`Deevi et al.
`
`I IIII IIIIII Ill Ill Ill Ill Ill II IIII II 11I111I1I11II1I
`US00569229 l A
`5,692,291
`[111 Patent Number:
`Dec. 2, 1997
`[451 Date of Patent:
`
`[54] METHOD OF MANUFACTURING AN
`ELECTRICAL HEATER
`
`[75]
`
`Inventors: Seetharama C. Deevi. Midlothian;
`Patrick H. Hayes. Chester; Bernard C.
`Laroy. Richmond: Donald E. Miser;
`William H. Stevens, both of
`Midlothian. all of Va.
`
`[73] Assignee: Philip Morris Incorporated, New
`York, N.Y.
`
`[21] Appl. No.: 450,840
`May 25, 1995
`
`[22] Filed:
`
`Related U.S. Application Data
`
`[51]
`
`[62] Division of Ser. No. 380,718, Jan. 30, 1995, Pat. No.
`5,666,978, and a division of Ser. No. 118,665, Sep. 10, 1993,
`Pat. No. 5,388,594, and a continuation-in-part of Ser. No.
`943,.504, Sep. 11, 199'2, Pat. No. 5,505,214.
`Int. Cl.6
`............................... B05B 3/00; H05B 3/10;
`H0lC 1/01
`[52] U.S. Cl . ............................ 29/611; 219/537; 219/539;
`219/552; 338/260; 338/319; 338/320
`[58] Field of Search ............................... 29/611; 219/537,
`219/539, 543, 552, 553; 338/203, 260,
`319,320
`
`[56]
`
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`
`Primary Examiner-P. W. Echols
`Attome:i, Agent, or Firm-Charles E. B. Glenn; James E.
`Schardt; James T. Moore
`
`U.S. PATENT DOCUMENTS
`
`[57]
`
`ABSTRACT
`
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`3/1961 Ellis .
`8/1965 Gilbert .
`4/1966 Curtis ...................................... 219/543
`6/1966 Selke .
`1/1968 Weber .
`9/1968 Hu ,
`12/1969 Hollabaugh .
`
`A smoking system is provided in which a replaceable
`cigarette containing tobacco flavor material is electrically
`heated by a set of electrical heater elements contained within
`a lighter to evolve tobacco flavors or other components in
`vapor or aerosol form for delivery to a smoker. The cigarette
`and lighter are adapted to provide air flow patterns through
`the smoking system such that air flows transversely into the
`cigarette. Such patterns improve aerosol and flavor delivery
`to the smoker and reduce the condensation of residual
`heater-region vapor/aerosol in the smoking system.
`
`14 Claims, 15 Drawing Sheets
`
`49A
`
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`47A,
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`105A
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`
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`
`95
`
`43 89
`
`159
`
`t
`
`87A
`
`Ex. 2012-0001
`
`
`
`5,692,291
`Page 2
`
`U.S. PATENr DOCUMENTS
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`5,060,671 1011991 Counts et al ..
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`5,285,050
`2/1994 Blackburn.
`
`Ex. 2012-0002
`
`
`
`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 1 of 15
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`1
`METHOD OF MANUFACTURING AN
`ELECTRICAL HEATER
`
`CROSS REFERENCE TO RELATED
`APPLIC.IITION
`This application is a divisional of U.S. patent application
`Ser. No. 08/380.718. filed Jan. 30, 1995, now U.S. Pat. No.
`5.621.189 and Ser. No. 08/118.665. filed Sep. 10, 1993,
`which issued as U.S. Pat. No. 5388,594 on Feb. 14, 1995.
`and being a continuation-in-part of commonly-assigned U.S.
`patent application Ser. No. 07/943,504, filed Sep. 11, 1992
`now U.S. Pat. No. 5,505.214.
