FILTERS FORMED FROM ARECA PLANT MATERIAL AND SMOKING ACCESSORIES INCLUDING THE SAME

TECHNICAL FIELD

This disclosure relates to flavored smoking materials. More specifically, this disclosure relates to filters formed of Areca plant material and elongated members having a flavor capsule 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 a cross-section of an embodiment of the hollow tube taken along the line 5-5 of FIG. 1.

FIG. 5 is another view of the cross section of FIG. 4.

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

FIG. 7 is graphical depiction of the hollow tube of FIG. 1 in use.

FIGS. 8A and 8B are perspective views of an embodiment of a filter in accordance with embodiments disclosed herein.

FIG. 9 is a perspective view of the filter of FIGS. 8A and 8B including an outer casing in accordance with embodiments disclosed herein.

FIG. 10 is a perspective view of the filter received by an elongated member in accordance with embodiments disclosed herein.

FIG. 11 is perspective view of the filter used with a hollow elongated member in accordance with embodiments disclosed herein.

FIGS. 12A-12H are perspective views of a method for forming a filter in accordance with an embodiment 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 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. 7). 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 Arecaceae 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 one or more thin sheets of 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, such as paper formed of Areca fibers, may provide material that is both thin and flexible, while resilient to breakage and/or tearing. Another benefit of palm paper, such as paper formed of Areca fibers, is that it is one of the slowest burning papers and tobacco-free. The Areca leaf (or fibers therefrom) is durable and absorbs liquid (e.g., from the capsule 130 as described below) in a manner that is more resilient than that provided by papers or leaf from other plants.

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 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 120 can be received within the first end 102 in an interference or friction fit. In some examples, filter 120 can be rolled into material 110 when forming the hollow tube 100. In some implementations, filter 120 can be removed and/or replaced from the hollow tube 100 as needed.

Filter 120 can have a filter wrapper 124 (e.g., a plug wrap) enclosing a filter element 126. Filter element 126 can be formed from 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 corn husk, Areca husk, 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. 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 120 can be completely formed of corn husk 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 (such as the profile shown in FIG. 12H). 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 or partly made of Cordia (e.g., palm paper). In other examples, filter wrapper 124 may be entirely or partly made of Areca (e.g., palm paper). In yet another example, filter wrapper 124 may be entirely or partly made of 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 120 can have an opening 128. Opening 128 can be formed in a surface of filter 120 along a curved face extending from the first end and the second end.

FIG. 4 is a cross-section of an embodiment of the hollow tube taken along the line 5-5 of FIG. 1. Opening 128 can be a recess, cavity, or orifice bored, punched, or otherwise formed in the surface of filter 120. Opening 128 can extend into the cylindrical body of filter 120. In some implementations, opening 128 can penetrate wrapper 124 and extend radially through filter element 126. Opening 128 can penetrate both filter wrapper 124 and filter element 126 extending completely through filter 120. In other implementations, opening 128 may not penetrate wrapper 124.

In general, capsule 130 can be set within opening 128 and thus contained within opening 128 by material 110 when filter 120 is inserted within the hollow tube 100. In some examples, wrapper 124 may operate to contain capsule 130 within opening 128, such as where opening 128 does not penetrate wrapper 124, in which case, wrapper 124 may cover the capsule.

Opening 128 can be sized to receive capsule 130. Opening 128, in some embodiments, may be sized to provide a friction fit with capsule 130 such that capsule is held within opening 128 by friction. Capsule 130 can be a flavor capsule containing a flavoring agent. Capsule 130 can be a gelatin capsule. In other implementations, capsule 130 can be formed from vegetable-based materials (e.g., a vegetable capsule). The flavoring agent can be a fluid, operable to penetrate filter element 126 and impart a flavor on the smoke drawn through filter 120. The flavoring agent can be released when capsule 130 is crushed. The flavoring agent within capsule 130 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).

