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US20160073686A1 - Tobacco-derived filter element - Google Patents

Tobacco-derived filter element Download PDF

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Publication number
US20160073686A1
US20160073686A1 US14/484,813 US201414484813A US2016073686A1 US 20160073686 A1 US20160073686 A1 US 20160073686A1 US 201414484813 A US201414484813 A US 201414484813A US 2016073686 A1 US2016073686 A1 US 2016073686A1
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Prior art keywords
pat
filter
tobacco
filter element
cellulosic pulp
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US14/484,813
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English (en)
Inventor
Evon L. Crooks
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RJ Reynolds Tobacco Co
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RJ Reynolds Tobacco Co
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Publication date
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Priority to US14/484,813 priority Critical patent/US20160073686A1/en
Assigned to R.J. REYNOLDS TOBACCO COMPANY reassignment R.J. REYNOLDS TOBACCO COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CROOKS, EVON L.
Priority to PCT/US2015/049625 priority patent/WO2016040768A1/fr
Publication of US20160073686A1 publication Critical patent/US20160073686A1/en
Abandoned legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06—Use of materials for tobacco smoke filters
    • A24D3/062—Use of materials for tobacco smoke filters characterised by structural features
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/02—Manufacture of tobacco smoke filters
    • A24D3/0204—Preliminary operations before the filter rod forming process, e.g. crimping, blooming
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/02—Manufacture of tobacco smoke filters
    • A24D3/0229—Filter rod forming processes
    • A24D3/0241—Filter rod forming processes by compacting particulated materials
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06—Use of materials for tobacco smoke filters
    • A24D3/067—Use of materials for tobacco smoke filters characterised by functional properties
    • A24D3/068—Biodegradable or disintegrable
    • A—HUMAN NECESSITIES
    • A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
    • A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
    • A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
    • A24D3/06—Use of materials for tobacco smoke filters
    • A24D3/08—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent
    • A24D3/10—Use of materials for tobacco smoke filters of organic materials as carrier or major constituent of cellulose or cellulose derivatives

Definitions

  • the present invention relates to tobacco products, such as smoking articles (e.g., cigarettes), and in particular, to filters for cigarettes.
  • the invention is directed to tobacco-derived materials that can be useful as a filtration media.
  • Popular smoking articles such as cigarettes, have a substantially cylindrical rod-shaped structure and include a charge, roll or column of smokable material, such as shredded tobacco (e.g., in cut filler form), surrounded by a paper wrapper, thereby forming a so-called “smokable rod” or “tobacco rod.”
  • a cigarette has a cylindrical filter element aligned in an end-to-end relationship with the tobacco rod.
  • a filter element comprises plasticized cellulose acetate tow circumscribed by a paper material known as “plug wrap.”
  • the filter element is attached to one end of the tobacco rod using a circumscribing wrapping material known as “tipping paper.” It also has become desirable to perforate the tipping material and plug wrap, in order to provide dilution of drawn mainstream smoke with ambient air.
  • tipping paper a circumscribing wrapping material
  • a cigarette is employed by a smoker by lighting one end thereof and burning the tobacco rod. The smoker then receives mainstream smoke into his/her mouth by drawing on the opposite end (e.g., the filter end) of the cigarette.
  • the discarded portion of the cigarette rod is primarily composed of the filter element, which typically consists of tightly-compacted and highly crimped cellulose acetate fibers bonded at their contact points and wrapped by the a plug wrap and tipping paper.
  • the filter element typically consists of tightly-compacted and highly crimped cellulose acetate fibers bonded at their contact points and wrapped by the a plug wrap and tipping paper.
  • the presence of the wrapping materials, the fiber-to-fiber bonding, and the compacted nature of conventional filter elements has a detrimental effect on the rate of degradation of cigarette filters in the environment. Unless the filter element is unwrapped and the fibers spread apart to increase exposure, biodegradation of the filter can take several years.
  • a number of approaches have been used in the art to promote an increased rate of degradation of filter elements.
  • One approach involves incorporation of additives (e.g., water soluble cellulose materials, water soluble fiber bonding agents, photoactive pigments, or phosphoric acid) into the cellulose acetate material in order to accelerate polymer decomposition.
  • additives e.g., water soluble cellulose materials, water soluble fiber bonding agents, photoactive pigments, or phosphoric acid
  • U.S. Pat. No. 5,453,144 to Kauffman et al. describes use of a water sensitive hot melt adhesive to adhere the plug wrap in order to enhance biodegradability of the filter element upon exposure to water.
  • U.S. Pat. No. 6,344,349 to Asai et al proposes to replace conventional cellulose acetate filter elements with a filter element comprising a core of a fibrous or particulate cellulose material coated with a cellulose ester to enhance biodegradability.
