Cigarette filter rods and process

Description

/ 21 CIGARETTE FILTER RODS AND PROCESS Cross-referencing to related applications

[001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 456,145, filed March 31, 2023, and U.S. Patent Application No. Field of invention

[002] The present invention relates generally to cigarettes and, in particular, to more environmentally friendly cigarette filters, which reduce the problems caused by discarded filters, which contribute to environmental pollution and litter, while providing similar tobacco smoke filtration efficiency properties. Related technique

[003] A typical cigarette includes a filter at one end, which has a core or body that filters the smoke generated by the combustion of tobacco, and a paper wrapper with one or more layers that surround the filter body. The filter core or body is usually made of synthetic filaments (cellulose acetate) that form a fibrous filtering material and added plasticizer (triacetin). After the user smokes the cigarette, the cellulose acetate filter (disposable plastic) or the cigarette butt is usually discarded. These filters are often discarded in outdoor areas such as beaches, parks, and similar locations. The materials that make up the filter core and the plasticizer, disposable plastic, degrade very slowly over long periods of time (10 to 15 years) and contribute significantly to environmental litter and pollution problems. Petition 870250088511, dated 09 / 30 / 2025, page 45 / 91 / 21

[004] U.S. Patent No. 10 / 076,135, incorporated herein, discloses a filter substrate that addresses the most widespread item on planet Earth, caused by cellulose acetate with the plasticizer (triacetin) used in the manufacture of cigarette filter stems. Due to its biodegradability, water dispersibility, and compostability properties, including its filtering capacity and sensory attributes, the filter substrate is a viable substitute for single-use plastic (SUP) cellulose acetate, which is used almost exclusively by the tobacco industry for smoke filtration worldwide.

[005] The described filter substrate comprises four main fibers: abaca, tencel, cotton, and hemp. Each fiber plays a specific role in the substrate, depending on its size, strength, cellular structure, chemical composition, flexibility, commercial availability, and cost. Each fiber is included in the substrate, according to its formulation, in a specific proportion in which each fiber can perform its ideal role, giving the filter substrate a competitive advantage and superior filterability, biodegradability, mechanical strength, and chemical and sensory performance when compared to paper substrates and even cellulose acetate. Fundamentals of the invention

[006] In one aspect of the disclosure, the filter rod manufacturing process processes a “paper-like” substrate using two main essential alternatives before the substrate (paper-like filter medium) is molded into a filter rod: 1) the substrate is crimped to expose the fibers and thus increase its filtering capacity, and 2) the substrate is stamped, where a stamping pattern is transferred to the substrate in order to promote a designed filtering performance that can be adapted to a wide range of product characteristics. In both Petition 870250088511, dated 09 / 30 / 2025, page 46 / 91 / 21 In the cases described above, the body of the substrate sheet remains preserved and is folded several times in a random pattern until it takes the shape of a rod, and is then wrapped in a paper known as plug-wrap.

[007] Although the amount of substrate folded into a rod shape is sufficient to produce the desired pressure drop or pull resistance, the folding process does not create sufficient backflow resistance to produce effective filtration of specific smoke compounds (particulate phase or vapor phase and, more specifically, carbon monoxide). The corrugation and embossing process creates turbulence, but without any vertical, physical or mechanical obstacles to backflow. Airways or channels are formed naturally when a low pressure drop or low suction resistance is desired. There is substantial axial resistance to airflow, but there is insufficient radial resistance to airflow and mechanical barriers due to the lack of physical bonding between the various fibers that form the substrate.Therefore, while existing rippling and engraving processes promote a level of turbulence, the airflow behavior can be better described as laminar flow than turbulent flow. The axial airflow resistance created by the innovative and revolutionary bonding design process multidimensionally increases the existence of physical obstacles and entrapments, promoting an increase in airflow turbulence, including vortex forces, reducing airflow velocity and consequently activating a further reduction in air channels, thus improving the filtration of TAR, nicotine and, most importantly, carbon monoxide and other particulate and vapor-phase compounds, through the production of improved turbulent airflow dynamics.

[008] Thus, the disclosure aspects involve a filter substrate and a manufacturing process for a bonding filter rod, which can be described as the innovative airflow turbulence enhancer, with multiple bonding areas or binders throughout the filter substrate or other biodegradable materials, single-fiber or multi-fiber, regardless of the(s) Petition 870250088511, dated 09 / 30 / 2025, page 47 / 91 / 21 paper(s) / substrate(s) having been corrugated, embossed or not, which improves the properties of the paper / substrate, including mechanical strength, filtering capacity for vapor and particulate phases, including TAR, nicotine and carbon monoxide, sensory neutrality, filter hardness, substrate processability and post-manufacturing visual improvement and stains after being smoked.