Opening 128 maybe be disposed at any axial position within filter 120 along the central axis 101. For example, opening 128 may be positioned closer to the first end 121 than the second end 123 along the axial direction. In this example, the first end 121 may be closer to a user's mouth than the second end 123, and thus opening 128 and flavor capsule 130 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, opening 128 may be positioned closer to second end 123 or anywhere in between the first end 121 and the second end 123.

In some examples, capsule 130 is removably received within opening 128. Opening 128 may be larger than the size of capsule 130, such that capsule 130 is moveable and held within opening 128. In these examples, capsule 130 may be removed from opening 128 and a different capsule inserted therein. As another example, capsule 130 may be easily inserted into opening 128 without applying force to capsule 130 and/or filter 120. This may minimize risk of bursting capsule 130 and/or deforming filter 120 during manufacture. Whereas, in some scenarios, if capsule 130 is held in place by friction fit, insertion of capsule 130 into opening 128 may result in damage to the capsule 130 and/or filter 120 unless the insertion is performed with extra care.

FIG. 5 is another view of the cross section of FIG. 4. When an external force (e.g., a pinching motion) is exerted on the closed end 102 of the hollow tube 100 (e.g., on filter 120 and capsule 130), capsule 130 can be burst, releasing the flavoring agent into filter element 126. External force may be applied anywhere along the length of filter 120 such that the external force induces a pinching force applied to capsule 130 within filter element 126, thereby causing capsule 130 to burst. The flavoring agent can be drawn into smoke that passes through filter 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 120 may be reduced such that bursting of the capsule may require less external force than required by a corn husk filter element.

While the illustrative examples herein provide for an opening 128 formed in the surface of filter 120, embodiments herein need not be so limited. For example, opening 128 may be formed within filter element 126 and capsule 130 contained therein. In some embodiments, the filter member may be formed around capsule 130, for example, by packing or rolling filter element 126 around capsule 130 forming cavity that contains capsule 130. Filter wrapper 124 may then be applied and wrapped around filter element 126. In another example, filter element 126 may be placed on an unrolled filter wrapper 124 and capsule 130 placed on filter element 126 (e.g., in a central position of filter element 126) and the filter wrapper 124 rolled to form filter 120, thereby packing or rolling filter element 126 around capsule 130. In yet another example, the opening 128 may be formed capsule 130 may be formed at an end of filter element 126 (e.g., one of ends 121 and 123) extending in a longitudinal direction into the filter element 126. In this example, the capsule 130 may be inserted into the longitudinally oriented opening. In an example where the filter element 126 has a spiral-shaped profile, as described above, a central channel along the central axis 101 may be formed based on rolling the material to form the filter element 126. The capsule 130 inserted into the formed central channel. In another example, the capsule 130 may be inserted into any of the channels formed between surfaces of the filter element 126.

Further, a density of filter element 126 may be controlled so as to efficiently transfer the external force to capsule 130 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 capsule 130, thus requiring additional force to be applied by a user so to burst the capsule. Whereas, a higher density filter element 126 may efficiently transfer the external force to the capsule 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. 6 is a cross-section of another embodiment of the hollow tube taken along the line 5-5 of FIG. 1. In some implementations, opening 128 can penetrate wrapper 124 and extend radially into a portion of filter element 126 but not all the way through filter 120. Thus, the opening 128 can form a pocket within filter 120.

FIG. 7 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 120.

FIGS. 8A and 8B are perspective views of an embodiment of filter 2220. In the illustrative example shown in FIG. 8A, filter 220 can have a body/shape having an outer diameter 225, extending from a first end 221 to a second end 223. Filter 220 can have a central axis 227 following an imaginary line through the center of filter 220 from the first end 221 to the second end 223. The description refers to axial and radial directions. Axial refers to directions along the central axis 227, while radial refers to a direction orthogonal to the central axis 227. Filter 220 may be substantively similar to filter 120 as described above in connection with FIGS. 1-6. That is, for example, filter 220 can have a filter wrapper 224 enclosing a filter element 226. The filter wrapper 224 and filter element 226 may be substantively similar to filter wrapper 124 and filter element 126, respectively. Additionally, filter 220 may be positioned within hollow tube 100, as described above with reference to filter 120.

