Bale of lyocell tow, filter for smoking article, smoking article, and method of preparing the same

Abstract

The present application relates to: a bale of lyocell tow; a filter for a smoking article including the lyocell tow; and a smoking article. The bale of lyocell tow and the filter for a smoking article according to the present application can replace conventional bales of cellulose acetate tow and filters in the art.

Description

Technical Field

[0001] The present application relates to a bale of lyocell tow, a filter including the same, a smoking article, and a method of preparing the same.Background Art

[0002] Until now, a cellulose acetate tow has been mainly used as a tow for cigarette filters. Cellulose acetate is known to be a biodegradable material, but filters made of cellulose acetate for smoking articles retain their original form for one or two years after being buried in soil and take a considerable time to completely biodegrade. Considering the quantity of tobacco articles that are discarded as waste after being used for smoking and then landfilled, as well as the quantity and toxicity of tobacco products that are discarded into the living environment and left unattended, it is necessary to further improve the biodegradability of filters for smoking articles. Accordingly, lyocell, which is more environmentally friendly than cellulose acetate, has recently been chosen as a substitute material for cellulose acetate.Disclosure of Invention Technical Problem

[0003] An object of the present application is to provide a bale of lyocell tow that may replace a commercially available cellulose acetate tow, for use as a filter for a smoking article.

[0004] Another object of the present application is to provide a bale of lyocell tow of which a manufacturing process is environmentally friendly and the biodegradability is excellent when discarded.

[0005] Another object of the present application is to provide a bale of lyocell tow that may implement excellent properties of a filter by having a low moisture regain.

[0006] Another object of the present application is to provide a lyocell filter for a smoking article.

[0007] Another object of the present application is to provide a smoking article (e.g., a cigarette) including the lyocell filter.

[0008] Another object of the present application is to provide a method of manufacturing a bale including a lyocell tow with low moisture regain.Solution to Problem

[0009] According to aspects of the present application, a bale of lyocell tow, a filter including the same, and a smoking article are provided.

[0010] According to an aspect, provided is a bale of lyocell tow, including: a compressed lyocell tow; and a packaging wrapper wrapping the compressed lyocell tow, wherein a moisture regain of the lyocell tow is 8 % or less.

[0011] In addition, provided is a filter for a smoking article, including a lyocell tow provided from the bale.

[0012] According to another aspect of the present application, provided is a smoking article including such a lyocell material or the filter.

[0013] According to another aspect of the present application, provided are methods of manufacturing the lyocell tow, the bale of lyocell tow, the filter including the same, and the smoking article.

[0014] In the present specification, the term 'smoking article' refers to an article, such as a tobacco (rolling tobacco) or a cigarette, that can generate aerosols. In this regard, the smoking article may include an aerosol-generating material or an aerosol-forming substrate. In addition, the smoking article may include a solid material based on tobacco raw materials such as flat-leaf tobacco, shredded tobacco leaves, or reconstituted tobacco. In addition, a smoking material may include a volatile compound.

[0015] Unless otherwise specifically defined in the present specification, if the characteristics of the lyocell material, the lyocell tow, the filter for a smoking article, or ingredients or compositions associated therewith are affected by temperature, the temperature at which such characteristics are exhibited or measured may be room temperature. Here, the room temperature refers to a temperature that is not specifically cooled or heated, and may be, for example, a temperature of 10 to 35 °C, specifically, 5 to 35 °C, 20 to 30 °C, or a temperature of about 25 °C.

[0016] As used herein, the term "crimp" or "crimped" may refer to the waviness, curliness, or undulating configuration imparted to materials such as fibers, (mono)filaments, multifilaments and / or yarns, inherently and / or through mechanical, thermal, or chemical processes. A crimp may be characterized by periodic deviations from a straight linear axis along the length of the material, fiber, (mono)filament, multifilament and / or yarn. One crimp of a material, fiber, (mono)filament, multifilament and / or yarn may be defined as one repetition unit of said periodic deviation. The presence of crimp contributes to properties such as elasticity, bulk, resilience, and texture in the material and fabrics made from it.

[0017] Hereinafter, the disclosure of the present application will be described in more detail.

[0018] The present application relates to a bale of lyocell tow. The lyocell tow may be used in a smoking article. Although not specifically limited, the lyocell tow may be used in a filter for a smoking article.

[0019] According to an aspect, provided is a bale of lyocell tow, including: a compressed lyocell tow; and a packaging wrapper wrapping the compressed lyocell tow, wherein a moisture regain of the lyocell tow is 8 % or less.