  • U.S. Pat. No. 8,434,498 to Sebastian suggests addition of starch particles to cellulose acetate fibers for purposes of increasing biodegradability of cigarette filters, US Pat. App. Publ. No.
  • the present invention relates to a smoking article, and in particular, a rod-shaped smoking article (e.g., a cigarette).
  • the smoking article includes a lighting end (i.e., an upstream end) and a mouth end (i.e., a downstream end).
  • a mouth end piece is located at the extreme mouth end of the smoking article, and the mouth end piece allows the smoking article to be placed in the mouth of the smoker to be drawn upon.
  • the mouth end piece has the form of a filter element comprising a filter material.
  • the filter material can comprise at least 10 dry weight percent, or at least 20 dry weight percent of cellulosic pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species.
  • the filter material can be in the form of a paper comprising the pulp or a fibrous tow comprising the pulp in esterified form.
  • the filter material can be in the form of a paper that is pleated or fluted to form a rod-like element.
  • the web of sheet-like material can have a basis weight of about 20 gsm to about 90 gsm.
  • a filter element for a smoking article can include one or more segments of a filter material comprising at least 10 dry weight percent, or at least 20 dry weight percent of cellulosic pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species, wherein the filter material can be in the form of a paper comprising the pulp or a fibrous tow comprising the pulp in esterified form.
  • a cigarette comprising a tobacco rod having a smokable filler material contained within a circumscribing wrapping material and a filter element connected to the tobacco rod at one end of the tobacco rod can be provided, wherein the filter element includes at least one segment of a filter material according to the present invention.
  • the present invention further provides a method for formation of a filter element of a smoking article, the method comprising: i) pulping a tobacco input comprising stalks, roots, or a combination thereof of a plant of the Nicotiana species to form a cellulosic pulp; ii) forming a web of sheet-like material comprising the cellulosic pulp; and iii) pleating the web of sheet-like material to form a rod-like element suitable for use in a filter element.
  • the web of sheet-like material can have a basis weight of about 20 gsm to about 90 gsm.
  • the web of sheet-like material can comprise at least 10 dry weight percent, or at least 20 weight percent of the cellulosic pulp.
  • the rod-like element can be adapted for use as a filter element in a smoking article.
  • Also provided herein is a method for formation of a filter element of a smoking article comprising: i) pulping a tobacco input comprising stalks, roots, or a combination thereof of a plant of the Nicotiana species to form a cellulosic pulp; ii) esterifying the cellulosic pulp to produce cellulose acetate; iii) dissolving the cellulose acetate in a solvent to form a cellulose acetate dope; iv) spinning the cellulose acetate dope into a plurality of filaments; and v) collecting, drying and crimping the plurality of filaments to form a tow material suitable for use in a filter element, the tow material comprising at least 10 dry weight percent, or at least 20 dry weight percent of cellulose acetate filaments made from the cellulosic pulp.
  • the method can further comprise blending the tow material with ethyl cellulose fibers, cellulose acetate-lignin blended fibers, or a combination thereof to form a biodegradable blend of filter tow material suitable for use in a filter element.
  • FIG. 1 is an exploded perspective view of a smoking article having the form of a cigarette, showing the smokable material, the wrapping material components, and the filter element of the cigarette;
  • FIG. 2 is a cross-sectional view of an embodiment of a filter element according to the invention.
  • FIG. 3 is a cross-sectional view of another embodiment of a filter element according to the invention.
  • embodiments of the disclosure relate to filter materials comprising tobacco-derived cellulosic pulp and to methods for producing filtration media from tobacco, and related systems, apparatuses, and products.
  • the tobacco-derived filtration materials can be employed, for example, in tobacco products suitable for oral use.
  • Traditional cigarette filter materials include cellulose acetate tow, gathered cellulose acetate web, polypropylene tow, gathered cellulose acetate web, gathered paper, strands of reconstituted tobacco, or the like.
  • cellulose acetate can be slow to degrade.
  • the present invention provides biodegradable filter materials that at least partially include cellulosic pulp derived from a plant of the Nicotiana species.
  • Pulp is conventionally produced from wood or other cellulose materials. However, as described herein, it can be desirable to instead produce pulp derived from alternative sources, such as, for example, tobacco.
  • the tobacco input can comprise one or more components from a plant of the Nicotiana species including leaves, seeds, flowers, stalks, roots, and/or stems.
  • the tobacco input can comprise flue-cured tobacco stalks, burley tobacco stalks, and/or whole-plant tobacco biomass (e.g., extracted green tobacco biomass). It can be advantageous to use roots, stalks, or a combination thereof from a plant of the Nicotiana species due to the relatively high portion of cellulose fibers in these parts of the plant.
