JP5438760B2 - Apparatus and associated method for forming filter parts of smoking articles, and smoking articles made therefrom - Google Patents

Description

  Embodiments of the present invention relate to the formation of tobacco products, such as smoking articles (eg, cigarettes), and more particularly to an apparatus and associated method for inserting an adsorbent material into a cigarette filter.

  Popular smoking articles, such as cigarettes, have a generally cylindrical rod-like structure, wrapping a packing, roll, or column of smokable material such as tobacco cuts (eg, cut filler form) Thus, a so-called “smokable rod” or “tobacco rod” is formed. Typically, cigarettes have a cylindrical filter element that is aligned with the tobacco rod and ends in an end-to-end relationship. Typically, the filter element comprises a plasticized cellulose acetate tow surrounded by a paper material known as a “plug wrap”. Some filter elements can include polyhydric alcohols. Typically, the filter element is attached to one end of the tobacco rod using a surrounding wrapping material known as “chipping paper”. A description of cigarettes and their various components is given in Davis et al. (Co-edition), “Tobacco Production, Chemistry and Technology” (1999). Cigarettes are used by smokers by igniting one end and burning a tobacco rod. At this time, the smoker receives mainstream smoke into his / her mouth by inhaling at the opposite end (eg, filter end) of the cigarette.

  Some cigarettes incorporate a filter element in which an adsorbent material such as activated carbon or charcoal material (collectively, carbonaceous material) in the form of fine particles or granules (ie, powder) is dispersed. For example, an example cigarette filter can have a plurality of segments, and at least one of the segments can include particles of a carbon-rich material. Various types of filters, including charcoal particles or activated carbon type materials, are described in Touy, U.S. Pat. No. 2,881,770, Seligman et al., U.S. Pat. No. 3,101,723, Irby et al., U.S. Pat. U.S. Pat. No. 3,236,244, U.S. Pat. No. 3,311,519 to Touy et al., U.S. Pat. No. 3,347,247 to Lloyd, U.S. Pat. 780, Davis et al. US Pat. No. 3,370,595, Sublett et al. US Pat. No. 3,413,982, Dock US Pat. No. 3,602,231, Tiglebeck U.S. Pat. No. 3,972,335, Blackley et al. U.S. Pat. No. 5,360,023, Veluz. US Pat. No. 6,537,186, US Patent Application Publication No. 2007/0056600 to Coleman, III et al., International Publication No. 2006/064371 to Banerjea et al., And International Publication No. 2006/64371 to Jupe et al. No. 051422, which are incorporated herein by reference.

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"Tobacco Production, Chemistry and Technology" (1999) by Davis et al. J. et al. Amer. Chem. Soc. Vol. 60 (2), pp. 309-319 (1938) Marsh (edition), “Activated Carbon Compendium” (2001) “Chemical and Biological Studies on New Cigarette Prototypes that Heat Institute of Burn Tobacco”, R.A. J. et al. Reynolds Tobacco Company Monograph (1988) “Inhalation Toxiology”, 12: 5, p. 1-58 (2000) Johnson, “Development of Cigarette Components to Meet Industry Needs”, 52nd T. S. R. C. (September 1998) "Polyacrylonitrile (PAN) Carbon Fibers Industrial Capability Assessment: OUSD (AT & L) Industrial Policy" (October 2005) Leffingwell et al., “Tobacco Flavoring for Smoke Products” J. et al. Reynolds Tobacco Company (1972)

  As noted above, such carbonaceous material types are typically in the form of particles or granules when incorporated into the filter element. For example, carbonaceous material granules can be incorporated into a “dalmation” type filter area using common types of techniques used in the manufacture of conventional dalmation filters. Manufacturing techniques for dalmation filters are known, and typical dalmation filters are available from Filtrona Greensboro Inc. Commercially available. Alternatively, granules of carbonaceous material can be incorporated into a “cavity” type filter region using common types of techniques used in the manufacture of conventional “cavity” filters. Alternatively, other known types of techniques and devices for producing filter segments that include granular material can be suitably modified to introduce carbonaceous material into the filter segment. However, such techniques are primitive in that the particulates or granules of carbonaceous material are roughly inserted into the filter element as a free powder or slurry, and such processes are inconsistent, for example, It can be said that it is wasteful and "messy".

  Accordingly, a need exists for an apparatus and method for inserting adsorbent material into a filter segment / filter element of a smoking article in a manner that facilitates a cleaner and more efficient process. Such an apparatus and method desirably should be able to insert various forms of adsorbent material into the filter element.

  The above and other needs are met by embodiments of the present invention that provide in accordance with various aspects an apparatus and method for inserting an adsorbent retained by a carrier material into a filter rod member of a smoking article. Accordingly, one aspect is an apparatus for forming a filter rod used in the manufacture of a smoking article, wherein at least a portion of an adsorbent material on each rod portion when the rod is subdivided longitudinally into rod portions. In which each rod has an adsorbent retained by a carrier material inserted into the filter rod along the length of the filter rod. The apparatus includes equipment for supplying a continuous feed of filter material (eg, a filter tow processing unit configured to supply filter tow to a continuous rod forming unit). In addition, exemplary devices include hopper and rotating wheel configurations such as those disclosed in, for example, Thomas et al. US Patent Application Publication No. 2007/0068540 (incorporated herein by reference). In order to supply the carrier material holding the filter material to the filter material, a filter supply facility can be operatively engaged. Other configurations for inserting objects into the filter material are described, for example, in Green, Jr. U.S. Pat. No. 4,862,905 (ie, insertion of individual strand portions), Thomas et al. U.S. Patent Application Publication No. 2007/0068540 (ie, insertion of capsules), U.S. Pat. No. 11 / 461,941 (ie, continuous strand insertion), Stokes et al. US Patent Application No. 11 / 760,983 (ie, continuous strand insertion), and Lanier, Jr. U.S. Pat. No. 7,074,170, all incorporated herein by reference.

  A continuous feed of filter material is formed into a continuous cylindrical rod member, for example by a rod forming unit. The carrier material holding the adsorbing substance is inserted into the rod member by the insertion unit. In some embodiments, a rod splitting unit is formed to subsequently form a continuous rod, a plurality of filter rods or rod portions or filter elements, each rod portion including at least a portion of an adsorbent material. Can be subdivided at predetermined intervals.

  In some aspects, a method of forming a cigarette filter rod member includes forming a continuous supply of filter material into a continuous cylindrical rod member and adsorption retained by the carrier material. Inserting the material into the rod member such that the adsorbent material is disposed within the rod member. Such a method can further include dividing the rod member into a plurality of rod portions on the longitudinal axis of the rod member such that each rod portion includes at least a portion of the adsorbent material.

  In one aspect, the invention comprises at least one filter segment having one or more composite fiber structures embedded therein, the composite fiber structure comprising carrier fibers and adsorbent fibers (eg, carbonaceous fibers). Thus, a cigarette filter in which the adsorbent fibers contain an adsorbent material is provided. Typical carbonaceous fibers can be made by carbonization of precursor fibers such as phenol fibers, cellulose fibers, rayon fibers, acrylic fibers, pitch fibers, and the like. In certain embodiments, the filter includes one or more segments of fibrous tow material such as cellulose acetate tow.

  The bicomponent fiber structure can include multiple carrier fibers or multiple adsorbent fibers. One or both of the carrier fibers and adsorbent fibers may be in the form of a knitting yarn. The entire composite fiber structure may be in the form of a knitting yarn. The carrier fiber functions as a carrier for the adsorbent fiber, for example, by winding the adsorbent fiber around the carrier fiber.

  In another aspect, the present invention provides a cigarette filter comprising at least one filter segment in which at least one degradable fiber (such as a biodegradable fiber) is embedded. The fiber may be any strand, yarn, or knitting yarn having any of a variety of cross sections, such as a circular cross section or a flat cross section. The fibers can make a visual difference or a texture / tactile difference in the filter element. The fiber itself can change the characteristics or properties of the smoke passing through the filter, or optionally an additive that can change the characteristics or properties of the smoke (eg one or more adsorbents, flavorings, deodorants Agent, or a combination thereof). Additives are absorbed into the fiber structure, the additive is coated onto the fiber structure, the solid additive is attached to the surface of the fiber, or the additive is in the form of a fiber (eg, carbonaceous fiber) Can be retained on the degradable fiber using various techniques, such as wrapping around the degradable fiber, or can be combined with the degradable fiber.

  Typical biodegradable fibers include cellulose fibers, polyvinyl alcohol, aliphatic polyesters, aliphatic polyurethanes, cis polyisoprene, cis polybutadiene, polyhydroxyalkanoic acids, polyanhydrides, and copolymers and mixtures thereof. Can be mentioned. In one embodiment, the biodegradable fiber is bamboo fiber or polylactic acid fiber.

  The present invention further provides a smoking article incorporating a filter element as described herein, such as a smoking article comprising a rod of smokable material wrapped with a packaging material attached to a cigarette filter according to the present invention. Including.

  In this way, embodiments of the present invention provide significant advantages as disclosed in greater detail herein.

  To assist in understanding embodiments of the present invention, reference is made to the accompanying drawings. The drawings are not necessarily to scale. The drawings are only examples and should not be construed as limiting the invention.

1 is an exploded perspective view of a smoking article having the form of a cigarette, showing the cigarette smokable material, packaging material parts, and filter elements. FIG. 1 is a cross-sectional view of a filter element according to one embodiment of the present invention incorporating an adsorbent material. FIG. 2 is a cross-sectional view of a smoking article having the form of a cigarette, showing the cigarette smokable material, the packaging material component, and the adsorbent-containing filter element. FIG. 2 is a cross-sectional view of a smoking article having the form of a cigarette, showing the cigarette smokable material, the packaging material component, and the adsorbent-containing filter element. FIG. 2 is a cross-sectional view of a smoking article having the form of a cigarette, showing the cigarette smokable material, the packaging material component, and the adsorbent-containing filter element. FIG. 2 is a cross-sectional view of a smoking article having the form of a cigarette, showing the cigarette smokable material, the packaging material component, and the adsorbent-containing filter element. 1 is a schematic view of a rod manufacturing apparatus according to an embodiment of the present invention including a portion of a filter tow processing unit, a source of adsorbent material held by a carrier material, an insertion unit, and a filter rod forming unit. FIG. 3 is a cross-sectional view of a filter element incorporating carbonaceous fibers held by carrier fibers. It is a perspective view of the carbonaceous fiber hold | maintained by the carrier fiber.