`
`2
`flavor unit having a "tube-in-tube" construction. wherein
`tobacco flavor material positioned on a carrier and formed
`into a cylinder around free-flow. back-flow. and mouthpiece
`filters is disposed within an aerosol barrier tube. Heater
`5 elements are placed between the aerosol barrier tube and the
`tobacco flavor unit to heat the tobacco flavor unit. The
`aerosol barrier rube prevents aerosols formed during heating
`of the tobacco flavor unit and the heaters from condensing
`on permanent portions of the electrical smoking article. That
`10 application also describes the use of phosphorous doped
`silicon heater elements having the ability to cycle to tem(cid:173)
`peratures of between 200° C. and 900° C. and deliver
`between 5 and 40 Joules of energy repeatedly without
`failure.
`In light of the above. it is therefore desirable to be able to
`provide an improved smoking system in which the heating
`elements of the lighter are reusable.
`It is also desirable to be able to provide such a system in
`which condensation of aerosol onto the heating elements and
`other structural components of the lighter is minimized.
`It is further desirable to provide a smoking article which
`is easier to manufacture.
`It is still further desirable to provide a smoking article
`which provides improved flavor delivery to the smoker.
`
`25
`
`BACKGROUND OF THE INVENTION
`This invention relates to smoking systems in which ciga- 15
`rettes are used with lighters. and methods for making the
`same.
`An electrical smoking article is described in commonly(cid:173)
`assigned U.S. Pat. No. 5,060,671, which is hereby incorpo- 20
`rated by reference in its entirety. That patent describes a
`smoking article which is provided with a disposable set of
`electrical heating elements. A charge of tobacco flavor
`medium containing, for example. tobacco or tobacco(cid:173)
`derived material is deposited on each of the heating ele-
`ments. The disposable heater/flavor unit is mated to a source
`of electrical energy such as a battery or capacitor, as well as
`to control circuitry to actuate the heating elements in
`response to a puff by a smoker on the article or in response
`to the depression of a manual switch. The circuitry is 30
`designed so that at least one. but less than all of the heating
`elements are actuated for any one puff, and so that a
`predetermined number of puffs. each containing a pre(cid:173)
`measured amount of tobacco flavor substance, e.g., an
`aerosol containing tobacco flavors or a flavored tobacco 35
`response. is delivered to the smoker. The circuitry also
`preferably prevents the actuation of any particular heater
`more than once, to prevent overheating of the tobacco flavor
`medium thereon.
`With such articles. the heater is thrown away with the
`spent remainder of tobacco material. Also, the electrical
`connections between the heaters and the battery must be able
`to endure repeated release and reconnection as flavor units
`are replaced.
`In copending, commonly-assigned U.S. patent application
`Ser. No. 07/666,926, filed Mar. 11. 1991, now abandoned in
`favor of Continuing application Ser. No. 08/012.799, filed
`Feb. 2. 1993, an electrical smoking article is disclosed that
`has reusable heating elements and a disposable portion for
`tobacco flavor generation. The disposable portion preferably
`includes a flavor segment and a filter segment, attached by
`a tipping paper or other fastening arrangement. Certain
`operational difficulties are, however, associated with reus(cid:173)
`able heating elements, particularly in that residual aerosol
`tends to settle and condense on the heating elements and
`other permanent structural components of the article.
`U.S. patent application Ser. No. 07/943,504, filed Sep. 11,
`1992, which is hereby incorporated by reference in its
`entirety, describes another electrical smoking article that has
`reusable heating elements and a disposable portion for
`tobacco flavor generation. That application addresses prob(cid:173)
`lems relating to the long-term use of heating elements and
`other permanent structural components of the article. That
`application also descnbes a manufacturing process for mak(cid:173)
`ing the disposable portion of the smoking article using
`conventional high-volume assembly machinery. More
`specifically. that application describes a disposable tobacco
`
`40
`
`45
`
`SUMMARY OF THE INVENTION
`Accordingly, a primary object of the present invention is
`to provide a novel smoking system which provides advan(cid:173)
`tages over prior systems.
`Another object of the present invention is to provide
`improved flavor delivery from a smoking system in which
`cigarettes are used with lighters.
`It is also an object of this invention to provide a smoking
`system in which the heating elements of a lighter are
`reusable, and of which the volume of disposable portions is
`minimized.
`It is also an object of this invention to provide a system
`in which condensation of aerosol onto heating elements and
`other structural components of a lighter is minimized.
