FILTER ASSEMBLY HAVING A DUAL MATERIAL HOLDER STRUCTURE AND SMOKING ACCESSORIES INCLUDING THE SAME

TECHNICAL FIELD

This disclosure relates to flavored smoking materials. More specifically, this disclosure relates to filters and elongated members having a flavor carrier housed therein.

DESCRIPTION OF RELATED ART

Hand-rolled cigarettes, cigars, or cigarillos generally do not have an incorporated filter. Filters can be purchased and included in such a hand-rolled smoke, but these are commonly formed from synthetic materials such as cellulose acetate (a plastic) and rayon. The cellulose acetate tow fibers are thinner than sewing thread, white, and packed tightly together to form a filter element and included in the hand-rolled smoke. Burning or inhaling such synthetic fibers can create a hazardous situation for the smoker. In addition, flavors are not easily added to hand-rolled cigarettes, cigars, or cigarillos

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure, in accordance with one or more various embodiments, is described in detail with reference to the following figures. The figures are provided for purposes of illustration only and merely depict typical or example embodiments.

FIG. 1 is a perspective view of an embodiment of a hollow tube in accordance with embodiments disclosed herein.

FIG. 2 is another perspective view of the hollow tube of FIG. 1.

FIG. 3 is an exploded view of the hollow tube of FIG. 1 and FIG. 2.

FIG. 4 is an exploded perspective view of an example filter assembly, according to embodiments disclosed herein.

FIG. 5A is a cross-section of an example flavor carrier holder structure taken along the line 6-6 of FIG. 1, in according to embodiments disclosed herein.

FIG. 5B is a cross-section of another example flavor carrier holder structure taken along the line 6-6 of FIG. 1, according to embodiments disclosed herein.

FIG. 6 is a cross-section of an embodiment of the hollow tube taken along the line 5-5 of FIG. 1.

FIG. 7 is another view of the cross section of FIG. 6.

FIG. 8 is graphical depiction of the hollow tube of FIG. 1 in use.

FIG. 9 is a perspective view of the filter received by an elongated member in accordance with embodiments disclosed herein.

FIG. 10 is perspective view of the filter used with a hollow elongated member in accordance with embodiments disclosed herein.

The figures are not exhaustive and do not limit the present disclosure to the precise form disclosed.

DETAILED DESCRIPTION

Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

FIG. 1 is a perspective view of an embodiment of a hollow elongated member. In the illustrative example of FIG. 1, the hollow member can be a hollow tubular member (referred to herein as a hollow tube 100) formed from one or more sheets of material 110. However, embodiments disclosed herein are not intended to be limited to tubular members, and may be any desired elongated member. For example, hollow tube 100 may be provided as a truncated conical member, such as those described in U.S. application Ser. No. 18/302,593, the disclosure of which is incorporated herein by reference in its entirety. The material 110 can extend from a first end 102 to a second end 104. The first end 102 can have a filter assembly 120, forming a closed end of the hollow tube 100. The hollow tube 100 can have a central axis 101 following an imaginary line through the center of the hollow tub from the first end 102 to the second end 104. The description refers to axial and radial directions. Axial refers to directions along the central axis 101, while radial refers to a direction orthogonal to the central axis 101.

FIG. 2 is another perspective view of the hollow tube of FIG. 1. FIG. 1 and FIG. 2 are referenced in the following description.

The second end 104 can open into an elongated internal cavity 108 having an inner diameter 106. Internal cavity 108 can receive smoking material 140 (see FIG. 8). In some implementations, material 110 can be one or more dried leaves, such as any natural plant leaves that can be rolled into a tube. In some examples, material 110 can be a tree or plant leaf such as, Cordia, manjack, bocote, Areca, palm, or other leaves. Cordia is a primary example used herein, but is not limiting on the disclosure. Cordia can include flowering plants (e.g., shrubs and trees) in the borage family, Boraginaceae. Areca can include flowering plants in the Aceraceae family. In general, material 110 can be a thick, pure, and all natural leaf (i.e., no additives) without glue or other adhesives and green leaf. Material 110 can also be tobacco free. Material 110 can provide a resilient and aesthetically appealing green that burns slowly.

In some implementations, material 110 can be a paper material, such as any thin sheet material produced by processing fibers derived from plant or tree sources in water. Pressing and drying the material produces a sheet of material 110. The paper material can be any type of paper, such as, but not limited to, rice paper, hemp paper, palm paper (e.g., made by processing Cordia fibers and/or Areca fibers), wood pulp, bleached paper (e.g., sometimes referred to as white paper), unbleached paper (e.g., sometimes referred to as brown paper), clear paper (e.g., paper made from cellulose resulting in a clear sheet), colored papers, gold rolling papers. For example, different paper material may be used to provide differing aesthetics, such as different colored papers or papers having designs printed thereon. In various examples, material 110 may be entirely made of palm paper (e.g. made by processing Cordia fibers and/or Areca fibers). Using paper material, such as hemp paper, palm paper, etc., may provide benefits, such as for example, but not limited to, being thinner and more flexible than the dried leaf embodiments described above. Particularly, palm paper may provide material that is both thin and flexible, while resilient to breakage and/or tearing. Another benefit of palm paper is that it is one of the slowest burning papers and tobacco-free. The Cordia leaf (or fibers therefrom) is durable and absorbs liquid (e.g., from flavor carrier 240 described below) in a manner that is more resilient than that provided by papers or leaf from other plants. Similar properties are attributable to Areca fibers.

The leaf and/or paper can be rolled around a form and dried in place to form material 110 of the hollow tube 100. In some embodiments, one or more sheets of paper (or leaf) may be rolled to form the hollow tube 100, such as a single sheet or leaf, two sheets or leaves, etc. In some other examples, material 110 can be (partially) dried and then rolled into the desired shape. Material 110 can be secured in a tubular form with a ring 112. Ring 112 can be a section of paper or other appropriate fastener wrapped around and adhered to itself, holding material 110 in its hollow form/tubular shape and preventing material 110 from unwrapping. Ring 112 can further be adhered to material 110 to maintain the tubular shape.

