polygonal in shape.
  • 12.) A washer according to any preceding paragraph wherein the element is substantially rectangular in shape.
  • 13.) A washer according to any preceding paragraph wherein the element is substantially square in shape.
  • 14.) A washer according to any preceding paragraph comprising at least one bore.
  • 15.) A washer according to paragraph 14 wherein the bore is at the centre of the washer.
  • 16.) A washer according to any preceding paragraph comprising at least one portion of the washer wherein part of the perimeter of the washer has been cut away.
  • 17.) A washer according to any preceding paragraph comprising at least one bore at the centre of the washer and at least one portion of the washer wherein part of the perimeter of the washer has been cut away.
  • 18.) A washer according to paragraph 17 comprising two separate portions of the washer wherein part of the perimeter of the washer has been cut away, wherein these portions are disposed on opposite sides of a bore positioned at the centre of the washer.
  • 19.) A washer according to any preceding paragraph wherein the washer has a diameter from 5 mm to 10 mm.
  • 20.) A washer according to any preceding paragraph wherein the washer has a thickness from 1 mm to 5 mm.
  • 21.) A washer comprising filamentary tow.
  • 22.) A washer comprising cellulose acetate.
  • 23.) A washer according to 21 wherein the filamentary tow is cellulose acetate filamentary tow.
  • 24.) A washer according to paragraphs 21 to 23 wherein the washer is an absorption washer.
  • 25.) A washer according to paragraphs 21 to 24 wherein the washer has a wettability from 50 mg/10 s to 90 mg/10 s.
  • 26.) A washer according to paragraphs 21 to 25 wherein the washer has a high level of liquid retention.
  • 27.) A washer according to paragraphs 2lto 26 having a liquid retention capacity such that removal of the washer from a liquid for 1 hour leads to a percentage weight loss of the washer from 0 to 20%, e.g. 10 to 20%.
  • 28.) A washer according to paragraphs 21 to 27 comprising at least one bore.
  • 29.) A washer according to paragraph 28 wherein the bore is at the centre of the washer.
  • 30.) A washer according to paragraphs 21 to 29 comprising at least one portion of the washer wherein part of the perimeter of the washer has been cut away.
  • 31.) A washer according to paragraphs 21 to 30 comprising at least one bore at the centre of the washer and at least one portion of the washer wherein part of the perimeter of the washer has been cut away.
  • 32.) A washer according to paragraphs 21 to 31 comprising two separate portions of the washer wherein part of the perimeter of the washer has been cut away, wherein these portions are disposed on opposite sides of a bore positioned at the centre of the washer.
  • 33.) A washer according to paragraphs 21 to 32 wherein the washer has a diameter from 5 mm to 10 mm.
  • 34.) A washer according to paragraphs 21 to 33 wherein the washer has a thickness from 1 mm to 5 mm.
  • 35.) A device comprising a washer according to any preceding paragraph wherein the washer engages with at least one surface of the device.
  • 36.) A device according to paragraph 35 where the device comprises a fluid (e.g. a liquid) containing reservoir.
  • 37.) A device according to paragraphs 35 and 36 wherein the device is a smoking article (e.g. an electronic cigarette).
  • 38.) A smoking article comprising: a housing;
  • a heating element;
  • a power source for at least the heating element;
  • a fluid reservoir;
  • and a washer according to paragraphs 1 to 34.
  • 39.) The use of a washer according to paragraphs 1 to 34 in a device comprising a fluid (e.g. a liquid) containing reservoir.
  • 40.) The use of a washer according to paragraph 39 wherein the device is a smoking article (e.g. an electronic cigarette).
  • 41.) The use of a washer according to paragraphs 39 to 40 wherein the washer is an absorption washer.
  • 42.) The use of a washer according to paragraph 41 wherein the absorption washer absorbs fluid (e.g. a liquid) that has escaped (e.g. leaked) from the fluid containing reservoir.
  • 43.) The use of a washer according to paragraphs 39 to 42 wherein the washer engages with at least one surface of the device.
  • 44.) The use of a washer according to paragraphs 39 to 43 in an electronic cigarette wherein the washer is positioned in between a battery and a fluid reservoir.
  • 45.) The use of a washer according to paragraph 44 wherein the washer facilitates the transfer of air from one region of the electronic cigarette to another region of the electronic cigarette.
  • 46.) The use of a washer according to paragraph 44 wherein the washer facilitates the transfer of electricity from one region of the electronic cigarette to another region of the electronic cigarette.
  • 47.) A pad comprising an element, the element comprising filamentary tow.
  • 48.) A pad comprising an element, the element comprising cellulose acetate.
  • 49.) A pad according to paragraph 47 wherein the filamentary tow is cellulose acetate filamentary tow.
  • 50.) A pad according to paragraphs 47 to 49 wherein the element is absorbent.
  • 51.) A pad according to paragraphs 47 to 50 wherein the pad is an absorption pad.
  • 52.) A pad according to paragraphs 47 to 51 wherein the pad has high wettability.
  • 53.) A pad according to paragraph 52 wherein the pad has a wettability from 50 mg/10 s to 90 mg/10 s.
  • 54.) A pad according to paragraphs 47 to 53 wherein the pad has a high level of liquid retention.
  • 55.) A pad according to paragraphs 47 to 54 having a liquid retention capability such that removal of the pad from a liquid for 1 hour leads to a percentage weight loss of the pad from 0 to 20%, e.g. 10 to 20%.
  • 56.) A pad according to paragraphs 47 to 55 wherein the element is disc shaped or substantially disc shaped.
  • 57.) A pad according to paragraphs 47 to 56 wherein the element is substantially polygonal in shape.
  • 58.) A pad according to paragraphs 47 to 57 wherein the element is substantially rectangular in shape.
  • 59.) A pad according to paragraphs 47 to 58 wherein the element is substantially square in shape.
  • 60.) A pad according to paragraphs 47 to 59 wherein the element is a washer (e.g. comprises at least one opening).
  • 61.) A pad comprising filamentary tow.
  • 62.) A pad comprising cellulose acetate.
  • 63.) A pad according to paragraph 61 wherein the filamentary tow is cellulose acetate filamentary tow.
  • 64.) A pad according to paragraphs 61 to 63 wherein the pad is an absorption pad.
  • 65.) A pad according to paragraphs 61 to 64 wherein the pad has a wettability from 50 mg/10 s to 90 mg/10 s.
  • 66.) A pad according to paragraphs 61 to 65 wherein the pad has a high level of liquid retention.
  • 67.) A pad according to paragraphs 61 to 66 having a liquid retention capacity such that removal of the pad from a liquid for 1 hour leads to a percentage weight loss of the pad from 0 to 20%, e.g. 10 to 20%.
  • 68.) A pad according to paragraphs 61 to 67 comprising at least one opening (e.g. a washer).