`It is a further object of this invention to provide a smoking
`article and manufacturing processes for making the same
`that are easier and cost effective, even at state-of-the-art
`mass production speeds.
`It is a still further object of this invention to provide
`improved aerosol and flavor delivery to the smoker.
`In accordance with one aspect of the present invention, a
`cigarette for use in a smoking system for delivering a
`50 flavored tobacco response to a smoker, the system including
`heating means, is provided. The cigarette includes a carrier
`having first and second ends spaced apart in a longitudinal
`direction and having first and second surfaces. The first
`surface defines a cavity between the first and second ends,
`55 and the second surface includes an area for being disposed
`adjacent heating means. Tobacco flavor material is disposed
`on the first surface of the carrier. The tobacco flavor material
`generates the flavored tobacco response in the cavity for
`delivery to a smoker when the tobacco flavor material is
`60 heated by the heating means. The carrier and the tobacco
`flavor material allow transverse air flow into the cavity.
`In accordance with another aspect of the present
`invention. a lighter for use in combination with a removable
`cigarette in a smoking system that delivers a flavored
`65 tobacco response to a smoker is provided. The lighter
`includes a heater fixture for receiving. through a first end, a
`removable cigarette. The heater fixture has means for pro-
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`viding a transverse flow of air to at least a portion of the
`FIG. 9 is a perspective view of a pin assembly according
`cigarette. A plurality of electrical heater elements are dis(cid:173)
`to an embodiment of the present invention;
`posed in the heater fixture. Each of the heater elements has
`FIG. HA is a schematic, side cross-sectional view of a
`a surface for being disposed adjacent a surface of the portion
`spacer according to an embodiment of the present invention;
`of the cigarette to which the transverse flow of air is 5
`FIG. 10B is a schematic view taken at section lOB-lOB
`provided. Means are provided for activating one or more of
`of FIG. lOA;
`the plurality of electrical heating means such that a prede(cid:173)
`FlG. lOC is a schematic view taken at section lOC-lOC
`termined quantity of flavored tobacco response is generated
`of FIG. lOA;
`in the cigarette. The transverse flow of air is generated when
`FIG. llA is a schematic, side cross-sectional view of a
`a smoker draws on a cigarette inserted in the lighter.
`base according to an embodiment of the present invention;
`In accordance with another aspect of the present
`invention. a smoking system for delivering a flavored
`FIG. llB is a schematic view taken at section llB-11B
`tobacco response to a smoker is provided. The system
`of FIG. llA;
`includes a removable cigarette, a lighter, and. means for
`FIG. UC is a schematic view taken at section UC-UC
`individually activating the plurality of electrical heating 15 of FIG. HA;
`means such that a predetermined quantity of flavored
`FIG. 12A is a schematic, perspective view of a combined
`tobacco response is generated in a cavity in the cigarette.
`spacer base member according to an embodiment of the
`In accordance with yet another aspect of the present
`present invention;
`invention, a heater element for use in a smoking system for
`FIG. 12B is a schematic. side cross-sectional view taken
`delivering a flavored tobacco response to a smoker is 20
`at section 12B-12B of FIG. 12A;
`provided. The heater element includes a first end, a second
`FIG. 12C is a schematic view taken at section 12C-12C
`end, and a plurality of curved regions between the first and
`of FIG. 12A;
`second ends for increasing electrical resistance of the heater
`element. The heater element is formed from resistive mate-
`FIG. 12D is a schematic view taken at section 12D-12D
`rial having first and second surfaces substantially oriented in 2s of FIG. 12A;
`a plane and having an overall length L, overall width W, and
`FIG. 13 is an end view of a ring according to an embodi(cid:173)
`thickness T. The effective electrical length of the heater
`ment of the present invention;
`element is greater than the length L and the effective
`FIG. 14A is a schematic, perspective view of a cap
`electrical cross-sectional area of the heater element is less
`according to an embodiment of the present invention;
`than the product of W and T.