  • Cellulose is understood to be a polysaccharide of the formula (C 6 H 10 O 5 ) n , wherein n can be a number from about 10 to over 10,000.
  • cellulose is commonly found in a mixture with hemicellulose, lignin, pectin, and other substances. For example, analysis of green tobacco stalks has revealed the presence of cellulose, hemi-cellulose, lignin, pectin, and sugars.
  • the tobacco stalks and/or roots can be separated into individual pieces (e.g., roots separated from stalks, and/or root parts separated from each other, such as big root, mid root, and small root parts) or the stalks and roots may be combined.
  • stalk is meant the stalk that is left after the leaf (including stem and lamina) has been removed.
  • Root and various specific root parts useful according to the present invention may be defined and classified as described, for example, in Mauseth, Botany: An Introduction to Plant Biology: Fourth Edition, Jones and Bartlett Publishers (2009) and Glimn-Lacy et al., Botany Illustrated, Second Edition, Springer (2006), which are incorporated herein by reference.
  • the harvested stalks and/or roots are typically cleaned, ground, and dried to produce a material that can be described as particulate (i.e., shredded, pulverized, ground, granulated, or powdered).
  • the tobacco material may comprise material from any part of a plant of the Nicotiana species, the majority of the material advantageously comprises material obtained from the stalks and/or roots of the plant.
  • the tobacco material comprises at least about 80%, at least about 90%, at least about 95%, or at least about 99% by dry weight of at least one of the stalk material and the root material of a harvested plant of the Nicotiana species.
  • the method employs stalks
  • entire stalks or only portions of the stalks may be used in the process.
  • the stalks may be directly processed in harvested form or may be physically altered by shredding or chopping prior to pulping.
  • the tobacco stalks may be prepared using a method by which the fibrous structure of the stalk rind surrounding the pith is used and the pith itself is isolated for another purpose.
  • a splitter device can be used to separate the rind from the pith. See, for example, U.S. Pat. Nos. 3,424,611, 3,424,612, and 3,464,877 to Miller et al.; U.S. Pat. No. 4,151,004 to Vukelic; and U.S. Pat. Nos.
  • the selection of the plant from the Nicotiana species (i.e., tobacco material) utilized in the products and processes of the invention can vary; and in particular, the types of tobacco or tobaccos may vary.
  • tobaccos that can be employed include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos.
  • flue-cured or Virginia e.g., K326)
  • burley sun-cured
  • Indian Kurnool and Oriental tobaccos including Katerini, Prelip, Komotini, Xanthi and
  • Tobacco compositions including dark air cured tobacco are set forth in U.S. Pat. No. 8,186,360 to Marshall et al., which is incorporated herein by reference. See also, types of tobacco as set forth, for example, in US Patent Appl. Pub. No. 2011/0247640 to Beeson et al., which is incorporated herein by reference.
  • Exemplary Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa , N, gossei, N. kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata , N. x sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N.
  • maritina N. megalosiphon, N. occidentalis, N. paniculata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii , N, linearis, N. miersii, N. nudicaulis, N.
  • obtusifolia N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia and N. spegazzinii.
  • Nicotiana species can be derived using genetic-modification or crossbreeding techniques (e.g., tobacco plants can be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes). See, for example, the types of genetic modifications of plants set forth in U.S. Pat. No. 5,539,093 to Fitzmaurice et al.; U.S. Pat. No. 5,668,295 to Wahab et al.; U.S. Pat. No. 5,705,624 to Fitzmaurice et al.; U.S. Pat. No. 5,844,119 to Weigl; U.S. Pat. No. 6,730,832 to Dominguez et al.; U.S. Pat. No.
  • the tobacco input can comprise reconstituted tobacco.
  • tobacco stems are used in making such a reconstituted tobacco sheet, because the fibrous nature of those stems provides strength and structural integrity to the resulting sheet. See, for example, U.S. Pat. No. 3,398,754 to Tughan; U.S. Pat. No. 3,847,164 to Mattina; U.S. Pat. No. 4,131,117 to Kite; U.S. Pat. No. 4,182,349 to Selke; U.S. Pat. No. 4,270,552 to Jenkins; U.S. Pat. No. 4,308,877 to Mattina; U.S. Pat. No. 4,341,228 to Keritsis; U.S. Pat. No.
  • pulps can be produced from raw materials either mechanically or chemically, as is known in the art.
  • raw tobacco materials can be chipped, and then fed between refiners where the chips are made into fibers between revolving metal disks, for example.
  • mechanical pulping techniques can be used to produce tobacco pulp (i.e., tobacco-derived cellulosic pulp) from raw tobacco stalk, raw tobacco root, or a combination thereof.