  The present invention will now be described in more detail below with reference to the accompanying drawings. The present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The same numbers refer to the same elements throughout. As used in the specification and claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. Including.

  Referring to FIG. 1, there is shown a smoking article 10 in the form of a cigarette and having certain representative components of the smoking article produced or formed according to the present invention. The cigarette 10 includes a generally cylindrical rod 12 that contains a fill or roll of smokable filler material contained within a surrounding packaging material 16. The rod 12 is conventionally called a “cigarette rod”. Both ends of the tobacco rod 12 are open, and the smokable filler material is exposed. The cigarette 10 is shown as having one optional band 22 (eg, a printed coating that includes a filming agent such as starch, ethyl cellulose, or sodium alginate) that is applied to the packaging material 16. A cigarette rod is wrapped transversely to the longitudinal axis of the cigarette. That is, the band 22 provides a transverse region relative to the longitudinal axis of the cigarette. The band 22 may be printed on the inner surface of the packaging material (i.e., facing the smokable filler material) or, although less preferred, may be printed on the outer surface of the packaging material. A cigarette can have a packaging material that has only one optional band, but a cigarette has a package with additional optional bands that are spaced two, three, or more in number. You may have material.

  An end of the tobacco rod 12 is an ignition end 18, and a filter element 26 is disposed at the suction end 20. Filter element 26 is positioned adjacent to one end of tobacco rod 12 such that the filter element and tobacco rod are axially aligned in an end-to-end relationship, and preferably abut one another. The filter element 26 may have a generally cylindrical shape, and its diameter may be essentially equal to the diameter of the tobacco rod. Both ends of the filter element 26 allow the passage of air and smoke.

  In some cases, the filter element 26 may be configured as shown in FIG. 2, where the filter is a first filter segment disposed adjacent one end of the tobacco rod 12. 32. The first filter segment 32 includes a filter material 40 (eg, cellulose acetate tow impregnated with a plasticizer such as triacetin). In other cases, the filter element 26 may not be divided into segments as shown in FIG. Still referring to FIG. 2, an adsorbent / particle 50 can be inserted into the filter material 40 of the first segment. In the past, such an adsorbent 50 has been roughly inserted into the filter material 40. That is, the adsorbing material 50 was inserted in the form of free fine particles such as powder or slurry. In addition, a breakable or rupturable capsule containing a plurality of particles 52 or flavoring agents may optionally be dispersed in the first segment of filter material 40. In some embodiments where a carbonaceous material is used as the adsorbent material 50, at least a portion of the carbonaceous material, and typically substantially all of the carbonaceous material, comprises an effective amount of a polyol ester (eg, triacetin). In intimate contact with a mixture with a polyol (eg, propylene glycol). If desired, the filter element can include other components that have the ability to change the characteristics of mainstream smoke passing through the filter element. See, for example, US Patent Application Publication No. 2004/0237984 to Figlar et al., US Patent Application Publication No. 2005/0268725 to Schluter et al., US Patent Application Publication No. 2006/0130861 to Luan et al., And Luan et al. U.S. Patent Application Publication No. 2006/0174899. These are incorporated herein by reference.

  Further, the filter element 26 can have a second filter segment 36 disposed longitudinally with respect to the first segment 32 and disposed at the extreme end of the mouthpiece of the cigarette 10. The second filter segment 36 includes a filter material 48 (eg, cellulose acetate tow impregnated with a plasticizer such as triacetin) that is surrounded by a plug wrap material 28 having a longitudinally extending surface surrounding it. Yes. The second filter segment 36 may be substantially free of adsorbent and destructible or ruptureable capsules, i.e. such additives when viewed at the extreme end of the filter element 26 inlet. Cannot be visually recognized.

  Filter element 26 is surrounded by a layer of outer plug wrap 28 along the outer periphery or longitudinal circumference of the filter element. The outer plug wrap 28 covers each of the first filter segment 32 and the second filter segment 36, resulting in a filter element that combines the two segments.

  The filter element 26 is attached to the tobacco rod 12 using a tipping material 46 (eg, essentially non-breathable tipping paper) that surrounds both the entire length of the filter element 26 and the region of the adjacent tobacco rod 12. The inner surface of the chipping material 46 is secured to the outer surface of the plug wrap 28 and the outer surface of the tobacco rod wrapping material 16 using a suitable adhesive, thus connecting the filter element and tobacco rod to each other. See also the tipping materials and configurations described in US Patent Application Publication No. 2008/0029111 to Dube et al., Which is incorporated herein by reference.

  A vented or air diluted smoking article can include an optional air dilution mechanism, such as a series of perforations 30 each extending through the tipping material and the plug wrap. The optional drilling 30 shown in FIG. 1 can be made by a variety of techniques known to those skilled in the art, such as laser drilling techniques. Alternatively, so-called off-line air dilution techniques (eg, by use of porous paper plug wrap and pre-perforated tipping paper) may be used. In an air diluted or ventilated cigarette, the amount or degree of air dilution or ventilation may vary. In many cases, the amount of air dilution in an air diluted cigarette is greater than about 10%, typically greater than 20%, often greater than 30%, and sometimes greater than 40%. Typically, the upper limit of air dilution in air diluted cigarettes is less than 80% and often less than 70%. As used herein, the term “air dilution” refers to the volume of air sucked through the air dilution means, of air and smoke that is sucked through the cigarette and exits the cigarette mouth end. Ratio to total volume (expressed as a percentage).

  In use, the smoker ignites the ignition end 18 of the cigarette 10 using a match or cigarette writer. Thus, the smokable material 12 begins to burn. The mouth end 20 of the cigarette 10 is placed on the lips of the smoker. Thermal decomposition products (eg, tobacco smoke components) produced by the combustible smokable material 12 pass through the cigarette 10 and through the filter element 26 into the smoker's mouth. When inhaled, a certain amount of the gaseous component of the mainstream smoke is removed or neutralized from the mainstream smoke by the adsorbent material 50 in the filter element 26. Filters that include such an adsorbent material 50, such as carbonaceous filter components (eg, activated carbon particles), have the ability to capture a wide range of mainstream tobacco smoke gas phase components. If desired, the smoker can optionally squeeze the filter element before, during or after smoking. As a result, at least a portion of the optionally breakable capsule remaining unbroken is broken and the flavor particles 52 contained within the capsule are released.

  Other filter element configurations may be manufactured or formed without departing from embodiments of the present invention. For example, the filter element 26 can include more segments than the two segments described in FIG. Although less preferred, the filter element 26 can also include a cavity formed between two segments of filter material, in which the adsorbent 50 and optional flavoring 52 are mixed. While it is preferred to avoid positioning the filter segment containing the adsorbent material 50 and optional flavoring 52 at the mouth end of the filter, the filter segment containing these additives must necessarily be located at the tobacco end of the filter. There is no. Rather, the filter segment in which the additive is dispersed can be more centrally located in the filter element 26, with one or more filter segments that do not contain the additive facing each end.

  The dimensions of an exemplary cigarette 10 may vary. A preferred cigarette is rod-shaped and can have a diameter of about 7.5 mm (eg, an outer circumference that is about 20 mm to about 27 mm, often about 22.5 mm to about 25 mm), and about 70 mm. Can have a total length of from about 80 mm to about 100 mm. The length of the filter element 30 may vary. A typical filter element can have a total length of from about 15 mm to about 40 mm, often from about 20 mm to about 35 mm. In a typical dual segment filter element, the downstream or inlet end filter segment often has a length of about 10 mm to about 20 mm, and the upstream or tobacco rod end filter segment is often In some cases has a length of about 10 mm to about 20 mm.

  If desired, a suitable catalyst compound can be incorporated into one or more segments of the filter element 26, for example, to convert carbon monoxide to carbon dioxide. Typical catalysts include noble metals (eg, silver, gold, platinum), metal oxides, ceramics, and mixtures thereof.

  As shown in FIG. 2, one filter element 26 that can be formed in accordance with the present invention includes a plurality of longitudinally extending segments. Each segment can have different properties and can include different materials that can filter or adsorb particulate matter and / or gas phase compounds from mainstream smoke. Typically, the filter elements of the various aspects of the present invention include 2 to 6 segments, often 2 to 4 segments. In some cases, the filter element 26 can include a mouth end segment and a tobacco end segment, with adsorbent material 50 and flavorant 52 dispersed in the tobacco end segment.

  As shown in FIG. 2, the filter element can include an adsorbent / particle 50. Such adsorbent material 50 may be a material having a relatively large surface area that can adsorb smoke constituents without high specificity, or may have a higher specificity, such as an ion exchange resin. The material which adsorb | sucks the specific compound which has may be sufficient. Exemplary adsorbent material types can include activated carbon, molecular sieves (eg, zeolite and carbon molecular sieves), clays, ion exchange resins, activated alumina, silica gel, gypsum, and combinations thereof. Any adsorbent material or mixture of materials having the ability to change the characteristics or properties of the mainstream smoke passing through the filter element can be used.