Filter 220 may be configured to be received within an end of a tubular member in an interference or friction fit, for example, as described below in connection to FIGS. 10-11. In some examples, filter 220 may be rolled into corn husk, dried leaf, or paper member (e.g., also referred to a wrap) when forming the tubular member. That is, in various embodiments, filter 220 could be a distinct body that may, while used in conjunction with a separately provided tubular member, operate as a smoking accessory acting on smoke drawn through filter 220.

Filter 220 can have an opening 228. Opening 228 can be substantively similar to opening 128 described above. For example, opening 228 can extend into the body of filter 220. In general, capsule 130 (such as the capsule described above in connection with FIGS. 1-6) can be set within opening 228 and thus contained within opening 228. A flavoring agent contained within capsule 130 can be a fluid, operable to penetrate filter element 226 and impart a flavor on smoke drawn through filter 220. As described above, the flavoring agent can be released when capsule 130 is crushed.

In some examples, filter 220 may also comprise one or more caps 210 that can be inserted into opening 228. FIG. 8A illustrates an exploded view of cap 210 insertable into opening 228, and FIG. 8B illustrates an example configuration in which cap 210 has been inserted therein. Cap 210 can be received within opening 228 in an interference or friction fit. In some embodiments, a glue or other food-grade adhesive may be applied to the interface between sides of opening 228 and cap 210. In examples comprising the cap 210, it may be configured to contain the capsule within opening 228. For example, after capsule 130 is set in opening 228, cap 210 can be pressed into opening 228 to cover capsule 130 within opening 228. Similar to opening 228, cap 210 can extend radially into filter element 226. Cap 210 may have a length that is less than the outer diameter 225, and in some embodiments less than the radius of filter 220 (e.g., half of outer diameter 225). More particularly, the length of cap 210 may be selected such that cap 210 can be received into opening 228 at a depth that holds capsule 130 in opening 228, without crushing capsule 130. In the case where opening 228 penetrates filter wrapper 224, cap 210 can extend through 224 as well. In embodiments in which opening 228 penetrates completely through filter 220, multiple caps 210 can be provided, one on each side of capsule 130, so to hold capsule 130 within opening 228.

In some embodiments, cap 210 may function to transfer an external force (e.g., a pinching motion) applied to filter 220 and to capsule 130 so to crush capsule 130 and release the flavoring agent. For example, an external force may be applied to an area of filter 220 corresponding to cap 210, which can be applied to cap 210 causing cap 210 to exert a crushing force on capsule 130. Cap 210 may have a higher rigidity than that of filter element 226, thus facilitating efficient transfer of an external force to the internal cavity of opening 228. Furthermore, where cap 210 is received by friction or interference fit, any amount of force applied to cap 210 can be transferred to capsule 130 causing capsule 130 to burst.

In some embodiments, when capsule 130 is crushed so as to release the flavoring agent, cap 210 may operate to hold the flavoring agent within filter element 226. In some cases where cap 210 is not used, flavoring agent may flow in the radial direction and out of opening 228 toward outer casing 229 (if used) and/or the tubular member (e.g., tubular member 300 and/or hollow tube 100). Thus, the flavoring agent may be absorbed directly into material 110, instead of the material of filter element 226. This reduces the amount of flavoring agent available to be drawn into the smoke that passes through filter 220 (or filter 120). Accordingly, cap 210 can function to provide a barrier that holds the flavoring agent within filter element 226 and maximizes the flavoring of the smoke passing through the filter.

