US20060260626A1 - Activated carbons with molecular sieve membranes and their use as adsorbents in smoking articles - Google Patents
Activated carbons with molecular sieve membranes and their use as adsorbents in smoking articles Download PDFInfo
- Publication number
- US20060260626A1 US20060260626A1 US11/311,420 US31142005A US2006260626A1 US 20060260626 A1 US20060260626 A1 US 20060260626A1 US 31142005 A US31142005 A US 31142005A US 2006260626 A1 US2006260626 A1 US 2006260626A1
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- US
- United States
- Prior art keywords
- filter
- composite
- cigarette
- substrate
- smoking article
- Prior art date
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- Abandoned
Links
- 230000000391 smoking effect Effects 0.000 title claims abstract description 36
- 239000012528 membrane Substances 0.000 title claims abstract description 23
- 239000002808 molecular sieve Substances 0.000 title claims description 27
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 title claims description 26
- 239000003463 adsorbent Substances 0.000 title description 3
- 239000002131 composite material Substances 0.000 claims abstract description 90
- 235000019504 cigarettes Nutrition 0.000 claims abstract description 63
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 61
- 239000000758 substrate Substances 0.000 claims abstract description 46
- 239000000779 smoke Substances 0.000 claims abstract description 41
- 241000208125 Nicotiana Species 0.000 claims abstract description 38
- 235000002637 Nicotiana tabacum Nutrition 0.000 claims abstract description 38
- 239000000470 constituent Substances 0.000 claims abstract description 36
- 239000010457 zeolite Substances 0.000 claims abstract description 36
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims abstract description 30
- 229910021536 Zeolite Inorganic materials 0.000 claims abstract description 27
- 239000000835 fiber Substances 0.000 claims abstract description 24
- 239000002245 particle Substances 0.000 claims abstract description 14
- 239000008187 granular material Substances 0.000 claims abstract description 5
- 239000004744 fabric Substances 0.000 claims abstract description 4
- 230000002194 synthesizing effect Effects 0.000 claims abstract 2
- 239000000463 material Substances 0.000 claims description 31
- 239000011148 porous material Substances 0.000 claims description 24
- 238000000034 method Methods 0.000 claims description 20
- 229910052799 carbon Inorganic materials 0.000 claims description 17
- -1 polypropylene Polymers 0.000 claims description 11
- 229920002301 cellulose acetate Polymers 0.000 claims description 9
- 239000000203 mixture Substances 0.000 claims description 9
- 239000004743 Polypropylene Substances 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 6
- 229920001155 polypropylene Polymers 0.000 claims description 6
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 5
- 150000001299 aldehydes Chemical class 0.000 claims description 4
- 229920002678 cellulose Polymers 0.000 claims description 4
- 239000001913 cellulose Substances 0.000 claims description 4
- 230000009977 dual effect Effects 0.000 claims description 4
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- 238000010899 nucleation Methods 0.000 claims description 4
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 238000009826 distribution Methods 0.000 claims description 3
- 239000000945 filler Substances 0.000 claims description 3
- LELOWRISYMNNSU-UHFFFAOYSA-N hydrogen cyanide Chemical compound N#C LELOWRISYMNNSU-UHFFFAOYSA-N 0.000 claims description 3
- 239000004215 Carbon black (E152) Substances 0.000 claims description 2
- 239000011324 bead Substances 0.000 claims description 2
- 229930195733 hydrocarbon Natural products 0.000 claims description 2
- 150000002430 hydrocarbons Chemical class 0.000 claims description 2
- 150000002576 ketones Chemical class 0.000 claims description 2
- 150000002894 organic compounds Chemical class 0.000 claims description 2
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims 3
- 229910000077 silane Inorganic materials 0.000 claims 3
- 125000003118 aryl group Chemical group 0.000 claims 1
- 150000002825 nitriles Chemical class 0.000 claims 1
- 230000004913 activation Effects 0.000 abstract description 3
- 239000012690 zeolite precursor Substances 0.000 abstract description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 22
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 12
- 238000001179 sorption measurement Methods 0.000 description 10
- 239000000377 silicon dioxide Substances 0.000 description 9
- 239000002594 sorbent Substances 0.000 description 9
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 7
- 239000000243 solution Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- 239000000796 flavoring agent Substances 0.000 description 5
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- 238000001027 hydrothermal synthesis Methods 0.000 description 5
- 238000011068 loading method Methods 0.000 description 5
- 239000002002 slurry Substances 0.000 description 5
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 4
- 229910052681 coesite Inorganic materials 0.000 description 4
- 229910052906 cristobalite Inorganic materials 0.000 description 4
- 239000000843 powder Substances 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 229910001388 sodium aluminate Inorganic materials 0.000 description 4
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 4
- 239000007787 solid Substances 0.000 description 4
- 238000003756 stirring Methods 0.000 description 4
- 229910052682 stishovite Inorganic materials 0.000 description 4
- 229910052905 tridymite Inorganic materials 0.000 description 4
- UHOVQNZJYSORNB-UHFFFAOYSA-N Benzene Chemical compound C1=CC=CC=C1 UHOVQNZJYSORNB-UHFFFAOYSA-N 0.000 description 3
- MWUXSHHQAYIFBG-UHFFFAOYSA-N Nitric oxide Chemical compound O=[N] MWUXSHHQAYIFBG-UHFFFAOYSA-N 0.000 description 3
- 239000004115 Sodium Silicate Substances 0.000 description 3
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 description 3
- ANBBXQWFNXMHLD-UHFFFAOYSA-N aluminum;sodium;oxygen(2-) Chemical compound [O-2].[O-2].[Na+].[Al+3] ANBBXQWFNXMHLD-UHFFFAOYSA-N 0.000 description 3
- 238000002425 crystallisation Methods 0.000 description 3
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- 229910052911 sodium silicate Inorganic materials 0.000 description 3
- 238000003786 synthesis reaction Methods 0.000 description 3
- HGINCPLSRVDWNT-UHFFFAOYSA-N Acrolein Chemical compound C=CC=O HGINCPLSRVDWNT-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 2
- 239000002250 absorbent Substances 0.000 description 2
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- 239000003054 catalyst Substances 0.000 description 2
- YCIMNLLNPGFGHC-UHFFFAOYSA-N catechol Chemical compound OC1=CC=CC=C1O YCIMNLLNPGFGHC-UHFFFAOYSA-N 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
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- 150000001993 dienes Chemical class 0.000 description 2
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- 239000012229 microporous material Substances 0.000 description 2
- RNVCVTLRINQCPJ-UHFFFAOYSA-N o-toluidine Chemical compound CC1=CC=CC=C1N RNVCVTLRINQCPJ-UHFFFAOYSA-N 0.000 description 2
- 239000004014 plasticizer Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 150000004756 silanes Chemical class 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 125000001424 substituent group Chemical group 0.000 description 2
- 239000011800 void material Substances 0.000 description 2
- 239000003039 volatile agent Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 description 2
- BNGXYYYYKUGPPF-UHFFFAOYSA-M (3-methylphenyl)methyl-triphenylphosphanium;chloride Chemical compound [Cl-].CC1=CC=CC(C[P+](C=2C=CC=CC=2)(C=2C=CC=CC=2)C=2C=CC=CC=2)=C1 BNGXYYYYKUGPPF-UHFFFAOYSA-M 0.000 description 1
- JBIJLHTVPXGSAM-UHFFFAOYSA-N 2-naphthylamine Chemical compound C1=CC=CC2=CC(N)=CC=C21 JBIJLHTVPXGSAM-UHFFFAOYSA-N 0.000 description 1
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 229910017119 AlPO Inorganic materials 0.000 description 1
- 241000269350 Anura Species 0.000 description 1
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 1
- 229920003043 Cellulose fiber Polymers 0.000 description 1
- 235000013162 Cocos nucifera Nutrition 0.000 description 1
- 244000060011 Cocos nucifera Species 0.000 description 1
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 1
- 229910019142 PO4 Inorganic materials 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- BOTDANWDWHJENH-UHFFFAOYSA-N Tetraethyl orthosilicate Chemical compound CCO[Si](OCC)(OCC)OCC BOTDANWDWHJENH-UHFFFAOYSA-N 0.000 description 1
