US20240324661A1

US20240324661A1 - Cigarette filter rod and process

Info

Publication number: US20240324661A1
Application number: US18/614,090
Authority: US
Inventors: Luis Antonio SANCHES; Tadas Lukas LISAUSKAS
Original assignee: GREENBUTTS LLC
Current assignee: GREENBUTTS LLC
Priority date: 2023-03-31
Filing date: 2024-03-22
Publication date: 2024-10-03
Also published as: KR20250165655A; MX2025011307A; WO2024206242A1

Abstract

A filter substrate and binder filter rod making process with multiple connecting binding areas or binders throughout the filter substrate or other biodegradable materials, mono-fiber or multi-fiber, regardless of whether the paper(s)/substrate(s) has been crimped, embossed, or not, which improve the substrate properties including mechanical strength, filtration capability for both vapor/gases and particulate/solids phases, TAR, Nicotine and especially Carbon Monoxide, sensorial neutrality, visual improvements before and after use and substrate processability.

Description

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 63/456,145, filed Mar. 31, 2023, under 35 U.S.C. 119, which is incorporated by reference herein.

BACKGROUND

Field of the Invention

The present invention relates generally to cigarettes and is particularly concerned with a more environmentally friendly cigarette filters to reduce the problems of discarded cigarette filters, which contribute to environmental pollution and litter while providing similar tobacco smoke filtration efficiency properties.

Related Art

A typical cigarette includes a filter at one end which has a core or body which filters the smoke generated from burning tobacco and a paper wrapper having one or more wrapper layers surrounding the filter body. The filter core or body is commonly made from synthetic filaments (cellulose acetate) forming a fibrous filter material and added plasticizer (triacetin). After a user smokes the cigarette, the cellulose acetate filter (single-use plastic) or cigarette butt is typically discarded. Such filters are often discarded in outdoor areas such as beaches, parks, and the like. The materials making up the filter core and plasticizer, single-use plastic, degrade only very slowly over lengthy periods of time (10 to 15 years) and significantly add to the problems of unsightly environmental litter and pollution.
U.S. patent Ser. No. 10/076,135, which is incorporated herein, discloses a filter substrate that addresses the most littered item on planet Earth, caused by cellulose acetate with the plasticizer (triacetin) utilized in the manufacturing of the cigarette filter rods. Due to the biodegradability, water dispersibility and compostability properties, including its filtration capability and sensorial attributes of the filter substrate, it is a viable replacement for the single-use plastic (SUP) cellulose acetate which is almost exclusively utilized by the tobacco industry for smoke filtration globally.
The filter substrate described comprises four main fibers: Abaca, Tencel, Cotton Flock and Hemp. Each fiber plays a particular role in the substrate, depending on its fiber size, strength, cellular construction, chemical composition, flexibility, commercial availability and cost. Each fiber is included in the substrate, according to its formulation, in a particular ratio where each of the fibers can perform within its ideal role, giving the filter substrate a competitive advantage and superior filterability, biodegradability, mechanical strength, chemical and sensorial performance when compared to paper substrates and even cellulose acetate.