[0020] In some embodiments, the moisture regain may be measured according to Equation 1: Moisture regain % = W − D / D × 100 wherein, in the equation, W represents the weight of a sample measured before drying, and D represents the weight of a sample measured after drying. In some embodiments, the drying is not particularly limited as long as the sample is dry, i.e. the sample does not contain moisture. The moisture regain is measured using an automatic moisture regain meter, for example a Precisa XM 60 Moisture Analyzer. Such an automatic moisture regain meter includes a scale for measuring the weight of a sample and a drying system. The weight of a sample measured before drying refers to the initial weight of a sample placed in the moisture regain meter. The weight of a sample measured after drying refers to the weight at which the weight change is less than 1 mg when the weight of a sample measured every 30 seconds at 120 °C in the drying system.

[0021] In some embodiments, the moisture regain of the lyocell tow may be from 1 % to 7.2 %.

[0022] In some embodiments, the moisture regain of the lyocell tow may be a value measured from the lyocell tow after opening the bale.

[0023] In some embodiments, the moisture regain of the lyocell tow may be a value measured from the lyocell tow within 10 minutes after opening the bale.

[0024] In some embodiments, the lyocell tow may include a crimped lyocell multifilament.

[0025] In some embodiments, the number of crimps in the lyocell multifilament may be 3.94 crimps / cm (10 crimps / inch) to 19.71 crimps / cm (50 crimps / inch).

[0026] In some embodiments, a single fiber fineness of the lyocell multifilament may be from 1.67 to 8.91 dtex (1.5 to 8.0 denier).

[0027] In some embodiments, a total fineness of the lyocell multifilament may be from 16,700 to 61,233 dtex (15,000 to 55,000 denier).

[0028] In some embodiments, the packaging wrapper may seal the lyocell tow.

[0029] In some embodiments, the packaging wrapper may include a resilient polymer film.

[0030] In some embodiments, the packaging wrapper may include low-density polyethylene (LDPE) or linear low-density polyethylene (LLDPE).

[0031] In some embodiments, the packaging wrapper may include a laminated film including one or more polyamide layers and one or more polyethylene layers.

[0032] In some embodiments, the packaging wrapper may be impermeable to moisture.

[0033] In some embodiments, the packaging wrapper may include a polymer film having a water vapor transmission rate of 5 g / (m 2< *d) or less.

[0034] In some embodiments, the water vapor transmission rate of the packaging wrapper may be measured according to DIN 53122 (2001-08) at 23 °C and 85 % relative humidity.

[0035] In some embodiments, the packaging wrapper may include a polymer film having a gas permeability of 10,000 cm 3< / (m 2< *d*bar) or less.

[0036] In some embodiments, the gas permeability of the packaging wrapper may be measured according to DIN 53380-V (2000-07) at 23 °C and 85 % relative humidity. It is noted that in some disclosures DIN 53380-V can correspond to DIN 53380-1.

[0037] In some embodiments, the packaging wrapper may include a polymer film having a tear strength of 10 N / 15 mm or more.

[0038] In some embodiments, the tear strength of the packaging wrapper may be measured according to DIN EN ISO 527-3 (2019-02).

[0039] In some embodiments, the packaging wrapper may include one or more air-tight connections.

[0040] In some embodiments, the pressure inside the bale may be negative pressure that is lower than the ambient pressure by 0.01 bar or more.

[0041] In some embodiments, the lyocell tow may be for use as a filter for a smoking article.

[0042] In another aspect, provided is a filter for a smoking article, including a lyocell tow provided from any one of the lyocell tow included in the bale of lyocell tow according to the invention.

[0043] In some embodiments, a hardness of the filter may be 80 % or more.

[0044] In some embodiments, the hardness of the filter may be a value measured according to Equation 2: Filter hardness % = DA − a / DA × 100 wherein, in the equation, DA represents the diameter of the initial filter, and a represents the distance from the diameter of the initial filter reduced by a weight of 300 g. In other words, the initial filter is loaded with a weight of 300 g and a is a value obtained by subtracting the diameter of the initial filter after the initial filter is loaded with the weight from the diameter of the initial filter.

[0045] In some embodiments, the hardness of the filter may be less than 7 %.

[0046] In some embodiments, a hardness reduction of the filter may be a value measured according to Equation 3: Hardness reduction of filter by addition of moisture % = H 1 − H 2 wherein, in the equation, H1 represents the filter hardness before injection of water, and H2 represents the filter hardness measured 5 minutes after injection of 20 µl of water into the filter.

[0047] According to another aspect, provided is a smoking article including a filter for a smoking article as described in the application.

