SEGMENT FOR A SMOKING ARTICLE COMPRISING A CALENDERED FIBER WEB
20250127208 ยท 2025-04-24
Inventors
Cpc classification
International classification
A24D3/04
HUMAN NECESSITIES
Abstract
The invention relates to a segment for a smoking article which comprises a wrapping material and a filter material, wherein the wrapping material wraps the filter material and at least 10% and at most 100% of the mass of the filter material is formed by a calendered fibre web, wherein at least 50% and at most 100% of the mass of the calendered fibre web is formed by organic polymer fibres. The calendered fibre web has a compression factor C of at least 0.45 and at most 0.85.
Claims
1. Segment for a smoking article, which comprises a wrapper material and a filter material, wherein the wrapper material wraps the filter material and at least 10% and at most 100% of the mass of the filter material is formed by a calendered fibrous web, wherein at least 50% and at most 100% of the mass of the calendered fibrous web is formed by organic polymer fibers, and wherein the calendered fibrous web has a compression factor C of at least 0.45 and at most 0.85, wherein the compression factor is calculated by
2. Segment according to claim 1, in which at least 20% and at most 90% of the mass of the filter material is formed by the calendered fibrous web.
3. Segment according to claim 1, in which the compression factor of the calendered fibrous web is at least 0.55 and at most 0.75.
4. Segment according to claim 1, in which at least 90% by weight of the organic polymer fibers are pulp fibers, fibers from regenerated cellulose or fibers from cellulose acetate.
5. (canceled)
6. (canceled)
7. Segment according to claim 1, in which the proportion of organic polymer fibers with respect to the mass of the calendered fibrous web is at least 70% and at most 95%.
8. Segment according to claim 1, in which the calendered fibrous web contains less than 20% fibers from cellulose acetate each with respect to the mass of the calendered fibrous web.
9. (canceled)
10. (canceled)
11. Segment according to claim 1, in which at least 1% and at most 9% of the mass of the calendered fibrous web is formed by one or more additives selected from the group consisting of sizing agents, alkylketene dimers (AKD), alkenyl succinic acid anhydrides (ASA), fatty acids, starch, starch derivatives, carboxy methyl cellulose, alginates, chitosan, wet strength agents, citrates, trisodium citrate, tripotassium citrate, malates, tartrates, acetates, nitrates, succinates, fumarates, gluconates, glycolates, lactates, oxalates, salicylates, -hydroxy caprylates, phosphates, polyphosphates, chlorides, hydrogen carbonates, triacetin, propylene glycol, ethylene glycol, sorbitol, glycerol, polyethylene glycol, polypropylene glycol, polyvinyl alcohol, triethyl citrate, catalysts, activated carbon, flavors and encapsulated flavors.
12. Segment according to claim 1, in which the basis weight of the calendered fibrous web is at least 23 g/m.sup.2 and at most 38 g/m.sup.2.
13. Segment according to claim 1, in which the thickness of the calendered fibrous web is at least 20 m and at most 50 m.
14. Segment according to claim 1, in which the tensile strength with respect to width of the calendered fibrous web, measured in accordance with ISO 1924-2:2008, in at least one direction is at least 8 N/15 mm and at most 60 N/15 mm.
15. Segment according to claim 1, in which the elongation at break of the calendered fibrous web, measured in accordance with ISO 1924-2:2008, in at least one direction is at least 0.8% and at most 3.0%.
16. Segment according to claim 1, in which the calendered fibrous web is coated on at least one side, wherein the coating on at least one side covers at least 20% and at most 100% of the surface area of this side of the calendered fibrous web, and the coating material comprises a material selected from the group consisting of sizing agents, alkylketene dimers (AKD), alkenyl succinic acid anhydrides (ASA), fatty acids, starch, starch derivatives, carboxy methyl cellulose, alginates, chitosan, wet strength agents, citrates, trisodium citrate, tripotassium citrate, malates, tartrates, acetates, nitrates, succinates, fumarates, gluconates, glycolates, lactates, oxalates, salicylates, -hydroxy caprylates, phosphates, polyphosphates, chlorides, hydrogen carbonates, triacetin, propylene glycol, ethylene glycol, sorbitol, glycerol, polyethylene glycol, polypropylene glycol, polyvinyl alcohol, triethyl citrate, catalysts, activated carbon, flavors and encapsulated flavors or comprises a mixture of two or more of these materials.
17. (canceled)
18. (canceled)
19. (canceled)
20. Segment according to claim 16, in which the amount of coating material that is applied to one or both sides of the calendered fibrous web is at least 0.5 g/m.sup.2 and at most 5.0 g/m.sup.2 wherein the amount in g/m.sup.2 is with respect to the surface area to which the coating material is actually applied.