Embodiments described throughout this disclosure (for example, filters 120, 220, and 450 described below) may provide various non-limiting advantages. For example, the filter and filter element packed therein may be configured to ensure that no loose smoking material inadvertently falls out of the tubular member. Additionally, the filter element (e.g., filter elements 126 and/or 226) may prevent unwanted oils from entering the mouth of a user, for example, by absorbing oils produced by burning smoking material into the material of the filter element. Furthermore, implementations of filters 120, 220, and/or 450 that employ husk as filter wrapper and/or filter element, may provide advantages over conventional paper, for example, by providing an all-natural smoking experience through the use of non-GMO, organic corn husk-filter material. Corn husk material may be exceptionally durable and resistant to tearing, enabling a user to manipulate the material free from damage concerns. While, Areca husk material may be softer than corn husk, which can result in requiring less external force to burst a capsule housed in the filter.

FIG. 9 is a perspective view of an embodiment of filter 220 including an outer casing 229. Filter 220 can have a hollow member formed as the outer casing 229 having an outer diameter of 222. The outer casing 229 can extend from the first end 221 to the second end 223.

Outer casing 229 can include elongated internal cavity extending between the first end 221 and the second end 223 along the central axis 227. The internal cavity can receive a filter wrapper 224 and filter element 226. Outer diameter 225 can be approximately equal to the diameter of the elongated internal cavity of the outer casing. Filter wrapper 224 and filter element 226 may be received within the first end 221 of the outer casing in an interference or friction fit. In the illustrative example of FIG. 9, outer casing 229 overlaps in the radial direction with filter wrapper 224 and filter element 226, along the entire length of filter wrapper 224. In another example, outer casing 229 may overlap with a portion of filter wrapper 224 that is less than the entire length, thereby leaving the remaining portion or portions of the filter wrapper exposed.

In some implementations, outer casing 229 can be formed from one or more sheets of material, such as material 110, as described above. In some implementations, outer casing 229 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 229 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 229. 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 220 together.

Outer casing 229 can be rolled around a form and dried in place to form the shape of filter 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 229 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 229 to maintain the tubular shape.

In an example method of forming the filter 220, the material of the filter element 226 may be layered on top of the material of filter wrapper 224, which is layered on top of the material of outer casing 229. This layered arrangement forms a sheet of various materials that may then be rolled (e.g., hand-rolled or machine-rolled) forming a long cylindrical shape. The resulting shape may be cut at desired intervals along the axial length of the shape to form individual filters, such as filter 220.

In examples comprising outer casing 229, the outer casing 229 may be configured to contain the capsule within opening 228. For example, where opening 228 penetrates filter wrapper 224, outer casing 229 may be provided to cover opening 228. When capsule 130 is housed within this opening 228, the outer casing 229 seals the opening and capsule 130 is securely held within the opening 228. Similarly, where the opening 228 does not penetrate filter wrapper 224 and capsule 130 is set within an indentation in filter wrapper 224, outer casing 229 may cover the indentation and thereby cover capsule 130. Accordingly, embodiments are able to securely contain capsule 130 within the designated area of filter 220 corresponding to opening 228 through the use of the outer casing.

In examples comprising outer casing 229, the outer casing 229 may be configured to cover cap 210. For example, when cap 210 is received within opening 228, outer casing 229 may ensure that cap 210 is securely held within the opening 228. Accordingly, embodiments are able to securely contain capsule 130 within the designated area of filter 220 corresponding to opening 228 through the use of outer casing 229 and cap 210.

As described above in connection to FIG. 5, when an external force 132 (e.g., a pinching motion) is exerted on filter 220 (e.g., on filter 220 and, thusly, capsule 130), capsule 130 can be burst, releasing the flavoring agent into the filter element 226. The external force may be applied to one or more of the first end 221, second end 223, and anywhere therebetween such that the external force induces a pinching force applied to capsule 130 within the filter element 226, thereby causing capsule 130 to burst. The flavoring agent can be drawn into smoke that passes through the filter 220.