SUMMARY

In an aspect of the disclosure, the filter rod manufacturing process processes “paper like” substrate currently utilizing two essential main alternatives before the substrate (paper-like filtration media) is formed into a filter rod: 1) the substrate is crimped in order to expose the fibers, and therefore, to enhance its filtration capability, and 2) the substrate is embossed where an embossing pattern is transferred to the substrate in order to promote a designed filtration performance which can be adapted for a wide range of product characteristics. In both cases described above, the body of the substrate sheet remains preserved, and it is folded multiple times in a random pattern, until it gains the rod shape, and it is then overwrapped by a paper known as plug-wrap.
Although the amount of substrate folded in a rod format is sufficient to produce the desired pressure drop or resistance to draw, the folding process does not create enough counterflow resistance to produce effective filtration to specific smoking compounds (particulate phase or vapor phase, and more specifically Carbon Monoxide). The crimping and the embossing process creates turbulences but without any vertical, physical, mechanical counterflow obstacles. Airways or channels are formed naturally when low pressure drop or low resistance to draw is desired. There is substantial axial airflow resistance, but not enough radial airflow resistance and mechanical barriers due to the inexistence of physical binding between the various fibers that form the substrate. Therefore, the existing crimping and embossing processes, although promote a level of turbulence, the airflow behavior can be better described and laminar flow rather than turbulent flow. The axial airflow resistance created by the binding innovative and breakthrough design process, boosts multidimensionally the existence of obstacles and physical entrapments, promoting an increase of airflow turbulence, including vortex forces, does reduce the airflow speed, and consequently activate further reduction of air channels, and thus improving filtration on TAR, Nicotine, and most importantly Carbon Monoxide and other particulate and vapor phase compounds by the producing of an enhanced turbulent airstream flow dynamic.
Accordingly, aspects of the disclosure involve a filter substrate and binding filter rod making process, that can be described as the breakthrough airstream flow turbulence enhancer, with multiple connecting binding areas or binders throughout the filter substrate or other biodegradable materials, mono-fiber or multi-fiber, regardless of whether the paper(s)/substrate(s) has been crimped, embossed, or not, which improve the paper/substrate properties including mechanical strength, filtration capability for both vapor and particulate phases including TAR, Nicotine, and Carbon Monoxide, sensorial neutrality, filter hardness, substrate processability and improved visual pos-manufacturing and staining after being smoked.
Another aspect of the disclosure involves a cigarette filter rod comprising a filter substrate including opposite surfaces; a plurality of binding areas on at least one of the opposite surfaces, wherein the filter substrate is folded multiple times into a rod shape and the plurality of binding areas bind at least one of the opposite surfaces together, the binding areas forming airflow barriers that function as air obstacles and cavities that trap gases and particulate matters and produce airstream flow turbulence, reducing airflow speed and increasing friction coefficient, enhancing entrapments for solids and gases as they travel through the filter rods.
One or more implementations of the aspect of the disclosure described immediately above includes one or more of the following: the filter substrate is crimped, exposing filter substrate fibers and enhancing filtration capability; the filter substrate is embossed with an embossing pattern, promoting filtration performance; the filter substrate is a biodegradable material; the filter substrate includes mono-fiber; the filter substrate includes multi-fiber; the filter substrate is made of at least one of Abaca, Tencel, Cotton Flock, and Hemp; the filter substrate includes a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder, the binding areas include an adhesive from one or more of water, glue, plant-based binder, synthetic binder, adherent, and agglutinant; and/or a plug wrap that surrounds the filter substrate.
A further aspect of the disclosure involves a method of manufacturing a cigarette filter rod comprising a filter substrate including opposite surfaces; a plurality of binding areas on at least one of the opposite surfaces, wherein the filter substrate is folded multiple times into a rod shape and the plurality of binding areas bind at least one of the opposite surfaces together, the binding areas forming airflow barriers that function as air obstacles and cavities that trap gases and particulate matters and produce airstream flow turbulence, reducing airflow speed and increasing friction coefficient, enhancing entrapments for solids and gases as they travel through the filter rods, the method comprising providing the filter substrate; adding binding material at a plurality of areas on at least one of the opposite surfaces of the filter substrate; folding the filter substrate multiple times into an elongated rod so that the plurality of binding areas bind at least one of the opposite surfaces together where the binding material was added to the plurality of areas; cutting the elongated rod into a plurality of individual filter rods.
One or more implementations of the aspect of the disclosure described immediately above includes one or more of the following: adding binding material including at least one of spraying a distribution of dots of binding material on at least one of the opposite surfaces of the filter substrate, spray jet, atomization, and continuous flow nozzle; funneling the sprayed filter material with a funnel; crimping filter substrate, exposing filter substrate fibers and enhancing filtration capability, prior to adding the binder material to the filter substrate; embossing the filter substrate with an embossing pattern, promoting filtration performance, prior to adding the binder material to the filter substrate; the filter substrate is made of at least one of Abaca, Tencel, Cotton Flock, and Hemp; the filter substrate includes a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder, the binder material is an adhesive from one or more of water, glue, plant-based binder, synthetic binder, adherent, and agglutinant; and/or surrounding the filter substrate with a plug wrap.
A further aspect of the disclosure involves a method of manufacturing a cigarette filter rod comprising a filter substrate including opposite surfaces; a plurality of binding areas on at least one of the opposite surfaces, wherein the filter substrate is folded multiple times into a rod shape and the plurality of binding areas bind at least one of the opposite surfaces together, the binding areas forming airflow barriers and cavities that function as air obstacles that trap gases and particulate matters and produce airstream flow turbulence, reducing airflow speed and increasing friction coefficient, enhancing entrapments for solids and gases as they travel through the filter rods, the method comprising providing a cigarette including a filter rod that is one of the individual filter rods; forming airflow barriers with the binding areas that function as air obstacles that trap gases and particulate matters and produce airstream flow turbulence, reducing airflow speed and increasing friction coefficient, enhancing entrapments for solids and gases as they travel through the filter rod.
One or more implementations of the aspect of the disclosure described immediately above includes one or more of the following: the filter substrate is made of at least one of Abaca, Tencel, Cotton Flock, and Hemp; the filter substrate includes a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder; and/or the binding areas include an adhesive from one or more of water, glue, plant-based binder, synthetic binder, adherent, and agglutinant.
Other features and advantages of the present disclosure will become more readily apparent to those of ordinary skill in the art after reviewing the following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The details of the present invention, both as to its structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:

FIG. 1 is a perspective view of an embodiment of a filter rod of a cigarette that may include the filter substrate;

FIG. 2 is a schematic of a paper/substrate filter rod making system including a binding process;

FIG. 3 is a top plan view of a filter substrate showing an example distribution of binding dots across a surface of the filter substrate;

FIG. 4 illustrates cross-sectional views of the filter rod of FIG. 1 and FIG. 4B illustrates binding areas/binders formed by the binding dots/process;

FIG. 5 illustrates end views of air channeling among filter rods manufactured with paper (mono fiber filter media) and biodegradable substrate (multi-fiber media) at various stages;

FIG. 6 is a flow chart of an exemplary paper/substrate filter rod making process including the binding process.

FIGS. 7-11 are tables of sample results/specifications for a number of tests performed related to the embodiments of the paper/substrate filter rod made without the binding process described herein.

FIG. 12 is a table of detection limits for a number of tests performed related to embodiments of the paper/substrate filter rod made by the binding process described herein.

FIGS. 13A and 13B are tables of sample results for a number of tests performed related to the embodiments of the paper/substrate filter rod made by the binding process described herein.

FIG. 14 is a table of sample coding for a number of tests performed related to the embodiments of the paper/substrate filter rod made by the binding process described herein.

FIG. 15 is a table of a constituents list for a number of tests performed related to the embodiments of the paper/substrate filter rod made by the binding process described herein.