  • the raw tobacco input can be pretreated with water and then refined with a plurality of passes through a machine that can chip the tobacco input, for example. See, for example, the machines discussed in U.S. Pat. No.
  • a chemical pulping process can be used to make a pulp from raw tobacco materials.
  • a chemical pulping process separates lignin from cellulose fibers by dissolving lignin in a cooking liquor such that the lignin, which binds the cellulose fibers together, can be washed away from the cellulose fibers without seriously degrading the cellulose fibers.
  • Soda pulping involves cooking raw material chips in a sodium hydroxide cooking liquor.
  • the kraft process evolved from soda pulping and involves cooking raw material chips in a solution of sodium hydroxide and sodium sulfide.
  • the acidic sulfite process involves using sulfurous acid and bisulfate ion in the cook.
  • Any chemical pulping process including, but not limited to the three examples listed above, can be used to produce a tobacco pulp from raw tobacco materials.
  • a cooking liquor can comprise a strong base.
  • a strong base refers to a basic chemical compound (or combination of such compounds) that is able to deprotonate weak acids in an acid-base reaction.
  • strong bases that can be useful in the present invention include, but are not limited to one or more of sodium hydroxide, potassium hydroxide, sodium sulfide, and combinations thereof.
  • the weight of the strong base can be greater than about 5%, greater than about 25%, or greater than about 40% of the weight of the tobacco input.
  • Various other chemicals and weight ratios thereof can also be employed to chemically pulp the tobacco input in other embodiments.
  • chemically pulping a tobacco input can include heating the tobacco input and the strong base. Heating the tobacco input and the strong base can be conducted to increase the efficacy of the chemical pulping. In this regard, an increase in either cooking temperature or time will result in an increased reaction rate (rate of lignin removal).
  • the method of producing a tobacco-derived pulp can include one or more additional operations in some embodiments. See, e.g., U.S. Patent Appl. Pub. No. 2013/0276801 to Byrd Jr. et al., herein incorporated by reference in its entirety.
  • the tobacco input can undergo further processing steps prior to pulping and/or the pulping method can include additional treatment steps (e.g., drying the tobacco input, depithing the tobacco input, milling the tobacco input, etc.).
  • these additional steps can be conducted to remove pith (which comprises lignin) from the tobacco input and/or tobacco pulp manually, and thus reduce the amount of chemicals necessary to delignify the tobacco input during a chemical pulping process, for example.
  • Mixing water with the tobacco-derived cellulosic pulp to form a slurry and filtering the slurry can be conducted, for example, to remove some of the non-cellulosic materials, such as pith, parenchyma, and tissue from the tobacco pulp.
  • Additional treatment steps e.g., milling the tobacco input
  • Steam- or water-based pre-hydrolysis of the tobacco stalk prior to pulping, for example, can reduce the amount of chemicals necessary in a bleaching operation.
  • Anthraquinone can be employed in a chemical pulping method in an attempt to provide a higher yield by protecting carbohydrates from the strong base during delignification, for example.
  • Other processing steps known in the papermaking art can be employed in pulping the raw tobacco input.
  • the tobacco pulp can optionally be exposed to a bleaching agent.
  • the bleaching operation can be conducted to remove the residual non-cellulosic materials left over after pulping without damaging the cellulose.
  • Exemplary processes for treating tobacco with bleaching agents are discussed, for example, in U.S. Pat. No. 787,611 to Daniels, Jr.; U.S. Pat. No. 1,086,306 to Oelenheinz; U.S. Pat. No. 1,437,095 to Delling; U.S. Pat. No. 1,757,477 to Rosenhoch; U.S. Pat. No. 2,122,421 to Hawkinson; U.S. Pat. No. 2,148,147 to Baier; U.S. Pat. No.
  • the pulp can optionally be refined to modify the surface structure of the fibers. Refining can physically modify fibers to fibrillate and make the fibers more flexible, such that better bonding can be achieved. Additionally, other additives known in the art can be used to alter characteristics of the pulp fibers.
  • a tobacco pulp can be used to produce a web of sheet-like material (i.e., a paper).
  • a paper is meant to include any sheet or board made from a fibrous cellulosic material and encompasses paperboard.
  • the thickness of paper i.e., caliper
  • Density is expressed in mass per unit volume and bulk is the reciprocal of density.
  • the paper filter material disclosed herein has various potential uses in filter elements; however, possible uses of the paper filter material are not limited to the embodiments discussed herein.
  • the paper material of the present invention can comprise at least 10%, at least 20%, at least 50%, or at least 75% of pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species. In certain embodiments, the paper material can comprise 100% pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species. In some embodiments, the paper material can include a blend of pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species and pulp derived from other cellulose materials such as wood, for example.