[0048] According to another aspect, provided is a method of manufacturing a bale of lyocell tow, the method including: spinning a lyocell dope; coagulating; obtaining a lyocell multifilament; water-washing; performing first emulsion treatment; crimp-imparting; performing second emulsion treatment; drying; plaiting; and wrapping a lyocell tow.

[0049] In addition, in some embodiments, during transfer of the lyocell tow from the drying to the plaiting, dry gas having a moisture content of 30 mg / m 3< or less is supplied to the surrounding of the lyocell tow.

[0050] In some embodiments, the moisture content in the dry gas may be from 0.1 to 25 mg / m 3< .

[0051] In some embodiments, the dry gas may include air or inert gas.

[0052] In some embodiments, the inert gas may include nitrogen, argon, helium, or a combination thereof.

[0053] In some embodiments, the dry gas may be supplied by a dehumidifier.

[0054] In some embodiments, a relative humidity inside the dehumidifier may be lower than a relative humidity outside the dehumidifier.

[0055] In some embodiments, from the drying to the plaiting, the lyocell tow may be transferred through the dehumidifier.

[0056] In some embodiments, the dehumidifier may include: a housing; an inlet located on one side of the housing; and an outlet located on another side of the housing.

[0057] In some embodiments, the dehumidifier may include one or more through-holes disposed on the surface of the housing, wherein the dry gas may be supplied into the housing through these through-holes.

[0058] In some embodiments, the lyocell tow may be supplied into the housing through the inlet of the dehumidifier, transferred along the longitudinal axis of the housing, and discharged outside the housing through the outlet of the dehumidifier.

[0059] In some embodiments, the housing of the dehumidifier may be impermeable to moisture.

[0060] In some embodiments, the lyocell tow may be transferred by a conveyor belt within the housing of the dehumidifier.

[0061] In some embodiments, the inlet of the dehumidifier may be positioned adjacent to a dehumidifier used in the drying, and the outlet of the dehumidifier may be positioned adjacent to a plaiting machine used in the plaiting.

[0062] In some embodiments, the performing of the second emulsion treatment may include spraying an emulsion-containing composition to a lyocell multifilament.

[0063] In some embodiments, the emulsion-containing composition may be an aqueous solution, and may have a water content of 50 to 80 wt% based on the total weight of the emulsion-containing composition.

[0064] In some embodiments, a moisture regain of the lyocell tow included in the bale may be 2 times or less than a moisture regain of the lyocell tow dried in the drying.

[0065] In some embodiments, the moisture regain of the lyocell tow included in the bale may be 1.5 times or less than the moisture regain of the lyocell tow dried in the drying.

[0066] In some embodiments, the moisture regain of the lyocell tow dried in the drying may be 4 % or less.

[0067] In some embodiments, the moisture regain of the lyocell tow compressed in the plaiting may be 8 % or less.

[0068] In some embodiments, the moisture regain of the lyocell tow included in the bale may be 8 % or less.

[0069] In some embodiments, the moisture regain of the lyocell tow included in the bale may be from 1 % to 7.2 %.

[0070] In some embodiments, the packaging wrapper may seal the lyocell tow in the wrapping.

[0071] In some embodiments, the bale of lyocell tow includes: a compressed lyocell tow; and a packaging wrapper wrapping the compressed lyocell tow, wherein the lyocell tow has a moisture regain of 8 % or less. In this regard, a filter including the lyocell tow provided from the bale of lyocell tow and having low moisture regain exhibits improved filter hardness and a decrease in the hardness reduction of the filter, and thus may be suitable for application in a smoking article.

[0072] For example, the filter for a smoking article including the lyocell tow provided from the aforementioned bale of lyocell tow may have a high hardness of 80 % or more. The high hardness of the filter for a smoking article may improve satisfaction of consumers when using a smoking article including the filter.

[0073] For example, the filter for a smoking article including the lyocell tow provided from the aforementioned bale of lyocell tow may have a hardness reduction of less than 7 %. The low hardness reduction of the filter for a smoking article may suppress defects such as rapid softening of the filter due to the saliva of users when using a smoking article including the filter.[Bale of lyocell tow]

[0074] The bale of lyocell tow according to the present application includes a compressed lyocell tow. The bale may refer to a large package of the lyocell tow or the like wrapped using a packaging wrapper. Before wrapping the lyocell tow, the lyocell tow is compressed by a press, and the compressed lyocell tow may be then wrapped using a packaging wrapper.

[0075] The moisture regain may be measured according to Equation 1: Moisture regain % = W − D / D × 100 wherein, in the equation, W represents the weight of a sample measured before drying, and D represents the weight of a sample measured after drying. Here, the sample is the lyocell tow. For a more specific method of measuring the moisture regain, reference is made to the other aspects, in particular to Evaluation Example 1.