[009] Another aspect of the disclosure involves a cigarette filter rod comprising a filter substrate including opposing surfaces; a plurality of bonding areas on at least one of the opposing surfaces, where the filter substrate is folded several times into a rod shape and the plurality of bonding areas connects at least one of the opposing surfaces, the bonding areas forming airflow barriers that act as air obstacles and cavities that retain gases and particles and produce turbulence in the airflow, reducing the airflow velocity and increasing the coefficient of friction, improving the retention of solids and gases as they pass through the filter rods.

[010] One or more implementations of the disclosure aspect described immediately above include one or more of the following: the filter substrate is crimped, exposing the fibers of the filter substrate and increasing the filtering capacity; the filter substrate is embossed with an embossing pattern, promoting filtering performance; the filter substrate is a biodegradable material; the filter substrate includes monofiber; the filter substrate includes multifiber; the filter substrate is made of at least one of the following materials: abaca, Tencel, cotton, and hemp; The filter substrate includes a fiber mixture of at least one of the following materials: abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0.50% cotton, 0-50% regenerated cellulose, 0-30% natural binder; the bonding areas include an adhesive of one or more of the following: water, glue, Petition 870250088511, dated 09 / 30 / 2025, p. 48 / 91 / 21 plant-based binder, synthetic binder, adhesive and binder; and / or a buffer wrapper that surrounds the filter substrate.

[011] Another aspect of the disclosure involves a method of manufacturing a cigarette filter rod comprising a filter substrate including opposing surfaces; a plurality of bonding areas on at least one of the opposing surfaces, wherein the filter substrate is folded multiple times into a rod shape and the plurality of bonding areas connect at least one of the opposing surfaces, the bonding areas forming barriers to airflow that act as air obstacles and cavities that retain gases and particles and produce turbulence in the airflow, reducing the airflow velocity and increasing the coefficient of friction, increasing the retention of solids and gases as they pass through the filter rods, the method comprising providing the filter substrate; adding bonding material to a plurality of areas on at least one of the opposing surfaces of the filter substrate;Fold the filter substrate multiple times into an elongated rod, so that the plurality of bonding areas connect at least one of the opposite surfaces where the bonding material was added to the plurality of areas; cut the elongated rod into a plurality of individual filter rods.

[012] One or more implementations of the disclosure aspect described immediately above include one or more of the following: adding binder material, including at least one of the following: spraying a dot distribution of binder material onto at least one of the opposite surfaces of the filter substrate, spray jet, atomization, and continuous flow nozzle; funneling the sprayed filter material with a funnel; crimping the filter substrate, exposing the fibers of the filter substrate and increasing the filtration capacity, before adding the binder material to the filter substrate; etching the filter substrate with an etching pattern, promoting filtration performance, before adding the binder material to the filter substrate; the filter substrate is made of at least one of the following materials: abaca, Tencel, cotton, and Petition 870250088511, dated 09 / 30 / 2025, page 49 / 91 / 21 hemp; the filter substrate includes a mixture of fibers of at least one of the following materials: abaca, sisal and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder, the binder material is an adhesive of one or more of the following: water, glue, plant-based binder, synthetic binder, adhesive and binder; and / or enclosing the filter substrate with a sealing casing.

[013] Another aspect of the disclosure involves a method of manufacturing a cigarette filter rod comprising a filter substrate including opposing surfaces; a plurality of bonding areas on at least one of the opposing surfaces, wherein the filter substrate is folded multiple times into a rod shape and the plurality of bonding areas connects at least one of the opposing surfaces, the bonding areas forming airflow barriers and cavities that function as air obstacles that retain gases and particles and produce turbulence in the airflow, reducing the airflow velocity and increasing the coefficient of friction, increasing the retention of solids and gases as they pass through the filter rods, the method comprising providing a cigarette that includes a filter rod that is one of the individual filter rods;The formation of barriers to airflow, with the connecting areas acting as obstacles to the air that retain gases and particles and produce turbulence in the airflow, reduces the airflow velocity and increases the coefficient of friction, thus increasing the retention of solids and gases as they pass through the filter rod.

[014] One or more implementations of the disclosure aspect described immediately above include one or more of the following: the filter substrate is made of at least one of the following materials: abaca, Tencel, cotton, and hemp; the filter substrate includes a mixture of fibers from at least one of the following materials: abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% Petition 870250088511, dated 09 / 30 / 2025, p. 50 / 91 / 21 cotton, 0-50% regenerated cellulose, 0-30% natural binder; and / or bonding areas include an adhesive of one or more of the following: water, glue, plant-based binder, synthetic binder, adhesive and binder.