21. Segment according to claim 16, in which the calendered fibrous web is coated on at least one side, wherein the coating covers on at least one side at least 20% and at most 100% of the area of this side of the calendered fibrous web, and the basis weight of the calendered fibrous web including the coating is at least 20 g/m.sup.2 and at most 35 g/m.sup.2, wherein the coating comprises a material that is selected from the group consisting of starch, starch derivatives, cellulose derivatives and mixtures of two or more thereof.
22. Segment according to claim 1, in which the calendered fibrous web is a calendered paper or a calendered nonwoven.
23. Segment according to claim 1, in which the filter material comprises the calendered fibrous web and a further filtration material, wherein the further filtration material is preferably selected from the group consisting of filter papers, cellulose-based nonwovens, hydroentangled nonwovens, tows comprising cellulose acetate, tows comprising regenerated cellulose and combination of two or more thereof.
24. (canceled)
25. Segment according to claim 23, in which the further filtration material is a filter paper, a cellulose-based nonwoven, a hydroentangled nonwoven or a combination of two or more thereof, wherein the further material is web-shaped and is laminated to the calendered fibrous web.
26. (canceled)
27. (canceled)
28. Segment according to claim 1, in which the wrapper material is a paper or a film.
29. (canceled)
30. Segment according to claim 1, wherein the segment is cylindrical with an approximately circular or oval outer boundary of the cross sectional surface and has a nominal diameter of at least 5 mm and at most 8 mm.
31. Segment according to claim 1, wherein the segment has a length of at least 4 mm and at most 40 mm.
32. Segment according to claim 1, for which the draw resistance per unit length of the segment is at least 0.05 mmWG/mm and at most 12.0 mmWG/mm.
33. (canceled)
34. (canceled)
35. Filter rod, wherein the filter rod is cylindrical with an approximately circular or oval outer boundary of the cross sectional surface, has a length of at least 40 mm and at most 200 mm and comprises at least one segment according to claim 1.
36. Filter rod according to claim 35, which comprises at least one segment according to one of claims 1 to 34 and at least one further segment with a filter material, wherein the segments are arranged one after the other in the longitudinal direction of the filter rod, and wherein the filter material of the further segment preferably-comprises cellulose acetate.
37. (canceled)
38. (canceled)
39. Smoking article which comprises at least two segments, wherein one of the segments is a segment according to claim 1 and at least one of the segments contains an aerosol-forming material.
40. Smoking article according to claim 39, which comprises at least three segments, wherein a first segment contains an aerosol-forming material, a second segment is a segment according to claim 1, and a third segment is provided, wherein the third segment in particular-serves for filtration, and wherein the second segment is arranged between the first and the third segment.
41. Smoking article according to claim 40, in which the draw resistance of the third segment is higher than that of the second segment.
42. Smoking article according to claim 40, in which the ratio of the length of the second segment to the length of the third segment is at least 1:2 and at most 5:1.
43. (canceled)
44. Smoking article according to claim 39, wherein the smoking article is a filter cigarette and the aerosol-forming material is tobacco.
45. Smoking article according to claim 39, wherein the aerosol-forming material is only heated but not burned during the intended use of the smoking article and the aerosol-forming material comprises a material that is selected from the group consisting of tobacco, reconstituted tobacco, nicotine, glycerol, propylene glycol, and flavors or a mixture of two or more of these materials.
46. Smoking article according to claim 45, wherein the aerosol-forming material is heated electrically during the intended use and wherein the aerosol-forming material is present as a gel or in liquid form.
Description
BRIEF DESCRIPTION OF THE FIGURE
[0082]
DESCRIPTION OF THE PREFERRED EMBODIMENTS AND SOME COMPARATIVE EXAMPLES
[0083] Some preferred embodiments of segments according to the invention will be described below and compared with examples not according to the invention.
Calculation of the Compression Factor
[0084] In the context of this invention, an exemplary fibrous web of a segment according to the invention with a basis weight of 32 g/m.sup.2, for which the mass per unit area consists of m.sub.1=27.0 g/m.sup.2 pulp fibers with a density .sub.1=1.5 g/cm.sup.3, of m.sub.2=3.2 g/m.sup.2 calcium carbonate particles with a density .sub.2=2.7 g/cm.sup.3, and the remaining mass of further additives, has a volume-weighted density .sub.o of the components of
[0085] In this regard, the further additives were neglected, because their influence on the density is small.