[0076] An upper limit of the moisture regain of the lyocell tow may be, for example, 8 % or less, 7.2 % or less, 7 % or less, 6.5 % or less, 6 % or less, 5.5 % or less, 5 % or less, 4.5 % or less, or 4 % or less. A lower limit of the moisture regain of the lyocell tow may be, for example, greater than 0 %, 0.1 % or more, 0.5 % or more, 1 % or more, 1.5 % or more, or 2.0 % or more. The low moisture regain of the lyocell tow may improve the hardness of the filter manufactured using the lyocell tow and suppress the hardness reduction of the filter. The moisture regain of the lyocell tow may be, for example, from 1 % to 7.2 %.

[0077] The moisture regain of the lyocell tow included in the bale may be a value measured from the lyocell tow after opening the bale. After opening the bale of lyocell tow, the lyocell tow is collected and the moisture regain of the collected lyocell tow is measured to determine the moisture regain of the lyocell tow included in the bale. The moisture regain of the lyocell tow may be a value measured within, for example, 10 minutes, 5 minutes, or, preferably, 3 minutes after opening the bale. The moisture regain may be measured by an automatic moisture regain meter. When the time elapsed after opening the bale of lyocell tow and before measuring the moisture regain is too long, the measured moisture regain of the lyocell tow may differ from the moisture regain of the lyocell tow included in the bale.

[0078] The packaging wrapper may, for example, seal the lyocell tow. When the packaging wrapper seals the lyocell tow, the lyocell tow may maintain a low moisture regain within the bale.

[0079] The packaging wrapper may include, for example, a resilient polymer film. When the packaging wrapper includes a resilient polymer film, cracking and damage of the packaging wrapper may be prevented while transferring the bale.

[0080] The packaging wrapper may be, for example, a polymer film including LDPE or LLDPE.

[0081] The packaging wrapper may include, for example, a laminated film including one or more polyamide layers and one or more polyethylene layers. The packaging wrapper in the form of a laminated film may be able to provide improved flexibility and durability at the same time.

[0082] The packaging wrapper may be, for example, impermeable to moisture. The packaging wrapper may be, for example, a moisture-impermeable polymer film. The packaging wrapper may be, for example, a moisture-impermeable laminated film.

[0083] The packaging wrapper may be, for example, a polymer film having a water vapor transmission rate of 5 g / (m 2< *d) or less, 1 g / (m 2< *d) or less, 0.5 g / (m 2< *d) or less, or 0.15 g / (m 2< *d) or less. The water vapor transmission rate of the packaging wrapper may be, for example, measured according to DIN 53122 (2001-08) at 23 °C and 85 % relative humidity.

[0084] The packaging wrapper may include, for example, a polymer film having a gas permeability of 10,000 cm 3< / (m 2< *d*bar) or less, 1,000 cm 3< / (m 2< *d*bar) or less, 100 cm 3< / (m 2< *d*bar) or less, 10 cm 3< / (m 2< *d*bar) or less, or 1 cm 3< / (m 2< *d*bar). The gas permeability of the packaging wrapper may be, for example, measured according to DIN 53380-V (2000-07) at 23 °C and 85 % relative humidity.

[0085] The packaging wrapper may include, for example, a polymer film having a tear strength of 10 N / 15mm or more, 50 N / 15mm or more, 100 N / 15mm or more, or 500 N / 15mm or more. The tear strength of the packaging wrapper may be, for example, measured according to DIN EN ISO 527-3 (2019-02).

[0086] The packaging wrapper may include, for example, one or more air-tight connections. The packaging wrapper wraps the compressed lyocell tow by the air-tight connections such that the contact between the lyocell tow and air and / or moisture may be effectively prevented.

[0087] The pressure inside the bale may be, for example, negative pressure that is lower than the pressure outside the bale. The pressure inside the bale may be, for example, negative pressure that is lower than the ambient pressure by 1000 Pa (0.01 bar) or more, 2000 Pa (0.02 bar) or more, 5000 Pa (0.05 bar) or more, 10000 Pa (0.1 bar) or more, 50000 Pa (0.5 bar), or more or 100000 Pa (1 bar) or more. The negative pressure is generated naturally by the expansion of a compressed lyocell filter, or artificially by exhausting air with a vacuum pump or the like.