[015] Other features and advantages of this disclosure will become more apparent to those skilled in the art after reviewing the detailed description below and the accompanying drawings. Brief description of the drawings

[016] The details of the present invention, both in relation to its structure and its operation, can be partially obtained by studying the accompanying drawings, in which similar reference numbers refer to similar parts, and in which:

[017] Figure 1 is a perspective view of an embodiment of a cigarette filter rod which may include the filter substrate;

[018] Figure 2 is a schematic of a paper / substrate filter rod manufacturing system, including a bonding process;

[019] Figure 3 is a top plan view of a filter substrate, showing an example of the distribution of attachment points along the surface of the filter substrate;

[020] Figure 4 illustrates cross-sectional views of the filter rod from Figure 1 and Figure 4B illustrates bonding areas / binders formed by the bonding points / process;

[021] Figure 5 illustrates final views of the air channeling between filter rods made of paper (monofiber filter medium) and biodegradable substrate (multifiber medium) in several stages;

[022] Figure 6 is a flowchart of an exemplary manufacturing process for a paper / substrate filter rod, including the bonding process.

[023] Figures 7-11 are sample results / specifications tables for a series of tests performed related to embodiments of the paper / substrate filter rod manufactured without the bonding process described herein. Petition 870250088511, dated 09 / 30 / 2025, page 51 / 91 / 21

[024] Figure 12 is a table of detection limits for various tests performed in relation to embodiments of the paper / substrate filter rod manufactured by the bonding process described herein.

[025] Figures 13A and 13B are sample result tables for various tests performed related to embodiments of the paper / substrate filter rod manufactured by the bonding process described herein.

[026] Figure 14 is a sample coding table for a series of tests performed related to embodiments of the paper / substrate filter rod manufactured by the bonding process described herein.

[027] Figure 15 is a table of a list of constituents for a series of tests carried out relating to embodiments of the paper / substrate filter rod manufactured by the bonding process described herein. Description of the invention

[028] With reference to figures 1-4 and 6, certain embodiments described herein provide for a filter substrate 100 and a manufacturing process for binder filter rods 110 with multiple binding areas or binders 120 along the filter substrate 100, regardless of whether the filter substrate 100 has been crimped, engraved or not, which improves the properties of the filter substrate, including mechanical strength, filtering capacity for vapor and particulate phases, sensory neutrality and processability.Although the manufacturing process of 110 bonding filter rods is generally described in conjunction with the expansion of the cellular structure of a fiber mixture of at least one of the following materials: abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder, the manufacturing process of 110 bonding filter rods is applicable to any type of paper or paper-like material that can be used in this bonding process in a wide range of industrial and personal applications. Furthermore, the 110 bonding process encompasses any possible adhesive, be it... Petition 870250088511, dated 09 / 30 / 2025, page 52 / 91 / 21 simply by applying water or any other type of glue, binders, whether of vegetable or synthetic origin, or any type of adhesive or binder.

[029] As illustrated in figure 1, the filter substrate 100 may be part of a filter rod 130 of a cigarette 140. The filter rod 130 includes the filter substrate 100 surrounded by a filling casing 150. The filter rod 130 and the cigarette paper 160 of a tobacco rod 165 carrying the contents of the cigarette 140 are rolled together with tip paper 170.

[030] As shown in Figure 2, Figure 4 and Figure 6, to increase radial resistance to airflow and thus improve filtration efficiency, the manufacturing process of the connecting filter rod 110 comprises, in step 180, supplying the filter substrate or paper 100 and, in the optional step 190, embossing or crimping the filter substrate 100 using an embossing or crimping head 200. The embossing process is described in European patent application No. EP 22207022.9, filed on November 11, 2022, which is incorporated by reference herein.In step 210, spray a distribution of binding points 212 across a surface 214 of the substrate or filter paper 100 with a bonding spray system 220; in step 230, funnel the sprayed filter substrate or paper 100 with a funnel 240, in step 250, make an elongated filter rod configuration with rod making bars 260, in step 270, cut the elongated filter rod configuration into individual filter rods 130 with a cutting head 280.After passing through the cutting head 280, the filter rods 130 are at the right size to be transferred by means of a conveyor belt or transfer drums to a tray filling machine, where the filter rods 130 will be stored and eventually transferred to cigarette manufacturing machines for a final step, where the filter rods 130 will undergo an additional cutting process before being attached to the tobacco rod 165 shown in figure 1. The attachment of the filter rod 130 and the tobacco rod 165 is made through the tip paper wrapper 170. Petition 870250088511, dated 09 / 30 / 2025, page 53 / 91 / 21