- YBCVMFKXIKNREZ-UHFFFAOYSA-N acoh acetic acid Chemical compound CC(O)=O.CC(O)=O YBCVMFKXIKNREZ-UHFFFAOYSA-N 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- JLDSOYXADOWAKB-UHFFFAOYSA-N aluminium nitrate Inorganic materials [Al+3].[O-][N+]([O-])=O.[O-][N+]([O-])=O.[O-][N+]([O-])=O JLDSOYXADOWAKB-UHFFFAOYSA-N 0.000 description 1
- 229910000329 aluminium sulfate Inorganic materials 0.000 description 1
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 150000001491 aromatic compounds Chemical class 0.000 description 1
- 238000003491 array Methods 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 229910002091 carbon monoxide Inorganic materials 0.000 description 1
- 230000009920 chelation Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 235000019506 cigar Nutrition 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000008119 colloidal silica Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 230000005493 condensed matter Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000001914 filtration Methods 0.000 description 1
- 229910021485 fumed silica Inorganic materials 0.000 description 1
- 239000010903 husk Substances 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 229910052909 inorganic silicate Inorganic materials 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 1
- 239000000391 magnesium silicate Substances 0.000 description 1
- 229910052919 magnesium silicate Inorganic materials 0.000 description 1
- 235000019792 magnesium silicate Nutrition 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 229910052901 montmorillonite Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 235000021317 phosphate Nutrition 0.000 description 1
- 150000003013 phosphoric acid derivatives Chemical class 0.000 description 1
- 239000011295 pitch Substances 0.000 description 1
- 229920005594 polymer fiber Polymers 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 238000002203 pretreatment Methods 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 239000011541 reaction mixture Substances 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 238000007086 side reaction Methods 0.000 description 1
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- 229910002027 silica gel Inorganic materials 0.000 description 1
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- 150000004760 silicates Chemical class 0.000 description 1
- 150000003384 small molecules Chemical class 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/16—Use of materials for tobacco smoke filters of inorganic materials
- A24D3/163—Carbon
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/16—Use of materials for tobacco smoke filters of inorganic materials
- A24D3/166—Silicic acid or silicates
Definitions
- activated carbon materials have been employed as sorbents in smoking articles to remove or reduce smoke constituents.
- Activated carbons are useful sorbents and have a large capacity; however, they lack selectivity. While they are effective in removing targeted constituents from tobacco smoke, they also may remove volatile constituents which contribute to flavor, aroma and other desirable attributes. Further, activated carbon in a cigarette filter may be rapidly inactivated during storage by the adsorption of volatile compounds, or by contact with various constituents of mainstream smoke.
- Zeolite-type molecular sieves have also been used in smoking articles to selectively remove constituents of tobacco smoke.
- Zeolite molecular sieve sorbents are capable of selectively removing one or more targeted constituents of mainstream smoke.
- zeolites have minimal capacities and are quickly exhausted before removing a significant amount of the targeted constituent.
- a smoking article which includes tobacco and a filter system comprising a composite composed of an activated carbon substrate and a zeolite-type membrane coated thereon. Also provided is a filter system, a method of making smoking articles containing said filter system and a method of selectively removing targeted constituents from tobacco smoke.
- a filter is prepared containing a composite made by the deposition of a molecular sieve membrane directly onto a carbon-containing substrate by hydrothermal synthesis of a given molecular sieve. Pre-treatment of the substrate may be desirable to achieve optimum adhesion and growth of the membrane on the substrate.
- cigarettes are prepared which contain tobacco and the filter mentioned above.
- a preferred smoking article is a traditional or non-traditional cigarette.
- the aforementioned composite preferably is incorporated into a filter of a cigarette.
- Another embodiment relates to a method of making a filter cigarette, comprising: (i) providing a cut filler to a cigarette making machine and forming a tobacco column; (ii) placing a paper wrapper around the tobacco column and forming a tobacco rod; (iii) attaching a cigarette filter comprising the composite described above to the tobacco rod to form the cigarette.
- a method is provided of treating mainstream smoke of a smoking article to preferentially remove one or more targeted constituents from mainstream smoke by contacting the mainstream smoke with a composite as described above.
- FIG. 1 is a view of a cigarette wherein folded paper containing a composite described above is inserted into a hollow portion of a tubular filter element of the cigarette.
- FIG. 2 is a view of another embodiment wherein a composite as described above is incorporated in folded paper and inserted into a hollow portion of a first free-flow sleeve of a tubular filter element next to a second free-flow sleeve.
- FIG. 3 is a view of another embodiment wherein a composite as described above is incorporated in a plug-space-plug filter element.
- FIG. 4 is a view of another embodiment wherein a composite is incorporated in a three-piece filter element having three plugs.
- FIG. 5 is a view of another embodiment wherein a composite is incorporated in a four-piece filter element having a plug-space-plug arrangement and a hollow sleeve.
- FIG. 6 is a view of still another embodiment wherein a composite is incorporated in a three-part filter element having two plugs and a hollow sleeve.
- Cigarette filters and smoking articles are provided preferably containing a porous composite comprising an activated carbon substrate and a zeolite molecular sieve membrane coated thereon and capable of selectively removing selected constituents from mainstream smoke.
- Methods for making such cigarette filters and smoking articles, as well as a method of treating mainstream smoke, are also provided.
- sorption denotes filtration by adsorption and/or absorption and is intended to encompass interactions on the outer surface of a sorbent, as well as interactions within the pores and channels thereof.
- a “sorbent” is a substance that has the ability to condense or hold molecules of other substances on its surface and/or the ability to take up other substances, i.e., through penetration of the other substances into its inner structure or into its pores.
- sorbent refers to either an adsorbent, an absorbent, or a substance that can function as both an adsorbent and an absorbent.
- remove refers to adsorption and/or absorption of at least some portion of a selected constituent of mainstream tobacco smoke.
- mainstream smoke includes the mixture of gases and aerosolized condensed matter which passes down a tobacco column and issues through the filter end, i.e., the amount of smoke issuing or drawn from the mouth end of a smoking article such as a cigarette during smoking.
- the mainstream smoke contains air that is drawn in through both the lit or heated region of the smoking article, as well as through the paper wrapper, and through any ventilation perforations that may be present.
- Non-traditional cigarettes include, for example, smoking articles which include combustible heat sources such as that shown in commonly assigned, U.S. Pat. No. 4,966,171, and cigarettes for electrical smoking systems as described in commonly-assigned U.S. Pat. Nos. 6,026,820; 5,988,176; 5,915,387; and 5,499,636.
- the substrate portion of the aforementioned composite comprises an activated carbon.
- Activated forms of carbon generally have strong physical sorption forces, and high volumes of sorbing porosity.
- the activated carbon could be manufactured by any suitable method. Such methods include the carbonization of coconut husk, coal, wood, pitch, cellulose fibers, or polymer fibers, for example. Carbonization is usually carried out at high temperatures, i.e., 200-1000° C. in an inert atmosphere, followed by activation.
- the activated carbon used as the composite substrate could be in the form of carbon granules, beads, powder, fiber, fabric or shaped monoliths.
- the substrate could also be an admixture of carbon and an inorganic material. Suitable inorganic materials may comprise porous and/or catalytically active metal compounds such as oxides, hydroxides, silicates and phosphates.