[0088] The negative pressure, which is lower than the ambient pressure, inside the bale may prevent cracks or damage to the packaging wrapper caused by the expansion of a compressed lyocell filter. In addition, the negative pressure, which is lower than the ambient pressure, inside the bale may allow the bale to easily maintain its reduced volume.[Multi-lobal cross-section]

[0089] One or more of the lyocell monofilaments included in the lyocell tow of the present application may have a multi-lobal cross-section. The term "multi-lobal" means that the shape of the outer contour of a cross-section is not circular, and the term "cross-section" refers to a cross-section obtained by cutting a lyocell monofilament imaginary or actually perpendicular to the lengthwise direction of the filament.

[0090] The outer contour of the multi-lobal cross-section may be tangent to each of a first imaginary circle and a second imaginary circle. In addition, the second imaginary circle may be drawn inside the first imaginary circle.

[0091] The first imaginary circle may be the circle with the smallest area value among circles drawn to completely include one cross-section of the monofilament. The second imaginary circle may be the circle with the largest area value among circles drawn within the cross-section of the monofilament.

[0092] If a circumscribed circle that can include the cross-section of the monofilament is drawn, the first imaginary circle may be the circumscribed circle. If an inscribed circle is drawn inside the cross-section of the monofilament, the second imaginary circle may be the inscribed circle.

[0093] The multi-lobal cross-section may have a shape including multiple projections, and for example, may be a Y-shaped cross-section including three projections. The multiple projections may be understood as being integrally formed with the second imaginary circle as a center, provided that ends of the projections are tangent to the first imaginary circle.

[0094] A multi-lobal ratio of the monofilament may be defined by Equation A: Multi − lobal ratio = r 1 / r 2 wherein r1 represents a radius of the first imaginary circle, and r2 represents a radius of the second imaginary circle.

[0095] For example, the radius of the first imaginary circle may be from 4 to 40 µm, and the radius of the second imaginary circle may be from 2 to 14 µm. The multi-lobal ratio may be from 1.01 to 10, 1.1 to 5, or 1.2 to 2.

[0096] In addition, a space occupancy of the monofilament may be defined by Equation B: Space occupancy = S 1 / S 2 × 100 % wherein S1 represents an area of the first imaginary circle, and S2 represents a cross-sectional area of the monofilament included in a lyocell tow.

[0097] For example, the monofilament having a multi-lobal cross-section may have a space occupancy of 120 to 600 %, 150 to 450 %, or 150 to 300 %.[Fineness]

[0098] The lyocell tow may include a lyocell multifilament, and the lyocell multifilament may have suitable fineness for manufacturing a filter for a smoking article and for ensuring functionality of the filter.

[0099] In some embodiments, a single fiber fineness of a filament constituting the lyocell multifilament may be 1.5 to 8.0 denier. Here, the single fiber fineness of the filament refers to fineness of a single monofilament separated from the multifilament. In other words, the single fiber fineness of a filament constituting the lyocell multifilament refers to the monofilament fineness.

[0100] An upper limit of the single fiber fineness of the filament may be, for example, 8.33 dtex (7.5 denier) or less, 7.78 dtex (7.0 denier) or less, 7.22 dtex (6.5 denier) or less, 6.67 dtex (6.0 denier) or less, 6.11 dtex (5.5 denier) or less, 5.56 dtex (5.0 denier) or less, 5.00 dtex (4.5 denier) or less, 3.89 dtex (3.5 denier) or less, 3.33 dtex (3.0 denier) or less, or 2.78 dtex (2.5 denier) or less. A lower limit of the single fiber fineness of the filament may be, for example, 2.22 dtex (2.0 denier) or more, 2.78 dtex (2.5 denier) or more, 3.33 dtex (3.0 denier) or more, 3.89 dtex (3.5 denier) or more, 4.44 dtex (4.0 denier) or more, 5.00 dtex (4.5 denier) or more, 5.56 dtex (5.0 denier) or more, 6.11 dtex (5.5 denier) or more, 6.67 dtex (6.0 denier) or more, 7.22 dtex (6.5 denier) or more, or 7.78 dtex (7.0 denier) or more. Satisfying the ranges above may be more advantageous for realizing physical properties, such as hardness or suction resistance, and ensuring processability of the filter for a smoking article.