[031] With reference to FIGURE 3, the bonding spray system 220 deposits liquid dots or droplets 212 across the entire surface 214 of the substrate / paper 100. The liquid dots / droplets 212 react with an existing binding element present in the composition of the substrate or filter paper 100 and / or create a new binding dot to build multiple bonding areas 310, as shown in figure 4, across the entire substrate or filter paper 100, regardless of whether the substrate / filter paper 100 has been crimped, embossed or not. Figure 3 illustrates an example of the arrangement and distribution of the bonding points 212 across the surface 214 of the substrate 100. Various design patterns different from that shown in Figure 3 can be provided / created on the substrate or paper 100. The spraying process 210 can be carried out on a single surface 214 or on both opposite surfaces 212, depending on the desired filtration, hardness and visual appearance.As shown in Figure 2, the Greenbinding™ brand bonding / linking process can be applied anywhere / at any point from bobbing 216 to trim 218, prior to filter rod formation, and different bonding methods can be used, such as, but not limited to, spray atomizers, continuous flow nozzles, spray jet or any other impregnation technique.

[032] The size, number and configuration of the attachment points 212 (e.g., by spray atomizers, continuous flow nozzles, spray jet or any other impregnation technique) can be adjusted depending on the desired filtration and / or to improve the filter hardness, which is a fundamental physical attribute of the filter design. Figure 3 represents only one among an unlimited number of combinations that are achieved and designed to improve selective filtration, the physical and visual aspects of the filter rod 130.

[033] The advantages of the filter substrate 100 and the manufacturing process of the connecting filter rod 110 with multiple connection areas or binders 120 Petition 870250088511, dated 09 / 30 / 2025, page 54 / 91 / 21 positioned radially throughout the substrate of filter 100, regardless of whether the substrate of filter 100 has been crimped, engraved or not, include the following.

[034] 1. Filtration efficiency

[035] As shown in Figure 4, airways or air channels are naturally produced during the filter rod manufacturing process, thus creating an undesirable laminar airflow dynamic. The filter substrate 100 and the filter rod manufacturing process 110 substantially reduce the axial channels produced by bending the substrate 100 during the filter rod manufacturing process, creating the bonding areas 120, which form barriers to airflow and cavities that act as air obstacles that retain gases and solid matter / particles and produce turbulence in the airflow, reducing the airflow velocity and increasing the coefficient of friction, improving the retention of solids and gases as they pass through the filter rods 130. The bonding areas or binders 120 become additional aerosol retention areas (vapor and particulate compounds).Increasing retention improves filtration efficiency and effectiveness by producing enhanced, yet controlled, turbulent airflow dynamics, thereby reducing airflow velocity, increasing airflow resistance and friction, and increasing surface area to improve retention properties and filtration efficiency.

[036] 2. Filter hardness and mechanical strength

[037] The filter substrate 100 and the manufacturing process of the connecting filter rod 110 greatly contribute to improving the physical attribute of the filter called hardness. The filter rods should provide consumers with a pleasant and ergonomic nozzle, designed to accommodate the product, not too hard, therefore uncomfortable, and not too soft, becoming unstable or not firm enough to be used properly. For products where a low pressure drop (low suction resistance) is desired, the amount of Petition 870250088511, dated 09 / 30 / 2025, page 55 / 91 / 21 substrate may not be sufficient to provide adequate hardness to the filter. The filter substrate 100 and the manufacturing process of the connecting filter rod 110 fill the air gaps between the various layers of the substrate 100 with the bonding / binding areas 120, creating rigid connections and additional mechanical support, thus improving the overall structure and rigidity of the filter.

[038] Improved mechanical strength also brings benefits in the storage, transport and manufacturing process of the filter.

[039] Higher levels of hardness can be achieved by adding more points / drops of binder liquid / greater impregnation 212 or by increasing the viscosity of the binder, without the need to increase the amount of substrate 100 used to manufacture the filter rod 130.

[040] Because it is water-soluble, the higher binder concentration does not compromise the biodegradability properties of the filter substrate 100.

[041] 3. Visual appearance

[042] As illustrated in figure 5, it is common to observe air channeling between filter rods made of paper (monofiber filter medium) and between the biodegradable filter substrate (multifiber medium). The filter substrate 100 and the manufacturing process of the binder filter rod 110 resolve the gaps between the substrate layers, filling the airway spaces and thus providing a better visual appearance to the filter rod before and after use.

