Alternative filter materials and components for an aerosol delivery device

Abstract

The present disclosure provides filter materials adapted for use as a filter element in an aerosol delivery device and methods of forming such filter materials suitable for use as a filter element in such devices. The disclosure provides, in some embodiments, a filter material which includes a plurality of fibers selected from the group consisting of regenerated cellulose, hemp, sisal, esparto, kenaf, jute, flax, wood, reconstituted tobacco, and combinations thereof, wherein the filter material is in the form of a nonwoven sheet or a fibrous tow.

What is claimed is: 
     
         1 . A filter material adapted for use as a filter element in an aerosol delivery device, the filter material comprising a plurality of fibers selected from the group consisting of regenerated cellulose, hemp, sisal, esparto, kenaf, jute, flax, wood, and combinations thereof, wherein the filter material is in the form of a nonwoven sheet or a fibrous tow. 
     
     
         2 . The filter material of  claim 1 , wherein the filter material is in the form of a pleated nonwoven sheet gathered to form a rod-like element. 
     
     
         3 . The filter material of  claim 1 , wherein the nonwoven sheet has a basis weight of about 20 gsm to about 90 gsm. 
     
     
         4 . The filter material of  claim 1 , wherein the nonwoven sheet has a basis weight of about 40 gsm to about 80 gsm. 
     
     
         5 . The filter material of  claim 1 , wherein the nonwoven sheet has a basis weight of about 50 gsm to about 70 gsm. 
     
     
         6 . The filter material of  claim 1 , wherein the denier per filament (dpf) of the filter material is about 1 dpf to about 30 dpf. 
     
     
         7 . The filter material of  claim 1 , wherein the denier per filament (dpf) of the filter material is about 1 dpf to about 25 dpf. 
     
     
         8 . The filter material of  claim 1 , wherein the denier per filament (dpf) of the filter material is about 1 dpf to about 5 dpf. 
     
     
         9 . The filter material of  claim 1 , wherein the filter material is optionally crimped. 
     
     
         10 . The filter material of  claim 9 , wherein the crimped filter material has a crimp depth of about 1 micron to about 180 microns. 
     
     
         11 . The filter material of  claim 9 , wherein the crimped filter material has a crimp depth of about 1 micron to about 150 microns. 
     
     
         12 . The filter material of  claim 9 , wherein the crimped filter material has a crimp depth of about 50 microns to about 100 microns. 
     
     
         13 . The filter material of  claim 1 , wherein the nonwoven sheet has a width of about 110 mm to about 160 mm. 
     
     
         14 . The filter material of  claim 1 , wherein the nonwoven sheet has a width of about 115 mm to about 150 mm. 
     
     
         15 . The filter material of  claim 1 , further comprising a plasticizer. 
     
     
         16 . The filter material of  claim 15 , wherein the plasticizer is triacetin. 
     
     
         17 . The filter material of  claim 1 , further comprising a binder. 
     
     
         18 . The filter material of  claim 17 , wherein the binder is selected from the group consisting of polyvinyl alcohol (PVOH), pectin, starch, microfibrillated cellulose (MFC), and combinations thereof. 
     
     
         19 . The filter material of  claim 1 , wherein the nonwoven sheet is a wetlaid nonwoven sheet, a drylaid nonwoven sheet, or an airlaid nonwoven sheet. 
     
     
         20 . A filter element adapted for use in an aerosol delivery device, the filter element comprising one or more segments of a filter material according to  claim 1 . 
     
     
         21 . The filter element of  claim 20 , wherein the one or more segments of filter material have a hardness of about 75 percent or higher. 
     
     
         22 . The filter element of  claim 20 , wherein the one or more segments of filter material have a hardness of about 80 percent or higher. 
     
     
         23 . The filter element of  claim 20 , wherein the one or more segments of filter material have a hardness of about 85 percent or higher. 
     
     
         24 . The filter element of  claim 20 , wherein the filter element exhibits a pressure drop in the range of about 40 mmWG to about 400 mmWG. 
     