- Carbon-containing materials suitable as substrates may have a distribution of micropores, mesopores and macropores.
- microporous generally refers to such materials having pore sizes of about 20 ⁇ or less while the term “mesoporous” generally refers to such materials with pore sizes of about 20 to 500 ⁇ .
- Macroporous materials have pore sizes above about 500 ⁇ .
- the relative amounts of micropores, mesopores and macropores in the carbon-containing substrate will depend upon the selected constituents from mainstream tobacco smoke that are to be targeted and removed. Thus, the pore sizes and pore distribution can be adjusted accordingly as needed for a certain application.
- molecular sieve refers to a porous structure composed of an inorganic silicate material.
- Zeolites have channels or pores of uniform, molecular sized dimensions. There are many known unique zeolite structures having different sized and shaped channels or pores. The size and shape of the channels or pores can significantly affect the properties of these materials with regard to adsorption and separation characteristics. Zeolites can be used to separate molecules by size and shape possibly related to the orientation of the molecules in the channels or pores, and/or by differences in strength of sorption. By using one or more zeolites having channels or pores larger than selected constituents of mainstream smoke, only selected molecules that are small enough to pass through the pores of the molecular sieve material are able to enter the cavities and be sorbed by the zeolite.
- Zeolite-type molecular sieves which are useful in the composites include crystalline aluminosilicates, silicoaluminophosphates (AlPO/SAPO) and mesoporous molecular sieves such as MCM-41, MCM-48 and SBA-15.
- AlPO/SAPO silicoaluminophosphates
- mesoporous molecular sieves such as MCM-41, MCM-48 and SBA-15.
- This family of materials contains regular arrays of uniformly-sized channels and tunable internal active sites, and admits molecules below a certain size into their internal space which makes them useful as catalysts and sorbents where selectivity is critical.
- Microporous and mesoporous molecular sieves are preferred. They are selected for use in the filter composites based on the particular constituent or constituents to be removed from the mainstream smoke.
- microporous molecular sieves generally refers to molecular sieve materials having pore sizes of about 20 ⁇ or less.
- mesoporous molecular sieves generally refers to such materials with pore sizes of about 20 to 500 ⁇ . Materials with pore sizes of about 500 ⁇ or larger may be referred to as “macroporous molecular sieves.”
- the composite preferably is prepared by a hydrothermal synthesis technique using zeolite precursor materials which form a coated membrane on the substrate.
- the hydrothermal synthesis of various zeolites can be accomplished by any techniques which would generate in situ a zeolite membrane on the carbon-containing substrate.
- Methods for the preparation of zeolite membranes on activated porous carbon monoliths and porous carbon membranes are disclosed in the following articles: “Preparation of hollow-fibre composite carbon-zeolite membranes,” Smith, S. P. J.; Linkov, V. M; Sanderson, R. D.; Petrik, L. F.; O'Connor, C. T.; Keiser, K., Microporous Materials, 1995, 4, pp.
- the substrates are contacted with the zeolite precursors and a hydrothermal synthesis conducted whereby the zeolite membrane is coated upon and/or into the pores of the substrate. If the carbon-containing substrate has not been activated before synthesis of the zeolite membrane, known activation techniques may be employed to remove volatiles and produce the final activated composite.
- the product is a composite filter system composed of a porous substrate of activated carbon having a zeolite membrane coated uniformly upon the surface and within the pores of the substrate.
- sodium hydroxide may be used as the alkaline source.
- Sodium aluminate (NaAlO 2 ), aluminum nitrate (Al(NO 3 ) 3 9H 2 O), aluminum sulfate (Al 2 (SO 4 ) 3 18H 2 O), aluminum chloride (AlCl 3 6H 2 O), aluminum hydroxide (Al(OH) 3 ), aluminum alkoxide and alumina gel, etc. can be used as the source of alumina.
- Colloidal silica, fumed silica, water glass (sodium silicate aqueous solution), silica gel, etc. can be used as the silica source.
- the factors affecting crystallization of aluminosilicate include the source of silica, the mole ratio of silica vs. alumina, pH, reaction temperature, reaction time, degree of aging in room temperature, presence of stirring, etc.
- the morphology and nature of zeolite produced are directly linked to these variations.
- a sodium aluminate solution is made by adding a source of alumina to sodium hydroxide solution and stirring for about 20 to 60 minutes at about 70 to 120° C. to dissolve completely.
- the concentration of sodium hydroxide in solution is about 20 to 50 wt. %, especially about 30 to 40 wt. %.
- a sodium silicate composition is produced by stirring the sodium hydroxide solution and the silica source at a temperature of about 25° to 70° C.
- the sodium aluminate solution is admixed with a sodium silicate composition in SiO 2 /Al 2 O 3 mole ratios of about 2.0 to 40.0, Na 2 O/SiO 2 mole ratios of about 0.4 to 2.0 and H 2 O/Na 2 O mole ratios of about 15.0 to 70.0. Gelation is brought about by homogeneously stirring.
- the gel composition is deposited onto and into the pores of the activated carbon substrate.
- the mole ratio of SiO 2 /Al 2 O 3 is under 2.0, some of the alumina component remains in the final product. If the mole ratio is greater than 40, crystallization of the zeolite becomes difficult. If the mole ratio of Na 2 O/SiO 2 is under 0.4, the activity of the silica component is low and it is slowly converted into zeolite. If the mole ratio is more than 2.0, a crystalline aluminosilicate is produced having a very low activity.
- the reaction mixture is allowed to age for about 2 to 96 hours at about 25 to 60° C. and crystallized at about 70 to 120° C., preferably at 80 to 100° C., and most preferably at 90 to 100° C. for 2 to 4 hours.
- the slurry phase is separated, the final product washed with water, and dried for about 4 to 12 hours at about 100 to 120° C. to provide the molecular sieve compound.
- Preferred complex molecular sieve compounds produced are composed of microporous zeolites such as A, ZSM-5, X or Y type finely distributed onto the surfaces of the activated carbon. Therefore, the composites have both hydrophilic and hydrophobic adsorption properties derived from the activated carbon and zeolite.
- silanes are applied to the substrate followed by a heat treatment preferably in an oxidizing atmosphere.
- Suitable silanes include alkoxysilanes such as tetraethoxysilane.
- hydrophilic clays such as bentonite and montmorillonite may be admixed with the carbon-containing material before, during or after preparation of the substrate material.
- the carbon-containing substrate includes activated carbon. As indicated above, if the substrate is not activated beforehand, it may be activated after deposition of the zeolite membrane such as by heating the composite which removes various volatiles used in the synthesis of the membrane while activating the substrate.
- the composite is located in a filter portion of a cigarette.
- about 10 mg to about 300 mg of the composite can be used in a cigarette filter.
- amounts such as at least about 20, 30, 50, 75, 100, 150, 200, or 250 mg of the composite can be used in the cigarette filter.
- Exemplary filter structures may be used to locate the composite.
- Exemplary filter structures that can be used include, but are not limited to, a mono filter, a dual filter, a triple filter, a cavity filter, a recessed filter or a free-flow filter.
- Mono filters typically contain cellulose acetate tow or cellulose paper materials.
- Dual filters typically comprise a cellulose acetate mouthpiece filter plug and a second, different filter plug or segment.
- the composite is preferably located closer to the smoking material or tobacco side of a cigarette. The length and pressure drop of the two segments of the dual filter can be adjusted to provide optimal adsorption, while maintaining acceptable draw resistance.
- Triple filters can include mouth and smoking material or tobacco side segments, and a middle segment comprising a material or paper.
- the aforementioned composite can be provided in the middle segment.