[043] With reference to figures 7-11, several tests will be described relating to embodiments of the paper / substrate filter rod manufactured without the bonding process described here and a determination of the concentration of selected analytes in the resulting cigarette smoke. Petition 870250088511, dated 09 / 30 / 2025, p. 56 / 91 / 21

[044] Figure 7 illustrates a table of test results for two non-binding / Greenbinding™ filter rods (108 mm long filter rod, 126 mm long filter rod) from prototype cigarettes that were produced in two different constructions and TAR levels (6 mg tar / 27 mm filter and 10 mg tar / 21 mm filter). The following evaluations were performed: visual appearance, physical / analytical parameters (including, but not limited to, shape, weight, filter hardness, pressure drop, tar, nicotine in smoke, carbon monoxide, inhalation resistance) and sensory perception (based on the evaluation of a panel of experts). Test results show reduced levels of TAR9.8 (-4.9%) and nicotine 0.67 (-9.5%) for the 21 mm filter sample and TAR3.8 (-5.0%) and nicotine 0.27 (-12.9%) for the 27 mm filter sample, when compared to the reference cigarette.Furthermore, the test results show a substantial increase in carbon monoxide for the 21 mm sample, 14.3 mg (55.4%), and also a substantial increase in carbon monoxide of 7.6 mg (61.7%) for the 27 mm sample when compared to the reference cigarette. Two important results from this test include: 1) the results of the physical analysis are largely in accordance with those of the cellulose acetate filter prototypes, and the carbon monoxide (CO) parameter is outside the ISO limits. The actual result shows 14.3 mg / cigarette. The tests were performed based on the filter specifications shown in Figure 8.

[045] Figures 9 and 10 illustrate tables of test results for filter rods produced with different specifications without binding / Greenbinding™ (108 mm long trays, 126 mm long trays) and using the Greenbossing™ branding process / technology. Prototype cigarettes were produced and the following evaluations were performed: visual appearance, physical / analytical parameters (including, but not limited to, shape, weight, filter hardness, pressure drop, tar, nicotine in smoke, carbon monoxide, draw resistance) and sensory perception (based on the evaluation of Petition 870250088511, dated 09 / 30 / 2025, p. 57 / 91 / 21 a panel of experts). As shown in the table in Figure 9, the test results show that sample 42981.D exhibits an increased tar level of 10.2 (10.9%) and a nicotine parity level of 0.74 (0%), and sample 42990.D exhibits an increased tar level of 10.2 (10.9%) and a marginally reduced nicotine level of 0.72 (-2.7%) when compared to the reference cigarette. The test results in Figure 9 also show that samples 42981.D and 42990.D exhibit a substantial increase in carbon monoxide of 13.8 (50.0%) when compared to the reference cigarette. As shown in the table in Figure 10, the test results show that samples 43012.D and 43013.D exhibit a reduction in TAR of 4.6 (-25.8%) and 4.8 (-22.6%) and in nicotine of 0.34 (-27.7%) and 0.35 (-25.5%) compared to the reference cigarette. The test results in Figure 10 also show that samples 43012.D and 43013.D exhibit an increase in carbon monoxide of 8.1 (19.1%) and 8.2 (20.6%) respectively compared to the reference cigarette. Three main results of this test include: 1) the results of the physical analysis are largely in accordance with those of the cellulose acetate filter prototypes; 2) the carbon monoxide (CO) parameter is outside the ISO limits for full-flavor prototype constructions (13.8 versus 10 mg / cigarette, ISO limit); and 3) lightweight constructions may only be suitable for cigarettes with a tar level equal to or less than 6 mg / cigarette in order to comply with the market limitation for CO levels. The tests were performed based on the filter specifications shown in Figure 11. The test results shown in Figures 7, 9, and 10 demonstrate that, prior to the bonding process described herein, there was a problem with high CO (carbon monoxide) levels due to inefficient CO filtration.

[046] With reference to figures 12-15, several tests performed relating to the embodiments of the paper / substrate filter rod made by the bonding process described herein and a determination of the concentration of Petition 870250088511, dated 09 / 30 / 2025, page 58 / 91 / 21 analytes selected from cigarette smoke, with Figure 12 illustrating a table of detection limits, as Figure 13A and Figure 13B illustrate tables of sample results, Figure 14 illustrates a sample coding table, and Figure 15 illustrates a table of a list of constituents for the tests performed.