  Typical ion exchange resins include polymer backbones such as styrene-divinylbenzene (DVB) copolymers, acrylates, methacrylates, phenol-formaldehyde condensates, and epichlorohydrin-amine condensates, and multiple attached to the polymer backbone. And may be a weakly basic anion exchange resin or a strongly basic anion exchange resin. As a commercial embodiment of such a resin, Mitsubishi Chemical Corp. An ion exchange resin called DIAION® (eg, WA30 and DCA11), commercially available from Rohm and Haas, an ion exchange resin called DUOLITE® (eg, DUOLITE® A7), and China Of Dalian Trico Chemical Co. XORBEX, which is commercially available from

A preferred adsorbent is a carbonaceous material that is a substance composed primarily of carbon, and the preferred carbonaceous material is substantially entirely composed of carbon. Typically, the carbonaceous material is greater than about 85% by weight, typically greater than about 90% by weight, often greater than about 95% by weight, and more often about 98% by weight. Contains carbon in excess. The carbonaceous material may be in the form of charcoal, but most preferably is an activated carbon material. The activated carbon material is a high surface area material. A typical activated carbon material has a surface area of J. Amer. Chem. Soc. Vol. 60 (2), pp. 309-319 (1938), measured using the Brunaver, Emmet and Teller (BET) method, greater than about 200 m ² / g, often greater than about 1000 m ² / g, and more often More than about 1500 m ² / g. Suitable examples of such carbonaceous materials are, for example, White et al., WO 2007/104908, Awty et al., WO 2007/093757, Fiebelkorn, WO 2007/010249, Lee. International Publication No. 2007/028957, Nunziata et al., International Publication No. 2006/136950, International Publication No. 2006/103404, Cashmore et al., International Publication No. 2005/118133, Bhattacharya et al. Publication No. 2005/112670, International Publication No. 2005/082180 of Sampson et al., International Publication No. 2 of Branton et al. 05/023026, Bray et al. International Publication No. 2004/095957, Grzonka International Publication No. 2004/014161, Ditrich et al. International Publication No. 2003/092416 Pamphlet, Abhulimen et al. Schluter et al., International Publication No. 2003/051144, Abhulimen et al., International Publication No. 2003/034848, Busby et al., International Publication No. 2001/041590, and Zhuang et al., US Pat. No. 7,370, No. 657 is disclosed.

  Filter element 26 may include an effective amount of adsorbent material 50, such as an effective amount of activated carbon. An effective amount is an amount that, when contained within a filter element 26, changes the mainstream smoke of the cigarette containing that filter element 26 by some desired degree. For example, a cigarette filter element comprising activated carbon particles or granules can function to reduce the production of certain gas phase components of mainstream smoke passing through the filter element. Typically, the amount of carbonaceous material or other adsorbent in the filter element is at least about 20 mg, often at least about 30 mg, and more often at least about 40 mg, by dry weight. It is. Typically, the amount of carbonaceous material or other adsorbent 50 in the filter element is about 500 mg or less, generally about 400 mg or less, often about 300 mg or less, by dry weight. Yes, more often about 200 mg or less.

  The carbonaceous material can be derived from synthetic or natural sources. Carbonized materials such as rayon or nylon and subsequent treatment with oxygen can result in activated carbonaceous materials. Materials such as wood and coconut shells can be carbonized and subsequently treated with oxygen to yield activated carbonaceous material. The level of carbon activity may vary. Typically, the carbon can have an activity of about 60 to about 150 Carbon Tetrachloride Activity (ie, carbon tetrachloride attached weight percent). Preferred carbonaceous materials are bituminous coal, tobacco material, softwood pulp, hardwood pulp, coconut shell, almond shell, grape seed, walnut shell, macadamia shell, kapok fiber, cotton fiber, cotton It is produced by carbonizing or pyrolyzing linters, etc. Examples of suitable carbonaceous materials are Calgon Corp. Activated coconut shell based carbon, commercially available as PCB and GRC-11 from PICA or as G277 from PICA, Calgon Corp. Coal-based carbon commercially available from S-Sorb, Sorbite, BPL, CRC-11F, FCA, and SGL, from wood based commercially available from Westvaco as WV-B, SA-20, and BSA-20 Carbon, Calcorp Corp. Carbonaceous materials commercially available from HMC, ASC / GR-1, and SC II, Witco Carbon No. commercially available from Rohm and Haas. 637, AMBERSORB 572, or AMBERSORB 563 resins, and Prominent Systems, Inc. There are various activated carbon materials commercially available from. Other carbonaceous materials include White et al. U.S. Pat. No. 4,771,795 and Clearman et al. U.S. Pat. No. 5,027,837, and European Patent Publication No. 236,922. It is described in European Patent Application Publication No. 419,733 and European Patent Application Publication No. 419,981.

  Preferred carbonaceous materials are Calgon Carbon Corporation, Gowishankar Chemicals, Carbon Activated Corp. , And General Carbon Corp. It is activated carbon of the kind of coconut shell available from such manufacturers. See also, for example, Marsh (ed.), “Activated Carbon Compendium” (2001), incorporated herein by reference.

  Some carbonaceous materials include transition metals (eg, silver, gold, copper, platinum, and palladium), nanoparticles, potassium bicarbonate, tobacco extract, polyethyleneimine, manganese dioxide, eugenol, and 4-ketononanoic acid The material can be impregnated with. The carbon composition can further include one or more fillers such as semolina. Grape seed extract may be included in the filter element 20 as a free radical scavenger. Sintered or foamed carbon materials (see, for example, US Pat. No. 7,049,382 to Haftka et al.) And pleated webs (eg, US Patent Application Publication No. 2008/0092912 to Robinson et al.). Specification and Coleman, III et al., US 2007/0056600) is another option for incorporating adsorbent material 50 into filter element 20.

  Various types of charcoal and activated carbon materials suitable for inclusion in cigarette filters, various other filter element component materials, various types of cigarette filter element configurations and formats, and carbonaceous materials included in cigarette filter elements Various modalities and methods for this are described in Berger et al. US Pat. No. 3,217,715, Berger et al. US Pat. No. 3,648,711, Sexstone US Pat. No. 3,957,563. US Pat. No. 4,174,720 to Hall, US Pat. No. 4,201,234 to Neukomm, US Pat. No. 4,223,597 to Lebert, US patent to Perfetti et al. No. 5,137,034, U.S. Pat. No. 5,360, Blackley et al. 23, Gentry et al., US Pat. No. 5,568,819, Arterbery et al., US Pat. No. 5,622,190, Veluz, US Pat. No. 6,537,186, Xue U.S. Pat. No. 6,584,979, Jupe et al. U.S. Pat. No. 6,761,174, Paine III U.S. Pat. No. 6,789,547, Bereman U.S. Pat. 789,548, Jupe et al., US 2002/0166563, Xue et al., US 2002/0020420, Xue et al., US 2003/0200973. US Patent Application Publication No. 2003/0154993 to Paine et al., US Patent Application Publication to Xue et al. No. 2003/0168070, U.S. Patent Application Publication No. 2004/0194792 to Zhuang et al., U.S. Patent Application Publication No. 2004/0226569 to Yang et al., U.S. Patent Application Publication No. 2004/0237984 to Figlar et al. U.S. Patent Application Publication No. 2005/0133051 to Luan et al., U.S. Patent Application Publication No. 2005/0049128 to Buhl et al., U.S. Patent Application Publication No. 2005/0066984 to Crooks et al., Luan. U.S. Patent Application Publication No. 2006/01444410, US Patent Application Publication No. 2006/0180164 of Paine, III et al., US Patent Application Publication No. 2007/0056600 of Coleman, III et al., White Europe Patent No. Application Publication No. 579,410, and are described in WO 2006/064371 pamphlet of Banerjea et al, which are incorporated herein by reference. A representative type of cigarette having a filter element that includes a carbonaceous material is Philip Morris Inc. "Benson & Hedges Multifilter" (commercially available as a trial sale brand of Philip Morris Inc. known as "Marlboro Ultra Smooth" in Florida in 2005) and "Mil Seven" of Japan Tobacco Inc.

  The above is related to inserting free particulates or granules of carbonaceous material into the filter element as free powder or slurry that can be inconsistent, wasteful, inefficient and / or "messy". In view of the above problem, one aspect of the present disclosure is that after the adsorbent material 50 is engaged with the carrier material 55, the resulting assembly is passed to the filter element 26, as shown, for example, in FIGS. Insert (and insert into a continuous filter rod before being cut longitudinally to form multiple filter elements 26). By selecting the appropriate carrier material 55, for example, improved manufacturing can be facilitated by more effectively and efficiently inserting the new “captured” adsorbent material 50 into the filter element 26. That is, the adsorbent 50 is carried by the carrier material 55 when inserted into the filter element 26. In some embodiments, a pellet that allows the carrier material 55 to receive and “hold” adsorbent material 50, for example, to facilitate insertion into the filter element 26 in a cleaner and more effective manner. (FIG. 3A), capsules (FIG. 3B), tubes (FIG. 3C), continuous elongated structures, continuous bands, strands, etc. (FIG. 3D). In some embodiments, individual or multiple forms of carrier material 55 can be inserted into the filter element 26. For example, individual or multiple capsules, tubes, pellets, etc., and combinations thereof can be inserted into the filter element 26 according to various aspects.

  In some cases, the carrier material 55 can include a matrix material (eg, a polymer material, etc.) that can be impregnated with the adsorbent material 50 (ie, the adsorbent material 50 is suspended in the matrix material, Alternatively, the adsorbent 50 can be carried by the matrix material to the filter element 26 along with the matrix material. For example, in some embodiments, the matrix material is impregnated with an adsorbent material 50, such as, for example, a carbonaceous material (eg, activated carbon, charcoal) dispersed, or otherwise having an adsorbent material 50. Density or low density polymeric materials (eg, polyethylene or polypropylene) can be included. Preferably, the adsorbent material 50 is dispersed relatively uniformly, but such uniform dispersion is not absolutely necessary. In embodiments where the carrier material 55 is formed of a tubular or capsule-like member, the adsorbent material 50 is tubular or capsule-like so that it can be accommodated by the tubular or capsule-like member upon insertion into the filter element 26. Can be inserted into the shaped member. In embodiments where the carrier material 55 is formed as a continuous elongate structure, the adsorbent material 50 is engaged with the continuous elongate structure so that the continuous elongate structure can be transported to the filter element 26. Can be brought into contact, contacted or otherwise interacted. In embodiments where the carrier material 55 is formed as a continuous band, the continuous band contains the adsorbent material 50 (ie, similar to a “tube”) for insertion into the filter element 26. It can be wound around the adsorbent material 50 in the longitudinal direction.