  • a paper material comprising pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species can be used to form a biodegradable filter element useful in a smoking article.
  • a web of sheet-like material can be passed through a web preforming unit and pleated to form a rod-like element 105 comprising a plurality of pleats 115 . See, for example, the filters, apparatuses and methods discussed in U.S. Pat. No. 4,807,809 to Pryor et al., herein incorporated by reference in its entirety.
  • the rod-like element 105 can then be circumscribed with wrapping material 110 thereby forming a continuous rod 100 that can be used as a filter element or a segment of a filter element, for example.
  • the width of the sheet-like material can vary and typically is a width capable of being pleated to form the rod.
  • the total width of the strip employed in providing a desired rod can depend upon factors such as the thickness of the sheet-like material, the number of pleats desired, the nature or character of the pleats produced, the surface character of the material (i.e., a fibrous surface character versus a smooth surface), the porosity of the material, the moisture content of the material, the lubricity properties of the material, the friction characteristics of the web preforming apparatus relative to the sheet-like material, and other such factors.
  • the tobacco-derived paper material can be embossed.
  • Basis weight and caliper are two parameters used to characterize paper.
  • the basis weights of paper comprising tobacco pulp described herein can range from about 20 to about 90 g/m 2 , about 30 to about 60 g/m 2 , or about 30 to about 45 g/m 2 .
  • the caliper of tobacco paper described herein can range from about 0.01 to about 4.0 mils, or about 0.01 to about 1.0 mils, or about 0.01 to about 0.5 mils, for example.
  • Preferred sheet-like materials are thin, and have reasonably high tensile strengths, resiliencies and relatively good flexibilities.
  • the web have a good “hand” to hold a fold but not tear, crinkle, shatter or otherwise break during the folding or pleating process.
  • the modulus of the web be such that pleating readily occurs.
  • the web should not be so hard that it does not pleat, nor should the web be so soft that rods of poor resiliency are provided.
  • the rod-like element of pleated web can be provided at a high speed and can be enclosed within the outer wrapping material.
  • rod 105 has a substantially cylindrical shape and a generally circular cross sectional shape.
  • the ends of the rod each form a plane perpendicular to the longitudinal axis thereof.
  • the rod most preferably includes a plurality of longitudinally extending pleats 115 in the web of sheet-like material.
  • the pleated web is contained in a wrapping material 110 such as cigarette paper wrap or paper plug wrap which is formed in a tubular shape around the pleats.
  • Filter rods can be produced using porous or non-porous plug wrap.
  • a pulp from stalks, roots, or a combination thereof of a plant of the Nicotiana species can be used to produce a fibrous tow material that can be useful as a filter element.
  • the process for making filter elements according to the invention can vary, but a process for making cellulose acetate filter elements typically begins with forming cellulose fibers. See, e.g., U.S. Pat. Pub. No. 2013/0180536 to Sebastian, which is herein incorporated by reference in its entirety.
  • the first step in conventional cellulose acetate fiber formation is esterifying a cellulose material. As discussed above, traditionally wood is used as a cellulose material. However, the present invention utilizes pulp derived from tobacco.
  • the tobacco-derived pulp can be used alone or in combination with pulp derived from other cellulose materials.
  • Cellulose is a polymer formed of repeating units of anhydroglucose. Each monomer unit has three hydroxyl groups available for ester substitution (e.g., acetate substitution).
  • Cellulose esters may be formed by reacting cellulose with an acid anhydride. To make cellulose acetate, the acid anhydride is acetic anhydride.
  • Cellulose pulp is typically mixed with acetic anhydride and acetic acid in the presence of an acid catalyst such as sulfuric acid.
  • esterification process of cellulose will often result in essentially complete conversion of the available hydroxyl groups to ester groups (e.g., an average of about 2.9 ester groups per anhydroglucose unit).
  • the polymer is typically hydrolyzed to drop the degree of substitution (DS) to about 2 to about 2.5 ester groups per anhydroglucose unit.
  • DS degree of substitution
  • the cellulose acetate is typically dissolved in a solvent (e.g., acetone, methanol, methylene chloride, or mixtures thereof) to form a viscous solution.
  • a solvent e.g., acetone, methanol, methylene chloride, or mixtures thereof
  • concentration of cellulose acetate in the solution is typically about 15 to about 35 percent by weight.
  • Additives such as whitening agents (e.g., titanium dioxide) can be added to the solution if desired.
  • the resulting liquid is sometimes referred to as a liquid “dope.”
  • the cellulose acetate dope is spun into filaments using a nonwoven fabric melt-spinning technique, which entails extruding the liquid dope through a spinerette.