While the forgoing description describes filter 220 comprising outer casing 229, this is for illustrative purposes only. It will be appreciated the description applies equally to embodiments of filter 220 with or without outer casing 229. Further, while FIGS. 8A-9 show an example filter 220 having a cylindrical shape, embodiments disclosed herein are not intended to be limited to cylindrical shapes, and may be any desired shape the extends along a central axis. For example, filter 220 may be provided having a truncated conical shape, 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.

FIG. 10 is a perspective view of an embodiment of a filter, according to the embodiments disclosed herein, being received by a tubular member. FIG. 11 is another perspective view of the tubular member of FIG. 10 having received the filter according to the embodiments herein. While FIGS. 10 and 11 each illustrate filter 220 comprising outer casing 229, this is for illustrative purposes only. The following description of FIGS. 10 and 11 each apply equally to embodiments of filter 220 with or without outer casing 229. 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 220 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 220, forming a closed end of the tubular member 300. Receiving herein may refer to inserting filter 220 into the first end 302 of the tubular member 300 (e.g., as shown by arrow 305). For example, where filter 220 comprises the outer casing 229, the outer diameter 222 of filter 220 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 220 onto the wrapper in an un-wrapped state and then forming the tubular member 300 around filter 220. As another example, where filter 220 does not include outer casing 229, the outer diameter 225 of filter 220 can be received within end 302 of a tubular member 300. That is, filter 220 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 220 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.

FIGS. 12A-12H are perspective views of a method for forming a filter in accordance with an embodiment disclosed herein. FIGS. 12A-12H illustrate steps 400A-400H for forming filter 450. The filter 450 may be substantively similar to filter 120 and/or filter 220 described herein, except as provided in the following description. In the illustrative example of FIGS. 12A-12H, filter 450 is formed by rolling a sheet of material 401 for form a body having a spiral profile along a central axis. The material 401 may be rolled to form a filter element, such as filter element 126 and/or filter element 226. A second material 440 is also rolled to from filter wrapper in some embodiments. The second material can be rolled so to surround the first material 401, thereby forming filter 450.

In more detail, step 400A comprises providing first material 401 as a sheet of material having sides 402-408, a first surface 410, and a second surface 412. First material 401 may have a length L1 and a width W1. First material 401 may be corn husk, Areca husk, and the like. In another example, first material 401 may be 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.

As shown at step 400B, with material 401 in a generally flat arrangement, edge 404 is rolled in rotational direction A toward edge 402. The edge 404 is rolled such that edge 404 is curved toward edge 402 and inward toward surface 410. The rolling of first material 401 continues along rotational direction A, such that edges 408 and 406 form respective spiral cross section profiles, as shown in step 400C of FIG. 12C. Edge 404 is rolled inward adjacent to a central axis, and in some cases forms a central axis of the spiral cross section. An unrolled section 416 having a length L2 of the first material 401 remains in a generally flat configuration, where length L2 is less than the length L1.

As shown in FIG. 12D, opening 428 is formed in a surface of first material 401 at step 400D. In the illustrative example of FIG. 12D, opening 428 is formed in an outer exposed section 414 of surface 412. Opening 428 may be bored, punched, cut, or otherwise formed in the exposed section 414 of surface 412. Capsule 130 is then inserted into opening 428. In some embodiments (not shown in FIG. 12D), a cap can then be placed into opening 428, such as cap 210 described above.

In either case, in the illustrative example of FIG. 12E, once capsule 130 is inserted into opening 428, the unrolled section 416 of material 401 can be used to cover the opening 428, which can assist with securing capsule 130 within opening 428. For example, at step 400E, edge 402 can roll in rotational direction B toward the opening 428. As a result, the unrolled section 416 is reduced in length to L3 and surface 410 covers opening 428 in the radial direction, as shown in FIG. 12E. Alternatively, material 401 could be rolled in the rotational direction A, such that opening 428 is rolled toward edge 402 and overlaps with surface 410 in the radial direction.