  Thus, the carrier material 55 causes the adsorbent material 50 to be compared to the free powder, granule, or particulate form of the adsorbent material 50 that is inserted into the filter element 26 of the smoking article in some prior art processes. A form that can generally be characterized as a storage or capture medium for the adsorbent 50 that holds the adsorbent 50 in a relatively secure manner so that it can be delivered to the filter element / filter rod 26 in a trapped manner by the material 55. Can have. Thus, the adsorbent 50 is retained in a manner that is “cleaner”, more consistent and efficient than the method of guiding the free powder adsorbent 50 or slurry thereof to the filter element 26. Insertion or introduction of the carrier material 55 into the filter element 26 can be achieved (i.e., because the adsorbent 50 is held "to be trapped", dirt, spills, overflow, contamination, cross contamination, Etc.) Such benefits can result in, for example, reduced maintenance, faster processes, higher efficiency, and / or more consistent delivery of adsorbent material 50, and improved safety. Furthermore, the carrier material 55 can be rapidly configured in any manner suitable to facilitate insertion into the individual filter elements 26. Another advantage is that a consistent size and / or amount of adsorbent can be introduced into the filter material of the filter element of the smoking article, can be partially dispersed, can be placed, closely located, , Can be positioned within, can be extended substantially throughout, or can be otherwise engaged. In some cases, a matrix material such as a gel-like material or other suitable material can be included in a form that allows the adsorbent material 50 to be incorporated into the individual filter elements 26 by, but not necessarily, impregnation. . In other cases, a strand, band, or other elongated structure in which the carrier material 55 holding the adsorbent material 50 is cut to form individual sites that can be inserted into the filter rod and / or filter element 26. Can be provided.

  In some cases, the carrier material 55 may be in the form of pellets. In such cases, the pellets were obtained from Vector Corporation's FL-M series granulation equipment (eg, FL-M-3) and Alexanderwerk, Inc. Can be manufactured using equipment such as WP 120V and WP 200VN. Typical compression devices, such as compression presses, are available from Vector Corporation as Colton 2216 and Colton 2247, and are available from Fette Compacting as 1200i, 2200i, 3200, 2090, 3090, and 4090. Equipment for providing an outer coating layer into a compacted and pelletized formulation is available from Thomas Engineering as CompuLab 24, CompuLab 36, Accela-Cota 48, and Accela-Cota 60.

  Pellets can be manufactured using a wide variety of extrusion techniques. For example, such pellets can be manufactured using co-extrusion techniques (eg, using a twin screw extruder). In such situations, successive wet or dry ingredients or ingredient mixtures can be placed in separate extrusion hoppers. Steam, gas (eg, ammonia, air, carbon dioxide, etc.), and a humectant (eg, glycerin or propylene glycol) are added to the extruder as each dry mixture is advanced, plasticized, and heated. Can be poured into the barrel. In this way, the various components are processed so that they mix very well and are therefore in full contact with each other. For example, component contact is such that individual components (e.g., adsorbents or flavors) can be successfully embedded in the extrusion matrix or extrudate. See, for example, US Pat. No. 4,821,749 to Toft et al., Incorporated herein by reference.

  Carrier material 55 holding adsorbent material 50 can be incorporated into the segment of the cavity filter (eg, can be incorporated as a pellet in the central cavity region of a three-segment or three-stage filter element). Alternatively, the carrier material 55 holding the adsorbent substance 50 is applied to a fibrous filter material (for example, as one segment of a filter element having a plurality of segments in the longitudinal direction (for example, a two-segment filter element) (for example, Can be dispersed as a pallet or pleated nonwoven web material distributed throughout the filter tow.

  In accordance with another aspect of the present invention, the adsorbent 50 is filtered from the carrier material 55 after the carrier material 55 / adsorbent 50 assembly is inserted into the filter element 26 (or continuous filter rod). Can be released into material. For example, the adsorbent material 50 may be released to the filter element 26 and / or dispersed or otherwise used so that the adsorbent material 50 can have a desired effect on mainstream smoke that is sucked through the filter element 26. The carrier material 55 can be dissolved, disintegrated, decomposed, or otherwise destroyed in situ so as to be effectively exposed. Thus, a typical cigarette filter element 26 has an adsorbent material 50 on at least one component or segment of the filter element in a manner sufficient to affect the removal of the mainstream smoke vapor phase in the filter element 26. be able to.

  In cases where the adsorbent material 50 includes a carbonaceous material, the moisture content of the carbonaceous material (or any other suitable adsorbent) may vary. Typically, the moisture content of the carbonaceous material or other adsorbent in the filter element is based on the combined weight of the carbonaceous material and moisture prior to use of the cigarette containing such filter element. Less than about 30%, often less than about 25%, and more often less than about 20%. Typically, the moisture content of the carbonaceous material or other adsorbent in the filter element is approximately about the total weight of the carbonaceous material and moisture prior to use of the cigarette containing the filter element. More than 3%, often more than about 5%, and more often more than about 8%.

  In some cases, in addition to the adsorbent material 50, optional flavorings can also be impregnated or otherwise suspended in the carrier material 55 or included in the carrier material 55. That is, the carrier material 55 can carry both the adsorbent 50 and optional flavoring to the filter element 26. Thus, the complexity of the process of forming the filter element 26 and / or smoking article can be reduced. For example, in some embodiments, the carrier material 55 can include a polymer matrix material impregnated with an adsorbent material 50, such as a carbonaceous material, and an optional flavoring agent. This allows the adsorbent material 50 and optional flavoring (and in the form of a ruptureable capsule) to be inserted into the filter element 26 rather than using multiple insertion devices / steps. Only one insertion device / step is required to insert the optional flavoring.

  In other embodiments of the present invention, the adsorbent material 50 may be a sphere, pellet, capsule, tube, or other structured object with or without the carrier material 55. Can be formed. For example, pellets can be manufactured using a wide variety of extrusion techniques. For example, such pellets can be manufactured using co-extrusion techniques (eg, using a twin screw extruder). For example, carbon spheres can be formed so that they can be more easily inserted into filter materials (eg, cellulose acetate tow). In some cases, for example, food-grade shellac, ethyl cellulose, any suitable hydrophobic coating, or electrostatically applied material is applied to an object composed of an adsorbent and remains formed. The adsorbent material 50 can be provided with a carrier material 55 in the form of an “outer shell”. The object so obtained is inserted by an object insertion device commonly known in the art, such as an object insertion device used to insert a fragile capsule containing a flavorant. can do. In this way, one skilled in the art will understand that a sphere, capsule, or other form of adsorbent material 50 can be inserted in a simpler manner (similar to the embodiment in which the carrier material 55 carries the adsorbent material 50). . For example, in such an embodiment, one or more carbon spheres can be placed inside the filter material of a smoking article. Such objects formed as spheres, pellets, tubes, etc. can provide a concentrated form of adsorbent material 50 to the filter material. Thus, the particles containing the object may need to be released and / or dispersed or otherwise exposed to the filter element 26 to have the desired effect. For example, with the object placed in place inside the filter element 26, the adsorbent 50 and / or carrier material 55 constituting the object is torn, split or otherwise broken and degraded, Alternatively, forces (physical, sonic, or other) can be used to disintegrate and disperse the adsorbent material 50 into the filter element 26 or otherwise release it. This step can occur at any point after the object is inserted into the filter material. That is, this step can be used later in the manufacturing process, such as after the entire manufacture of the smoking article. In other cases, the process may occur immediately after inserting the object into the filter rod.

  Capsule size and weight may vary. Certain types of capsules are generally spherical. However, suitable capsules can have other types of shapes, such as generally linear, rectangular, elliptical, or oval. Typical generally spherical capsule diameters are less than about 3.5 mm, generally less than about 1.5 mm, often less than about 1 mm, and more often about 0.5 mm. Is less than. For example, a plurality of capsules can be used, and the diameter of the capsules can range from about 0.25 mm to about 2 mm. Multiple very small capsules (commonly referred to as “microcapsules”) can be incorporated into the filter element (eg protecting active ingredients (from oxidation, moisture, etc.) and exposed to precise mechanical action) Available from Euroli, which allows the active ingredient to be released at the desired moment by rupturing the membrane, or for the long-term effect, to release the active ingredient by long-term diffusion through the membrane (See various options for possible microencapsulation), such microcapsules can in some cases be held together in a coupled manner by a suitable binder material. The total weight of the capsules contained within the filter may vary, but is typically greater than about 10 mg, often greater than about 20 mg, and can be greater than about 30 mg. is there. The total weight of the capsule is typically less than about 200 mg, often less than about 100 mg, and may be less than 50 mg.

  The number of capsules contained within the filter element varies depending on factors such as capsule size, payload (ie, adsorbent, optional flavoring, or both) characteristics or properties, capsule position within the filter element, etc. It may be. The number of capsules contained in the corresponding region of the filter element may exceed about 5, may exceed about 10, may exceed about 20, may exceed about 40, It may exceed about 100. In certain embodiments, the number of capsules may be greater than about 500, and even greater than about 1,000. The larger number of capsules in certain embodiments may be advantageous because the smoker has more control over the smoking-dependent properties of the payload.

  Filter elements of the present invention are disclosed in Clearman et al. US Pat. No. 4,756,318, Banerjee et al. US Pat. No. 4,714,082, White et al. US Pat. No. 4,771,795. 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. U.S. Pat. No. 4,961,438, Serrano et al. U.S. Pat. No. 4,966,171, Bale et al. U.S. Pat. No. 4,969,476, Serrano et al. U.S. Pat. No. 4,991. , 606, Farrier et al., US Pat. No. 5,020,548, Shannon et al., US Pat. No. 5,027,836, Clearman et al., US Pat. No. 5,033,483, Schlatter et al., US Pat. No. 5,040,551, Creighton et al., US Pat. No. 5,050,621. US Pat. No. 5,052,413 to Baker et al., US Pat. No. 5,065,776 to Lawson, US Pat. No. 5,076,296 to Nystrom et al., Farrier et al. U.S. Pat. No. 5,076,297, Clearman et al. U.S. Pat. No. 5,099,861, Drewett et al. U.S. Pat. No. 5,105,835, U.S. Pat. No. 105,837, US Pat. No. 5,115,820 to Hauser et al., US Pat. No. 5, Best et al. No. 5,148,821, Hayward et al. US Pat. No. 5,159,940, Riggs et al. US Pat. No. 5,178,167, Clearman et al. US Pat. No. 5,183,062. US Pat. No. 5,211,684 to Shannon et al., US Pat. No. 5,240,014 to Deevi et al., US Pat. No. 5,240,016 to Nichols et al., Clearman et al. US Pat. No. 5,345,955, Casey, III et al., US Pat. No. 5,396,911, Riggs et al., US Pat. No. 5,551,451, Bensalem et al., US Pat. No. 5,595,577, Meiring et al., US Pat. No. 5,727,571, Barnes et al., US Pat. No. 5,819,751, U.S. Pat. No. 6,089,857 to Matsuura et al., U.S. Pat. No. 6,095,152 to Beven et al., U.S. Pat. No. 6,578,584 to Beven et al. US Patent Application Publication No. 2007/0215167 to Crooks et al., And US Patent Application Publication No. 2008/00092912 to Robinson et al., Which are incorporated herein by reference. Can be incorporated into certain types of cigarettes. For example, the filter element of the present invention may be referred to as R.I. J. et al. It can be incorporated into cigarettes of the type commercially available from Reynolds Tobacco Company under the brand names “Premier” and “Eclipse”. For example, “Chemical and Biological Studios on New Cigarette Prototypes that Heat Institute of Burn Tobacco”, R.A. J. et al. Reynolds Tobacco Company Monograph (1988) and “Inhalation Toxicology”, 12: 5, p. See cigarettes of the type described in 1-58 (2000), which are incorporated herein by reference.