- Cavity filters typically include two segments, e.g., acetate-acetate, acetate-paper or paper-paper, separated by a cavity.
- the composite can preferably be provided in the cavity.
- Recessed filters include an open cavity on the mouth side, and the composite can be incorporated into the plug material.
- the filters may also optionally be ventilated, and/or comprise additional sorbents (such as activated carbon, charcoal or magnesium silicate), catalysts, flavorants or other additives.
- FIG. 1 illustrates a cigarette 2 having a tobacco rod 4 , a filter portion 6 , and a mouthpiece filter plug 8 .
- the composite can be loaded onto folded paper 10 inserted into a hollow cavity such as the interior of a free-flow sleeve 12 forming part of the filter portion 6 .
- FIG. 2 shows a cigarette 2 having a tobacco rod 4 and a filter portion 6 , wherein the folded paper 10 is located in the hollow cavity of a first free-flow sleeve 13 located between the mouthpiece filter 8 and a second free-flow sleeve 15 .
- the paper 10 can be used in forms other than as a folded sheet. For instance, the paper 10 can be deployed as one or more individual strips, a wound roll, etc. In whichever form, a desired amount of the composite can be provided in the cigarette filter portion by adjusting the amount per unit area of the paper and/or the total area of coated paper employed in the filter (e.g., higher amounts of composite can be provided simply by using larger pieces of coated paper).
- the tobacco rod 4 and the filter portion 6 are joined together with tipping paper 14 .
- the filter portion 6 may be held together by filter overwrap 11 .
- the composite can be incorporated into the filter paper in a number of ways.
- particles or powders of the aforementioned composites can be mixed with water to form a slurry.
- the slurry can then be coated onto preformed filter paper and allowed to dry.
- the filter paper can then be incorporated into the filter portion of a cigarette in a manner shown in FIGS. 1 and 2 .
- the dried paper can be wrapped into a plug shape and inserted into a filter portion of the cigarette.
- the paper can be wrapped into a plug shape and inserted as a plug into the interior of a free-flow filter element such as a polypropylene or cellulose acetate sleeve.
- the paper can comprise an inner liner of such a free-flow filter element.
- the composite may be added to filter paper during the paper-making process.
- the composite can be mixed with bulk cellulose to form a cellulose pulp mixture. The mixture can be then formed into filter paper.
- the aforementioned composite may be incorporated into the fibrous material of the cigarette filter portion itself.
- filter materials include, but are not limited to, fibrous filter materials including paper, cellulose acetate fibers, and polypropylene fibers.
- FIG. 3 shows a cigarette 2 comprised of a tobacco rod 4 and a filter portion 6 in the form of a plug-space-plug filter having a mouthpiece filter 8 , a plug 16 , and a space 18 .
- the plug 16 can comprise a tube or solid piece of material such as polypropylene or cellulose acetate fibers.
- the tobacco rod 4 and the filter portion 6 are joined together with tipping paper 14 .
- the filter portion 6 may include a filter overwrap 11 .
- the filter overwrap 11 containing traditional fibrous filter material and the composite can be incorporated in or on the filter overwrap 11 such as by being coated thereon.
- the composite can be incorporated in the mouthpiece filter 8 , in the plug 16 , and/or in the space 18 .
- the composite can be incorporated in any element of the filter portion of a cigarette.
- the filter portion may consist only of the mouthpiece filter 8 and the composite can be incorporated in the mouthpiece filter 8 and/or in the tipping paper 14 .
- FIG. 4 shows a cigarette 2 comprised of a tobacco rod 4 and filter portion 6 .
- This arrangement is similar to that of FIG. 3 except the space 18 is filled with granules of composite or a plug 15 made of material such as fibrous polypropylene or cellulose acetate containing the composite.
- the plug 16 can be hollow or solid and the tobacco rod 4 and filter portion 6 are joined together with tipping paper 14 .
- FIG. 5 shows a cigarette 2 comprised of a tobacco rod 4 and a filter portion 6 wherein the filter portion 6 includes a mouthpiece filter 8 , a filter overwrap 11 , tipping paper 14 to join the tobacco rod 4 and filter portion 6 , a space 18 , a plug 16 , and a hollow sleeve 20 .
- the composite can be incorporated into one or more elements of the filter portion 6 .
- the composite can be incorporated into the sleeve 20 or granules of the composite can be filled into the space within the sleeve 20 .
- the plug 16 and sleeve 20 can be made of material such as fibrous polypropylene or cellulose acetate containing the composite.
- the plug 16 can be hollow or solid.
- FIG. 6 shows a further modification of the filter portion 6 .
- cigarette 2 is comprised of a tobacco rod 4 and filter portion 6 .
- the filter portion 6 includes a mouthpiece filter 8 , a filter overwrap 11 , a plug 22 , and a sleeve 20 .
- the composite can be incorporated in one or more of these filter elements.
- the plug 22 can be solid or hollow.
- the tobacco rod 4 and filter portion 6 are joined together by tipping paper 14 .
- the composite can be added to the filter fibers before they are formed into a filter cartridge, e.g., a tip for a cigarette.
- the composite can be added to the filter fibers, for example, in the form of a dry powder or a slurry. If the composite is applied in the form of a slurry, the fibers are allowed to dry before they are formed into a filter cartridge.
- the composite is employed in a hollow portion of a cigarette filter.
- some cigarette filters have a plug/space/plug configuration in which the plugs comprise a fibrous filter material and the space is simply a void between the two filter plugs. That void can be filled with the aforementioned composite.
- An example of this embodiment is shown in FIG. 3 .
- the composite can be in granular form or can be loaded onto a suitable support such as a fiber or thread.
- composite can be incorporated in various support materials.
- the particles may have an average particle diameter of about 5 to 100 ⁇ m, preferably about 10 to 50 ⁇ m.
- larger particles may be used.
- Such particles preferably have a mesh size from about 25 to 60, and more preferably from about 35 to 60 mesh.
- the amount of composite employed in the cigarette filter by way of incorporation on a suitable support such as filter paper and/or filter fibers depends on the amount of constituents in the tobacco smoke and the amount of constituents desired to be removed.
- the filter paper and the filter fibers may contain from 10% to 50% by weight of the composite.
- One embodiment relates to a method of making a filter.
- the method comprises incorporating the aforementioned composite into a cigarette filter.
- Most filters contain four main components: filter tow, plasticizer, plug wrap and adhesive.
- the filter tow comprises a bundle of cellulose acetate fibers or papers, that are bound together using the plasticizer, which acts as a hardening agent.
- the filter is contained in the plug wrap, usually a paper wrapper, which is secured using an adhesive. Any conventional or modified method of making cigarette filters may be used to incorporate the composite.
- Another embodiment relates to methods for making cigarettes.
- the method comprises: (i) providing a cut filler to a cigarette making machine to form a tobacco rod; (ii) placing a paper wrapper around the tobacco rod; and (iii) attaching a cigarette filter incorporating a composite to the tobacco rod to form the cigarette.
- the composites may be used to prepare impregnated fibers. Particles or powders of the composite are first mechanically mixed with the fiber in a closed volume. The resulting impregnated fibers will thus have a Loading Factor (LF), which term is defined as the ratio of the weight of material in the fiber micro cavities divided by the weight of the fiber itself.
- LF Loading Factor
- the Loading Factor may be expressed as a percentage or as a decimal number.
- the Loading Factor may vary between about 1% and about 150%. More preferably, the Loading Factor is between about 20% and about 80%, e.g., the Loading Factor can be about 40-60%.
- the fibers that are impregnated with the composite are formed into a cylindrical segment which is inserted in the space of a cigarette with a plug/space/plug filter configuration. Preferably, the segment is packed to a density to achieve a desired resistance to draw and contains an amount of the composite effective to filter out the selected smoke gas phase constituents. Tipping paper attaches the tobacco to the filter rod.