FIG. 3 is an exploded view of the hollow tube of FIG. 1 and FIG. 2. Filter assembly 120 can have a cylindrical body/shape having an outer diameter 122 extending from a first end 121 to a second end 123. The outer diameter 122 can be approximately equal to the inner diameter 106 of the first end 102 of the hollow tube 100. Filter assembly 120 can be received within the first end 102 in an interference or friction fit. In some examples, filter assembly 120 can be rolled into material 110 when forming the hollow tube 100. In some implementations, filter assembly 120 can be removed and/or replaced from the hollow tube 100 as needed.

Filter assembly 120 can have a filter wrapper 124 (e.g., a plug wrap) enclosing one or more filter elements 126. Filter element 126 can be formed from a filter material, for example, comprising natural fibers. In some examples, filter element 126 can be formed from husks of a plant or tree. For example, filter element 126 can be formed from husk material, such as corn husk, palm husk (e.g., Cordia husk, Areca husk, etc.), and the like. In various embodiments, the filter element can be formed by rolling husk material. For example, the husks can be shredded and rolled (e.g., hand-rolled or machine-rolled) into a cylindrical shape, forming the filter element 126, or portions thereof. In some implementations, filter element 126 can be held in the cylindrical shape by filter wrapper 124. Filter wrapper 124 can be a section of ordinary paper wrapped around filter element 126. In other implementations, filter element 126 can be completely formed of husk material without any paper. In some other implementations, filter wrapper 124 can be one or more sections (e.g., lengths) of string formed from natural fibers. The string can be wrapped and tied around, for example, the ends of filter element 126 to maintain a round shape.

Filter element 126 may comprise an elongated structure that extends between ends 121 and 123 having shaped profiles at each end 121 and 123. The elongated structure form one or more channels extending along the filter element 126. The channels may provide for fluid communication between second end 123 and first end 121. The channels may be formed between surfaces of the filter element 126 and/or between a surface of filter element 126 and filter wrapper 124.

In an example implementation, filter element 126 can be formed by rolling the material into a cylindrical shape, including ends having spiral cross-sectional profile when viewed along central axis 101. That is, end 121 may have a spiral-shaped edge or end that is extruded along central axis 101 to second end 123 to define the filter element 126. In some embodiments, the cross-sectional profile comprises an Archimedean spiral (also referred to as a arithmetic spiral) shaped edge when viewed along central axis 101. Rolling material to form filter element 126 in this way, forms one or more channels that can facilitate fluid flow between end first, end 121, and second end 123. In one example, the one or more channels may include a channel having a spiral-shaped profile along the central axis 101 defined by the space between surfaces of the rolled filter element 126 and/or filter wrapper 124. For example, neighboring surfaces of the rolled filter element 126 may form a channel. As another example, a channel may be formed between an outer surface of rolled filter element 126 and an inner surface of the filter wrapper 124. The tightness of the spiral-shaped profile may be modified to adjust the fluid flow through the channel. That is, fluid flow may be restricted where filter element 126 is rolled too tightly resulting in turnings of the spiral being having a small space therebetween. While a looser rolling of filter element 126 may improve air flow, but result in a loss filter that may not hold its shape.

In some implementations, filter wrapper 124 can be a paper material, as described above, in connection to material 110. The paper material can be any type of paper, such as, but not limited to, rice paper, hemp paper, Cordia (also referred to herein as palm paper), Areca paper, wood pulp, bleached paper (e.g., sometimes referred to as white paper), unbleached paper (e.g., sometimes referred to as brown paper), clear paper (e.g., paper made from cellulose resulting in a clear sheet), colored papers, or gold rolling papers. In various examples, filter wrapper 124 may be entirely made of Cordia (e.g., palm paper). In other examples, filter wrapper 124 may be made of Areca (e.g., palm paper) or husk material.

Similarly, filter element 126 may be made of a paper material, such as, but not limited to, rice paper, hemp paper, palm paper (e.g., made by processing Cordia and/or Areca fibers), wood pulp, bleached paper (e.g., sometimes referred to as white paper), unbleached paper (e.g., sometimes referred to as brown paper), clear paper (e.g., paper made from cellulose resulting in a clear sheet), etc. In various examples, material 110 may be entirely made of palm paper (e.g. made by processing Cordia fibers and/or Areca fibers).

In some implementations, the hollow tube 100 may be made entirely from a single sheet material, for example, dried plant leaf, corn husk, paper material, etc. In some implementations, the hollow tube 100 may be made entirely from palm paper (e.g., made from Cordia and/or Areca). For example, material 110, filter wrapper 124, and filter element 126 may each be formed of palm paper. As another example, material 110 and filter wrapper 124 may be formed of palm paper, while the filter element formed of husk, or other material as set forth above.

Filter assembly 120 can have an opening 128. Opening 128 can be formed in a surface of filter assembly 120 along a curved face extending from the first end and the second end.

FIG. 4 is a schematic view of an example filter assembly 120 according to embodiments disclosed here. FIG. 4 is an exploded perspective view of the filter assembly 120 comprising a plurality of filter sections 210 and 220, a flavor carrier holder structure 230, and a flavor carrier 240.

In the illustrative example shown in FIG. 4, the flavor carrier 240 can be held within the flavor carrier holder structure 230. A distal end of first filter section 210 may correspond to first end 121 and a distal end of filter section 220 may correspond to second end 123. A proximal end 202 of first filter section 210 is adjacent to and may contact the flavor carrier holder structure 230 on a first end 231 of the flavor carrier holder structure 230 and a proximal end 222 of second filter element 220 is adjacent to and may contact the flavor carrier holder structure 230 on a second end 233 of flavor carrier holder structure 230. The first filter section 210, flavor carrier holder structure 230, and filter section 220 are aligned along a common central axis 201, which may be aligned with the central axis 101 when inserted into material 110. In one example, the material 110 of FIG. 1 may operate to hold the first filter section 210; the flavor carrier holder structure 230, including the flavor carrier 240 held therein; and the filter section 220 within the elongated internal cavity 108 by friction fit. In another example, an optional outer casing 250 may be provided surrounding the filter assembly 120 in the radial direction.