Claims

1. A washer comprising a substantially flat element configured to be positioned between a plurality of surfaces during use, the element comprising at least one opening,

the element further comprising filamentary tow.

2. A washer according to claim 1 wherein the filamentary tow is cellulose acetate filamentary tow.

3. A washer according to claim 1 wherein the element is absorbent.

4. A washer according to claim 1 wherein the washer has high wettability.

5. A washer according to claim 4 wherein the washer has a wettability from 50 mg/10 s to 90 mg/10 s.

6. A washer according to claim 1 wherein the washer has a high level of liquid retention.

7. A washer according to claim 1 having a liquid retention capability such that removal of the washer from a liquid for 1 hour leads to a percentage weight loss of the washer from 0 to 20%, e.g. 10 to 20%.

8. A washer according to claim 1 wherein the element is disc shaped or substantially disc shaped.

9. A washer according to claim 1 wherein a surface of the element is substantially polygonal in shape, or

is substantially rectangular in shape, or
is substantially square in shape.

10. A washer according to claim 1 comprising at least one bore.

11. A washer according to claim 10 wherein the bore is at the centre of the washer.

12. A washer according to claim 1 comprising at least one portion of the washer wherein part of the perimeter of the washer has been cut away.

13. A washer according to claim 1 comprising at least one bore at the centre of the washer and at least one portion of the washer wherein part of the perimeter of the washer has been cut away.

14. A washer according to claim 13 comprising two separate portions of the washer wherein part of the perimeter of the washer has been cut away, wherein these portions are disposed on opposite sides of a bore positioned at the centre of the washer.

15. A washer according to claim 1 wherein the washer has a diameter from 5 mm to 10 mm.

16. A washer according to claim 1 wherein the washer has a thickness from 1 mm to 5 mm.

17. A device comprising a washer according to claim 1 wherein the washer engages with at least one surface of the device.

18. A device according to claim 17 wherein the device comprises a fluid (e.g. a liquid) containing reservoir.

19. A smoking article comprising: a housing;

a heating element;
a power source for at least the heating element;
a fluid reservoir;
and a washer according to claim 1.

20. A device according to claim 16 wherein the device is a smoking article (e.g. an electronic cigarette or a hybrid smoking article that comprises both a liquid reservoir and a Heated Tobacco portion).

21. A pad comprising a substantially flat element configured to be positioned between a plurality of surfaces during use, the element comprising filamentary tow.

22. A pad according to claim 21 wherein the filamentary tow is cellulose acetate filamentary tow.

23. A pad according to claim 21 wherein the element is absorbent.

24. A pad according to claim 21 wherein the pad has high wettability.

25. A pad according to claim 24 wherein the pad has a wettability from 50 mg/10 s to 90 mg/10 s.

26. A pad according to claim 21 wherein the pad has a high level of liquid retention.

27. A pad according to claim 21 having a liquid retention capability such that removal of the pad from a liquid for 1 hour leads to a percentage weight loss of the pad from 0 to 20%, e.g. 10 to 20%.

28. A pad according to claim 21 wherein the element is disc shaped or substantially disc shaped.

29. A pad according to claim 21 wherein a surface of the element is substantially polygonal in shape, or

is substantially rectangular in shape, or
is substantially square in shape.

30. A pad according to claim 21 wherein the element is a washer (e.g. comprises at least one opening).

Patent History
Publication number: 20220061383
Type: Application
Filed: Nov 10, 2021
Publication Date: Mar 3, 2022
Inventors: Patrick MEREDITH (Singapore), Michael GREGG (Sidoarjo), Harismal NATANEGARA (Sidoarjo), Arief RAHMAN (Sidoarjo), WURYANTO (Sidoarjo), Sudirman WIDIARTO (Sidoarjo), Yesi OKTAWATI (Sidoarjo)
Application Number: 17/523,302
Classifications
International Classification: A24F 40/40 (20060101); A24F 40/10 (20060101);