[047] Five samples were tested (Control (Cellulose Acetate Filter 1R6F, Baseline (Greenbossing™), 8% Greenbinding™, 16% Greenbinding™ and 24% Greenbinding™), as listed in Table I of Figure 14. Five replicates per sample were used for the test. 1R6F cigarettes (whole tobacco bud and original tip paper) were used for the Baseline, 8%, 16% and 24% Greenbinding™ SKUs and only the filter element without plugwrap was replaced. All physical parameters and chemical characteristics of the 1R6F were preserved, except for the filter tubes, which were replaced with cellulose acetate filters by the filter substrate or 100 paper with the bonding process described herein.

[048] The lists of specific compounds of interest identified in each analyte group to be reported are listed in Table II of Figure 15. Summaries and results of the analytical methods are shown and / or discussed here. The type of laboratory control used for acceptance is included in each table for a given test method, if applicable. The tests and data generation presented here were performed by McKinney Specialty Labs, LLC of Richmond, Virginia, in accordance with AM-001.

[049] With reference to figures 13A and 13B, which include sample result tables for a series of tests performed related to embodiments of the paper filter rod / substrate manufactured by the Greenbinding™ process described herein, the reference samples showed increased levels of TAR 9.21 (1.7%) and carbon monoxide 11.5 (8.5%) and a reduction in nicotine 0.61 (-14%), 8% of the Greenbinding™ samples showed Petition 870250088511, dated 09 / 30 / 2025, page. 59 / 91 / 21 reduced levels of TAR 8.85 (-2.3%) and nicotine 0.61 (-14.7%), and a marginal increase in carbon monoxide 10.8 (1.9%) when compared with control cigarettes, 16% of Greenbinding™ samples showed reduced levels of TAR 7.77 (-14.2%) and nicotine 0.54 (-24.9%) and a marginal / parity increase in carbon monoxide 10.7 (0.9%) when compared with control cigarettes, and 24% of Greenbinding™ samples showed increased levels of tar 9.64 (6.4%) and an increase in carbon monoxide 11.2 (5.7%) and a decrease in nicotine 0.67 (-6.2%) when compared with control cigarettes.

[050] The paper / substrate filter rod manufactured by the bonding process described herein demonstrates improved filtration efficiency performance and a higher level of carbon monoxide (CO) retention, as can be seen in the table in Figure 8A (Greenbinding™ 8% with CO 1.9%), in the table in Figure 8B (Greenbinding™ 16% with CO 0.9%; Greenbinding™ 24% with CO 5.7%) when compared with filters without the bonding process described herein, and a substantial improvement in filtration performance and carbon monoxide retention levels when compared with samples without the bonding process described herein.

[051] The paper / substrate filter rod manufactured by the bonding process described herein demonstrates active modulation and filtration efficiency in TAR, nicotine and, especially, carbon monoxide, as seen in figures 13A and 13B, when compared with samples without the bonding process described herein, with a notable difference and a much superior performance in carbon monoxide.

[052] The filters containing the paper / substrate filter rod manufactured by the bonding process described here were manufactured using a high-speed filter manufacturing machine, which guarantees the commercial potential for a global-scale implementation. Petition 870250088511, dated 09 / 30 / 2025, pages 60 / 91 / 21

[053] The paper / substrate filter rod manufactured by the bonding process described herein is inert in terms of flavor, therefore it does not add any extraneous sensory attributes to the tobacco smoke and, due to its similarities to the filtering performance of cellulose acetate, the consumer experience is maintained when disposable plastic (cellulose acetate) is replaced by biodegradable filters with the paper / substrate filter rod manufactured by the bonding process described herein.

[054] Due to its carbon monoxide filtering and retention capacity, the paper / substrate filter rod manufactured by the bonding process described here is the only innovative resource capable of meeting the maximum limits set by ISO for TAR, nicotine and carbon monoxide in the EU, thus allowing the immediate migration from disposable plastic to a truly biodegradable plant-based filter solution.

[055] For combustible smoke analyses, smoke from the products was performed using SM450 20-port linear analytical smoke machines. Each product was placed in a holder and smoked according to the applicable analytical method(s) and collected on Cambridge filter pads or impingers. Each product was smoked in replicates of five using the ISO smoke regime. The ISO Smoke Regime included smoking products using a 35 ml puff every 60 seconds, using a bell-shaped curve, and the vent holes were not covered.

[056] Depending on the analysis performed, analyte concentrations are determined by an internal or external standard calibration method, using the regression equation derived from the calibration curve. The results are then converted and typically reported by weight, by device / cigarette(s), or by puff. Examples of calculations are provided below for various types of analysis. Note that in the calculation examples, nanograms (ng) are shown, but the results may be expressed in other units (mg, pg, pg). Factors of Petition 870250088511, dated 09 / 30 / 2025, page 61 / 91 / 21 dilution can also be used in some methods, depending on the sample preparation procedure.