In some embodiments, as shown in FIG. 4, the filter assembly 120 includes plurality of filter elements, such as filter sections 210 and 220. Each filter element includes a proximal end, a distal end, and respective filter bodies 205A and 205B (referred to herein individually as filter body 205 or collectively as filter bodies 205). The filter bodies 205 may have respective side walls 204A and 204B (referred to herein individually as side wall 204 or collectively as side walls 204) extending from the proximal end to the distal end. In some embodiments, the filter bodies 205 are generally cylindrical with a generally circular cross-section. However, it is understood that the filter bodies may include other shapes (e.g., frustum or conical shaped), with other shaped cross sections (e.g., oval) and any combinations thereof. In some examples, the side walls 204 may comprise a wrapping material, such as filter wrapper 124 described above in connection with FIGS. 1-3. In some examples, side walls 204 may be examples of portions of filter wrapper 124 described above in connection with FIGS. 1-3.

Filter section 210 and 220 comprise respective filter elements 206A and 206B (referred to herein individually as filter element 206 or collectively as filter elements 206). In some embodiments, the filter elements 206 may be bunched together and generally aligned to extend between the respective filter element's proximal end and distal end of a respective filter element. Additionally, filter element 206 may be provided as one or more of the filter materials described above in connection filter element 126 of FIGS. 1-3. In some examples, each filter element 206 may be an example of a portions of filter element 126 described above in connection with FIGS. 1-3. In some examples, the filter elements 206 may be formed as a single element and split (e.g., cut or otherwise divided) into separate bodies. In another example, each filter element 206 may be formed individually.

The first filter section 210 and filter section 220 may be formed from the same type of filter material, or different filter materials. For example, filter element 206A may be formed of a first type of material, while filter element 206B may be formed of a different type. Similarly, side wall 204A may be of a different type of material than side wall 204B. In some examples, one of filter element 206 may be formed from a material described above in connection with FIGS. 1-3, while the other filter element formed for a completely different material (e.g., cotton, materials formed of cotton fiber, or other porous material). In some examples, the other filter element may comprise a polymer, such as silicone (e.g., food grade silicone). In other examples, the other filter element may comprise rubber, plastic, other types of polymers, paper, a gelatinous substance (e.g., gelatin or other gelatinous substances), foam, webbing, other compressible materials, and any combinations thereof. Thus, at least one filter element comprises a material described above in connection with FIGS. 1-3, while the other may comprise such materials or other materials. In some embodiments, the flavor carrier 240 may be provided as a capsule containing a flavoring agent. Flavor carrier 240 can be a gelatin capsule. In other implementations, flavor carrier 240 can be formed from vegetable-based materials (e.g., a vegetable capsule). The flavoring agent can be a fluid, operable to penetrate (e.g., absorbed into) one or more of the filter sections 210 and 220 and impart a flavor on the smoke drawn through filter assembly 120. The flavoring agent can be released when flavor carrier 240 is crushed. The flavoring agent within flavor carrier 240 can be, for example, a food-grade essential oil or food-grade candy oil. In some implementations, the flavoring agent can also include natural terpene liquid in various flavors (e.g., fruit or dessert flavors). The flavoring agent may be any type of type of solid, liquid, or gas (and any combinations thereof) that may release one or more flavors when activated. In some implementations, flavor carrier 240 may be designed to be activated by heat (e.g., during smoking or by other activation techniques, and by any combinations thereof.

While the flavor carrier 240 is described herein primarily as spherically shaped capsule, it is understood that the flavor carrier 240 may be formed as an ovoid, a cuboid, a cylinder, tubular, pill-shaped, as any other suitable shape, and as any combinations thereof. It is understood that any other type(s) and/or shapes of flavor carrier 240 may be used, and that the scope the present disclosure is not limited in any way by the type of flavor carrier 240 used.

In some embodiments, the flavor carrier holder structure 230 (also referred to as simply the holder structure) includes a holder wrapper 232 enclosing a holder element 234 in the radial direction. The holder element 234 is adapted to receive and generally surround and hold the flavor carrier 240 in at least the radial direction (e.g., orthogonal to central axis 201). The holder element 234 includes holder body securing the flavor carrier holder structure 230 including a first end 231, a second end 233 and a holder body with side walls extending from the first end 231 to the second end 233. The holder wrapper 232 may be provided to surround the holder element 234, for example, in the radial direction. That is, the holder wrapper 234 may be wrapped around the side walls of the holder body. In some examples, the holder wrapper may be in direct contact with the side walls of the holder element 234. In other examples, an intermediate material may be between the holder element 234 and the holder wrapper 232.

in examples, flavor carrier holder structure 230 comprises a holder element 234 having a generally tubular structure that includes a first end 231, a second end 233 and a holder body with side walls 235 extending from the first end 231 to the second end 233. The holder body can include the inner space 236 between it's the first end 231 to its second end 233. The inner space 236 may be designed to receive and secure flavor carrier 240 within the holder structure 230. For example, the flavor carrier 240 may be inserted into the inner space 236 and held in place in at least the radial direction relative to the central axis 201 by the holder body. In examples, the flavor carrier 240 may be secured in the longitudinal direction between ends 231 and 233 and by one or more of the holder body (e.g., as shown in FIG. 5B) and filter sections 210 and 220 (e.g., by ends 202 and 222, respectively). In some embodiments, the holder body include generally circular cross-sections. However, it is understood that the holder body may include other shapes (e.g., frustum or conical shaped), with other shaped cross sections (e.g., oval) and any combinations thereof.

The holder body may comprise a compressible material. In some embodiments, the holder body is compressible so that the holder body may be squeezed using normal human strength to deflect the side walls inward. This deflection may in turn compress a flavor carrier 240 held within the holder body so that the flavor carrier 240 may burst or otherwise open and release the flavoring agent as described below.