DETAILED DESCRIPTION

With reference to FIGS. 1-4 and 6 , certain embodiments as disclosed herein provide for a filter substrate 100 and binding filter rod making process 110 with multiple connecting binding areas or binders 120 throughout the filter substrate 100, regardless of whether the filter substrate 100 has been crimped, embossed, or not, which improve the filter substrate properties including mechanical strength, filtration capability for both vapor and particulate phases, sensorial neutrality and processability. While the binding filter rod making process 110 will generally be described in conjunction with the fiber cell structure expansion of a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder, the binding filter rod making process 110 is applicable to any type of paper or paper like material that could be used in this binding process in a wide range of industrial and personal applications. Further, the binding process 110 covers any possible adhesive whether simply applying water, or any other type of glue, binders, whether plant based or synthetic, or any kind of adherent or agglutinant.
As illustrated in FIG. 1 , the filter substrate 100 may be part of a filter rod 130 of a cigarette 140. The filter rod 130 includes the filter substrate 100 surrounded by a plug wrap 150. The filter rod 130 and cigarette paper 160 of a tobacco rod 165 carrying the contents of the cigarette 140 are wrapped together with tipping paper 170.
As shown in FIG. 2 , FIG. 4 , and FIG. 6 , to increase radial airflow resistance and, therefore, enhance filtration efficiency, the binding filter rod making process 110 comprises, at step 180, supplying the filter substrate or paper 100, at optional step 190, embossing or crimping the filter substrate 100 using an embossing or crimping head 200. The embossing process is described in European patent application no. EP 22207022.9, filed Nov. 11, 2022, which is incorporated by reference herein. At step 210, spraying a distribution of binding dots 212 across a surface 214 of the filter substrate or paper 100 with a binding sprayer system 220, at step 230, funneling the sprayed filter substrate or paper 100 with a funnel 240, at step 250, making an elongated filter rod configuration with rod making bars 260, at step 270, cutting the elongated filter rod configuration into individual filter rods 130 with cutting head 280. After passing through the cutting head 280, the filter rods 130 are in the right size to be transferred via a conveyor belt or transfer drums to a tray-filler machine where the filter rods 130 will be stored and eventually transferred to cigarette maker machines for a final step, where the filter rods 130 will pass through an additional cutting process before being attached to the tobacco rod 165 shown in FIG. 1 . The attachment of the filter rod 130 and the tobacco rod 165 is done through the tipping paper wrapper 170.
With reference to FIG. 3 , the binding sprayer system 220 deposits liquid dots or drops 212 across the surface 214 of the substrate/paper 100. The liquid dots/drops 212 react with an existing binder element present in the composition of the filter substrate or paper 100 and/or create a new binder spot to build multiple connecting binding areas 310, as shown in FIG. 4 , throughout the filter substrate or paper 100 regardless of whether the filter substrate/paper 100 has been crimped, embossed, or not. FIG. 3 illustrates an example disposition and distribution of the binding dots 212 across the surface 214 of the substrate 100. Multiple design patterns other than that shown in FIG. 3 may be provided/created on the substrate or paper 100. The spraying process 210 can be performed on one surface 214 individually or on both opposite surfaces 212 depending on desired filtration, hardness, and visual appearance. As shown in FIG. 2 , binding/Greenbinding™ brand binding process may be applied anywhere/anypoint from bobbing 216 to garniture 218 before filter rod formation and different binding methods may be utilized such as, but not limited to, spray atomizers, continuous flow nozzles, spray jet, or any other impregnation technique.
The size, number, and configuration of binding dots 212 (e.g., by spray atomizers, continuous flow nozzles, spray jet, or any other impregnation technique) can be adjusted depending on the desired filtration and/or to improve the filter hardness which is a key physical filter design attribute. FIG. 3 only represents one among an unlimited number of combinations that are achieved and designed to improved selective filtration, improved physical, and visual aspects of the filter rod 130.
Advantages of the filter substrate 100 and binding filter rod making process 110 with multiple radially positioned connecting binding areas or binders 120 throughout the filter substrate 100, regardless of whether the filter substrate 100 has been crimped, embossed, or not, include the following.

1. Filtration Efficiency

As shown in FIG. 4 , airways or air channels are naturally produced during the filter rod manufacturing process, creating therefore a laminar and undesirable laminar airflow dynamic. The filter substrate 100 and binding filter rod making process 110 substantially reduce the axial channels produced by the folding of the substrate 100 during the filter rod manufacturing process by creating the binding areas 120, which form airflow barriers and cavities that function as air obstacles that trap gases and solid/particulate matters and produce airstream flow turbulence, reducing the airflow speed and increasing friction coefficient, enhances entrapments for solids and gases as they travel through the filter rods 130. The binding areas or binders 120 become additional aerosol (vapor and particulate compounds) entrapment areas. The increase of entrapments improves the filtration efficiency and effectiveness by producing an enhanced, yet controlled, turbulent airstream flow dynamic, therefore reducing airflow speed, enhancing airflow resistance and friction, and by increasing the surface area for enhanced entrapment propertied and filtration efficiency.

2. Filter Hardness and Mechanical Strength

The filter substrate 100 and binding filter rod making process 110 help tremendously with the improvement of the filter physical attribute called hardness. Filter rods must give the consumers a pleasant and an ergonomic mouthpiece designed to accommodate the product, not too hard, therefore uncomfortable, and not too soft, becoming unstable, or not firm enough to be properly utilized. For products where a low pressure drop (low resistance to draw) is desired, the amount of substrate may not be enough to deliver a proper filter hardness. The filter substrate 100 and binding filter rod making process 110 fill the air gaps between the various layers of substrate 100 with the binding areas/binders 120, creating rigid connections and additional mechanical support, enhancing therefore the overall filter structure and rigidity.
The mechanical strength improvement has benefits also in filter storage, transportation and manufacturing process.
Higher levels of hardness can be achieved by adding more binding liquid dots/drops/higher impregnation 212 or by increasing the viscosity of the binder without the need of increasing the amount of the substrate 100 utilized to manufacture the filter rod 130.
By being water soluble, the higher concentration of binder does not compromise the biodegradability properties of the filter substrate 100.