  Cigarette rods are typically manufactured using a cigarette making machine, such as a conventional automatic cigarette rod making machine. Typical cigarette rod making machines are Molins PLC or Hauni-Werke Korber & Co. This is a type of manufacturing machine commercially available from KG. For example, a cigarette rod making machine of the type known as MkX (commercially available from Molins PLC) or PROTOS (commercially available from Hauni-Werke Korber & Co. KG) can be used. The PROTOS cigarette making machine is described in line 5 from column 48 to column 8 of Brand US Pat. No. 4,474,190, incorporated herein by reference. Furthermore, suitable types of equipment for the manufacture of cigarettes are disclosed in La Hue US Pat. No. 4,781,203, Holznagel US Pat. No. 4,844,100, Gentry US Pat. 131,416, Holmes et al., US Pat. No. 5,156,169, Myracle, Jr. U.S. Pat. No. 5,191,906, Blau et al. U.S. Pat. No. 6,647,870, Kitao et al. U.S. Pat. No. 6,848,449, Kitao et al. U.S. Pat. US Patent Application Publication No. 6,904,917, Hartman US Patent Application Publication No. 2003/0145866, Hancock et al. US Patent Application Publication No. 2004/0129281, Barnes et al. US Patent Application Publication No. 2005/0039764. In the specification and in US Patent Application Publication No. 2005/0076929 to Fitzgerald et al., Each of which is incorporated herein by reference.

  The components and operation of a conventional automatic cigarette making machine will be readily apparent to those skilled in the art of cigarette making machine design and operation. For example, a description of the components and operation of several types of chimneys, tobacco filler feeders, suction conveyor systems, and garniture systems is provided by Molins et al., US Pat. No. 3,288,147, Heitmann et al. U.S. Pat. No. 3,915,176, Frank et al. U.S. Pat. No. 4,291,713, Rudszinat et al. U.S. Pat. No. 4,574,816, Heitmann et al. U.S. Pat. No. 4,736,754, Pinck et al. US Pat. No. 4,878,506, Heitmann US Pat. No. 5,060,665, Kertissis et al. US Pat. No. 5,012,823. US Pat. No. 6,360,751, Fagg et al., Mulle. U.S. Patent Application Publication No. 2003/0136419 Pat (each of which is incorporated herein by reference) have been described in. An automatic cigarette making machine of the type described herein provides a shaped continuous cigarette rod or smokable rod that can be subdivided into a desired length of shaped smokable rod.

Various types of cigarette components can be used, including tobacco types, tobacco blends, top dressing and casing materials, blend packing densities, and tobacco rod wrapping paper material types. See, for example, “Development of Cigarette Components to Meet Industry Needs” by Johnson, 52 ^nd T.C. S. R. C. (September 1998), Jakob et al., US Pat. No. 5,101,839, Arzonico et al., US Pat. No. 5,159,944, Gentry, US Pat. No. 5,220,930. Kraker, U.S. Patent No. 6,779,530, Ashcraft et al., U.S. Patent Application Publication No. 2005/0016556, Nestor et al., U.S. Patent Application Publication No. 2005/0066986, Fitzgerald, et al. Published application 2005/0076929, Coleman, III et al. US Patent Application Publication 2007/0056600, Thomas et al. US patent application 11 / 375,700 dated March 14, 2006, And Oglesby's US patent dated April 21, 2006. Various representative types of cigarette components as described in application Ser. No. 11 / 408,625, each of which is incorporated herein by reference, as well as various cigarette designs, See format, configuration, and characteristics. Most preferably, the entire smokable rod is composed of a smokable material (eg, tobacco cutting filler) and a surrounding layer of exterior material.

  Accordingly, another aspect of the present invention is to filter smoking articles by incorporating adsorbent material 50 by carrier material 55, optionally incorporating flavorant 52, and incorporating carrier material 55 that retains adsorbent material 50. Including a device configured to be suitable for forming the element and / or forming the smoking article itself having such a filter element comprising carrier material 55 / adsorbent material 50. For this purpose, an apparatus for providing filter rods for use in the manufacture of smoking articles, wherein each rod carries one or more forms of carrier material 55 (eg pellets, capsules) , Strands, or combinations thereof) disposed along the length of the rods, each rod portion holding an adsorbent material 50 when the rod is subdivided into rod portions. Devices have been developed that include one form of carrier material 55. See, for example, Deal US Pat. No. 7,115,085, which is incorporated herein by reference in its entirety. Such an apparatus can comprise equipment for continuously supplying filter material (eg, a filter tow processing unit configured to supply filter tow to a continuous rod forming unit). As a representative apparatus for supplying a particular form of carrier material 55 carrying an adsorbent 50 to a filter material, see, eg, Thomas et al. US 2007/0068540 (hereby incorporated by reference). And an object delivery device such as a hopper and rotating wheel configuration disclosed in US Pat. In yet other instances, multiple forms of carrier material 55 (ie, pellets and / or strands, or a combination of at least one of pellets or strands and at least another of pellets or strands) are delivered by the object insertion unit. Can be inserted into the filter material. Arrangements for inserting such strands / objects into filter materials are described, for example, in Nelson et al. US Patent Application No. 11 / 461,941 (US Patent Application Publication No. 2008/0029118) and Stokes. U.S. patent application Ser. No. 11 / 760,983, which is hereby incorporated by reference.

  A rod making apparatus 210 as shown in FIG. 4 includes a forming unit 450 configured to engage the adsorbent material 50 with the carrier material 55 in some cases in an online or offline manner to form an insert. Can be included. For example, in the forming unit 450, the adsorbing substance 50 is inserted into a tube-shaped or capsule-shaped member made of the carrier material 55, and the adsorbing substance 50 is suspended in the base material made of the carrier material 55. The adsorbent material 50 can be engaged with a continuous elongated member and / or can be configured to wrap a continuous strip of carrier material 55 around the adsorbent material 50. Once the insert is formed, the insert is delivered from the forming unit 450 to an insertion unit / device 214 configured to insert the carrier material 55 holding the adsorbent material 50 into the filter material. Can do. In some cases, the forming unit can cooperate with such an insertion unit / device 214 or be otherwise linked to such insertion unit / device 214 (ie, Online vs offline). In still other embodiments, the forming unit 450 and the insertion unit / device 214 both function to form the carrier material 55 that holds the adsorbent material 50 and to insert the carrier material 55 that holds the adsorbent material 50 into the filter material. May be a single unit configured to perform

  In the manufacturing process, the filter material can be formed into a continuous rod having a carrier material 55 holding the adsorbent material 50 disposed therein and extending along the longitudinal axis. The continuous rods can then be subdivided at predetermined intervals to form a plurality of filter rods or rod portions, each including at least a portion of the adsorbent material 50. For example, in the case of carrier material 55 containing pellets and strands, the pellets can be placed in place along the filter rod or filter element inside the filter rod or filter element, while the strand (if present) ) Extends through the filter rod or filter element.

  As shown in FIG. 4, a typical rod making apparatus 210 includes a rod forming unit 212 (eg, a unit called KDF-2 available from Hauni-Werke Korber & Co. KG) and insert (s) as filter material. And an object insertion unit 214 suitably configured for placement along the 40 continuous lengths. A continuous length or web of filter material can be supplied from a source (not shown) such as a storage bale, bobbin, spool, or the like. In general, the filter material 40 can be processed using the filter material processing unit 218. The continuous length of filter material is introduced with the carrier material 55 holding the adsorbent material 50 by the object insertion unit 214, and then the filter material is passed through the rod forming unit 212 to form the continuous rod 220. . The continuous rod 220 may be subdivided into a plurality of rod portions 205 each using at least a portion of the adsorbent material 50 using a rod cutting assembly 222. The continuous or multiple rod portions 205 can be collected in a collection device 226, which can be a tray, a rotating collection drum, a transport system, etc. for use. If desired, the rod portion may be carried directly to the cigarette making apparatus.

  The filter material 40 can vary and can be any material of the type that can be used to produce a tobacco smoke filter for cigarettes. Preferably, conventional cigarette filter materials such as cellulose acetate tow, pleated cellulose acetate web, polypropylene tow, pleated cellulose acetate web, pleated paper, recycled tobacco strands, etc. are used. Filamentous tows such as cellulose acetate and polyolefin (polypropylene, etc.) are particularly preferred. One highly preferred filter material that can provide a suitable filter rod is cellulose acetate tow with 3 denier per filament and 40,000 total denier. As another example, a cellulose acetate tow of 3 denier per filament and 35,000 total denier can provide a suitable filter rod. As another example, a cellulose acetate tow with 8 denier per filament and 40,000 total denier can provide a suitable filter rod. For further examples see Neurath U.S. Pat. No. 3,424,172, Cohen et al. U.S. Pat. No. 4,811,745, Hill et al. U.S. Pat. No. 4,925,602, Takegawa. No. 5,225,277, et al., And Arzonico et al., US Pat. No. 5,271,419.

  Filamentous tows, such as cellulose acetate, were obtained from Arston Equipment Corp. of Winston-Salem. , N.M. It can be processed using a conventional filter tow processing unit 218, such as the commercially available E-60 supplied by C. Other types of commercially available tow processing equipment known to those skilled in the art can be used as well. Typically, a plasticizer such as triacetin or carbowax is applied to the filament tow in conventional amounts using known techniques. In one embodiment, the plasticizer component of the filter material comprises triacetin and carbowax in a 1: 1 weight ratio. The total amount of plasticizer is generally about 4% to about 20% by weight, preferably about 6% to about 12% by weight. Other suitable materials or additives used in connection with the construction of the filter element will be readily apparent to those skilled in the art of cigarette filter design and manufacture. See, eg, Rivers US Pat. No. 5,387,285, which is incorporated herein by reference.