In some embodiments, the holder body may comprise a cotton and/or materials formed of cotton fibers. The material of the holder body may be one or more of Batting/wadding; Bark weave; Basketweave; Batiste; Bengaline; Broadcloth; Broderie anglaise; Brushed cotton; Calico; Cambric; Canvas; Chambray; Cheesecloth; Chenille; Chino; Chintz; Corduroy; Crepe; Cross weave; Damask; Denim; Double gauze; Drill; Flannel; Fleece; French terry; Gabardine; Gauze; Gingham; Herringbone; Jacquard; Jersey; Lawn; Rib knit; Madras; Moleskin; Mousseline; Muslin; Organdie/organdy; Oxford; Pique; Plaid; Plisse; Pointelle; Poplin; Quilting cotton; Sateen; Seersucker; Ticking; Toweling; Twill; Velvet/velveteen; Velour; Voile; Waffle/honeycomb; and Windowpane.

In some embodiments, the holder body may comprise a polymer. In some embodiments, the holder body includes silicone (e.g., food grade silicone). In other embodiments, the holder body may comprise rubber, plastic, other types of polymers, paper, a gelatinous substance (e.g., gelatin or other gelatinous substances), foam, webbing, other compressible materials, and any combinations thereof.

In some embodiments, the holder body may be solid, porous, and any combinations thereof.

While the holder body may be formed of any of the above referenced materials, a porous material (and more particularly cotton) may provide for better absorption of a flavoring agent so to more evenly distribute the flavoring agent throughout the filter assembly 120. In this way, smoke drawn through the filter can be imparted with flavor, regardless as to which section of the filter the smoke is drawn through. Furthermore, porous materials (and more particularly cotton) may be provided for reduce force necessary to release the flavor agent from flavor carrier 240. That is, for example, silicon or other solid, rigid materials may require greater forces be applied to the filter assembly 120 so to release the flavor. The use of a compressible material, such as cotton, may reduce this force needed to burst the flavor carrier 240, which increases ease of use of the filter assembly 120. Further still, porous (and more particularly cotton materials) may provide for consistent fluid flow and uniform disbursement through the filter material as a solid material need not be used to secure the flavor carrier 240. A solid material may funnel fluids to certain regions of the filter in larger quantities than desired, which could depart from a uniform distribution of the flavor into the filter material. Furthermore, the cotton used for holder body can be one or more of naturally sustainable, biodegradable, hypoallergenic, and odor free.

The holder wrapper 232 may operate to secure material of the holder body in a desired shape. For example, holder wrapper 232 may be wrapped around the sidewalls of holder element 234. That is, an outer diameter D4 of the holder element 234 (illustratively shown in FIGS. 5A and 5B) may approximately match the inner diameter of the holder wrapper 232. In this way, the holder wrapper 232 may operation to secure the material forming the holder body within the holder wrapper 232. Thus, the holder body may be formed as a result of being restrained in the longitudinal direction by first filter section 210 and filter section 220, while restrained in the radial direction by holder wrapper 232. Such configurations may assist with manufacturing of the holder structure 230, for example, by maintaining a shape that is aligned with the filter sections 210 and 220, which can make it easier to assembly. Whereas, without the holder, the holder body may shift and change shape during assembly.

In some examples, the material of the holder element 234 may be compressed by the holder wrapper 232 during manufacture. As such, the outer diameter of the holder element 234 may be dependent on the inner diameter of the holder wrapper 232. In any case, the holder element 234 may be held within the holder wrapper 232 by friction between inner side walls of holder wrapper 232 and side walls 235 of the holder element 234. In some examples, an adhesive (e.g., a food grade adhesive) may be used to further secure the holder element 234 within holder wrapper 232.

The holder wrapper 232 may be formed of a material that is a different type from that of the holder element 234. In various implementations, the holder wrapper 232 can be formed from a material having a rigidity that is greater than the rigidity of the material from which the holder element 234 is formed (e.g., less compressible). For example, if the materials are the same composition, then the holder element 234 may be formed of a material that is less dense, and thus less rigid, than the material of the holder wrapper 232. By having a greater rigidity, the holder wrapper 232 can provide for a stiffer or stable holder structure 230 that does not bend or permit the flavor carrier 240 to shift from the desired position within the holder structure 230. In another example, the holder element 234 may be formed from cotton, and the holder wrapper 232 formed from a paper material. In this way, holder wrapper 232 can operate to secure the material of the holder body within the filter assembly 120. While the holder wrapper 232 may be may formed of materials having greater rigidity, the additional force needed to burst the flavor carrier 240 may be negligible due to the thickness of the material forming the holder wrapper 232 being less than (e.g., substantially less than) the thickness of the holder element 234.

In some implementations, holder wrapper 232 can comprise a paper material, such as described above in connection to material 110. The paper material can be any type of paper, such as, but not limited to, rice paper, hemp paper, Cordia (also referred to herein as palm paper), Areca paper, wood pulp, bleached paper (e.g., sometimes referred to as white paper), unbleached paper (e.g., sometimes referred to as brown paper), clear paper (e.g., paper made from cellulose resulting in a clear sheet), colored papers, or gold rolling papers. In various examples, holder wrapper 232 may be entirely made of Cordia (e.g., palm paper). In other examples, holder wrapper 232 may be made of Areca (e.g., palm paper). In some embodiments, holder wrapper 232 may be formed of husk material, such as, but not limited to, corn husk and palm husk (e.g., Areca husk).

In some embodiments, an outer diameter D8 of the flavor carrier holder structure 230A (e.g., holder wrapper 232) may be approximately the same as the diameter D1 of the filter sections 210 and 220. In this case, outer sidewalls of first filter section 210, filter section 220, and flavor carrier holder structure 230A form a surface curved in the radial direction, and all of the components of filter assembly 120 can fit snugly within elongated internal cavity 108 and/or outer casing 250 as described below. In another example, diameter D8 may be smaller than diameter D1. In another example, the side walls of holder wrapper 232 may be integrally formed as part of one of side walls 204A and 204B. That is, in an example, the material forming side walls 204A may comprises a continuous material providing side wall 204A and holder wrapper 232. Alternatively, the material forming side walls 204B may comprises a continuous material providing for side wall 204B and holder wrapper 232. In another example, outer diameter D8 may be smaller than the diameter D1 of the filter sections 210 and 220.