     
         25 . The filter element of  claim 20 , wherein the filter element exhibits a pressure drop in the range of about 200 mmWG to about 300 mmWG. 
     
     
         26 . An aerosol delivery device comprising the filter element according to  claim 20 . 
     
     
         27 . A method for forming a filter material suitable for use as a filter element in an aerosol delivery device, the method comprising:
 receiving a nonwoven sheet or a fibrous tow, the nonwoven sheet or the fibrous tow comprising a plurality of fibers selected from the group consisting of regenerated cellulose, hemp, sisal, esparto, kenaf, jute, flax, wood, and combinations thereof;   processing the nonwoven sheet or the fibrous tow to provide a filter material suitable for use as a filter element for an aerosol delivery device.   
     
     
         28 . The method of  claim 27 , further comprising forming the nonwoven sheet or fibrous tow. 
     
     
         29 . The method of  claim 28 , wherein the nonwoven sheet is formed using a wetlaid, airlaid, or drylaid forming process. 
     
     
         30 . The method of  claim 28 , wherein the nonwoven sheet is formed using a forming process selected from the group consisting of hydroentangling, needle punching, spun-bonding, melt-blowing, spun-lacing, carding, point-bonding, spinning, and combinations thereof. 
     
     
         31 . The method of  claim 28 , wherein forming the fibrous tow comprises:
 blending the plurality of fibers to provide a mixed fiber blend; and   drawing the mixed fiber blend to provide the fibrous tow.   
     
     
         32 . The method of  claim 27 , wherein the processing comprises gathering the nonwoven sheet or fibrous tow to form a rod-like element suitable for use as a filter element. 
     
     
         33 . The method of  claim 32 , wherein the processing further comprises wrapping the rod-like element with a circumscribing wrapping material thereby forming a continuous rod suitable for use as a filter element. 
     
     
         34 . The method of  claim 27 , wherein the processing comprises crimping the nonwoven sheet or fibrous tow. 
     
     
         35 . The method of  claim 34 , wherein the crimped nonwoven sheet or the crimped fibrous tow have a crimp depth of about 1 micron to about 180 microns. 
     
     
         36 . The method of  claim 34 , wherein the crimped nonwoven sheet or the crimped fibrous tow have a crimp depth of about 1 micron to about 150 microns. 
     
     
         37 . The method of  claim 34 , wherein the crimped nonwoven sheet or the crimped fibrous tow have a crimp depth of about 50 microns to about 100 microns. 
     
     
         38 . The method of  claim 27 , further comprising applying a plasticizer to the nonwoven sheet or fibrous tow. 
     
     
         39 . The method of  claim 38 , wherein the plasticizer is triacetin. 
     
     
         40 . The method of  claim 27 , further comprising applying a binder to the nonwoven sheet or fibrous tow. 
     
     
         41 . The method of  claim 40 , wherein the binder is selected from the group consisting of polyvinyl alcohol (PVOH), pectin, starch, microfibrillated cellulose (MFC), and combinations thereof. 
     
     
         42 . The method of  claim 27 , wherein the nonwoven sheet has a basis weight of about 20 gsm to about 90 gsm. 
     
     
         43 . The method of  claim 27 , wherein the nonwoven sheet has a basis weight of about 40 gsm to about 80 gsm. 
     
     
         44 . The method of  claim 27 , wherein the nonwoven sheet has a basis weight of about 50 gsm to about 70 gsm. 
     
     
         45 . The method of  claim 27 , wherein the denier per filament (dpf) of the filter material is about 1 dpf to about 30 dpf. 
     
     
         46 . The method of  claim 27 , wherein the denier per filament (dpf) of the filter material is about 1 dpf to about 25 dpf. 
     
     
         47 . The method of  claim 27 , wherein the denier per filament (dpf) of the filter material is about 1 dpf to about 5 dpf. 
     
     
         48 . The method of  claim 27 , wherein the nonwoven sheet has a width of about 110 mm to about 160 mm. 
     
     
         49 . The method of  claim 27 , wherein the nonwoven sheet has a width of about 115 mm to about 150 mm.