- Activated carbons and zeolite-type molecular sieves when combined together can produce composite materials with tailored sorption capacity and selectivity for application in smoking articles to selectively reduce targeted smoke constituents.
- the composite can be provided with a surface area effective to preferentially sorb selected constituents from cigarette smoke. While surface area is inversely proportional to particle size, sorbents having small particle size may pack together too densely to permit mainstream smoke to flow through the filter during smoking. If particle size is too large, there will be less than desired surface area. Therefore, these factors should be considered in manufacturing a composite having a particular particle size.
- the zeolite and activated carbon used in making the composite may be chosen to target selected constituents in mainstream smoke, while prolonging the shelf life of the activated carbon during storage of smoking articles containing the composite.
- the selection of starting materials permits the preferential removal of one or more selected constituents from mainstream smoke, while retaining other constituents, such as those relating to flavor.
- smoke substituents relating to flavor of large size and/or molecular weight can pass through the filter to a greater extent than smaller smoke substituents, such as light gases, various aldehydes or other small molecules which may be targeted for removal.
- the selectivity of the composite can be fine tuned, particularly by the selection of zeolites and activated carbons as well as the choice of particle sizes and pore sizes. Mixtures of molecular sieves with varying compositions and geometries can be employed to tailor the removal of selected constituents of tobacco smoke while controlling access to the pores of the activated carbon substrate.
- Selected constituents of mainstream smoke may be removed by the composite through one or more mechanisms such as molecular sieving, ion exchange, hydrophobic interactions, chelation, and/or chemical binding.
- the selected constituents of mainstream smoke that are removed preferably are composed of at least one of a hydrocarbon, a polar organic and/or non-polar organic compound.
- the selected constituent of mainstream smoke that is removed is an aldehyde, ketone, diene or aromatic compound.
- constituents which may be removed include carbon monoxide, 1,3-butadiene, isoprene, acrolein, acrylonitrile, hydrogen cyanide, o-toluidine, 2-naphthylamine, nitrogen oxide, benzene, phenol, and/or catechol. More preferably, the constituent is an aldehyde or diene.
Abstract
A composite for use in smoking articles such as cigarettes is described comprising a zeolite membrane coated upon an activated carbon-containing substrate. The substrate may be a fiber, fabric, particle, granule or monolith. The composite is prepared by contacting zeolite precursors with the substrate and hydrothermally synthesizing the membrane upon the substrate. The substrate may be pretreated to provide activation sites for adhesion and growth of the membrane. By selection of the zeolite components, the composite may be tailored to selectively remove constituents of tobacco smoke while simultaneously controlling access to the substrate thereby prolonging the shelf life of the activated carbons.
Description
- Various activated carbon materials have been employed as sorbents in smoking articles to remove or reduce smoke constituents. Activated carbons are useful sorbents and have a large capacity; however, they lack selectivity. While they are effective in removing targeted constituents from tobacco smoke, they also may remove volatile constituents which contribute to flavor, aroma and other desirable attributes. Further, activated carbon in a cigarette filter may be rapidly inactivated during storage by the adsorption of volatile compounds, or by contact with various constituents of mainstream smoke.
- Zeolite-type molecular sieves have also been used in smoking articles to selectively remove constituents of tobacco smoke. Zeolite molecular sieve sorbents are capable of selectively removing one or more targeted constituents of mainstream smoke. However, zeolites have minimal capacities and are quickly exhausted before removing a significant amount of the targeted constituent.
- There is interest in a filter system for use in smoking articles which can readily be manufactured in various shapes from commercially available activated carbons and zeolite materials and can be tailored to produce components which selectively remove or reduce the concentration of various smoke constituents while retaining desirable flavor constituents and having an extended shelf life.
- A smoking article is provided which includes tobacco and a filter system comprising a composite composed of an activated carbon substrate and a zeolite-type membrane coated thereon. Also provided is a filter system, a method of making smoking articles containing said filter system and a method of selectively removing targeted constituents from tobacco smoke.
- In one embodiment, a filter is prepared containing a composite made by the deposition of a molecular sieve membrane directly onto a carbon-containing substrate by hydrothermal synthesis of a given molecular sieve. Pre-treatment of the substrate may be desirable to achieve optimum adhesion and growth of the membrane on the substrate.
- In another embodiment, cigarettes are prepared which contain tobacco and the filter mentioned above. A preferred smoking article is a traditional or non-traditional cigarette. The aforementioned composite preferably is incorporated into a filter of a cigarette.
- Another embodiment relates to a method of making a filter cigarette, comprising: (i) providing a cut filler to a cigarette making machine and forming a tobacco column; (ii) placing a paper wrapper around the tobacco column and forming a tobacco rod; (iii) attaching a cigarette filter comprising the composite described above to the tobacco rod to form the cigarette.
- In another embodiment, a method is provided of treating mainstream smoke of a smoking article to preferentially remove one or more targeted constituents from mainstream smoke by contacting the mainstream smoke with a composite as described above.
-
FIG. 1 is a view of a cigarette wherein folded paper containing a composite described above is inserted into a hollow portion of a tubular filter element of the cigarette. -
FIG. 2 is a view of another embodiment wherein a composite as described above is incorporated in folded paper and inserted into a hollow portion of a first free-flow sleeve of a tubular filter element next to a second free-flow sleeve. -
FIG. 3 is a view of another embodiment wherein a composite as described above is incorporated in a plug-space-plug filter element. -
FIG. 4 is a view of another embodiment wherein a composite is incorporated in a three-piece filter element having three plugs. -
FIG. 5 is a view of another embodiment wherein a composite is incorporated in a four-piece filter element having a plug-space-plug arrangement and a hollow sleeve. -
FIG. 6 is a view of still another embodiment wherein a composite is incorporated in a three-part filter element having two plugs and a hollow sleeve. - Cigarette filters and smoking articles are provided preferably containing a porous composite comprising an activated carbon substrate and a zeolite molecular sieve membrane coated thereon and capable of selectively removing selected constituents from mainstream smoke. Methods for making such cigarette filters and smoking articles, as well as a method of treating mainstream smoke, are also provided.
- The term “sorption” denotes filtration by adsorption and/or absorption and is intended to encompass interactions on the outer surface of a sorbent, as well as interactions within the pores and channels thereof. A “sorbent” is a substance that has the ability to condense or hold molecules of other substances on its surface and/or the ability to take up other substances, i.e., through penetration of the other substances into its inner structure or into its pores. The term “sorbent” as used herein refers to either an adsorbent, an absorbent, or a substance that can function as both an adsorbent and an absorbent.
- The term “remove” as used herein refers to adsorption and/or absorption of at least some portion of a selected constituent of mainstream tobacco smoke.
- The term “mainstream smoke” includes the mixture of gases and aerosolized condensed matter which passes down a tobacco column and issues through the filter end, i.e., the amount of smoke issuing or drawn from the mouth end of a smoking article such as a cigarette during smoking. The mainstream smoke contains air that is drawn in through both the lit or heated region of the smoking article, as well as through the paper wrapper, and through any ventilation perforations that may be present.
- Smoking articles, such as cigarettes, cigarillos and cigars, as well as non-traditional cigarettes, are provided. Non-traditional cigarettes include, for example, smoking articles which include combustible heat sources such as that shown in commonly assigned, U.S. Pat. No. 4,966,171, and cigarettes for electrical smoking systems as described in commonly-assigned U.S. Pat. Nos. 6,026,820; 5,988,176; 5,915,387; and 5,499,636.