FIGS. 5A and 5B illustrate example implementations of the flavor carrier holder structure according to embodiments disclosed herein. FIG. 5A is a cross-section of an example implementation of flavor carrier holder structure 230, shown as flavor carrier holder structure 230A in which the inner space 236 is implemented as an inner channel 236A. FIG. 5B is a cross-section of an example of another implementation of flavor carrier holder structure 230, shown as flavor carrier holder structure 230B in which the inner space 236 is implemented as an inner cavity 236B. In either case, the flavor carrier holder structures 230A and 230B are substantially the same as flavor carrier holder structure 230, except as provided herein. More particularly, aside from the implementation of the inner space 236 (e.g., inner channel 236A and inner cavity 236B), flavor carrier holder structure 230A and flavor carrier holder structure 230B are substantially the same as each other, as well as relative to flavor carrier holder structure 230.

FIG. 5A shows a cross-sectional schematic of the flavor carrier holder structure 230 taken along the line 6-6 of FIG. 3. As shown in FIG. 5A, the inner channel 236A extends through the holder element 234A in a direction approximately parallel to the central axis 201. While inner channel 236A is shown as formed along the central axis 201, embodiments disclosed herein are not limited thereto and the inner channel 236A may be offset form the central axis 201, as well as extending in a non-parallel direction relative to the central axis 201. In this example, holder element 234A is designed to receive and secure flavor carrier 240 within inner channel 236A. As shown in FIG. 5A, flavor carrier holder structure 230A generally surrounds and holds the flavor carrier 240 within inner channel 236A. As such, the flavor carrier 240 may secured in the radial direction relative to the central axis 201 by the holder element 234.

In some embodiments, the flavor carrier 240 can be located within the inner channel 236A between the first end 231 and the second end 233. In an example implementation, flavor carrier 240 may be positioned at approximately the midpoint between the first end 231 and the second end 233. In some embodiments, the length L2 of the flavor carrier holder structure 230A may be greater than the diameter D2 of the flavor carrier 240 so that a first gap G1 exists between the first end 231 and the flavor carrier 240, and a second gap G2 exists between the second end 233 and the flavor carrier 240.

In some embodiments, a width or diameter D5 of the inner channel 236A may approximately match the width or diameter D2 of the flavor carrier 240, or in some cases be. In this way, the flavor carrier 240 may be held by the holder element 234A within the inner channel 236A by friction between the flavor carrier 240 and the inner side walls of the holder element 234A. In this case, gaps G1 and G2 may both exist such that the filter sections 210 and 220 are not be in physical contact with the flavor carrier 240. In other words, the flavor carrier 240 may fit entirely within the inner channel 236A. The first gap G1 and the second gap G2 need not be equal in length, one may be larger than the other. In other examples, the first gap G1 and the second gap G2 may be approximately equal.

In some embodiments, the width or diameter D5 of the inner channel 236A may be chosen to be slightly less than the width or diameter D2 of the flavor carrier 240. In this way, the inner channel 236A may expand upon receiving the flavor carrier 240 to accommodate the slightly wider width D2 of flavor carrier 240. The material of the holder element 234A may compress to receive the flavor carrier 240. Given this, the flavor carrier 240 may be held within the inner space 236A by friction between the flavor carrier 240 and the inner side walls of the holder element 234A, the friction being increased by the compressive force applied to the flavor carrier 240 by the expanded inner channel 236A. Similar to the above, the filter sections 210 and 220 may not be in physical contact with the flavor carrier 240, such that flavor carrier 240 may fit entirely within the inner channel 236A.

In another example, the width or diameter D5 may be larger than the width or diameters D2. In this case, the flavor carrier 240 may be unrestrained and free to shift with the inner channel 236A. In this case, filter sections 210 and 220 (e.g., ends 202 and 222, respectively) may function to the secure the flavor carrier 240 within the channel 236A. In this case, flavor carrier 240 may come into direct physical contact with one of sections 210 and 220 due to rolling or shifting within the inner channel 236A.

In the example of FIG. 5A, the inner channel 236A is shown as a tubular channel having a generally circular cross-sections. However, it is understood that the inner channel 236A may include other shapes (e.g., frustum or conical shaped), with other shaped cross sections (e.g., circular, cuboid, ovoid, polygonal, include other shapes and any combination thereof).

In some examples, inner channel 236A need not extend fully through the holder element 234A. For example, inner channel 236A may having an opening on one of first end 231 and second end 233 and extend from the one of first end 231 and second end 233 into the holder body of holder element 234A, terminating at a desired depth from the opening (e.g., a blind hole in the holder body). In this case, the flavor carrier holder structure 230 can be inserted into the blind hole at the depth of the hole.

In another example, as shown in FIG. 5B, flavor carrier holder structure 230B comprises an inner space 236 provided as a cavity 236B, opposed to a channel 236A extending through the length of flavor carrier holder structure 230A. In this case, holder element 234B includes a generally cylindrical structure including first end 231, second end 233, and a holder body with side walls 235 extending from first end 231 and second end 233. The holder body includes an inner cavity 236B surrounded by the holder body. That is, cavity 236B can be enclosed within the holder body (e.g., surrounded in both longitudinal and radial directions) so to secure flavor carrier 240 therein. In this case, the inner cavity 236B may have a shape that generally matches the shape of the flavor carrier 240. For example, in the case of a spherical capsule, cavity 236B may be spherical cavity. However, the inner cavity 236B may have other shapes as desired and need not be dependent on the shape of the flavor carrier 240. For example, the inner cavity 236B may be cuboid (e.g., cube, rectangular cuboid or the like), while the flavor carrier 240 may be spherical.