  • the filaments pass through a curing/drying chamber, which solidifies the filaments prior to collection.
  • the collected fibers are combined into a tow band, crimped, and dried. Conventional crimp ratios are in the range of 1.2 to 1.8.
  • the fibers are typically packaged in bales that are suitable for later use in filter element formation processes.
  • the process of forming the actual filter element typically involves mechanically withdrawing the cellulose acetate tow from the bale and separating the fibers into a ribbon-like band.
  • the tow band is subjected to a “blooming” process wherein the tow band is separated into individual fibers. Blooming can be accomplished, for example, by applying different tensions to adjacent sections of the tow band or applying pneumatic pressure.
  • the bloomed tow band then passes through a relaxation zone that allows the fibers to contract, followed by passage into a bonding station.
  • the bonding station typically applies a plasticizer such as triacetin to the bloomed fibers, which softens the fibers and allows adjacent fibers to fuse together.
  • the bonding process forms a homogenous mass of fibers with increased rigidity.
  • the final cellulose acetate tow can comprise at least 10%, at least 20%, at least 50%, or at least 75% of esterified pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species.
  • the cellulose acetate tow can comprise 100% esterified pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species.
  • the cellulose acetate tow can include a blend of esterified pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species and esterified pulp derived from other cellulose materials such as wood, for example.
  • the tow material comprising esterified tobacco pulp can be blended with ethyl cellulose fibers, cellulose acetate-lignin blended fibers, or a combination thereof to form a biodegradable blend of filter tow material suitable for use in a filter element.
  • Filter element components or segments for filter elements for multi-segment filtered cigarettes typically are provided from filter rods that are produced using traditional types of rod-forming units, such as those available as KDF-2 and KDF-3E from Hauni-Werke Korber & Co. KG.
  • the filter rods of the present invention can comprise a filter material comprising at least 10 dry weight percent of pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species, wherein the filter material is in the form of a paper comprising the pulp or a fibrous tow comprising the pulp in esterified form.
  • filter material such as filter tow (i.e., pulp in esterified form) is provided using a tow processing unit.
  • An exemplary tow processing unit has been commercially available as E-60 supplied by Arjay Equipment Corp., Winston-Salem, N.C.
  • Other exemplary tow processing units have been commercially available as AF-2, AF-3, and AF-4 from Hauni-Werke Korber & Co. KG.
  • representative manners and methods for operating a filter material supply units and filter-making units are set forth in U.S. Pat. No. 4,281,671 to Byrne; U.S. Pat. No. 4,862,905 to Green, Jr. et al.; U.S. Pat. No. 5,060,664 to Siems et al.; U.S. Pat. No. 5,387,285 to Rivers; and U.S.
  • the cigarette 10 includes a generally cylindrical rod 12 of a charge or roll of smokable filler material contained in a circumscribing wrapping material 16 .
  • the rod 12 is conventionally referred to as a “tobacco rod.”
  • the ends of the tobacco rod 12 are open to expose the smokable filler material.
  • the cigarette 10 is shown as having one optional band 22 (e.g., a printed coating including a film-forming agent, such as starch, ethylcellulose, or sodium alginate) applied to the wrapping material 16 , and that band circumscribes the cigarette rod in a direction transverse to the longitudinal axis of the cigarette. That is, the band 22 provides a cross-directional region relative to the longitudinal axis of the cigarette.
  • the band 22 can be printed on the inner surface of the wrapping material (i.e., facing the smokable filler material), or less preferably, on the outer surface of the wrapping material.
  • the cigarette can possess a wrapping material having one optional band, the cigarette also can possess wrapping material having further optional spaced bands numbering two, three, or more.
  • At one end of the tobacco rod 12 is the lighting end 18 , and at the mouth end 20 is positioned a filter element 26 .
  • the filter element 26 positioned adjacent one end of the tobacco rod 12 such that the filter element and tobacco rod are axially aligned in an end-to-end relationship, preferably abutting one another.
  • Filter element 26 may have a generally cylindrical shape, and the diameter thereof may be essentially equal to the diameter of the tobacco rod.
  • the ends of the filter element 26 permit the passage of air and smoke therethrough.
  • the filter element 26 is circumscribed along its outer circumference or longitudinal periphery by a layer of outer plug wrap 28 . In a multi-segment filter embodiment, the outer plug wrap 28 overlies each of the segments so as to provide a combined, multi-segment filter element.
  • the filter element 26 is attached to the tobacco rod 12 using tipping material (not pictured) that circumscribes both the entire length of the filter element 26 and an adjacent region of the tobacco rod 12 .