`FIG. 14B is a schematic, side cross-sectional view taken
`In accordance with still another aspect of the present
`at section 14B-14B of FIG. 12A;
`invention. a method for manufacturing an integrated heater
`FIG. 14C is a schematic view taken at section 14C-14C
`assembly for use in a smoking system for delivering a
`of FIG. 14A;
`flavored tobacco response to a smoker is described. Accord-
`ing to the method, a sheet of resistive material is cut to form 35
`FIG. 14D is a schematic view taken at section 14D-14D
`a plurality of heater elements connected to one another at at
`of FIG. 14A;
`least one end. The sheet is formed into a cylindrical shape.
`FIG. 15A is a schematic side view of a heater sleeve
`according to an embodiment of the present invention;
`BRIEF DESCRJPITON OF THE DRAWINGS
`FIG. 158 is an end view taken at section 158-ISB of
`The present invention can be further understood with
`40 FIG. 15A;
`reference to the following description in conjunction with
`FIGS. 16 and 17 are schematic side cross-sectional views
`the appended drawings, wherein the same elements are
`of portions of a smoking system showing air flow paths in
`provided with the same reference numerals. In the drawings:
`the smoking system; and
`FIG. 1 is a schematic perspective view of a smoking
`FIG. 18 is a schematic circuit diagram showing circuitry
`system according to an embodiment of the present inven- 45
`according to an embodiment of the invention.
`tion;
`FIG. 2 is a partially broken. schematic perspective view of
`a smoking system according to an embodiment of the
`present invention;
`FlG. 3A is a side. cross-sectional view of a heater fixture
`according to an embodiment of the present invention;
`FIG. 3B is an end view of taken at section 3B-3B of FIG.
`3A;
`FIG. 4A is a schematic perspective view of a cigarette
`according to an embodiment of the present invention;
`FIG. 4B is a side cross-sectional view taken at section
`4B-4B of FIG. 4A;
`FIG. 5 is a schematic assembly view of a heater fixture
`according to another embodiment of the present invention;
`FIG. 6 is a perspective view of a heater assembly accord(cid:173)
`ing to an embodiment of the present invention;
`FIG. 7 is an outline of a heater assembly according to an
`embodiment of the present invention;
`FIG. 8 is a perspective view of a portion of a heater
`element according to an embodiment of the present inven-
`tion;
`
`DETAILED DESCRJPITON
`A smoking system 21 according to the present invention
`so is seen with reference to FIGS. 1 and 2. The smoking system
`21 includes a cigarette 23 and a reusable lighter 25. The
`cigarette 23 is adapted to be inserted in and removed from
`an orifice 27 at a front end 29 of the lighter 25. The smoking
`system 21 is used in much the same fashion as a conven-
`ss tional cigarette. The cigarette 23 is disposed of after one or
`more puff cycles. The lighter 25 is preferably disposed of
`after a greater number of puff cycles as the cigarette 23.
`The lighter 25 includes a housing 31 and has front and
`rear portions 33 and 35. A power source 37 for supplying
`60 energy to heating elements for heating the cigarette 23 is
`preferably disposed in the rear portion 35 of the lighter 25.
`The rear portion 35 is preferably adapted to be easily opened
`and closed. such as with screws or with soap-fit components,
`to facilitate replacement of the power source 37. The front
`65 portion 33 preferably houses heating elements and circuitry
`in electrical communication with the power source 37 in the
`rear portion 35. The front portion 33 is ireferably easily
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`Ex. 2012-0019
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`joined to the rear portion 3S. such as with a dovetail joint or
`by a socket fit The housing 31 is preferably made from a
`hard. heat-resistant material. Preferred materials include
`metal-based or. more preferably, polymer-based materials.
`The housing 31 is preferably adapted to fit comfortably in
`the hand of a smoker and. in a presently preferred
`embodiment. has overall dimensions of 10.7 cm by 3.8 cm
`by 1.5 cm.
`The power source 37 is sized to provide sufficient power
`for heating elements that heat the cigarette 23. The power
`source 37 is preferably replaceable and rechargeable and
`may include devices such as a capacitor or, more preferably.
`a battery. In a presently preferred embodiment. the power
`source is a replaceable, rechargeable battery (actually fom
`nickel cadmium battery cells connected in series) with a
`total, non-loaded voltage of approximately 4.8 to 5.6 volts.