The holder element 234B may be designed to receive and secure flavor carrier 240 within inner cavity 236B. FIG. 5B shows a cross-sectional schematic of the flavor carrier holder structure 230B taken along the line 6-6 of FIG. 3. As shown in FIG. 5B, flavor carrier holder structure 230B surrounds and holds the flavor carrier 240 within inner cavity 236B. As shown in FIG. 5B, the inner cavity 236B may be positioned along the central axis 201. While cavity 236B is shown as formed along the central axis 201, embodiments disclosed herein are not limited thereto and the inner channel 236A may be offset form the central axis 201. In various embodiments, the holder body fully surrounds the flavor carrier 240 in all directions. The diameter D9 of the inner cavity 236B may approximately match the width or diameter D2 of the flavor carrier 240. In this way, the flavor carrier 240 may be held within the holder body (e.g., within the cavity 236B) between the flavor carrier 240 and the inner walls of the inner cavity 236B.

In some embodiments, the diameter D2 of the inner cavity 236B may be chosen to be slightly less than the diameter D2 of the flavor carrier 240. In this way, the cavity 236B may expand upon receiving the flavor carrier 240 to accommodate the slightly wider width D2 of flavor carrier 240. The material of the holder body may compress to receive the flavor carrier 240. Given this, the flavor carrier 240 may be held within the holder body by friction between the flavor carrier 240 and the inner side walls of the inner cavity 236B, the friction being increased by the compressive force applied to the flavor carrier 240 by the expanded cavity 236B.

In another embodiment, the diameter D2 of the inner cavity 236B may be chosen to be larger than the diameter D2 and flavor carrier 240 secured as a result of being completely housed in the holder body. In this case, the holder body may be formed around the flavor carrier 240 with minimal risk of applying an inadvertent or otherwise unintentional force that bursts flavor carrier 240 during manufacturing or shipping.

As described above, the inner cavity 236B may be positioned between the first end 231 and the second end 233. In an example implementation, inner cavity 236B may be positioned at approximately the midpoint between the first end 231 and the second end 233; however, the present disclosure is not limited to the midpoint and other positions may be used as desired. In some embodiments, the height L2 of the flavor carrier holder structure 230B may be greater than the diameter D9 so that a first gap G3 exists between the first end 231 and the flavor carrier 240, and a second gap G4 exists between the second end 233 and the flavor carrier 240. In this way, the filter sections 210 and 220 may not be in physical contact with the flavor carrier 240. In other words, the flavor carrier 240 may fit entirely within the inner cavity 236B. Furthermore, since the flavor carrier 240 is fully surrounded by material of the holder body, flavoring agent released by flavor carrier 240 can be absorbed in all directions, such as in the longitudinal direction, radial direction, and directions angled from the longitudinal direction. In this way, smoke drawn through the filter can be imparted with flavor, regardless as to which section of the filter the smoke is drawn through. In the case of positioning at the midpoint, the third gap G3 and the fourth gap G4 may be approximately equal. In other cases, one gap may be larger than the other as desired.

Referring again to FIG. 4, in embodiments comprising the optional outer casing 250, the optional outer casing 250 includes a shell cavity 252 adapted to receive and generally surround and hold the filter assembly 120. That is, optional outer casing 250 may receive first filter section 210, filter section 220, and the flavor carrier holder structure 230 (including a flavor carrier 240).

In some embodiments, optional outer casing 250 may include a generally tubular structure including a first end 251, a second end 253, and a shell body with side walls 255 extending from the first end to the second end. Being generally tubular, the shell body includes a shell cavity 252 (also referred to as an internal elongated cavity or cavity) defined by inner sidewalls extending from its first end to its second end. In some embodiments, the shell body and the cavity 252 include generally circular cross-sections. However, it is understood that the shell body may include other shapes (e.g., frustum shaped), with other shaped cross sections (e.g., oval) and any combinations thereof. It also is understood that the cavity 252 may include other shapes (e.g., may be frustum shaped) and that the cross section of the cavity 252 may be circular, cuboid, ovoid, polygonal, include other shapes and any combination thereof.

The cavity 252 may be adapted to receive and securely hold at least the first filter section 210, a flavor carrier holder structure 230 (including at least one flavor carrier 240), and the second filter section 220 along the longitudinal axis of each of the first filter section 210, the flavor carrier holder structure 230, and the second filter section 220. The longitudinal axis (e.g., common central axis 201) may be generally aligned with the longitudinal axis of the outer casing 250.

In some embodiments, the length of the optional outer casing 250 may generally match the length of filter assembly 120. For example, the length of optional outer casing 250 may generally match the combined length of the first filter section 210 (L1), flavor carrier holder structure 230 (L2), and filter section 220 (L3), so that the first and second filter sections 210, 220 and the flavor carrier holder structure 230 may be entirely received into the shell cavity 252. Length L1 and L3 may be generally the same. In this way, flavor carrier holder structure 230 may be positioned at approximately the midpoint of filter assembly 120. However, L1 and L2 need not be the same, such that flavor carrier holder structure 230 may be located at any point between first end 121 and second end 123 as desired.

In some embodiments, the shell cavity 252 includes an inner diameter D7. The diameter D7 may be chosen to generally match the diameter D1 of the first and second filter sections 210 and 220, as well as the diameter of the flavor carrier holder structure 230. In this way, the first and second sections 210, 220 and the flavor carrier holder structure 230 may be inserted into the shell cavity 252 and be held snugly therein.

The optional outer casing 250 includes an outer diameter D6. The diameter D6 may be chosen to generally match the inner diameter 106 of elongated internal cavity 108. In this way, the filter assembly 120 contained in optional outer casing 250 may be inserted into the elongated internal cavity 108 and be held snugly therein.

In embodiments that do not include optional outer casing 250, the diameter D1 may be chosen to generally match the inner diameter 106 of elongated internal cavity 108. In this way, the first and second sections 210, 220 and the flavor carrier holder structure 230 may be inserted into the shell cavity 252 and be held snugly therein.