  • tipping material are described, for example, in U.S. Pat. No. 7,789,089 to Dube et al., and in U.S. Pat. App. Publ. Nos. 2007/0215167 to Crooks et al., 2010/0108081 to Joyce et al., 2010/0108084 to Norman et al., and 2013/0167849 to Ademe et al.; and PCT Pat. App. Pub. No. 2013/160671 to Dittrich et al., each of which is incorporated by reference herein.
  • the inner surface of the tipping material is fixedly secured to the outer surface of the plug wrap 28 and the outer surface of the wrapping material 16 of the tobacco rod, using a suitable adhesive; and hence, the filter element and the tobacco rod are connected to one another.
  • a ventilated or air diluted smoking article can be provided with an optional air dilution means, such as a series of perforations 30 , each of which extend through the tipping material and plug wrap 28 .
  • the optional perforations 30 shown in FIG. 1 , can be made by various techniques known to those of ordinary skill in the art, such as laser perforation techniques.
  • so-called off-line air dilution techniques can be used (e.g., through the use of porous paper plug wrap and pre-perforated tipping paper).
  • the amount or degree of air dilution or ventilation can vary. Frequently, the amount of air dilution for an air diluted cigarette is greater than about 10 percent, generally is greater than about 20 percent, often is greater than about 30 percent, and sometimes is greater than about 40 percent. Typically, the upper level for air dilution for an air diluted cigarette is less than about 80 percent, and often is less than about 70 percent.
  • air dilution is the ratio (expressed as a percentage) of the volume of air drawn through the air dilution means to the total volume and air and smoke drawn through the cigarette and exiting the extreme mouth end portion of the cigarette.
  • the smoker lights the lighting end 18 of the cigarette 10 using a match or cigarette lighter.
  • the smokable material 12 begins to burn.
  • the mouth end 20 of the cigarette 10 is placed in the lips of the smoker.
  • Thermal decomposition products e.g., components of tobacco smoke
  • the filter element 26 and any residual portion of the tobacco rod 12 can be discarded.
  • the filter element of the invention typically comprises one or more longitudinally-extending rods or segments.
  • Each rod or segment can have varying properties and may include various materials capable of filtration or adsorption of particulate matter and/or vapor phase compounds.
  • the filter element of the invention includes 1 to 6 segments, frequently 2 to 4 segments.
  • the filter element includes a mouth end segment and a tobacco end segment.
  • Typical rod sizes range in length from about 40 mm to about 140 mm, and from about 16 mm to about 28 mm in circumference.
  • Multi-segment filter rods can be carried out using the types of rod-forming units that traditionally have been employed to provide multi-segment cigarette filter components.
  • Multi-segment cigarette filter rods can be manufactured using a cigarette filter rod making device available under the brand name Mulfi from Hauni-Werke Korber & Co. KG of Hamburg, Germany.
  • Representative types of filter designs and components, including representative types of segmented cigarette filters, are set forth in U.S. Pat. No. 4,920,990 to Lawrence et al.; U.S. Pat. No. 5,012,829 to Thesing et al.; U.S. Pat. No. 5,025,814 to Raker; U.S. Pat. No.
  • Multi-segment filter elements typically are provided from so-called “six-up” filter rods, “four-up” filter rods and “two-up” filter rods that are of the general format and configuration conventionally used for the manufacture of filtered cigarettes can be handled using conventional-type or suitably modified cigarette rod handling devices, such as tipping devices available as Lab MAX, MAX, MAX S or MAX 80 from Hauni-Werke Korber & Co. KG. See, for example, the types of devices set forth in U.S. Pat. No. 3,308,600 to Erdmann et al.; U.S. Pat. No. 4,281,670 to Heitmann et al.; U.S. Pat. No.
  • FIG. 3 An exemplary multi-segment filter element 200 configuration is shown in FIG. 3 ; the filter including a first filter segment 205 positioned adjacent one end of the tobacco rod 12 (see, e.g., FIG. 1 ).
  • the first filter segment 205 can include filter material 212 (e.g., cellulose acetate tow comprising esterified tobacco pulp).
  • Filter element 200 also possesses a second filter segment 210 longitudinally disposed relative to the first segment 205 and positioned at the extreme mouth end of the cigarette 10 .
  • the second filter segment 210 includes filter material 214 .
  • the filter material 214 of the second filter segment 210 can be the same or different from the filter material 212 of the first filter segment 205 .
  • the first filter material 212 can be a cellulose acetate tow comprising esterified tobacco pulp (or a pleated paper material made from tobacco pulp) and the second filter material 214 can also be a cellulose acetate tow comprising esterified tobacco pulp (or a pleated paper material made from tobacco pulp), or the second filter material 214 can be a cellulose acetate tow that does not include tobacco pulp.