3. Visual Appearance

As illustrated in FIG. 5 , it is common to observe the air channeling among filter rods manufactured with paper (mono fiber filter media) and among filter biodegradable substrate (multi-fiber media). The filter substrate 100 and binding filter rod making process 110 address the gaps between the layers of substrate by filling the airways spaces and therefore delivering a better visual appearance to the filter rod before and after being used.
With reference to FIGS. 7-11 , a number of tests performed related to embodiments of the paper/substrate filter rod made without the binding process described herein and a determination of a concentration of selected analytes in cigarette smoke therefrom will be described.
FIG. 7 illustrates a table of test results of two filter rods without binding/Greenbinding™ (filter rod with 108 mm length, filter rod with 126 mm length] of cigarette prototypes that were produced on 2 different constructions and TAR levels (6 mg Tar/27 mm filter plug and 10 mg Tar/21 mm filter plug). The following assessments were performed: visual appearance, physical/analytical parameters (including but not limited to format, weight, filter hardness, pressure drop, tar, smoke nicotine, carbon monoxide, resistance-to-draw), and sensory perception (based on expert panel evaluation). The test results show decreased levels of TAR9.8 (−4.9%) and Nicotine 0.67 (−9.5%) for the 21 mm sample and TAR3.8 (−5.0%) and Nicotine 0.27 (−12.9%) for the 27 mm filter sample when compared against the reference cigarette. Further, the test results show a substantial increase of carbon monoxide for the 21 mm sample 14.3 (55.4%) and also a substantial increase of Carbon Monoxide of 7.6 (61.7%) for the 27 mm sample when compared against the reference cigarette. Two key results from this testing include: 1) the results of physical analysis are mostly in line with the ones of prototypes from Cellulose Acetate filters, and Carbon monoxide (CO) parameter is out of ISO limits. The actual result shows 14.3 mg/cig. The tests were performed based on the filter specifications shown in FIG. 8 .
FIGS. 9 and 10 illustrate tables of test results for filter rods produced with different specifications without binding/Greenbinding™ (trays with 108 mm length, trays with 126 mm length) and using embossing/Greenbossing™ brand embossing process/technology. Cigarette prototypes were produced and the following assessments were performed: visual appearance, physical/analytical parameters (including but not limited to format, weight, filter hardness, pressure drop, tar, smoke nicotine, carbon monoxide, resistance-to-draw), and sensory perception (based on expert panel evaluation). As shown in the table of FIG. 9 , the test results show sample 42981.D delivering an increased level of TAR 10.2 (10.9%) and parity level of Nicotine 0.74 (0%) and sample 42990.D delivering an increased level of TAR 10.2 (10.9%) and marginal decreased level of Nicotine 0.72 (−2.7%) when compared to the reference cigarette. The test results in FIG. 9 also show samples 42981.D and 42990.D delivering a substantial increase of Carbon Monoxide of 13.8 (50.0%) when compared to the reference cigarette. As shown in the table of FIG. 10 , the test results show samples 43012.D and 43013.D delivering reduction in TAR 4.6 (−25.8%) and 4.8 (−22.6%) and in Nicotine 0.34 (−27.7%) and 0.35 (−25.5%) when compared to the reference cigarette. The test results in FIG. 10 also show samples 43012.D and 43013.D delivering an increase of Carbon Monoxide of 8.1 (19.1%) and 8.2 (20.6%) when compared to the reference cigarette. Three key results from this testing include: 1) the results of physical analysis are mostly in line with the ones of prototypes from Cellulose Acetate filters; Carbon monoxide (CO) parameter is out of ISO limits for full flavor construction prototypes (13.8 vs. 10 mg/cig ISO limit); and 3) light constructions may be suitable only for cigarette with Tar level equal or less than 6 mg/cig to be compliant with Market limitation for CO level. The tests were performed based on filter specifications shown in FIG. 11 . The test results shown in FIGS. 7, 9, and 10 demonstrate that prior to the binding process described herein, there was an issue with high CO (Carbon Monoxide) levels due to CO filtration inefficiencies.
With reference to FIGS. 12-15 , a number of tests performed related to embodiments of the paper/substrate filter rod made by the binding process described herein and a determination of a concentration of selected analytes in cigarette smoke therefrom will be described with FIG. 12 illustrating a table of detection limits, FIGS. 13A and 13B illustrating tables of sample results, FIG. 14 illustrating a table of sample coding, and FIG. 15 illustrating a table of a constituents list for the performed tests.