[057] Note that the approximate Limit of Detection (LOD) and Limit of Quantification (LOQ) values ​​are calculated using averages for each assay and are not specific to individual samples.

[058] E-liquid and tobacco analysis results can be reported based on mass / mass, gross weight (ng) or mass / volume (ng / mL). The calculation is as follows: Analyte concentration (ng / g) = Concentration (ng / mL) x Dilution factor x Extraction volume (mL) / Weight of e-liquid or tobacco (g)

[059] In cases where results must be reported on a dry weight basis (DWB), the moisture content of a sample (expressed as moisture or furnace volatiles) can be determined by any of several different analytical methods. The following calculation is used to convert an “as is” result into a “dry weight” result: Analyte concentration (ng / g DWB) = Analyte concentration (ng / g) x 100 / (100 - % moisture)

[060] The final results of aerosol or smoke analysis can be reported based on captured weight (ng), ng / puff, ng / cigarette, ng / device, or ng / g of collected aerosol mass (ACM). The final sample concentrations are calculated using the following equations: Amount of analyte (ng / puff) = Concentration (ng / mL) x Dilution factor x Extraction volume (mL) / Total number of puffs Amount of analyte (ng / cigarette or ng / device) = Concentration (ng / mL) x Dilution factor x Extraction volume (mL) / Total number of cigarettes or devices Petition 870250088511, dated 09 / 30 / 2025, pp. 62 / 91 / 21 Amount of analyte (ng / g MCA) = Concentration (ng / mL) x Dilution factor x Extraction volume (mL) / MCA (g)

[061] LOD and LOQ values ​​are calculated using the same formulas as above. The LOD / LOQ value in mass / mL is converted to the final unit by multiplying by the extraction volume and dividing by the preferred unit (grams, puffs, device, etc.). An example calculation is shown below: Limit of detection (ng / g) = LOD (ng / mL) x Dilution factor x Extraction volume (mL) / Weight of electronic liquid or tobacco (g)

[062] Any deviations from the method that occurred during the course of this study are discussed further below.

[063] Smoke particles are collected in a Cambridge filter (CFP) and agitated in extraction solution (isopropanol with internal standards). An aliquot of the sample solution is analyzed by gas chromatography (GC) and the water, nicotine and menthol content of the smoke condensate is determined.

[064] Since water is a measured and significant constituent for this analytical method, the ambient water content must be uniform throughout sample collection and analysis. Method blanks are collected by extracting conditioned and unused CFPs. The method blanks are used to determine the inherent water concentration of the CFPs and the extraction solution. The average water content of the method blanks is subtracted from the water content of the sample extracts to obtain the final corrected water content for each tobacco sample.

[065] Nicotine can be separated from other constituents using a Carbowax or HP-5 capillary column connected to a Flame Ionization Detector (FID), although the capillary column is preferable. A Porapak QS column and a Thermal Conductivity Detector (TCD) are used for the determination of water. Menthol is analyzed independently of nicotine due to requirements of Petition 870250088511, dated 09 / 30 / 2025, page 63 / 91 / 21 exclusive conditioning and a peak interference in the HP-5 column. The filled Carbowax column and the FID should be used for the determination of menthol.

[066] Tar (nicotine-free dry particulate matter or NFDPM) is calculated by subtracting nicotine and water from TPM. Results are typically reported in milligrams per cigarette (mg / cig) for each smoke sample.

[067] Carbon monoxide (CO) data were generated by McKinney Specialty Labs in accordance with McKinney SL AM-007 method. The objective of this procedure is to describe the collection and quantification of carbon monoxide (CO) in the vapor phase of the main smoke using a non-dispersive infrared (NDIR) detector.

[068] This procedure is applicable to the collection and quantification of CO in the main smoke of cigarettes and cigars. The range for the method is linear up to 6% by volume for cigarettes and 15% by volume for cigars.

[069] The main smoke is collected in gas sampling bags attached to the smoking machine. The CO level present in a smoke sample is quantified with an external standard calibration technique using primary standard gases. Using the number of cigars (cigarettes), the cigar (cigarette) puff count, the puff volume and the environmental conditions, the % CO is converted to milligrams per cigar (cigarette) (mg / cig).

[070] After reading this description, it will be clear to a specialist in the field how to implement the invention in various alternative embodiments and alternative applications. However, although several embodiments of the present invention are described herein, it is understood that these embodiments are presented only by way of example and not by way of limitation.