`Toe characteristics required of the power source 37 are.
`however, selected in view of the characteristics of other
`oomponents in the smoking system 21. particularly the
`characteristics of the heating elements. U.S. Pat. No. 5,144.
`%2 describes several forms of power sources useful in
`connection with the smoking system of the present
`invention. such as rechargeable battery power sources and
`quick-discharging capacitor power sources that are charged
`by batteries. and is hereby incorporated by reference.
`A substantially cylindrical heating fixture 39 for heating
`the cigarette 23, and, preferably, for holding the cigarette in
`place relative to the lighter 25. and electrical control cir(cid:173)
`cuitry 41 for delivering a predetermined amount of energy
`from the power source 37 to heating elements (not seen in 30
`FIGS. I and 2) of the heating fixture are preferably disposed
`in the front 33 of the lighter. In the presently preferred
`embodiment, the heating fixture 39 includes eight radially
`spaced heating elements 43, seen in FIG. 3A, that are
`individually energized by the power source 37 under the 35
`oontrol of the circuitry 41 to heat eight areas around the
`periphery of the cigarette 23 to develop eight puffs of a
`flavored tobacco response. While other numbers of heating
`elements 43 may be provided, eight heater elements are
`preferred, at least because there are nominally eight puffs on 40
`a conventional cigarette and because eight heater elements
`lend themselves to electrical control with binary devices.
`The circuitry 41 is preferably activated by a puff-actuated
`sensor 45, seen in FIG. 2, that is sensitive either to pressure
`changes or air flow changes that occur when a smoker draws 45
`on the cigarette 23. The puff-actuated sensor 45 is preferably
`disposed in the front 33 of the lighter 25 and communicates
`with a space inside the heater fixture 39 and near the
`cigarette 23 through a passageway 47 extending through a
`spacer 49 and a base 50 of the heater fixture and. if desired, so
`a puff sensor tube (not shown). A puff-actuated sensor 4S
`suitable for use in the smoking system 21 is described in
`U.S. Pat No. 5,060,671, the disclosure of which is incor(cid:173)
`porated by reference, and is in the form of a Model
`163PC01D35 silicon sensor, manufactured by the 55
`MicroSwitch division of Honeywell, Inc., Freeport, ID.,
`which activates an appropriate one of the heater elements 43
`as a result of a change in pressure when a smoker draws on
`the cigarette 23. Flow sensing devices, such as those using
`hot-wire anemometry principles. have also been success- 60
`fully demonstrated to be useful for activating an appropriate
`one of the heater elements 43 upon detection of a change in
`air flow.
`An indicator SI is preferably provided on the exterior of
`the lighter 25, preferably on the front 33, to indicate the 65
`number of puffs remaining on a cigarette 23 inserted in the
`lighter. The indicator 51 preferably includes a seven-
`
`6
`segment liquid crystal display. In the presently preferred
`embodiment, the indicator SI displays the digit "8" when a
`light beam emitted by a light sensor 53. seen in FIG. 2, is
`reflected off of lhe front of a newly inserted cigarette 23 and
`s detected by the light sensor. The light sensor 53 is preferably
`mounted in an opening 55 in the spacer 49 and the base SO
`of the heater fixture 39. seen. for example. in FIG. 3A. Toe
`light sensor S3 provides a signal to the circuitry 41 which.
`in turn. provides a signal to the indicator SI. The display of
`10 the digit "8" on the indicator 51 reflects that the preferred
`eight puffs provided on each cigarette 23 are available. i.e ..
`none of the heater elements 43 have been activated to heat
`the new cigarette. After the cigarette 23 is fully smoked. the
`indicator displays the digit "O". When the cigarette 23 is
`15 removed from the lighter 25. the light sensor S3 does not
`detect the presence of a cigarette 23 and the indicator 51 is
`turned off. The light sensor 53 is modulated so that it does
`not constantly emit a light beam and provide an unnecessary
`drain on the power source 37. A presently preferred light
`20 sensor S3 suitable for use with the smoking system 21 is a
`Type OPR5005 Light Sensor. manufactured by OPrEK
`Technology, Inc., 1215 West Crosby Road, Carrollton. Tex.