Five samples (Control (Cellulose Acetate Filter—1R6F, Baseline (Greenbossing™), 8% Greenbinding™, 16% Greenbinding™, and 24% Greenbinding™) as listed in Table I of FIG. 14 were tested. Five replicates per sample were used for testing. 1R6F cigarettes (whole tobacco rod and original tipping paper) were used for the Baseline, 8%, 16% and 24% Greenbinding™ SKUs and only the filter element without plugwrap were replaced. All physical parameters and chemical characteristics of the 1R6F were preserved except the filter rods which were replace from Cellulose Acetate filters by the filter substrate or paper 100 with the binding process described herein.
Lists of specific compounds of interest identified in each analyte group to be reported are listed in Table II of FIG. 15 . Analytical method summaries and results are shown and/or discussed herein. The laboratory control type used for acceptance is included on each table for a given test method, if applicable. The testing and data generation shown herein was performed by Mckinney Specialty Labs, LLC of Richmond, Virginia in accordance with AM-001.
With reference to FIGS. 13A and 13B, which include the tables of sample results for a number of tests performed related to the embodiments of the paper/substrate filter rod made by the binding/Greenbinding™ brand process described herein, baseline samples delivered increased levels of TAR 9.21 (1.7%) and Carbon Monoxide 11.5 (8.5%) and reduction of Nicotine 0.61 (−14%), 8% Greenbinding™ samples delivered decreased levels of TAR 8.85 (−2.3%) and Nicotine 0.61 (−14.7%), and a marginal increase of Carbon Monoxide 10.8 (1.9%) when compared to the Control cigarettes, 16% Greenbinding™ samples delivered decreased levels of TAR 7.77 (−14.2%) and Nicotine 0.54 (−24.9%) and marginal increase/parity of Carbon Monoxide 10.7 (0.9%) when compared to the Control cigarettes, and 24% Greenbinding™ samples delivered increased levels of TAR 9.64 (6.4%) and an increase of Carbon Monoxide 11.2 (5.7%) and a decrease of Nicotine 0.67 (−6.2%) when compared to the Control cigarettes.
The paper/substrate filter rod made by the binding process described herein demonstrates an improved filtration efficiency performance and higher level of Carbon Monoxide (CO) retention as seen in the table of FIG. 8A (Greenbinding™ 8% with CO 1.9%), the table of FIG. 8B (Greenbinding™ 16% with CO 0.9%; Greenbinding™ 24% with CO 5.7%) when compared with filters without the binding process described herein and a substantial filtration performance improvement and Carbon Monoxide retention levels when compared with samples without the binding process described herein.
The paper/substrate filter rod made by the binding process described herein demonstrates the active modulation and filtration efficiency on TAR, Nicotine and especially Carbon Monoxide as seen in FIGS. 13A and 13B when compared with samples without the binding process described herein, with a noticeable difference and much higher performance on Carbon Monoxide.
Filters containing the paper/substrate filter rod made by the binding process described herein were manufactured using high speed filter making machine which assures the commercial potential of a global scale implementation.
The paper/substrate filter rod made by the binding process described herein is flavor inert, therefore does not add any foreigner tobacco sensorial attributes to the smoke and due to its similarities to the filtration performance of cellulose acetate the consumer experience is maintained once the single-use plastic (cellulose acetate) is replaced by biodegradable filters with the paper/substrate filter rod made by the binding process described herein.
Due to its filtration capability and Carbon Monoxide retention, the paper/substrate filter rod made by the binding process described herein is the only innovative feature able to deliver the established ISO TAR, Nicotine and Carbon Monoxide ceiling limits for EU and therefore allowing immediate migration from single-use plastic to a truly biodegradable, plant-based filter solution.
For combustible smoke analyses, smoking of the products was carried out using SM450 20-port linear analytical smoking machines. Each product was placed into a holder and smoked according to the applicable analytical method(s) and collected on Cambridge filter pads or impingers. Each product was smoked in replicates of five via the ISO smoking regime. The ISO Smoking Regime included products smoked using a 35 mL two second puff every 60 seconds using a bell curve, and ventilation holes were not covered.
Depending on the analysis conducted, analyte concentrations are determined by either an internal or external standard calibration method using the regression equation derived from the calibration curve. Results are then converted and typically reported on a per weight, per device/cigar(ette), or per puff basis. Example calculations are provided below for varying analysis types. Please note in the example calculations, nanograms (ng) are shown, however the results may be expressed in other units (mg, μg, pg). Dilution factors may also be used in some methods depending on the sample preparation procedure.