  • the filter element could also include a cavity formed between two filter material segments (not pictured). Still further, the filter segment comprising tobacco pulp can be more centrally located within the filter element with one or more filter segments that do not contain tobacco pulp on each side. Alternatively, all filter segments could include tobacco pulp.
  • a filter element can comprise a first filter segment comprising a first filter material in the form of a paper comprising pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species and a second filter segment comprising a second filter material in the form of a fibrous tow comprising pulp derived from stalks, roots, or a combination thereof of a plant of the Nicotiana species.
  • Other filter element arrangements could be used without departing from the invention.
  • a plurality of degradable particles can be dispersed within the either or all of filter materials 212 , 214 .
  • the filter element can also incorporate other components that have the ability to alter the properties of the mainstream smoke that passes throughout the filter element, such as adsorbent materials or flavorants.
  • adsorbent materials include activated carbon and ion exchange resins
  • exemplary flavorants include flavorant-containing capsules and solid botanical additives such as peppermint or spearmint leaves or other plant-based flavorants in particulate form. See, for example, U.S. Pat. No. 6,041,790 to Smith et al. and US Pat. Application Publication Nos.
  • a representative cigarette 10 can vary.
  • Preferred cigarettes are rod-shaped, and can have diameters of about 7.5 mm (e.g., circumferences of about 20 mm to about 27 mm, often about 22.5 mm to about 25 mm); and can have total lengths of about 70 mm to about 120 mm, often about 80 mm to about 100 mm.
  • the length of the filter element 30 can vary. Typical filter elements can have total lengths of about 15 mm to about 40 mm, often about 20 mm to about 35 mm.
  • the downstream or mouth end filter segment often has a length of about 10 mm to about 20 mm; and the upstream or tobacco rod end filter segment often has a length of about 10 mm to about 20 mm.
  • Various types of cigarette components including tobacco types, tobacco blends, top dressing and casing materials, blend packing densities and types of paper wrapping materials for tobacco rods, can be employed. See, for example, the various representative types of cigarette components, as well as the various cigarette designs, formats, configurations and characteristics, that are set forth in Johnson, Development of Cigarette Components to Meet Industry Needs, 52 nd T.S.R.C. (September, 1998); U.S. Pat. No. 5,101,839 to Jakob et al.; U.S. Pat. No. 5,159,944 to Arzonico et al.; U.S. Pat. No. 5,220,930 to Gentry and U.S. Pat. No.
  • the entire smokable rod is composed of smokable material (e.g., tobacco cut filler) and a layer of circumscribing outer wrapping material.
  • smokable material e.g., tobacco cut filler
  • Filter elements of the present invention can be incorporated within the types of cigarettes set forth in U.S. Pat. No. 4,756,318 to Clearman et al.; U.S. Pat. No. 4,714,082 to Banerjee et al.; U.S. Pat. No. 4,771,795 to White et al.; U.S. Pat. No. 4,793,365 to Sensabaugh et al.; U.S. Pat. No. 4,989,619 to Clearman et al.; U.S. Pat. No. 4,917,128 to Clearman et al.; U.S. Pat. No. 4,961,438 to Korte; U.S. Pat. No.
  • filter elements of the present invention can be incorporated within the types of cigarettes that have been commercially marketed under the brand names “Premier” and “Eclipse” by R. J. Reynolds Tobacco Company. See, for example, those types of cigarettes described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, p. 1-58 (2000); which are incorporated herein by reference.
  • Cigarette rods typically are manufactured using a cigarette making machine, such as a conventional automated cigarette rod making machine.
  • exemplary cigarette rod making machines are of the type commercially available from Molins PLC or Hauni-Werke Korber & Co. KG.
  • MIA commercially available from Molins PLC
  • PROTOS commercially available from Hauni-Werke Korber & Co. KG
  • a description of a PROTOS cigarette making machine is provided in U.S. Pat. No. 4,474,190 to Brand, at col. 5, line 48 through col. 8, line 3, which is incorporated herein by reference. Types of equipment suitable for the manufacture of cigarettes also are set forth in U.S. Pat.
  • Preferred cigarettes of the present invention exhibit desirable resistance to draw.
  • an exemplary cigarette exhibits a pressure drop of between about 50 and about 200 mm water pressure drop at 17.5 cc/sec. air flow.
  • Preferred cigarettes exhibit pressure drop values of between about 60 mm and about 180, more preferably between about 70 mm to about 150 mm, water pressure drop at 17.5 cc/sec. air flow.
  • pressure drop values of cigarettes are measured using a Filtrona Cigarette Test Station (CTS Series) available from Filtrona Instruments and Automation Ltd.

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  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Biodiversity & Conservation Biology (AREA)
  • Cigarettes, Filters, And Manufacturing Of Filters (AREA)
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