[0101] In some embodiments, a total fineness of the lyocell material may be 1,667 to 6,111 tex (15,000 to 55,000 denier). For example, a lower limit of the total fineness may be, 1,778 tex (16,000 denier) or more, 1,833 tex (16,500 denier) or more, 1,889 tex (17,000 denier) or more, 1,944 tex (17,500 denier)or more, 2,000 tex (18,000 denier) or more, 2,056 tex (18,500 denier) or more, 2,111 tex (19,000 denier) or more, 2,167 tex (19,500 denier) or more, 2,222 tex (20,000 denier) or more, 2,278 tex (20,500 denier) or more, 2,333 tex (21,000 denier) or more, 2,389 tex (21,500 denier) or more, 2,444 tex (22,000 denier) or more, 2,500 tex (22,500 denier) or more, 2,556 tex (23,000 denier) or more, 2,611 tex (23,500 denier) or more, 2,667 tex (24,000 denier) or more, 2,722 tex (24,500 denier) or more, 2,778 tex (25,000 denier) or more, 2,833 tex (25,500 denier) or more, 2,889 tex (26,000 denier) or more, 2,944 tex (26,500 denier) or more, 3,000 tex (27,000 denier) or more, 3,056 tex (27,500 denier) or more, 3,111 tex (28,000 denier) or more, 3,167 tex (28,500 denier) or more, 3,222 tex (29,000 denier) or more, 3,287 tex (29,500 denier) or more, 3,333 tex (30,000 denier) or more, 3,389 tex (30,500 denier) or more, 3,444 tex (31,000 denier) or more, 3,500 tex (31,500 denier) or more, 3,556 tex (32,000 denier) or more, 3,611 tex (32,500 denier) or more, 3,667 tex (33,000 denier) or more, 3,722 tex (33,500 denier) or more, 3,778 tex (34,000 denier) or more, 3,833 tex (34,500 denier) or more, 3,889 tex (35,000 denier) or more, 3,944 tex (35,500 denier) or more, 4,000 tex (36,000 denier) or more, 4,056 tex (36,500 denier) or more, 4,111 tex (37,000 denier) or more, 4,167 tex (37,500 denier) or more, 4,222 tex (38,000 denier) or more 4,278 tex (38,500 denier) or more, 4,333 tex (39,000 denier) or more, 4,389 tex (39,500 denier) or more, 4,444 tex (40,000 denier) or more 4,500 tex (40,500 denier) or more, 4,556 tex (41,000 denier) or more, 4,611 tex (41,500 denier) or more, 4,667 tex (42,000 denier) or more, 4,722 tex (42,500 denier) or more, 4,778 tex (43,000 denier) or more, 4,833 tex (43,500 denier) or more, 4,889 tex (44,000denier) or more, 4,944 tex (44,500 denier) or more, 5,000 tex (45,000 denier) or more, 5,056 tex (45,500 denier) or more, 5,111 tex (46,000 denier) or more, 5,167 tex (46,500 denier) or more, 5,222 tex (47,000 denier) or more, 5,278 tex (47,500 denier) or more, 5,333 tex (48,000 denier) or more 5,389 tex (48,500 denier) or more, 5,444 tex (49,000 denier) or more, 5,500 tex (49,500 denier) or more, 5,556 tex (50,000 denier) or more 5,611 tex (50,500 denier) or more, 5,667 tex (51,000 denier) or more, 5,722 tex (51,500 denier) or more, 5,778 tex (52,000 denier) or more, 5,833 tex (52,500 denier) or more, 5,889 tex (53,000 denier) or more, 5,944 tex (53,500 denier) or more, 6,000 tex (54,000 denier) or more, or 6,056 tex (54,500 denier) or more. An upper limit of the total fineness may be, for example, 6,056 tex (54,500 denier) or less, 6,000 tex (54,000 denier) or less, 5,944 tex (53,500 denier) or less, 5,889 tex (53,000 denier) or less, 5,833 tex (52,500 denier) or less, 5,778 tex (52,000 denier) or less, 5,722 tex (51,500 denier) or less, 5,667 tex (51,000 denier) or less, 5,611 tex (50,500 denier) or less, 5,556 tex (50,000 denier) or less, 5,500 tex (49,500 denier) or less, 5,444 tex (49,000 denier) or less, 5,389 tex (48,500 denier) or less, 5,333 tex (48,000 denier) or less, 5,278 tex (47,500 denier) or less, 5,222 tex (47,000 denier) or less, 5,167 tex (46,500 denier) or less, 5,111 tex (46,000 denier) or less, 5,056 tex (45,500 denier) or less, 5,000 tex (45,000 denier) or less, 4,944 tex (44,500 denier) or less, 4,889 tex (44,000 denier) or less, 4,833 tex (43,500 denier) or less, 4,778 tex (43,000 denier) or less, 4,722 tex (42,500 denier) or less, 4,667 tex (42,000 denier) or less, 4,611 tex (41,500 denier) or less, 4,556 tex (41,000 denier) or less, 4,500 tex (40,500 denier) or less, 4,444 tex (40,000 denier) or less, 4,389 tex (39,500 denier) or less, 4,333 tex (39,000 denier) or less, 4,278 tex (38,500 denier) or less, 4,222 tex (38,000 denier) or less, 4,167 tex (37,500 denier) or less, 4,111 tex (37,000 denier) or less, 4,056 tex (36,500 denier) or less, 4,000 tex (36,000 denier) or less, 3,944 tex (35,500 denier) or less, 3,889 tex (35,000 denier) or less, 3,833 tex (34,500 denier) or less, 3,778 tex (34,000 denier) or less, 3,722 tex (33,500 denier) or less, 3,667 tex (33,000 denier) or less, 3,611 tex (32,500 denier) or less, 3,556 tex (32,000 denier) or less, 3,500 tex (31,500 denier) or less, 3,444 tex (31,000 denier) or less, 3,389 tex (30,500 denier) or less, 3,333 tex (30,000 denier) or less, 3,278 tex (29,500 denier) or less, 3,222 tex (29,000 denier) or less, 3,167 tex (28,500 denier) or less, 3,111 tex (28,000 denier) or less, 3,056 tex (27,500 denier) or less, 3,000 tex (27,000 denier) or less, 2,944 tex (26,500 denier) or less, 2,889 tex (26,000 denier) or less, 2,833 tex (25,500 denier) or less, 2,778 tex (25,000 denier) or less, 2,722 tex (24,500 denier) or less, 2,667 tex (24,000 denier) or less, 2,611 tex (23,500 denier) or less, 2,556 tex (23,000 denier) or less, 2,500 tex (22,500 denier) or less, 2,444 tex (22,000 denier) or less, 2,389 tex (21,500 denier) or less, 2,333 tex (21,000 denier) or less, 2,278 tex (20,500 denier) or less, 2,222 tex (20,000 denier) or less, 2,167 tex (19,500 denier) or less, 2,111 tex (19,000 denier) or less, 2,056 tex (18,500 denier) or less, 2,000 tex (18,000 denier) or less, 1,944 tex (17,500 denier) or less, 1,889 tex (17,000 denier) or less, 1,833 tex (16,500 denier) or less, 1,778 tex (16,000 denier) or less, or 1,722 tex (15,500 denier) or less. When the total fineness is not within the ranges above, continuous processing by cutting is impossible, resulting in reduction in manufacturing the filter for a smoking article. In addition, when the total fineness is not within the ranges above, the content of tow filling a filter paper may be too little or too much when manufacturing the filter for a smoking article, resulting in problems in securing filter properties such as hardness or suction resistance.