Please note that approximate Limit of Detection (LOD) and Limit of Quantitation (LOQ) values are calculated using averages for each assay and are not specific to individual samples.
E-liquid and tobacco analysis results may be reported on a mass/mass basis, catch weight basis (ng) or mass/volume (ng/mL) basis. The calculation is as follows:
Analyte Concentration (ng/g)=Concentration (ng/mL)×Dilution Factor×Extraction Volume (mL)/E-Liquid or Tobacco Weight (g)
In instances where results are required to be reported on a dry weight basis (DWB), the moisture content of a sample (expressed as moisture or oven volatiles) can be determined by any one of several different analytical methods. The following calculation is used to convert an “as is” result to a “dry weight basis” result:
$Analyte Concentration (ng / g DWB) = Analyte Concentration (ng / g) \times 100 / (100 - % Moisture)$
The final results for aerosol or smoke analysis may be reported as catch weight basis (ng), ng/puff, ng/cig, ng/device, or ng/g Aerosol Collected Mass (ACM). The final sample concentrations are calculated using the following equations:
Analyte Amount (ng/puff)=Concentration (ng/mL)×Dilution Factor×Extraction Volume (mL)/Total #of Puffs
Analyte Amount (ng/cig or ng/device)=Concentration (ng/mL)×Dilution Factor×Extraction Volume (mL)/Total #of Cigar(ette)s or Devices
Analyte Amount (ng/g ACM)=Concentration (ng/mL)×Dilution Factor×Extraction Volume (mL)/ACM (g)
The LOD and LOQ values are calculated using the same formulas above. The LOD/LOQ value in mass/mL is converted to the final unit by multiplying by the extraction volume and dividing by the preferred unit (grams, puffs, device, etc.). An example calculation is shown below:
Limit of Detection (ng/g)=LOD (ng/mL)×Dilution Factor×Extraction Volume (mL)/E-Liquid or Tobacco Weight (g)
Any method deviation(s) that occurred during the course of this study are discussed further below.
Smoke particulate is collected on a Cambridge filter pad (CFP) and shaken in extraction solution (isopropanol with internal standards). An aliquot of the sample solution is analyzed by gas chromatography (GC) and the water, nicotine, and menthol content of the smoke condensate is determined.
Since water is a measured and significant constituent for this analytical method, environmental water content should be uniform throughout sample collection and analysis. Method blanks are collected by extracting conditioned, unused CFPs. The method blanks are used to determine the concentration of water inherent in the CFPs and extraction solution. The average water content of the method blanks is subtracted from the water content of the sample extracts to obtain the final, corrected water content for each smoke sample.
Nicotine may be separated from other constituents using a packed Carbowax or capillary HP-5 column connected to a Flame Ionization Detector (FID), although the capillary column is preferred. A packed Porapak QS column and Thermal Conductivity Detector (TCD) are used for the determination of water. Menthol is analyzed independently of nicotine due to unique conditioning requirements and a peak interference on the HP-5 column. The packed Carbowax column and FID must be used for menthol determination.
The tar (nicotine free dry particulate matter or NFDPM) is calculated by subtracting nicotine and water from the TPM. Results are typically reported in milligrams per cigarette (mg/cig) for each smoke sample.
Carbon Monoxide (CO) data was generated by Mckinney Specialty Labs in accordance with Mckinney SL method AM-007. The purpose of this procedure is to describe the collection and quantification of carbon monoxide (CO) in the vapor phase of mainstream smoke using a non-dispersive Infrared (NDIR) detector.
This procedure is applicable to the collection and quantification of CO in mainstream smoke from cigarettes and cigars. The range for the method is linear up to six percent by volume for cigarettes and 15 percent volume for cigars.
The mainstream smoke is collected in gas sampling bags attached to the smoking machine. The level of CO present in a smoke sample is quantified with an external standard calibration technique using primary standard gases. Using the number of cigar(ette)s, the cigar(ette) puff count, the puff volume, and ambient conditions, the % CO is converted to milligrams per cigar(ette) (mg/cig).
After reading this description it will become apparent to one skilled in the art how to implement the invention in various alternative embodiments and alternative applications. However, although various embodiments of the present invention will be described herein, it is understood that these embodiments are presented by way of example only, and not limitation.
The above description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles described herein can be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it is to be understood that the description and drawings presented herein represent a presently preferred embodiment of the invention and are therefore representative of the subject matter which is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art.