In another example, opening 428 may be formed in material 401 prior to step 400C. For example, opening 428 may be formed into material 401 so to form a cutout in an unrolled sheet of material 401. Capsule 130 may then be inserted into opening 428, and material 401 rolled around capsule 130. In this example, opening 428 may not penetrate outer exposed section 414 of surface 412 and opening 428 and capsule 130 may be surrounded by sections of material 401. In either case, opening 428 can be covered at least by unrolled section 416 as shown in FIG. 12E.

Next, at step 400F, second material 440 can be placed on surface 410 of first material 401, such that a section 445 of the second material 440 overlaps with a section 418 of first material 401. Section 418 may be portion of unrolled section 416 that is adjacent to edge 402. Second material 440 comprises edges 442-448, first surface 441, and second surface 443. Second material 440 can be a paper material, such as that described above, in connection to material 110. 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 another example, second material 440 may be husk material, such as corn husk and/or Areca husk. Second material 440 may have a width W2 that can be equal to, shorter than, or longer than width W1 of first material 401.

First material 401 is then rolled in a rotational direction C, such that the rolled section of first material 401 is rotated toward edge 402 and second material 440. Rotational direction C may be the same as rotational direction A. As shown in FIG. 12G, as a result of rolling at step 400G, first material 401 forms a cylindrical spiral body with edges 408 and 406 having spiral cross-section profiles. A section of second material 440 is rolled into spacing between spiraled sections of first material 401, such that edge 448 and 446 have a spiraled cross-sectional profile. Next, glue or other food-grade adhesive 447 is applied on surface 443 adjacent to edge 442 of second material 440.

The combined body of the first and second materials is rolled along rotational directing C until the glue or other food-grade adhesive 447 contacts an exposed section of surface 441 of the second material. Once dried, the glue or other food-grade adhesive 447, hold the edge 442 in place along the surface 441, thereby forming filter 450, as shown in FIG. 12H. In this example, first material 401 in the rolled configuration shown in FIG. 12H, functions as a filter element (e.g., filter element 126 and/or 226) and second material 440 functions as the filter wrapper (e.g., filter wrapper 124 and/or 224) or outer casing (e.g., outer casing 229). Second material 440 may have a length L3 selected, such that the length L3 is equal to or larger than the circumference of first material 401 in a rolled configuration. More particularly, the length L3 may be provided such that second material 440 surrounds the circumference of first material 401 in the rolled configuration greater than one full revolution. As noted above and shown in FIG. 12H, second material 440 comprises an section 445 that overlaps with a section 418 of the first material in the radial direction, such that section 445 is located between surfaces 410 and 412 of first material 401, as shown in FIG. 12H. Further, as shown in FIG. 12H, second material 440 may overlap with itself in the radial direction one or more times.

In some embodiments, sections (e.g., lengths) of string 452 formed from natural fibers may be optionally wrapped and tied around, for example, the ends of filter 450 to maintain a round shape. The string may be used in place of or in combination with the glue or other food-grade adhesive 447, to maintain the shape of filter 450.

While the above example provides for opening 428 can be covered at least by unrolled section 416 (as well as second material 440), embodiments disclosed herein are not intended to be limited thereto. For example, as described in connection with FIGS. 3, 8A, and 8B, the opening 428 need not be covered by a section of material 401. According to one example, the opening 428 may not be covered by any portion of material 401 (e.g., formed into an outer surface of the material 401 rolled to form a filter element) and covered by the material 440 upon rolling at step 400G. In yet another example, the opening 428 may be formed after step 400G is performed. For example, once filter 450 is, opening 428 may be formed on an outer surface of material 440 and extend radially into material 440 and material 401. In an example opening 428 may extend through material 400 and into material 401.

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.

FILTERS FORMED FROM ARECA PLANT MATERIAL AND SMOKING ACCESSORIES INCLUDING THE SAME

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