[0102] Methods of measuring the fineness are not particularly limited. For example, first, a 2-meter (m) lyocell tow sample to be measured is prepared. The sample is then left in a constant temperature and constant humidity room at a temperature of 20 °C and humidity of 5 % for 24 hours to be stabilized. After fixing one end of the stabilized lyocell tow sample, a 2-kilogram (kg) weight is attached to the other end. The lyocell tow is stabilized by holding it in an elongation state under load for 5 seconds. Next, the elongated lyocell tow is cut into 90 centimeters (cm) long to obtain a sample, and the sample is weighed to calculate the total fineness. The fineness is converted according to a denier conversion method by multiplying the measured weight by 10000. When the total fineness of the sample is divided by the number of monofilaments in the sample, the single fiber fineness of the monofilament in the sample is calculated.

[0103] As such, the total fineness of the lyocell multifilament may be determined by the single fiber fineness of filament and the number of crimps. In the present application, the single fiber fineness and the number of crimps may be controlled, and the total fineness of tow suitable for manufacturing the filter for a smoking article and ensuring functionality may be secured.[Number of crimps]

[0104] The lyocell tow may include, for example, a crimped lyocell multifilament.

[0105] In some embodiments, the lyocell multifilament may have 3.94 to 19.7 crimps per centimeter (10 to 50 crimps per inch). For example, the number of crimps may be 5.91 crimps / cm (15 crimps / inch) or more, 7.87 crimps / cm (20 crimps / inch) or more, 9.84 crimps / cm (25 crimps / inch) or more, 11.81 crimps / cm (30 crimps / inch) or more, 13.78 crimps / cm (35 crimps / inch) or more, 15.75 crimps / cm (40 crimps / inch) or more, or 17.72 crimps / cm (45 crimps / inch) or more. An upper limit of the number of crimps may be, for example, 21.69 crimps / cm (55 crimps / inch) or less, 19.69 crimps / cm (50 crimps / inch) or less, 17.72 crimps / cm (45 crimps / inch) or less, 15.75 crimps / cm (40 crimps / inch) or less, 13.78 crimps / cm (35 crimps / inch) or less, 11.81 crimps / cm (30 crimps / inch) or less, or 9.84 crimps / cm (25 crimps / inch) or less. The lyocell multifilament may have, for example, 19 crimps to 32 crimps per 2.54 cm (19 crimps to 32 crimps per inch). The number of crimps and uniformity of crimps may be controlled by pressure and temperature conditions in the crimp-imparting which will be described below.