Claims

We claim:

1. A cigarette filter rod, comprising:

a filter substrate including opposite surfaces;

a plurality of binding areas on at least one of the opposite surfaces,

wherein the filter substrate is folded multiple times into a rod shape and the plurality of binding areas bind at least one of the opposite surfaces together, the binding areas forming airflow barriers that function as air obstacles and cavities that trap gases and particulate matters and produce airstream flow turbulence, reducing airflow speed and increasing friction coefficient, enhancing entrapments for solids and gases as they travel through the filter rods.

2. The cigarette filter rod of claim 1, wherein the filter substrate is crimped, exposing filter substrate fibers and enhancing filtration capability.

3. The cigarette filter rod of claim 1, wherein the filter substrate is embossed with an embossing pattern, promoting filtration performance.

4. The cigarette filter rod of claim 1, wherein the filter substrate is a biodegradable material.

5. The cigarette filter rod of claim 1, wherein the filter substrate includes mono-fiber.

6. The cigarette filter rod of claim 1, wherein the filter substrate includes multi-fiber.

7. The cigarette filter rod of claim 1, wherein the filter substrate includes a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder.

8. The cigarette filter rod of claim 1, wherein the binding areas include an adhesive from one or more of water, glue, plant-based binder, synthetic binder, adherent, and agglutinant.

9. The cigarette filter rod of claim 1, further including a plug wrap that surrounds the filter substrate.

10. A method of manufacturing the cigarette filter rod of claim 1, comprising:

providing the filter substrate;

adding binding material at a plurality of areas on at least one of the opposite surfaces of the filter substrate;

folding the filter substrate multiple times into an elongated rod so that the plurality of binding areas bind at least one of the opposite surfaces together where the binding material was added to the plurality of areas;

cutting the elongated rod into a plurality of individual filter rods.

11. The method of claim 10, wherein adding binding material including at least one of spraying a distribution of dots of binding material on at least one of the opposite surfaces of the filter substrate, spray jet, atomization, and continuous flow nozzle.

12. The method of claim 11, further including funneling the sprayed filter material with a funnel.

13. The method of claim 10, further comprising crimping filter substrate, exposing filter substrate fibers and enhancing filtration capability, prior to adding the binder material to the filter substrate.

14. The method of claim 10, further comprising embossing the filter substrate with an embossing pattern, promoting filtration performance, prior to adding the binder material to the filter substrate.

15. The method of claim 10, wherein the filter substrate includes a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder.

16. The method of claim 10, wherein the binder material is an adhesive from one or more of water, glue, plant-based binder, synthetic binder, adherent, and agglutinant.

17. The method of claim 10, further comprising surrounding the filter substrate with a plug wrap.

18. A method of using the cigarette filter rod of claim 1, comprising:

providing a cigarette including a filter rod that is one of the individual filter rods;

forming airflow barriers and cavities with the binding areas that function as air obstacles that trap gases and particulate matters and produce airstream flow turbulence, reducing airflow speed and increasing friction coefficient, enhancing entrapments for solids and gases as they travel through the filter rod.

19. The method of claim 18, wherein the filter substrate includes a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder.

20. The method of claim 18, wherein the binding areas include an adhesive from one or more of water, glue, plant-based binder, synthetic binder, adherent, and agglutinant.