In examples, cavity 252 can receive a filter assembly 120, as described above, so to be aligned along central axis 201. For example, filter assembly 120 may be received within the first end 121 of the outer casing in an interference or friction fit. The outer casing 250 overlaps in the radial direction with filter assembly 120, along the entire length of filter assembly 120. In another example, outer casing 250 may overlap with a portion of filter assembly 120 that is less than the entire length, thereby leaving the remaining portion or portions of the filter assembly 120 exposed.

The outer casing 250 can be formed from one or more sheets of material, such as material 110, as described above. In some implementations, outer casing 250 can be a paper material, such as any thin sheet material produced by processing fibers derived from plant or tree sources in water and then pressing and drying the material produce a sheet of material. The paper material can be any type of paper, such as, but not limited to, rice paper, hemp paper, palm paper (e.g. made by processing Cordia and/or Areca fibers), wood pulp, bleached paper (e.g., sometimes referred to as white paper), unbleached paper (e.g., sometimes referred to as brown paper), clear paper (e.g., paper made from cellulose resulting in a clear sheet), colored papers, gold rolling papers. For example, different paper material may be used to provide differing aesthetics, such as different colored papers or papers having designs printed thereon. In various examples, the outer casing 250 may be entirely made of palm paper. Using paper material such as hemp paper, palm paper, etc., may provide benefits, such as for example, but not limited to, being thinner and more flexible than the dried leaf embodiments described above. Particularly, palm paper may provide a material that is both thin and flexible, while resilient to breakage and/or tearing.

In some examples, dried leaf can be any natural plant leaf that can be rolled into a tube. In some examples, the dried leaf can be a tree or plant leaf such as, Cordia, Areca, manjack, bocote, palm, or other leaves. In general, the dried leaf can be a pure and all natural leaf (i.e., no additives), without glue or other adhesives, and green leaf. Dried leaf can also be tobacco free. Dried leaf can provide a resilient and aesthetically appealing green that burns slowly. When the outer casing is formed of husk, the husk can be rolled to form the hollow shape of the outer casing 250. The husk may be pure and all natural (e.g., organic with no additives and non-GMO), without glue or other adhesives. The husk may be resilient to tearing and durable to provide a casing that holds the filter assembly 120 together.

Outer casing 250 can be rolled around a form and dried in place to form the shape of filter section 220. In some examples, paper, dried leaf or husk can be (fully or partially) dried and then rolled into the desired shape. The outer casing 250 can be secured with a ring or string (not shown). The ring or string can be a section of paper or other appropriate fastener wrapped around and adhered to itself holding the outer casing in its hollow form/tubular shape and prevent the filter from unwrapping. The ring can further be adhered to outer casing 250 to maintain the tubular shape.

In an example method of forming the filter assembly 120, the filter assembly 120 may be placed on top of the material of filter the material of outer casing 250. This layered arrangement may then be rolled (e.g., hand-rolled or machine-rolled) forming a long cylindrical shape.

While the filter assembly 120 is described herein primarily as comprising two filter elements that sandwich a flavor carrier holder structure, it is understood the scope of the present disclosure is not limited to this illustrative example. Other configurations are possible, such as any N-number of filter elements that sandwich M-number of flavor carrier holder structure, where N and M are integers and M is one less than N. That is, for example, three filter elements may be provide with a first holding structure sandwich between a first and third filter element and a second holder structure sandwiched between a second and the third filter element (e.g., the third filter element being sandwiched between the first and second holder structures). In this example, each holder structure may carry a separate flavor carrier, thereby providing multiple flavors that can be released individually as desired by applying a force to a position corresponding to each flavor carrier.

FIG. 6 is a cross-section of an embodiment of the hollow tube taken along the line 5-5 of FIG. 1.

In general, flavor carrier 240 can be set within inner space 236 and thus contained within inner space 236 by the holder body. In some examples, holder wrapper 232 may operate to secure holder element 234 within the flavor carrier holder structure 230, such that the holder element 234 and the flavor carrier 240 is kept in place.

As described above, flavor carrier holder structure 230 maybe be disposed at any axial position within filter assembly 120 along the central axis 101. For example, flavor carrier holder structure 230 may be positioned closer to the first end 121 than the second end 123 along the axial direction, with a first filter section 210 that is smaller in length than the filter section 220. In this example, the first end 121 may be closer to a user's mouth than the second end 123, and thus flavor carrier 240 may be adjacent to the mouth. In this arrangement, a user may have an improved experience as the flavoring agent is dispersed closer to the mouth of the user. In another example, flavor carrier holder structure 230 may be positioned closer to second end 123 or anywhere in between the first end 121 and the second end 123.

In some examples, flavor carrier 240 may be removably received within inner space 236. For example, inner space 236 may be larger than the D2, such that flavor carrier 240 is moveable and held within inner space 236. In these examples, flavor carrier 240 may be removed and replaced with a different flavor carrier 240. As another example, flavor carrier 240 may be easily inserted into inner space 236 without applying force to 240 and/or filter assembly 120. This may minimize risk of bursting flavor carrier 240 and/or deforming the filter assembly 120 during manufacture. Whereas, in some scenarios, if flavor carrier 240 is held in place by friction fit, insertion of flavor carrier 240 into inner space 236 could result in damage to the flavor carrier 240 and/or filter assembly 120 unless the insertion is performed with extra care.

FIG. 7 is another view of the cross section of FIG. 6. In the illustrative example shown in FIG. 7, when an external force (e.g., a pinching motion) is exerted adjacent the closed end 102 of the hollow tube 100 along the length of filter assembly 120, flavor carrier 240 can be burst, releasing the flavoring agent into filter element 126. External force may be applied anywhere along the length of filter assembly 120 such that the external force induces a pinching force applied to flavor carrier 240 within filter element 126, thereby causing flavor carrier 240 to release the flavoring agent. The flavoring agent can be drawn into smoke that passes through filter assembly 120.

Areca husk and/or materials formed from Areca husk (or formed from Areca fibers) may be softer and less rigid than corn husk-based materials. Thus, in the case of filter element 126 formed from Areca husk, the rigidity of filter assembly 120 may be reduced such that bursting of the flavor carrier may require less external force than required by a corn husk filter element.