- The substrate portion of the aforementioned composite comprises an activated carbon. Activated forms of carbon generally have strong physical sorption forces, and high volumes of sorbing porosity. The activated carbon could be manufactured by any suitable method. Such methods include the carbonization of coconut husk, coal, wood, pitch, cellulose fibers, or polymer fibers, for example. Carbonization is usually carried out at high temperatures, i.e., 200-1000° C. in an inert atmosphere, followed by activation. The activated carbon used as the composite substrate could be in the form of carbon granules, beads, powder, fiber, fabric or shaped monoliths. The substrate could also be an admixture of carbon and an inorganic material. Suitable inorganic materials may comprise porous and/or catalytically active metal compounds such as oxides, hydroxides, silicates and phosphates.
- Carbon-containing materials suitable as substrates may have a distribution of micropores, mesopores and macropores. The term “microporous” generally refers to such materials having pore sizes of about 20 Å or less while the term “mesoporous” generally refers to such materials with pore sizes of about 20 to 500 Å. “Macroporous” materials have pore sizes above about 500 Å. The relative amounts of micropores, mesopores and macropores in the carbon-containing substrate will depend upon the selected constituents from mainstream tobacco smoke that are to be targeted and removed. Thus, the pore sizes and pore distribution can be adjusted accordingly as needed for a certain application.
- Another material in the filter system is a molecular sieve zeolite membrane. The term “molecular sieve” as used herein refers to a porous structure composed of an inorganic silicate material. Zeolites have channels or pores of uniform, molecular sized dimensions. There are many known unique zeolite structures having different sized and shaped channels or pores. The size and shape of the channels or pores can significantly affect the properties of these materials with regard to adsorption and separation characteristics. Zeolites can be used to separate molecules by size and shape possibly related to the orientation of the molecules in the channels or pores, and/or by differences in strength of sorption. By using one or more zeolites having channels or pores larger than selected constituents of mainstream smoke, only selected molecules that are small enough to pass through the pores of the molecular sieve material are able to enter the cavities and be sorbed by the zeolite.
- Zeolite-type molecular sieves which are useful in the composites include crystalline aluminosilicates, silicoaluminophosphates (AlPO/SAPO) and mesoporous molecular sieves such as MCM-41, MCM-48 and SBA-15. This family of materials contains regular arrays of uniformly-sized channels and tunable internal active sites, and admits molecules below a certain size into their internal space which makes them useful as catalysts and sorbents where selectivity is critical. Microporous and mesoporous molecular sieves are preferred. They are selected for use in the filter composites based on the particular constituent or constituents to be removed from the mainstream smoke.
- The term “microporous molecular sieves” generally refers to molecular sieve materials having pore sizes of about 20 Å or less. The term “mesoporous molecular sieves” generally refers to such materials with pore sizes of about 20 to 500 Å. Materials with pore sizes of about 500 Å or larger may be referred to as “macroporous molecular sieves.”
- The composite preferably is prepared by a hydrothermal synthesis technique using zeolite precursor materials which form a coated membrane on the substrate. The hydrothermal synthesis of various zeolites can be accomplished by any techniques which would generate in situ a zeolite membrane on the carbon-containing substrate. Methods for the preparation of zeolite membranes on activated porous carbon monoliths and porous carbon membranes are disclosed in the following articles: “Preparation of hollow-fibre composite carbon-zeolite membranes,” Smith, S. P. J.; Linkov, V. M; Sanderson, R. D.; Petrik, L. F.; O'Connor, C. T.; Keiser, K., Microporous Materials, 1995, 4, pp. 385-390; “Preparation of an MFI zeolite coating on activated carbon,” van der Vaart, R.; Bosch, H.; Keizer, K.; Reith, T., Microporous Materials, 1997, 9, pp. 203-207, the entire disclosures of both articles incorporated herein in their entirety. In general, the substrates are contacted with the zeolite precursors and a hydrothermal synthesis conducted whereby the zeolite membrane is coated upon and/or into the pores of the substrate. If the carbon-containing substrate has not been activated before synthesis of the zeolite membrane, known activation techniques may be employed to remove volatiles and produce the final activated composite. The product is a composite filter system composed of a porous substrate of activated carbon having a zeolite membrane coated uniformly upon the surface and within the pores of the substrate.
- In the hydrothermal synthesis of crystalline aluminosilicates, sodium hydroxide may be used as the alkaline source. Sodium aluminate (NaAlO2), aluminum nitrate (Al(NO3)39H2O), aluminum sulfate (Al2(SO4)318H2O), aluminum chloride (AlCl36H2O), aluminum hydroxide (Al(OH)3), aluminum alkoxide and alumina gel, etc. can be used as the source of alumina. Colloidal silica, fumed silica, water glass (sodium silicate aqueous solution), silica gel, etc. can be used as the silica source.
- The factors affecting crystallization of aluminosilicate include the source of silica, the mole ratio of silica vs. alumina, pH, reaction temperature, reaction time, degree of aging in room temperature, presence of stirring, etc. The morphology and nature of zeolite produced are directly linked to these variations.
- An example of a method of preparing a molecular sieve compound is described in U.S. Pat. No. 6,117,810, the entire disclosure of which is incorporated herein by reference. A sodium aluminate solution is made by adding a source of alumina to sodium hydroxide solution and stirring for about 20 to 60 minutes at about 70 to 120° C. to dissolve completely. The concentration of sodium hydroxide in solution is about 20 to 50 wt. %, especially about 30 to 40 wt. %. A sodium silicate composition is produced by stirring the sodium hydroxide solution and the silica source at a temperature of about 25° to 70° C. Thereafter, the sodium aluminate solution is admixed with a sodium silicate composition in SiO2/Al2O3 mole ratios of about 2.0 to 40.0, Na2O/SiO2 mole ratios of about 0.4 to 2.0 and H2O/Na2O mole ratios of about 15.0 to 70.0. Gelation is brought about by homogeneously stirring.
- Following gelation, the gel composition is deposited onto and into the pores of the activated carbon substrate. In the above process, if the mole ratio of SiO2/Al2O3 is under 2.0, some of the alumina component remains in the final product. If the mole ratio is greater than 40, crystallization of the zeolite becomes difficult. If the mole ratio of Na2O/SiO2 is under 0.4, the activity of the silica component is low and it is slowly converted into zeolite. If the mole ratio is more than 2.0, a crystalline aluminosilicate is produced having a very low activity.
- If the mole ratio of H2O/Na2O is under 15, alkalinity in solution is so high that side reactions can easily occur. If the ratio is more than 70.0, higher pressures and temperatures are required for the synthesis reaction.
- The reaction mixture is allowed to age for about 2 to 96 hours at about 25 to 60° C. and crystallized at about 70 to 120° C., preferably at 80 to 100° C., and most preferably at 90 to 100° C. for 2 to 4 hours.
- Upon completion of crystallization, the slurry phase is separated, the final product washed with water, and dried for about 4 to 12 hours at about 100 to 120° C. to provide the molecular sieve compound.
- Preferred complex molecular sieve compounds produced are composed of microporous zeolites such as A, ZSM-5, X or Y type finely distributed onto the surfaces of the activated carbon. Therefore, the composites have both hydrophilic and hydrophobic adsorption properties derived from the activated carbon and zeolite.
- To facilitate adhesion and growth of the zeolite membrane on the carbon-containing substrate, it may be desirable to pretreat the substrate to provide sufficient nucleation sites. Preferably, silanes are applied to the substrate followed by a heat treatment preferably in an oxidizing atmosphere. Suitable silanes include alkoxysilanes such as tetraethoxysilane. Alternatively, hydrophilic clays such as bentonite and montmorillonite may be admixed with the carbon-containing material before, during or after preparation of the substrate material. Preferably, the carbon-containing substrate includes activated carbon. As indicated above, if the substrate is not activated beforehand, it may be activated after deposition of the zeolite membrane such as by heating the composite which removes various volatiles used in the synthesis of the membrane while activating the substrate.