[0086] If a calendered fibrous web with a thickness of d=28 m is manufactured from these components, the compression factor C is
[0087] In the context of this invention, a further exemplary fibrous web of a segment according to the invention with a basis weight of 25 g/m.sup.2, for which the mass per unit area consists of m.sub.1=22.5 g/m.sup.2 polyethylene fibers with a density .sub.1=0.95 g/cm.sup.3 and of m.sub.2=2.0 g/m.sup.2 titanium dioxide particles with density .sub.2=4.2 g/cm.sup.3 and the remaining mass made up of further additives, has a density .sub.o of the components of
[0088] In this regard, the further additives were neglected, because their influence on the density is small.
[0089] If a calendered fibrous web with a thickness of d=30 m is manufactured from these components, the compression factor C is
[0090] The densities of the components of the calendered fibrous web are in general known in the art. By way of example. Table 1 shows some typical values.
TABLE-US-00001 TABLE 1 Density g/cm.sup.3 Pulp 1.5 Regenerated Cellulose 1.5 Cellulose Acetate 1.3 Polylactide 1.2-1.4 Polyethylene 0.9-1.0 Polypropylene 0.9 Calcium Carbonate 2.7 Titanium Dioxide 4.2 Talcum 2.6-2.8
Manufacture of the Calendered Fibrous Web
Calendered Fibrous Web a
[0091] A mixture of pulp fibers consisting of 80% pulp fibers from spruce and pine and 20% pulp fibers from birch was used for the manufacture of the calendered fibrous web. The pulp fibers from spruce and pine were refined to a degree of refining of 67SR, measured in accordance with ISO 5267-1:1999. Starch was added to the fibrous web so that about 95% of its mass consisted of pulp fibers and 5% of starch. The fibrous web was manufactured on a conventional paper machine and calendered at elevated moisture content of the fibrous web in a calendar integrated into the paper machine.
[0092] The density of the components, neglecting the starch, was thus .sub.o=1.5 g/m.sup.3.
[0093] The basis weight was 35 g/m.sup.2 and the thickness 33 m, thus the compression factor is
[0094] The tensile strength and the elongation at break of the calendered fibrous web A were measured according to ISO 1924-2:2008, wherein for the tensile strength in the machine direction a value of 51.6 N/15 mm and for the elongation at break in the machine direction, a value of 1.1% was obtained.
[0095] The fibrous web was also calendered more and less intensively so that other thicknesses and compression factors resulted, as are further shown in Table 3.
Calendered Fibrous Web B
[0096] Fibers from regenerated cellulose were refined to a degree of refining of 73 SR, measured in accordance with ISO 5267-1:1999. From the fibers, a fibrous web was formed on a paper machine using suitable process aids, so that about 99% of the mass of the fibrous web consisted of fibers of regenerated cellulose. The fibrous web was calendered at elevated moisture content of the fibrous web in a calender integrated into the paper machine.
[0097] The density of the components was thus .sub.o=1.5 g/m.sup.3.
[0098] The basis weight was 42 g/m.sup.2 and the thickness 38 m, thus the compression factor is
[0099] The tensile strength and the elongation at break of the calendered fibrous web B were measured according to ISO 1924-2:2008, wherein for the tensile strength in the machine direction a value of 61.7 N/15 mm and for the elongation at break in the machine direction, a value of 1.0% was obtained.
Relationship Between Draw Resistance and Filtration Efficiency
[0100] Cylindrical filter rods with a length of 108 mm and a diameter of about 7.1 mm were manufactured from each of the calendered fibrous webs A and B, wherein the filter material of the filter rods was entirely formed by the calendered fibrous web and was wrapped with a suitable wrapper material with a basis weight of 78 g/m.sup.2. The width of the fibrous web that was used for manufacturing the filter rods varied between 60 mm and 242 mm, whereupon different amounts of filter material were present in the filter rod, in order to vary the draw resistance. The length of the calendered fibrous web that was used for the manufacture of the filter rods was about 108 mm.
[0101] Filter cigarettes were manufactured from the 108 mm long filter rods, wherein the filter rods, cut to segments with a length of 18 mm, served as a filter segment in the filter cigarette. The tobacco blend of the filter cigarette was an American Blend and within the usual production tolerances, the filter cigarettes differed only in respect of the filter segment.
[0102] The filtration efficiency for nicotine was measured as a characteristic parameter for the filtration efficiency. The filter cigarettes were smoked according to a method specified in ISO 3308:2012 and the mass of nicotine (m) exiting from the mouth end as well as the mass of nicotine contained in the filter segment (m.sub.Filter) were determined and by using
m.sub.Filter/(m+m.sub.Filter) [0103] the filtration efficiency for nicotine was calculated. It can be expressed as a percentage and describes the ratio of the amount of nicotine retained in the filter to the amount of nicotine flowing into the filter.