  A continuous length of the filter material 40 can be pulled through the block 230 by the action of the rod forming unit 212, and the carrier material 55 holding the adsorbent material 50 is moved along the length of the filter material, It can be inserted into the web of filter material. However, it is also possible to introduce the carrier material 55 holding the adsorbent material 50 into the filter material at other points in the process, and this exemplary embodiment is not intended to be limited in that respect. Absent. The filter material can be further guided to the gathering region 232 of the rod forming unit 212. The gathering region may have a tongue and corner configuration, a gathering funnel configuration, a stuffer or transport jet configuration, or other suitable type of gathering device. A strand or filament of filter material in which the tongue 232 results in further gathering, compression, transformation, or formation of the cylindrical composite from the block 230 into a generally cylindrical shape (ie, rod shape), resulting in continuous extension Extends essentially along the longitudinal axis of the cylinder thus formed. In some cases, the carrier material 55 holding the adsorbent material 50 may be placed into the filter material in the gathering region 232 if appropriate.

  Filter material 40 compressed into a cylindrical composite is further received into rod forming unit 212. The cylindrical composite is fed into a wrapping mechanism 234 that includes an endless decorative conveyor belt 236 or other decorative device. The decorative conveyor belt 236 is continuously advanced longitudinally using an advancement mechanism 238, such as a ribbon wheel or cooperating drum, to carry the cylindrical composite through the wrapping mechanism 234. The wrapping mechanism provides a band 28 of wrapping material (eg, non-porous paper plug wrap) to the outer surface of the cylindrical composite to produce a continuous packaged rod 220. In some cases, the carrier material 55 holding the adsorbent material 50 may be engaged with the filter material in a wrapping or decorative region 232, if appropriate. For example, an elongate member as otherwise disclosed herein may be in the form of a packaging material 28 that is accompanied by or otherwise engaged with a carrier material 55 holding an adsorbent material 50. Also good.

  In general, a band or web of packaging material 28 can be supplied from a rotating bobbin 242. The packaging material can be withdrawn from the bobbin, advanced past a series of guide rollers, and passed under the block 232 to enter the lapping mechanism 234 of the rod forming unit. An endless decorative conveyor belt 236 extends longitudinally through the wrapping mechanism 234 while wrapping or covering both the strip of packaging material and the cylindrical composite around the cylindrical composite. Carry in form.

  An adhesive (eg, a hot melt adhesive) is applied in the applicator region 244 to the seam formed by the overlapping edge portions of the packaging material so that the packaging material can form a tubular container for the filter material. Alternatively, hot melt adhesive may be applied immediately upstream of the packaging material entry into the decorative portion of the wrapping mechanism 234 or block 230, as the situation requires. The adhesive can be cooled using a cold bar 246 to quickly cure the adhesive. It should be understood that a variety of other sealing devices and other types of adhesives can be used to provide a continuous packaged rod.

  A continuous prepackaged rod 220 passes from the sealing device and at a desired predetermined length using a cutting assembly 222 that includes a rotary cutter, very sharp knife, or other suitable rod cutting or subdividing device. Subdivided (eg, cut) at regular intervals. It is particularly desirable that the cutting assembly does not flatten the rod or otherwise adversely affect the shape of the rod. The rate at which the cutting assembly cuts the continuous rod at the desired point is controlled by an adjustable mechanical gear train (not shown) or other suitable device. For the carrier material 55 holding the adsorbent material 50, the speed of insertion of the filter material into the continuous web can be directly related to the speed of operation of the rod making machine. The insertion unit can be linked to the drive assembly of the rod making device in a direct drive relationship. Alternatively, the insertion unit 214 may have a direct drive motor that is synchronized to the drive assembly of the rod forming unit. In some cases, the insertion unit 214 can be configured to communicate with the inspection / detection system 247, for example in the form of a feedback loop, and any defects detected by the inspection / detection system 247 can be It can be removed by adjusting the unit 214. In light of the relationship between the speed of insertion of the object and the rod making machine, embodiments of the present invention can be used in the rod making machine without adversely affecting the placement of the carrier material 55 holding the adsorbent 50 into the filter material. It is also aimed at maintaining or improving production speed.

  The insertion unit 214 can include a rotary insertion member 248 having the shape of a wheel that can be arranged to rotate in a vertical plane. Further, the insertion unit 214 may include a hopper assembly 252 and / or other transport device for feeding or otherwise transporting various forms (eg, pellets, etc.) of the carrier material 55 into the insert member 248. it can. As the insertion member 248 rotates, the carrier material 55 on the outer peripheral surface of the wheel is brought into contact with the filter material 40 at block 230 and the carrier material 55 is discharged from the pockets into the collected filter material 40. Details of such an object insertion mechanism are described, for example, in US Pat. No. 7,115,085 to Deal, Green, Jr. U.S. Pat. No. 4,862,905 (ie, insertion of individual strand portions), Thomas et al. U.S. Patent Application Publication No. 2007/0068540 (ie, insertion of capsules), U.S. Pat. Further details in patent application Ser. No. 11 / 461,941 (ie, insertion of continuous strands) and US Patent Application No. 11 / 760,983 of Stokes et al. (Ie, insertion of continuous strands). Yes.

  Such an object insertion device may be, for example, a tongue or tongue portion configured to collect a supply of filter material into a continuous rod, and / or a tubular member having adsorbent material 50 therein to the filter material. And an insertion unit for insertion. In some cases, various forms of carrier material 55 can be successively attached or otherwise engaged with each other to form a continuous chain, and the insertion unit 214 can be connected to the continuous chain. Can be arranged into the filter material. Also, certain forms of carrier material 55 can be attached or otherwise engaged to the elongate member, and the elongate member can include, for example, a strand, thus making the carrier material 55 by the strand. Can be a stretch. Multiple forms of carrier material 55 (ie, pellets and / or strands) or a combination of at least one of pellets or strands and at least another of pellets or strands may be inserted into the filter material by insertion unit 214. it can. One mechanism for inserting the strand into the filter material is disclosed, for example, in US Patent Application No. 11 / 461,941 to Nelson et al., Which is incorporated herein by reference. In other examples, the elongate member can be configured to spread laterally (ie, as a two-dimensional sheet). Thus, the rod forming device 210 surrounds the filter material and adsorbent material 50 by an elongated member, as disclosed in Stokes et al. US patent application Ser. No. 11 / 760,983, which is incorporated herein by reference. A decorative device can be included that is configured to wrap an elongate member having adsorbent material 50 attached around the filter material so that a packet is formed.

  After the carrier material 55 holding the adsorbent material 50 is inserted into a continuous rod of filter material, the adsorbent material can be released from the carrier material into the filter material. For example, the carrier may be used to release and / or disperse the adsorbent material 50 to the filter element 26 so that the adsorbent material 50 can have a desired effect on mainstream smoke that is sucked through the filter element. The material 55 can be dissolved, disintegrated, decomposed, or otherwise destroyed. Release of adsorbent material into the filter material may occur before or after the continuous rod is cut into filter segments (eg, filter element 26). Such release may occur during the manufacturing process, but in some cases may be achieved by the user prior to smoking the smoking article. In some embodiments, the adsorbent release unit 400 can be provided downstream of the insertion unit 214 in the production line, and the adsorbent release unit 400 can be adsorbed from, for example, a thermal process, an ultrasonic process, or a carrier material 55. Any other suitable mechanism for releasing the substance 50 is used to in situ interact with the carrier material 55 inside the filter element to release the adsorbed substance 50 into the filter material. be able to.

  More specifically, the adsorbent material 50 is, for example, plasticized (ie, formed a “paste”) such that the resulting object is elastic, flexible, and / or otherwise handleable. (See, for example, US Pat. No. 4,862,905 to Green, Jr. et al.). Once the object is inserted into the filter material, the adsorbent material 50 is processed into a releasable form, for example, by heating and / or drying procedures applied to the filter element having the object therein. be able to. That is, the plasticizer can be removed from the object by a heating / drying process, making the object fragile or breakable. The filter element is then expanded, for example, with a counter roller, an “impact” process (ie, sonic vibration, heating / cooling cycle, etc.), and / or irradiation treatment (ie, liquid / gas combined with the object) It can be mechanically processed by microwave energy) which causes decomposition of the structure of the object.

  In some cases, the adsorbent material 50 in various forms (ie, strands, beads, pellets, capsules, or combinations thereof) can be placed in a closed cell foam as the carrier material 55. Once inserted into the filter element 20, irradiation or heating can be applied to break up the foam and release the adsorbent. Alternatively, the carrier material 55 can comprise an open cell foam, for example, once the object is inserted into the filter material 20, the adsorbent material using air and / or physical forces 50 can be released.

  In other cases, the carrier material 55 is provided in the form of a breakable capsule, an “intracapsule capsule”, or a strand, for example formed of a polymer that is soluble in water or other liquid, to hold the adsorbent material 50. Can be configured. Such soluble polymers include, for example, polylactic acid, polyvinyl alcohol (PVA), starch and / or starch-based polymers, carrageenan, polyvinyl acetate, hydroxypropyl cellulose, pullulan, carboxymethyl cellulose and salts thereof (ie, alkali metals Salt), alginic acid and salts thereof, gelatin, and / or any other suitable polymer, or combinations thereof. Since the releasable form of the carrier material 55 causes the adsorbate to disperse, allowing the mainstream smoke to pass through the filter element and interact with the adsorbent, the object is inserted into the filter element so far. It may be relatively larger than the “solid state” object (ie, may be relatively larger than between about 2 mm and about 3.5 mm).