`75006.
`As one of several possible alternatives to using the
`25 above-noted light sensor SJ. a mechanical switch (not
`shown) may be provided to detect the presence or absence
`of a cigarette 23 and a reset button (not shown) may be
`provided for resetting the circuitry 41 when a new cigarette
`is inserted in the lighter 25, e.g .• to cause the indicator SI to .
`display the digit "8", etc. Power sources, circuitry. puff(cid:173)
`actuated sensors. and indicators useful wilh the smoking
`system 21 of lhe present invention are described in U.S. Pat
`No. 5,060,671 and U.S. patent application Ser. No. 07/943,
`504, both of which are incorporated by reference. The
`passageway 47 and the opening SS in the spacer 49 and lhe
`heater fixture base 50 are preferably air-tight during smok-
`ing.
`A presently prderred cigarette 23 for use with the smok(cid:173)
`ing system 21 is seen in detail in FIGS. 4A and 4B. although
`the cigarette may be in any desired form capable of gener(cid:173)
`ating a flavored tobacco response for delivery to a smoker
`when the cigarette is heated by lhe heating elements 43. The
`cigarette 23 includes a tobacco web 57 formed of a carrier
`or plenum 59 which supports tobacco flavor material 61.
`preferably including tobacco. The tobacco web S7 is
`wrapped around and supported by a cylindrical back-flow
`filter 63 at one end and a cylindrical first free-flow filter 65
`at an opposite end. The first free-flow filter 65 is preferably
`an "open-tube" type filter having a longitudinal passage 67
`extending through the center of the first free-flow filter and.
`hence, provides a low resistance to draw or free flow.
`If desired, cigarette overwrap paper 69 is wrapped around
`the tobacco web S7. Types of paper useful as the overwrap
`paper 69 include a low basis weight paper. preferably a
`paper with a tobacco flavor coating, or a tobacco-based
`paper to enhance the tobacco flavor of a flavored tobacco
`response. A concentrated extract liquor in full or diluted
`strength may be coated on the overwrap paper 69. Toe
`overwrap paper 69 preferably possesses a minimal base
`weight and caliper while providing sufficient tensile strength
`for machine processes. Presently preferred characteristics of
`a tobacco-based paper include a basis weight (at 60%
`relative humidity) of between 20-25 grams/m2
`, minimum
`permeability of 0-25 CORESTA (defined as the amount of
`air, measured in cubic centimeters, that passes through one
`square centimeter of material. e.g .• a paper sheet. in one
`minute at a pressure drop of 1.0 kilopascal), tensile
`
`Ex. 2012-0020
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`strength~2000 gramsn7 mm width (1 in/min). caliper
`1.3-1.5 mils. CaC03 content~5%, citrate 0%. Materials for
`forming the overwrap paper 69 preferably include~75%
`tobacco-based sheet (non-cigar, flue- or flue-lair-cured mix
`filler and bright stem). Flax fiber in amounts no greater than
`that necessary to obtain adequate tensile strength may be
`added. The overwrap paper 69 can also be conventional flax
`fiber paper of basis weight 15-20 g/m2 or such paper with
`an extract coating. Binder in the form of citrus pectin may
`be added in amounts less than or equal to 1%. Glycerin in
`amounts no greater than necessary to obtain paper stiffness
`similar to that of conventional cigarette paper may be added.
`The cigarette 23 also preferably includes a cylindrical
`mouthpiece filter 71, which is preferably a conventional
`RfD-type (Resistance To Draw) filter, and a cylindrical
`second free-flow filter 73. The mouthpiece filter 71 and the
`second free-flow filter are secured to one another by tipping
`paper 7S. The tipping paper 7S extends past an end of the
`second free-flow filter 73 and is attached to the overwrap
`paper 69 to secure an end of the first free-flow filter 65 in
`position adjacent an end of the second free-flow filter. Like
`the first free-flow filter 6S, the second free-flow filter 73 is
`preferably formed with a longitudina