- In a preferred embodiment, the composite is located in a filter portion of a cigarette. Typically, about 10 mg to about 300 mg of the composite can be used in a cigarette filter. For example, amounts such as at least about 20, 30, 50, 75, 100, 150, 200, or 250 mg of the composite can be used in the cigarette filter.
- Various filter constructions may be used to locate the composite. Exemplary filter structures that can be used include, but are not limited to, a mono filter, a dual filter, a triple filter, a cavity filter, a recessed filter or a free-flow filter. Mono filters typically contain cellulose acetate tow or cellulose paper materials. Dual filters typically comprise a cellulose acetate mouthpiece filter plug and a second, different filter plug or segment. The composite is preferably located closer to the smoking material or tobacco side of a cigarette. The length and pressure drop of the two segments of the dual filter can be adjusted to provide optimal adsorption, while maintaining acceptable draw resistance.
- Triple filters can include mouth and smoking material or tobacco side segments, and a middle segment comprising a material or paper. The aforementioned composite can be provided in the middle segment. Cavity filters typically include two segments, e.g., acetate-acetate, acetate-paper or paper-paper, separated by a cavity. The composite can preferably be provided in the cavity. Recessed filters include an open cavity on the mouth side, and the composite can be incorporated into the plug material. The filters may also optionally be ventilated, and/or comprise additional sorbents (such as activated carbon, charcoal or magnesium silicate), catalysts, flavorants or other additives.
-
FIG. 1 illustrates acigarette 2 having atobacco rod 4, afilter portion 6, and amouthpiece filter plug 8. The composite can be loaded onto foldedpaper 10 inserted into a hollow cavity such as the interior of a free-flow sleeve 12 forming part of thefilter portion 6. -
FIG. 2 shows acigarette 2 having atobacco rod 4 and afilter portion 6, wherein the foldedpaper 10 is located in the hollow cavity of a first free-flow sleeve 13 located between themouthpiece filter 8 and a second free-flow sleeve 15. Thepaper 10 can be used in forms other than as a folded sheet. For instance, thepaper 10 can be deployed as one or more individual strips, a wound roll, etc. In whichever form, a desired amount of the composite can be provided in the cigarette filter portion by adjusting the amount per unit area of the paper and/or the total area of coated paper employed in the filter (e.g., higher amounts of composite can be provided simply by using larger pieces of coated paper). In the cigarettes shown inFIGS. 1 and 2 , thetobacco rod 4 and thefilter portion 6 are joined together with tippingpaper 14. In both cigarettes, thefilter portion 6 may be held together byfilter overwrap 11. - The composite can be incorporated into the filter paper in a number of ways. For examples, particles or powders of the aforementioned composites can be mixed with water to form a slurry. The slurry can then be coated onto preformed filter paper and allowed to dry. The filter paper can then be incorporated into the filter portion of a cigarette in a manner shown in
FIGS. 1 and 2 . Alternatively, the dried paper can be wrapped into a plug shape and inserted into a filter portion of the cigarette. For example, the paper can be wrapped into a plug shape and inserted as a plug into the interior of a free-flow filter element such as a polypropylene or cellulose acetate sleeve. In another arrangement, the paper can comprise an inner liner of such a free-flow filter element. - Alternatively, the composite may be added to filter paper during the paper-making process. For example, the composite can be mixed with bulk cellulose to form a cellulose pulp mixture. The mixture can be then formed into filter paper.
- In another embodiment, the aforementioned composite may be incorporated into the fibrous material of the cigarette filter portion itself. Such filter materials include, but are not limited to, fibrous filter materials including paper, cellulose acetate fibers, and polypropylene fibers. This embodiment is illustrated in
FIG. 3 , which shows acigarette 2 comprised of atobacco rod 4 and afilter portion 6 in the form of a plug-space-plug filter having amouthpiece filter 8, aplug 16, and aspace 18. Theplug 16 can comprise a tube or solid piece of material such as polypropylene or cellulose acetate fibers. Thetobacco rod 4 and thefilter portion 6 are joined together with tippingpaper 14. Thefilter portion 6 may include afilter overwrap 11. Thefilter overwrap 11 containing traditional fibrous filter material and the composite can be incorporated in or on thefilter overwrap 11 such as by being coated thereon. Alternatively, the composite can be incorporated in themouthpiece filter 8, in theplug 16, and/or in thespace 18. Moreover, the composite can be incorporated in any element of the filter portion of a cigarette. For example, the filter portion may consist only of themouthpiece filter 8 and the composite can be incorporated in themouthpiece filter 8 and/or in the tippingpaper 14. -
FIG. 4 shows acigarette 2 comprised of atobacco rod 4 andfilter portion 6. This arrangement is similar to that ofFIG. 3 except thespace 18 is filled with granules of composite or aplug 15 made of material such as fibrous polypropylene or cellulose acetate containing the composite. As in a previous embodiment, theplug 16 can be hollow or solid and thetobacco rod 4 andfilter portion 6 are joined together with tippingpaper 14. There is also afilter overwrap 11. -
FIG. 5 shows acigarette 2 comprised of atobacco rod 4 and afilter portion 6 wherein thefilter portion 6 includes amouthpiece filter 8, afilter overwrap 11, tippingpaper 14 to join thetobacco rod 4 andfilter portion 6, aspace 18, aplug 16, and ahollow sleeve 20. The composite can be incorporated into one or more elements of thefilter portion 6. For instance, the composite can be incorporated into thesleeve 20 or granules of the composite can be filled into the space within thesleeve 20. If desired, theplug 16 andsleeve 20 can be made of material such as fibrous polypropylene or cellulose acetate containing the composite. As in the previous embodiment, theplug 16 can be hollow or solid. -
FIG. 6 shows a further modification of thefilter portion 6. InFIG. 6 ,cigarette 2 is comprised of atobacco rod 4 andfilter portion 6. Thefilter portion 6 includes amouthpiece filter 8, afilter overwrap 11, aplug 22, and asleeve 20. The composite can be incorporated in one or more of these filter elements. Theplug 22 can be solid or hollow. Thetobacco rod 4 andfilter portion 6 are joined together by tippingpaper 14. - Various techniques can be used to apply the composite to filter fibers or other substrate supports. For example, the composite can be added to the filter fibers before they are formed into a filter cartridge, e.g., a tip for a cigarette. The composite can be added to the filter fibers, for example, in the form of a dry powder or a slurry. If the composite is applied in the form of a slurry, the fibers are allowed to dry before they are formed into a filter cartridge.
- In another embodiment, the composite is employed in a hollow portion of a cigarette filter. For example, some cigarette filters have a plug/space/plug configuration in which the plugs comprise a fibrous filter material and the space is simply a void between the two filter plugs. That void can be filled with the aforementioned composite. An example of this embodiment is shown in
FIG. 3 . The composite can be in granular form or can be loaded onto a suitable support such as a fiber or thread. - As explained above, composite can be incorporated in various support materials. When the composite is used in filter paper, the particles may have an average particle diameter of about 5 to 100 μm, preferably about 10 to 50 μm. When the composite is used in filter fibers or other mechanical supports, larger particles may be used. Such particles preferably have a mesh size from about 25 to 60, and more preferably from about 35 to 60 mesh.
- The amount of composite employed in the cigarette filter by way of incorporation on a suitable support such as filter paper and/or filter fibers depends on the amount of constituents in the tobacco smoke and the amount of constituents desired to be removed. As an example, the filter paper and the filter fibers may contain from 10% to 50% by weight of the composite.