  In controlling this process, the control system can include appropriate control hardware and / or software. A typical control system 290 may include, for example, a Siemens 315-2DP processor, a Siemens FM352-5 Boolean processor, and a 16 input / 16 output bit module. Such a system can utilize a system display device 293, such as a display device called MP370 from Siemens. A typical rod making unit 212 may include a controller configured to adjust the speed of the cutting unit knife to match the speed of continuous rod formation for a desired length of rod. it can. In such cases, the first encoder 296 connected to the drive belt of the rod making unit and the control unit 299 of the insertion unit provide a reference for the knife position of the cutting assembly relative to the position of the wheel of the insertion unit. Can do. In this way, the first encoder 296 can provide one way to control the speed of rotation of the insertion unit wheels relative to the speed of the continuous web of filter tows passing through the rod making unit. A typical first encoder 296 is available as an encoder 2058 from Heidenhain.

  In one embodiment of the invention, both the adsorbent material 50 and the carrier material 55 are in the form of fibers, and the fibers of the adsorbent material consist of or are described herein as adsorbent materials. It contains adsorbents as The fibers can include conventional staple fibers as well as substantially continuous structures (such as continuous filaments). The fibers of the present invention may be hollow or solid and may have a substantially round or circular cross section, or a non-circular cross section (eg, oval, square, rectangular, multilobe, etc.) ). The fibers may be in the form of a single yarn or filament, or in the form of a plurality of yarns or filaments structure (multiple filaments joined, twisted, or intertwined) knitting yarns or other structures Form). If the fibers are twisted, joined, or entangled, the fibers can be configured to unravel after insertion into the filter to increase the effective surface area of the adsorbent fibers. The fibers can be formed by fiber forming processes known in the art such as extrusion, melt spinning, solution spinning, and the like. The color of each fiber may vary, but the adsorbent fibers often appear black when they are carbonaceous fibers as described herein.

  The fibers used for the adsorbent 50 or carrier material 55 can be composed of natural or synthetic materials. Typical natural fibers include cotton, linen, jute, hemp, cotton, wool, and wood pulp. Typical synthetic fibers that can be used to form fibers include polyamide, polyamine, polyimide, polyacrylic acid, polycarbonate, polydiene, polyepoxide, polyester, polyether, polyfluorocarbon, polyolefin, polyphenylene, silicon-containing polymer, polyurethane, Examples thereof include polyvinyl, polyacetal, polyarylate, modified cellulosic fibers (for example, cellulose acetate), copolymers thereof, terpolymers thereof, and mixtures thereof. Examples of specific polymeric materials useful as the fiber material according to the present invention include, but are not limited to: Nylon 6, nylon 6/6, nylon 12, polyaspartic acid, polyglutamic acid, polyacrylamide, polyacrylonitrile, esters of methacrylic acid and acrylic acid, polybisphenol A carbonate, polypropylene carbonate, polybutadiene, polyisoprene, polynorbornene, polyethylene terephthalate , Polybutylene terephthalate, polytrimethylene terephthalate, polycaprolactone, polyglycolic acid, polylactide, polyhydroxybutyrate, polyhydroxyvalerate, polyethylene adipate, polybutylene adipate, polypropylene succinate, polyethylene glycol, polybutylene glycol, polypropylene oxide, Polyoxymethylene, polytetramethylene ether, poly Trahydrofuran, polyepichlorohydrin, urea formaldehyde, melamine-formaldehyde, phenol formaldehyde, polyethylene, polypropylene, polybutylene, polybutene, polyoctene, polyphenylene oxide, polyphenylene sulfide, polyethersulfone, polyphenylene ethersulfone, polydimethylsiloxane, polycarbomethyl Silane, polyvinyl butyral, polyvinyl alcohol, esters and ethers of polyvinyl alcohol, polyvinyl acetate, polystyrene, polymethyl styrene, polyvinyl chloride, polyvinyl pyrrolidone, polymethyl vinyl ether, polyethyl vinyl ether, polyvinyl methyl ketone, polyethylene-vinyl acetate copolymer Polymer, polyethylene-acrylic acid copolymer Polybutylene terephthalate - polyethylene terephthalate copolymers, and polylauryllactam - polytetrahydrofuran block polymers.

  The adsorbent material 50 attaches adsorbent particles to the fiber, embeds or suspends the adsorbent particles inside the fiber, or chemically alters the fiber so that the adsorbent is formed after the fiber is formed. Can be incorporated into the adsorbent fibers by any method known in the art, such as, for example, carbonization of fibers. In one embodiment, the adsorbent fibers are composed of a carbonaceous material (ie, carbon fibers).

  Carbon fibers can be described as fibers obtained by controlled pyrolysis of precursor fibers. Since carbon is typically difficult to form into a fiber form, commercially available carbon fibers often extrude the precursor material into filaments, which are then usually carbonized at high temperatures. Done. Common precursors of carbon fibers include rayon, acrylic fibers (such as polyacrylonitrile or PAN), and pitches (isotropic and anisotropic mesophase pitches and meltblown pitch fibers). Other precursors such as cellulose can also be converted to carbon fibers. KYNOL (TM) novoloid fiber (available from American Kynol, Inc., Pleasantville, NY) is a high-performance phenolic fiber that is converted to activated carbon in a single step process that combines both carbonization and activation It is. The formation of carbon fibers from rayon or acrylic generally consists of stabilization, carbonization, and graphitization, each performed at progressively higher temperatures to sufficiently remove non-carbon species such as oxygen, nitrogen, and hydrogen. The Fabrication of fibers using pitch also typically involves stabilization and carbonization, while pitch is typically spun as part of the carbon fiber formation process, while fibers previously formed with rayon or acrylic Can be used directly. Activation may in some cases add further manufacturing steps. Carbon fiber suppliers include Toray Industries, Toho Tenax, Mitsubishi, Sumitomo Corporation, and Hexcel Corp. , Cytec Industries, Zoltek Companies, and SGL Group.

  Carbon fibers are often classified in three separate ways. First, classification based on elastic modulus and strength is possible. Examples include ultra high modulus (UHM) fiber (modulus> 450 Gpa), high modulus (HM) fiber (modulus between 350 and 450 Gpa), medium modulus (IM) fiber (between 200 and 350 Gpa). Elastic modulus), low modulus high tensile (HT) fibers (elastic modulus <100 Gpa and tensile strength> 3.0 Gpa), and ultra high tensile (SHT) fibers (tensile strength> 4.5 Gpa). Second, carbon fibers can be classified based on the precursor material used to make the fibers (eg, PAN, rayon, pitch, mesophase pitch, isotropic pitch, or vapor grown fiber). . Third, carbon fibers can be classified based on the final heat treatment temperature. Examples include Type I high heat treatment (HTT) fibers (final heat treatment temperature above 2,000 ° C.), Type II medium heat treatment (IHT) fibers (final heat treatment temperature of about 1,500 ° C.), And type III low heat treatment (LHT) fibers (final heat treatment temperature is 1,000 ° C. or less). Any of the above-described carbon fiber classifications can be used in the present invention.

  Examples of starting materials and methods for making carbon-containing fibers, and types of carbon-containing fibers are described in Chamberlain US Pat. No. 3,319,629, Sublett et al. US Pat. No. 3,413,982, U.S. Pat. No. 3,904,577 to Buisson, U.S. Pat. No. 4,281,671 to Bynre et al., U.S. Pat. No. 4,876,078 to Arakawa et al., U.S. Pat. No. 4,947,874, Iizuka US Pat. No. 5,230,960, Paul, Jr. U.S. Pat. No. 5,268,158, Noland et al. U.S. Pat. No. 5,338,605, Endo U.S. Pat. No. 5,446,005, Bair U.S. Pat. No. 5,482. No. 5,773, Nagata et al. U.S. Pat. No. 5,536,486, Arterbury et al. U.S. Pat. No. 5,622,190, Panter et al. U.S. Pat. No. 7,223,376. Zhang et al., US Patent Application Publication No. 2006/0201524, and Newberry et al., US Patent Application Publication No. 2006/0231113, all of which are incorporated herein by reference. . In particular, the disclosure of PAN-based carbon fibers (including their manufacture), “Polyacrylonitrile (PAN) Carbon Fibers Industrial Assessment: OUSD (AT & L) Industrial Month 10”, which is incorporated herein by reference, “Our (US & L) Industrial Policy Year 10”. It is presented in a report to the title meeting and is available online at http: // www. acq. osd. mil / ip / docs / pan_carbon_fiber_report_to_congress_10-2005. Available at pdf.

  The size of the carrier fibers and adsorbent fibers (eg, carbon fibers) may vary without departing from the present invention. Typically, fiber sizes vary from about 0.5 denier to about 20 denier. The size of the adsorbent fibers often depends at least in part on the amount of adsorbent desired in the filter element. For example, the size of the adsorbent fibers can be determined based on the weight of adsorbent desired in the filter, such as the weight range of the carbonaceous materials described herein.

  Carrier fibers and adsorbent fibers (eg, carbon fibers) are wrapped together in two types of fibers, entangled, joined together using weaving, adhesives or binders, co-extruded, or separately Can be connected together for the purpose of insertion into a cigarette filter material using any of a variety of methods, such as tying using a connecting element (such as a separate thread or clip), or Can be combined with each other. Each composite fiber structure (ie, a combination of carrier fibers and adsorbent fibers) can include one or more fibers of each type, ie, each fiber structure can have, for example, from 1 to about 20 carriers. It means that it can contain fibers and from 1 to about 20 adsorbent fibers.

In other embodiments of the present invention, the filter material comprises a degradable fiber material, i.e., the fiber degrades, for example, the fiber into degradation products under environmental conditions relating to the disposal of the fiber material. It can be degraded or decomposed by chemical reaction. One typical type of degradation is biodegradation. As used herein, the term “biodegradable fiber” refers to carbon dioxide / methane, water under aerobic and / or anaerobic conditions in the presence of bacteria, fungi, algae, and other microorganisms. And refers to a polymeric fiber material that decomposes into biomass (materials containing heteroatoms may result in other products such as ammonia or sulfur dioxide). “Biomass” generally refers to a portion of a metabolite that is taken up into the cellular tissue of an existing organism or converted into a humus portion that is indistinguishable from material of biological origin. Typical biodegradable fibers include, but are not limited to, cellulose or other organic plant-derived fibers (eg, cotton, wool, cedar, hemp, bamboo, kapok, or flax), polyvinyl alcohol, fat Aliphatic polyester, aliphatic polyurethane, cis polyisoprene, cis polybutadiene, polyhydroxyalkanoic acid, polyanhydrides, and copolymers and mixtures thereof. The term “aliphatic polyester” refers to a polymer having the structure — [C (O) —R—O] _n —, where n is an integer representing the number of monomer units in the polymer chain, and R is Group hydrocarbon, preferably C1 to C10 alkylene, more preferably C1 to C6 alkylene (eg, methylene, ethylene, propylene, isoprene, butylene, isobutylene, etc.), and the alkylene group is linear However, it may be branched. Typical aliphatic polyesters include polyglycolic acid (PGA), polylactic acid (PLA) (eg, poly (L-lactic acid) or poly (DL-lactic acid)), polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), polycaprolactone (PCL), and copolymers thereof.