[071] The above description of the disclosed embodiments is provided to enable anyone skilled in the art to manufacture or use the invention. Various modifications to these embodiments will be readily apparent to those Petition 870250088511, dated 09 / 30 / 2025, p. 64 / 91 / 21. Those skilled in the art, and the generic principles described herein, may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, it should be understood that the description and drawings presented herein represent a currently preferred embodiment of the invention and are therefore representative of the subject matter that is broadly contemplated by the present invention. It is further understood that the scope of the present invention fully encompasses other embodiments that may become obvious to those skilled in the art. Petition 870250088511, dated 09 / 30 / 2025, pp. 65 / 91

Claims

1 / 4 CLAIMS 1. CIGARETTE FILTER ROD, characterized by comprising: a filter substrate including opposing surfaces; a plurality of bonding areas on at least one of the opposing surfaces, wherein the filter substrate is folded several times into a rod shape and the plurality of bonding areas connects at least one of the opposing surfaces, the bonding areas forming barriers to airflow that act as air obstacles and cavities that retain gases and particles and produce turbulence in the airflow, reducing the airflow velocity and increasing the coefficient of friction, improving the retention of solids and gases as they pass through the filter rods.

2. CIGARETTE FILTER ROD, according to claim 1, characterized in that the filter substrate is crimped, exposing the fibers of the filter substrate and increasing the filtering capacity.

3. CIGARETTE FILTER ROD, according to claim 1, characterized in that the filter substrate is engraved with an engraving pattern, promoting filtering performance.

4. CIGARETTE FILTER STICK, according to claim 1, characterized in that the filter substrate is a biodegradable material.

5. CIGARETTE FILTER ROD, according to claim 1, characterized in that the filter substrate includes a single fiber.

6. CIGARETTE FILTER ROD, according to claim 1, characterized in that the filter substrate includes multifiber.

7. CIGARETTE FILTER STEM, according to claim 1, characterized by the filter substrate including a mixture of fibers of at least one of the following: abaca, sisal and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder.

8. CIGARETTE FILTER STICK, according to claim 1, characterized by the bonding areas including an adhesive of one or more of the following: water, glue, plant-based binder, synthetic binder, adhesive and binder.

9. CIGARETTE FILTER STICK, according to claim 1, characterized by further including a buffer housing that encloses the filter substrate.

10. A METHOD FOR MANUFACTURING A CIGARETTE FILTER ROD, described in claim 1, characterized by comprising: providing the filter substrate; adding binding material in several areas on at least one of the opposite surfaces of the filter substrate; bending the filter substrate several times into an elongated rod, so that the various binding areas join at least one of the opposite surfaces where the binding material was added to the various areas; and cutting the elongated rod into several individual filter rods.

11. METHOD, according to claim 10, characterized by adding binding material including at least one of the following options: spraying a dot distribution of binding material onto at least one of the opposite surfaces of the filter substrate, spray jet, atomization, and continuous flow nozzle.

12. METHOD, according to claim 10, characterized by further including channeling the pulverized filter material with a funnel. Petition 870250088511, dated 09 / 30 / 2025, pp. 80 / 91 3 / 4 13. METHOD, according to claim 10, characterized by further comprising corrugating the filter substrate, exposing the fibers of the filter substrate and increasing the filtering capacity, prior to adding the binding material to the filter substrate.

14. METHOD, according to claim 10, characterized by further comprising etching the filter substrate with an etching pattern, promoting filtration performance, prior to the addition of the binding material to the filter substrate.

15. METHOD, according to claim 10, characterized in that the filter substrate includes a mixture of fibers of at least one of the following materials: abaca, sisal and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder.

16. METHOD, according to claim 10, characterized in that the binding material is an adhesive of one or more of the following: water, glue, plant-based binder, synthetic binder, adherent and binder.

17. METHOD, according to claim 10, characterized by further comprising enclosing the filter substrate with a buffer housing.

18. METHOD OF USING A CIGARETTE FILTER ROD, described in claim 1, characterized by comprising: providing a cigarette that includes a filter rod which is one of the individual filter rods; forming airflow barriers and cavities with bonding areas that act as air obstacles that retain gases and particles and produce turbulence in the airflow, reducing the airflow velocity and increasing the coefficient of friction, improving the retention of solids and gases as they pass through the filter rod. Petition 870250088511, dated 09 / 30 / 2025, p. 81 / 91 4 / 4 19. METHOD, according to claim 18, characterized by the filter substrate including a mixture of fibers of at least one of the following materials: abaca, sisal and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder.

20. METHOD, according to claim 18, characterized by the bonding areas including an adhesive of one or more of the following: water, glue, plant-based binder, synthetic binder, adhesive and binder. Petition 870250088511, dated 09 / 30 / 2025, pp. 82 / 91

Images