Further, a density of filter element 126 may be controlled so as to efficiently transfer the external force to flavor carrier 240 via the material of filter element 126. For example, a lower density filter element 126 may provide for more fluid flow between first end 121 and second end 123 due to larger or more numerous channels. Yet, the lower density may not effectively transfer the external force to the flavor carrier 240, thus requiring additional force to be applied by a user so to burst the flavor carrier. Whereas, a higher density filter element 126 may efficiently transfer the external force to the flavor carrier due to the presence of more material, but with a tradeoff of reduced fluid flow due to smaller or fewer channels. In an example implementation, density of filter element 126 may be dependent on how tightly filter element 126 is rolled when formed. For example, a tighter roll results in greater density of material and smaller channels (e.g., smaller distance between surfaces of the material forming the filter element 126), while a looser roll results in lower density and larger channels (e.g., larger distance between surfaces of the material forming the filter element 126). In another example, filter element 126 can be formed by packing filter material (or fibers of material) to form a filter, and the density of the pack can be adjusted to address the above-described tradeoff between fluid flow and force transfer.

FIG. 8 is graphical depiction of the hollow tube of FIG. 1 in use. In some embodiments, smoking material 140 can be inserted into the open end 104 of the hollow tube 100. A packing stick 150 can be used to compress the smoking material within the hollow tube 100 against filter assembly 120.

FIG. 9 is a perspective view of an embodiment of a filter assembly 120, according to the embodiments disclosed herein, being received by a tubular member. FIG. 10 is another perspective view of the tubular member of FIG. 9 having received the filter according to the embodiments herein. While FIGS. 9 and 10 each illustrate filter assembly 120 comprising outer casing 250, this is for illustrative purposes only. The following description of FIGS. 9 and 10 each apply equally to embodiments of filter assembly 120 with or without outer casing 250. Furthermore, any shaped member may be used in place of a tubular member, such as a truncated conical member.

Tubular member 300 can be a leaf tube formed from a dried leaf, paper material or a wrapper for enclosing smoking material (such as plant-based smoking material). The tubular member 300 may be formed by a wrapper (e.g., kraft paper, dried leaf, or the like) that is rolled to form the tubular member 300. The material of tubular member 300 may include material 110 described herein. In some embodiments, a sheet of material 110 may be rolled around filter assembly 120 to form the tubular member 300.

The tubular member 300 can extend from a first end 302 to a second end 304. The first end 302 can be formed to receive filter assembly 120, forming a closed end of the tubular member 300. Receiving herein may refer to inserting filter assembly 120 into the first end 302 of the tubular member 300 (e.g., as shown by arrow 305). For example, where filter assembly 120 comprises the outer casing 250, the outer diameter 322 (e.g., diameter D6 of FIG. 4) of outer casing 250 can be received within end 302 of a tubular member 300 in an interference or friction fit. In another example, receiving, as used herein, may refer to placing filter assembly 120 onto the outer casing 250 in an un-wrapped state and then forming the tubular member 300 around filter assembly 120. As another example, where filter assembly 120 does not include outer casing 250, the outer diameter D1 of filter assembly 120 can be received within end 302 of a tubular member 300, as described above. That is, filter assembly 120 can be rolled into dried leaf or paper member when forming the tubular member 300.

Tubular member 300 can have a central axis 301 following an imaginary line through the center of the tubular member 300 from the first end 302 to the second end 304. A central axis 327 of filter assembly 120 may be substantially aligned with the central axis 301 of the tubular member 300. The second end 304 can open into an elongated internal cavity 308 having an inner diameter 306. The internal cavity 308 can receive smoking material 340.

Examples disclosed herein have been described having a generally cylindrical or tubular shape. However, embodiments according to the present disclosure are not intended to be limited to cylindrical or tubular shapes. The embodiments disclosed herein may be frustum shaped or other desired shape. For example, embodiments disclosed herein may have a conical shaped body having a minor diameter at one end and a larger, major diameter at the other end. As an illustrative example, the elongated member 100 may be an elongated conical member, where the diameter at end 102, in a direction orthogonal to the axis 101, is a minor diameter that is smaller than the diameter at end 104, in the direction orthogonal to the axis 101. As another example, the filter assembly 120 may have a generally conical shape, where the diameter at end 123, in a direction orthogonal to the axis 201, is a minor diameter that is smaller than the diameter at end 121 in the direction orthogonal to the axis 201. Similarly, where optional out casing 250 is used, it also may have a conical shape.

Although the present disclosure provides certain example embodiments and applications, other embodiments that are apparent to those of ordinary skill in the art, including embodiments which do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Accordingly, the scope of the present disclosure is intended to be defined only by reference to the appended claims.

It should be understood that various features, aspects and functionality described in one or more of the individual embodiments, are not limited in their applicability to the particular embodiment with which they are described. Instead, they can be applied, alone or in various combinations, to one or more other embodiments, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present application should not be limited by any of the above-described exemplary embodiments.

Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing, the term “including” should be read as meaning “including, without limitation” or the like. The term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof. The terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known.” Terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time. Instead, they should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances, shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “component” does not imply that the aspects or functionality described or claimed as part of the component are all configured in a common package. Indeed, any or all of the various aspects of a component, whether control logic or other components, can be combined in a single package or separately maintained and can further be distributed in multiple groupings or packages or across multiple locations.

Combinations such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” include any combination of A, B, and/or C, and may include multiples of A, multiples of B, or multiples of C. Specifically, combinations such as “at least one of A, B, or C,” “one or more of A, B, or C,” “at least one of A, B, and C,” “one or more of A, B, and C,” and “A, B, C, or any combination thereof” may be A only, B only, C only, A and B, A and C, B and C, or A and B and C, where any such combinations may contain one or more member or members of A, B, or C.

Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration.

FILTER ASSEMBLY HAVING A DUAL MATERIAL HOLDER STRUCTURE AND SMOKING ACCESSORIES INCLUDING THE SAME

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