[0104] Table 2 shows the width of the fibrous web (W), the draw resistance (PD), and filtration efficiency (FE) used for nicotine each for a 18 mm long segment, manufactured from the calendered fibrous webs A and B.
[0105] These results were compared with filters produced from paper, which was very similar to calendered fibrous web A with respect to composition and basis weight but not calendered, and from cellulose acetate. The results are shown in
TABLE-US-00002 TABLE 2 W PD FE Fibrous web [mm] [mmWG] [%] A 40 1.2 37.3 A 79 9.2 37.1 A 119 27.8 39.7 A 159 46.4 36.4 B 60 1.8 56.8 B 121 14.1 56.1 B 181 42.3 54.6 B 242 70.7 55.4
Influence of the Compression Factor
[0106] In order to determine in which range of the compression factor for the calendered fibrous web the draw resistance and the filtration efficiency are essentially uncoupled, a fibrous web with a composition of the fibrous web A was calendered using different settings of the calender, so that different thicknesses and densities of the calendered fibrous web resulted. Filter rods with a length of 108 mm were respectively manufactured from a 40 mm and a 159 mm wide calendered fibrous web and cut into 18 mm long segments. The draw resistance of the segments, p.sub.40, for the 40 mm wide fibrous web and p.sub.159 for the 159 mm wide fibrous web, and the filtration efficiency for nicotine of the segments, F40 for the 40 mm wide fibrous web and F159 for the 159 mm wide fibrous web, were determined as described before and a mean rate of change of the filtration efficiency for nicotine was determined relative to the change in draw resistance therefrom by
[0107] The results are shown in Table 3 wherein, for comparison, a mean rate of change of the filtration efficiency for nicotine determined in an analogous manner is also provided for the segment from the non-calendered filter paper (Y), .sub.o=1.5 g/cm.sup.3, and from cellulose acetate (Z) based on the data in
TABLE-US-00003 TABLE 3 D F/P Material [m] C [%/mmWG] A 48 0.462 0.33 A 41 0.541 0.08 A 33 0.672 0.02 A 27 0.821 0.03 A 25 0.887 0.15 Y 52 0.426 0.46 Z 0.45
[0108] It can be seen from Table 3 that in a range of the compression factor of the calendered fibrous web from about 0.45 to about 0.85, the draw resistance and the filtration efficiency for nicotine are essentially uncoupled. However, also at a compression factor of greater than 0.85, the mean rate of change of the filtration efficiency (F/AP) is still small, but the pressure required for the calendering is already very high, so that it is beneficial not to choose the compression factor greater than 0.85.
[0109] Furthermore, in relation to Table 2 the data for the calendered fibrous web B show that an uncoupling of draw resistance and filtration efficiency is essentially independent of the composition of the calendered fibrous web. The range of the compression factor according to the invention is thus valid independently of the composition of the fibrous web.
Effect of the Coating
Calendered Fibrous Web C
[0110] A fibrous web with a basis weight of 23 g/m.sup.2 was manufactured from a mixture of pulp fibers consisting of 45% pulp fibers from spruce and pine and 55% pulp fibers from eucalyptus. The pulp fibers from spruce and pine were refined to a degree of refining of 94 SR, measured in accordance with ISO 5267-1:1999. The fibrous web was manufactured on a conventional paper machine and then coated with starch over the entire surface on both sides on a separate coating unit and calendered at elevated moisture content of the fibrous web on a further device in order to obtain the calendered fibrous web C.
[0111] The amount of starch applied to both sides by coating taken together was about 1.5 g/m.sup.2, i.e. 6.12% of the mass of the calendered fibrous web, so that a basis weight of 24.5 g/m.sup.2 resulted.
[0112] The density of the components, neglecting the starch was thus .sub.o=1.5 g/cm.sup.3.
[0113] From a thickness of 20 m, the resulting compression factor is
[0114] The tensile strength and the elongation at break of the calendered fibrous web C were measured in accordance with ISO 1924-2:2008, wherein for the tensile strength in the machine direction, a value of 29 N/15 mm and for the elongation at break in the machine direction a value of 2.0% was obtained.
[0115] A calendered fibrous web D was manufactured in the same manner but without the coating.