- One embodiment relates to a method of making a filter. The method comprises incorporating the aforementioned composite into a cigarette filter. Most filters contain four main components: filter tow, plasticizer, plug wrap and adhesive. Often the filter tow comprises a bundle of cellulose acetate fibers or papers, that are bound together using the plasticizer, which acts as a hardening agent. The filter is contained in the plug wrap, usually a paper wrapper, which is secured using an adhesive. Any conventional or modified method of making cigarette filters may be used to incorporate the composite.
- Another embodiment relates to methods for making cigarettes. For example, the method comprises: (i) providing a cut filler to a cigarette making machine to form a tobacco rod; (ii) placing a paper wrapper around the tobacco rod; and (iii) attaching a cigarette filter incorporating a composite to the tobacco rod to form the cigarette.
- The composites may be used to prepare impregnated fibers. Particles or powders of the composite are first mechanically mixed with the fiber in a closed volume. The resulting impregnated fibers will thus have a Loading Factor (LF), which term is defined as the ratio of the weight of material in the fiber micro cavities divided by the weight of the fiber itself. The Loading Factor may be expressed as a percentage or as a decimal number.
- The Loading Factor may vary between about 1% and about 150%. More preferably, the Loading Factor is between about 20% and about 80%, e.g., the Loading Factor can be about 40-60%. The fibers that are impregnated with the composite are formed into a cylindrical segment which is inserted in the space of a cigarette with a plug/space/plug filter configuration. Preferably, the segment is packed to a density to achieve a desired resistance to draw and contains an amount of the composite effective to filter out the selected smoke gas phase constituents. Tipping paper attaches the tobacco to the filter rod.
- Activated carbons and zeolite-type molecular sieves when combined together can produce composite materials with tailored sorption capacity and selectivity for application in smoking articles to selectively reduce targeted smoke constituents. The composite can be provided with a surface area effective to preferentially sorb selected constituents from cigarette smoke. While surface area is inversely proportional to particle size, sorbents having small particle size may pack together too densely to permit mainstream smoke to flow through the filter during smoking. If particle size is too large, there will be less than desired surface area. Therefore, these factors should be considered in manufacturing a composite having a particular particle size.
- The zeolite and activated carbon used in making the composite may be chosen to target selected constituents in mainstream smoke, while prolonging the shelf life of the activated carbon during storage of smoking articles containing the composite. The selection of starting materials permits the preferential removal of one or more selected constituents from mainstream smoke, while retaining other constituents, such as those relating to flavor. For example, smoke substituents relating to flavor of large size and/or molecular weight can pass through the filter to a greater extent than smaller smoke substituents, such as light gases, various aldehydes or other small molecules which may be targeted for removal. The selectivity of the composite can be fine tuned, particularly by the selection of zeolites and activated carbons as well as the choice of particle sizes and pore sizes. Mixtures of molecular sieves with varying compositions and geometries can be employed to tailor the removal of selected constituents of tobacco smoke while controlling access to the pores of the activated carbon substrate.
- Selected constituents of mainstream smoke may be removed by the composite through one or more mechanisms such as molecular sieving, ion exchange, hydrophobic interactions, chelation, and/or chemical binding. The selected constituents of mainstream smoke that are removed preferably are composed of at least one of a hydrocarbon, a polar organic and/or non-polar organic compound. Preferably, the selected constituent of mainstream smoke that is removed is an aldehyde, ketone, diene or aromatic compound. Specific constituents which may be removed include carbon monoxide, 1,3-butadiene, isoprene, acrolein, acrylonitrile, hydrogen cyanide, o-toluidine, 2-naphthylamine, nitrogen oxide, benzene, phenol, and/or catechol. More preferably, the constituent is an aldehyde or diene.
- Variations and modifications of the foregoing embodiments will be apparent to those skilled in the art. Such variations and modifications are to be considered within the purview and scope of the claims appended hereto.
Claims (19)
1. A smoking article comprising tobacco and a filter component comprising a composite comprising at least one activated carbon-containing substrate coated with at least one zeolite molecular sieve layer.
2. The smoking article of claim 1 , wherein said substrate comprises a fiber, fabric, particle, granule or monolith, and the zeolite comprises a crystalline alumino-silicate, a silicoaluminophosphate or a micro- or meso-porous molecular sieve.
3. The smoking article of claim 2 , wherein the zeolite comprises a molecular sieve selected from ZSM-5, X, Y or A type zeolites.
4. The smoking article of claim 1 , wherein the article is a cigarette.
5. The smoking article of claim 1 , wherein the substrate is pretreated to provide nucleation sites.
6. The smoking article of claim 5 , wherein the pretreatment comprises reaction with a silane.
7. The smoking article of claim 1 , wherein the activated carbon of the substrate has a distribution of micropores, mesopores and macropores.
8. The smoking article of claim 4 , wherein the filter component is a mono filter, a dual filter, a triple filter, a cavity filter, a recessed filter or a free-flow filter, the filter component comprises cellulose acetate tow, cellulose paper, polypropylene fiber or combinations thereof, and the composite is incorporated into at least one cigarette filter part selected from a shaped paper inset, a plug, a space, cigarette filter paper or a free-flow sleeve.
9. A smoking article comprising a filter component composed of a composite comprising at least one activated porous carbon substrate and at least one zeolite molecular sieve membrane coated on the surface of and/or in the pores of the substrate.
10. The smoking article of claim 9 , wherein said carbon substrate is pretreated to provide nucleation sites.
11. The smoking article of claim 10 , wherein pretreatment comprises reaction with a silane.
12. The smoking article of claim 9 comprising tobacco cut filler, cigarette paper and cigarette filter material, wherein the a composite is capable of selectively removing constituents from cigarette smoke, and wherein the composite is prepared by hydrothermally synthesizing a zeolite molecular sieve layer on said substrate.
13. The smoking article of claim 12 , wherein said article is a cigarette.
14. A method of treating cigarette smoke produced by the cigarette of claim 4 , comprising lighting the cigarette to form tobacco smoke and drawing the tobacco smoke through the cigarette, wherein the composite reduces the amount of selected constituents in the tobacco smoke, and wherein the composite is located in a filter component of the cigarette.
15. The cigarette according to claim 13 comprising tobacco and a filter element, wherein the filter element includes the composite comprising an activated porous carbon substrate having a zeolite molecular sieve membrane coated upon and within the pores of the substrate, wherein the carbon substrate comprises a fiber, fabric, particle, granule or monolith.
16. The cigarette of claim 15 , wherein the carbon substrate has been pretreated with a silane to provide nucleation sites.
17. A method of manufacturing a cigarette filter, comprising incorporating into a cigarette filter a composite comprising a porous activated carbon-containing substrate and a zeolite molecular sieve membrane coated upon and within the pores thereof, the composite being loaded on a support, or incorporated in a support, or incorporated with a support, in a plug-space-plug arrangement, in bead form, and/or in monolith form.
18. A method of treating mainstream smoke of a smoking article of claim 13 , by contacting mainstream smoke with the porous composite, wherein the porous composite selectively removes at least one selected constituent from mainstream smoke.
19. The method of claim 18 , wherein said selected constituent removed is at least one of an aldehyde, ketone, hydrocarbon, aromatic, HCN, a nitrile, CO, a polar or non-polar organic compound or mixtures thereof.
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US11/311,420 US20060260626A1 (en) | 2005-01-05 | 2005-12-20 | Activated carbons with molecular sieve membranes and their use as adsorbents in smoking articles |
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US64113405P | 2005-01-05 | 2005-01-05 | |
US11/311,420 US20060260626A1 (en) | 2005-01-05 | 2005-12-20 | Activated carbons with molecular sieve membranes and their use as adsorbents in smoking articles |
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WO (1) | WO2006072889A1 (en) |
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