  In certain embodiments, the biodegradable fiber is bamboo fiber or PLA fiber. Suitable bamboo fibers are described, for example, in Zhou et al. US Pat. No. 7,313,906, incorporated herein by reference. Bamboo fiber is available from China Bambro Textile Co. , Ltd., Ltd. Commercially available. PLA fibers can be derived from corn or can be produced synthetically. Suitable PLA fibers are described in Kaijiyama et al., US Pat. No. 7,445,841, incorporated herein by reference, and are commercially available from NatureWorks LLC.

  The degradable fibers can be utilized in the form of a single strand or can be utilized as part of a multi-strand knitting yarn structure. In certain embodiments, the fibrous material can be used in the form of a sheet. Degradable fibers can be combined with different types of degradable fiber materials into a woven fabric or otherwise in a monolithic structure, or a combination of degradable fibers with non-degradable fibers and / or adsorbent fibers can be woven or Can be used in combinations involving multiple fiber types, such as combined into a monolithic structure in other ways (for example, bamboo fiber, cotton fiber, and carbon fiber are only one, such as a single knitted yarn structure) To the fiber structure). Alternatively, multiple fiber types can be combined into a single fiber strand or mixed together.

  Where the fiber is described as comprising a particular type of fiber material, the fiber is often composed primarily of a given fiber material (eg, greater than about 50% by weight based on the total weight of the fiber) or essentially Configured (eg, greater than about 90% by weight), or substantially fully composed (eg, greater than about 98% by weight or about 100% by weight). For example, a fiber described as “bamboo fiber” can include a relatively small amount of bamboo fiber material (eg, in combination with other types of fiber materials, or in combination with additives), or It may be composed primarily, essentially composed of bamboo fiber material, or substantially completely composed of bamboo fiber material.

  Degradable fibers can function as carrier fibers for adsorbents (eg, carbon fibers) as described herein, and other configured to change the flavor or aroma of the smoking article It can function as a carrier for the additive, or it can function as a carrier for both the adsorbent and flavor / aroma additive. Alternatively, the inherent properties of the degradable fiber itself may change the characteristics or properties of the smoke passing through the filter. Typical flavors or fragrances include any solid or liquid composition that can be incorporated into the fiber structure, for example, by absorption, adhesion, or physical entanglement. The additive may be any composition that can change the characteristics or properties of smoke passing through the filter material, such as by the action of a flavor or deodorant. Typical additives include natural or synthetic flavors that can change the flavor and / or aroma of mainstream smoke, and the flavor characteristics that it provides are not limited to these, but are fresh Can be expressed as sweet, herb, confectionary, floral, fruity, or spice. Specific types of flavors or fragrances include, but are not limited to, vanilla, coffee, chocolate / cocoa, cream, mint, spearmint, menthol, peppermint, wintergreen, eucalyptus, lavender, cardamom, nutmeg, Cinnamon, clove, cascarilla, sandalwood, honey, jasmine, ginger, anise, sage, licorice, lemon, orange, apple, peach, lime, cherry, strawberry, and any combination thereof. Leffingwell et al., “Tobacco Flavoring for Smoke Products”, R. W., incorporated herein by reference. J. et al. See also Reynolds Tobacco Company (1972). The flavoring agent can also include ingredients that are considered humectants, cooling agents, or leveling agents, such as eucalyptus. These flavors may be supplied straight (ie, alone) or in a mixture (eg, spearmint and menthol, or orange and cinnamon). Typical deodorants include any composition configured to shield or remove the scent of tobacco smoke. One exemplary composition includes an inorganic salt and an odor adsorbent, as described in Leskovitz US Pat. No. 7,407,922, incorporated herein by reference. Other deodorizing compositions include a tangerine essential oil component, as described in US Pat. No. 7,434,586 to Higashi et al., Also incorporated herein by reference.

  Degradable fibers can be incorporated into the filter material in the same manner as described herein with respect to the carrier fiber / adsorbent material embodiments. For example, degradable fibers can be used as carrier fibers in the composite fiber structure shown in FIGS. Alternatively, degradable fibers can be embedded in the filter material without using a second fiber structure. For example, degradable fibers containing flavoring agents can be added to the filter material. In yet another embodiment, a degradable fiber (with or without additives as described herein) may be used as a filter for smoking articles, such as plug wrap materials or chipping materials. Can be incorporated into any packaging material used.

  In other embodiments, the degradable fiber is any of a number of synthetic fiber materials described herein that are typically not considered degradable (eg, polyethylene terephthalate or Non-degradable fibers such as polypropylene). Non-degradable fibers can be used for any of the applications described herein for degradable fibers. Both degradable and non-degradable fibers can be derived from natural materials, synthetic materials, or chemically modified materials of natural origin.

  The number of degradable and non-degradable fibers embedded in the filter element may vary. A typical range for the number of fiber inserts into the segment of the filter element is 1 to about 500, more typically 1 to about 100, and often 1 to about 50.

  FIG. 5 shows an example of a composite fiber structure 60 embedded in the filter segment 32. Although multiple composite fiber structures 60 are shown in FIG. 5, the number of composite fiber structures may vary. A typical range for the number of composite fiber structures 60 incorporated into the filter 26 is 1 to about 500, more typically 1 to about 100, and often 1 to about 50. The composite fiber structure 60 can be included in a single segment 32 of the multi-segment filter 26 as shown in FIG. 5, or the composite fiber structure has only one single segment. It can be embedded into the filter element, or the composite fiber structure may extend throughout the multiple sites of the multi-segment filter. The composite fiber structure 60 may extend linearly in the longitudinal direction of the cigarette filter as shown in FIG. 5, extend transversely to the longitudinal axis of the filter element, or vary throughout the filter segment. It may be randomly distributed at any angle. As shown in FIG. 6, the composite fiber structure 60 can include at least one carrier fiber 62 and at least one adsorbent fiber 64.

  As shown in FIGS. 5 and 6, one way to connect the two types of fibers is to wrap the adsorbent fibers 64 around the carrier fibers 62. The number of wraps of adsorbent fibers 64 per unit length of carrier fibers 62 may vary, but depends on several factors, such as the amount of adsorbent desired for the filter element. A typical range for winding the adsorbent fibers 64 around the carrier fibers 62 is to wrap the adsorbent fibers circumferentially from 1 to about 50 turns per inch of carrier fiber.

  Many modifications and other embodiments of the invention may occur to those skilled in the art to which the invention pertains by taking advantage of the teachings presented in the foregoing description. It will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are within the scope of the appended claims. Although specific terms are used herein, they are used generically and for illustrative purposes only, and not for purposes of limitation.

Claims (13)

An apparatus for forming a cigarette filter rod member defining a longitudinal axis comprising:
A rod forming unit configured to form a continuous supply of filter material into a continuous cylindrical rod member;
Inserting an adsorbent material retained by a carrier material including one of a capsule member, a tubular member, a continuous elongated member, a carrier matrix, a continuous strip member, and combinations thereof into the rod member An insertion unit configured to, and
An adsorbent release unit configured to release the adsorbent from the carrier material after the adsorbent held by the carrier material is disposed within the rod member.   The rod splitting unit further configured to split the rod member into a plurality of rod portions in the longitudinal direction of the rod member so that each rod portion includes at least a part of the adsorbing substance. The device described in 1.   The apparatus of claim 1, further comprising an adsorbent forming unit configured to engage the adsorbent material with the carrier material.   The apparatus of claim 1, wherein the insertion unit is further configured to insert the adsorbent material retained by the carrier material into the rod member in the form of one of a tab, a pellet, and a strand.   The apparatus of claim 1, wherein the adsorbent release unit is further configured to perform one of dissolution, disintegration, and decomposition of the carrier material. A method of forming a cigarette filter rod member defining a longitudinal axis comprising:
Forming a continuous supply of filter material into a continuous cylindrical rod member;
The adsorbent rod rods the adsorbent retained by the carrier material including one of a capsule member, a tubular member, a continuous elongated member, a carrier matrix, a continuous strip member, and combinations thereof. Inserting into the rod member to be placed inside the member;
Splitting the rod member into a plurality of rod portions on the longitudinal axis of the rod member such that each rod portion includes at least a portion of the adsorbent material;
After the adsorbent retained by the carrier material is inserted into the filter material, the adsorbent is released in-situ from the carrier material to the filter material and then combined with the divided rod portion with the released adsorbent. Packing the as-formed cigarette.   7. The method of claim 6, wherein inserting the adsorbent material further comprises inserting an adsorbent material comprising a carbonaceous material held by the carrier material into the rod member.   The step of inserting the adsorbent further includes inserting the adsorbent retained by the carrier material into the rod member, the carrier material including at least one of a high density polymer material and a low density polymer material. The method according to claim 6.   7. The method of claim 6, wherein inserting the adsorbent further comprises inserting an adsorbent retained by a carrier material configured as at least one of a tube, a pellet, and a strand into the rod member. The method described.   The method of claim 6, wherein inserting the adsorbent further comprises inserting an adsorbent retained by the carrier material, the carrier material further retaining a flavorant.   Inserting the adsorbent material into the capsule member, inserting the adsorbent material into the continuous tubular member, engaging the adsorbent material with the continuous elongated member, and suspending the adsorbent material in the carrier matrix. The method of claim 6, further comprising one of the steps of:   The step of inserting the adsorbent further includes the step of inserting the adsorbent retained by the carrier material that includes the continuous strip, and wraps the continuous strip longitudinally around the adsorbent. The method of claim 6, further comprising a step.   The method of claim 6, wherein releasing the adsorbent material comprises one of dissolving the carrier material, disrupting the carrier material, and decomposing the carrier material.

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