[0116] Filter rods with a length of 108 mm were manufactured from the calendered fibrous webs, wherein the calendered fibrous web C was used with a width of 120 mm and 180 mm and the calendered fibrous web D was used with a width of 120 mm and 180 mm, in order to manufacture four different segments. The length of the calendered fibrous web approximately agreed in all cases with the length of the filter rods of 108 mm. The filter rods were wrapped with a wrapper material with a basis weight of 78 g/m.sup.2. The filtration efficiency for nicotine was determined in the same manner as for the fibrous webs A and B and in Table 4, the width (W) of the calendered fibrous web, the draw resistance (PD) of an 18 mm long segment and the filtration efficiency (FE) for nicotine are shown.
TABLE-US-00004 TABLE 4 W PD FE Fibrous web [mm] [mmWG] [%] C 120 5.9 29.3 C 220 22.5 30.8 D 120 2.9 35.9 D 180 6.7 37.4
[0117] While for the segments according to the invention manufactured from the calendered fibrous web D, the filtration efficiency still somewhat depends on the draw resistance and changes with a rate of change of (37.4-35.9)/(6.7-2.9)=0.39%/mmWG, this rate of change for the segments according to the invention manufactured from the coated and calendered fibrous web C is only (29.3-30.8)/(22.5-5.9)=0.09%/mmWG. This shows that due to the coating, the draw resistance and the filtration efficiency can be uncoupled even better.
[0118] A comparison of these rates of change of segments from the calendered fibrous webs A and B with a basis weight of 35 g/m.sup.2 and 42 g/m.sup.2, respectively, with segments from the calendered fibrous webs C and D with a basis weight of 24.5 g/m.sup.2 and 23 g/m.sup.2, respectively, also shows that the positive effect of the calendering is lower at a low basis weight of the calendered fibrous web and this effect can be compensated for well by a coating.
Combination with Filtration Material
[0119] Starting from an 18 mm long filter segment produced from cellulose acetate with a draw resistance of about 30 mmWG and a filtration efficiency for nicotine of 22.4%, the mass of cellulose acetate was reduced and a 79 mm wide, calendered fibrous web A was added to the filter material. The 18 mm long segment then had a draw resistance of about 15 mmWG and a filtration efficiency of 22.8%. This shows that with the segment according to the invention it is possible to reduce the draw resistance to about a half and keep the filtration efficiency for nicotine approximately constant. If such a reduction of the draw resistance were to be achieved without using the calendered fibrous web A, the filtration efficiency for nicotine would be too low and the hardness of the filter segment would be insufficient.
[0120] The results therefore show that the segment according to the invention can offer great advantages with respect to the adjustment of the draw resistance and the filtration efficiency under consideration of the hardness of the segment and that also, further improvements can be achieved with respect to the biodegradability.
Smoking Article from Three Segments
[0121] A filter cigarette F according to the invention with a length of 83 mm and a diameter of 7.8 mm was manufactured from three segments, wherein the first segment contained an American Blend as tobacco blend, the second segment was a segment according to the invention from the calendered fibrous web C and the third segment contained a filter paper. The second segment was arranged between the first and the third segment and the third segment formed the mouth end of the filter cigarette.
[0122] The second segment had a length of 18 mm with a draw resistance of 22 mmWG, while the third segment was 9 mm long and had a draw resistance of 46 mmWG.
[0123] The filter paper in the third segment was a paper essentially consisting of 100% pulp fibers with a basis weight of 35 g/m.sup.2 and a thickness of 88 m.
[0124] As a comparative example not according to the invention, a filter cigarette X was manufactured with 83 mm, a diameter of 7.8 mm and an American Blend tobacco blend and a 27 mm long filter segment produced from cellulose acetate. The filter segment had a draw resistance of 84 mmWG.
[0125] The filter cigarette F according to the invention and the filter cigarette X not according to the invention serving as comparative example contained the same mass of tobacco and were ventilated by a perforation in the region of the filter, wherein the degree of ventilation was adjusted such that both filter cigarettes had an open draw resistance of about 100 mmWG.
[0126] Both filter cigarettes were smoked according to the standardized methods in ISO 3308 and ISO 4387 and the total particulate matter (TPM), nicotine and carbon monoxide (CO), as well as the puff count (PC) were determined.
[0127] The values shown in Table 5 were obtained.
TABLE-US-00005 TABLE 5 TPM Nicotine CO Cigarette mg/cig mg/cig mg/cig PC F 10.7 0.68 13.6 7.8 X 10.5 0.70 13.4 7.7
[0128] It can be seen from these data that by the combination of the segment according to the invention with a further segment serving for filtration, the smoke yields can be adjusted very well to an otherwise identical filter cigarette with a filter from cellulose acetate. Apart from the flexibility when adjusting the draw resistance and the filtration efficiency, substantial ecological advantages are also generated, because poorly biodegradable cellulose acetate can be avoided.