[0106] Although not particularly limited, the number of crimps may be, for example, measured using a monofilament property evaluation device (e.g., Favimat). Specifically, the prepared lyocell tow sample may be left for 24 hours and stabilized under conditions of a temperature of 20±2 °C and a humidity of 65±4 %. Then, the sample may be collected without damaging the crimps from the stabilized sample. The collected sample may be mounted on a special jig with a gauge length of 10 to 30 mm. During measurement, the initial load may be 0.45 g / tex (0.05 g / denier), and the crimp sensitivity may be 0.01 mm. The number of crimps may be measured under the same conditions as described above (i.e., a temperature of 20±2 °C and a humidity of 65±4 %).

[0107] Although not particularly limited, the lyocell tow manufactured to satisfy the aforementioned single fiber fineness, total fineness, and / or number of crimps may be used in a smoking article.[Binder]

[0108] In some embodiments, the lyocell tow may further include a binder. The binder may be, for example, on the surface of the lyocell multifilament, or between the lyocell multifilaments (or monofilaments). The binder increases the hardness of the filter for a smoking article, and thus may prevent problems such as filter jamming during a manufacturing process of a filter or a manufacturing process of a smoking article (e.g., a cigarette).

[0109] Types of available binders are not particularly limited, and any known binder that does not impair the purpose of the present disclosure may be used. For example, the binder that provides sufficient compatibility with an emulsion used in the present application, improves the hardness of the filter, and provides excellent binding force may be used.

[0110] For example, the binder may include a polyester-based binder, a cellulose-based binder, and / or a vinyl-based binder.

[0111] Although not particularly limited, the polyester-based binder may include one or more selected from the group consisting of alkylene, arylene, and heteroarylene, each having 5 to 12 carbon atoms.

[0112] The cellulose-base binder may include, for example, hydroxypropyl methylcellulose (HPMC), ethyl cellulose (EC) and / or methyl cellulose (MC), carboxymethyl cellulose(CMC), and the like, but is not limited thereto.

[0113] According to certain embodiments, the cellulose-based binder is selected from the group consisting of hydroxypropyl methyl cellulose (HPMC), ethyl cellulose (EC), methyl cellulose (MC), carboxymethyl cellulose (CMC), or a combination thereof.

[0114] The vinyl-based binder may include, for example, polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), and / or ethylene vinyl acetate (EVAc), and the like, but is not limited thereto.

[0115] According to certain embodiments, the vinyl-based binder is selected from the group consisting of polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), ethylene vinyl acetate (EVAc), or a combination thereof.

[0116] Methods of applying (coating) the binder on a lyocell material will be described below.[Emulsion]

[0117] The lyocell tow may include: a lyocell multifilament; and an emulsion coating the lyocell multifilament. The emulsion may include: (a) an esterified product of fatty acid having 16 or more carbon atoms and aliphatic monovalent alcohol; and (b) an esterified product of sorbitan and fatty acid having 16 or more carbon atoms. Such an emulsion may be applied partially or entirely to the monofilament or multifilament that constitutes a lyocell material. In addition, the emulsion may penetrate between the filaments.

[0118] The emulsion including at least the ingredients (a) and (b) may have hydrophobicity. As a result, the lyocell tow treated with the emulsion may exhibit excellent spreading properties.

[0119] In some embodiments of the present application, the lyocell tow may include a predetermined content of the emulsion. Here, the content of the emulsion may refer to OPU (wt%) which will be described below. The "OPU" stands for "oil pick up ratio". For example, the lyocell tow may include the emulsion in the content of 0.1 wt% or more based on total 100 wt% of the lyocell tow. A lower limit of the content of the emulsion may be, for example, 0.5 wt% or more, 1.0 wt% or more, 1.5 wt% or more, 2.0 wt% or more, 2.5 wt% or more, 3.0 wt% or more, specifically, 3.5 wt% or more, 4.0 wt% or more, 4.2 wt% or more, 4.5 wt% or more, 5.0 wt% or more, 5.5 wt% or more, 6.0 wt% or more, 6.5 wt% or more, 7.0 wt% or more, 7.5 wt% or more, 8.0 wt% or more, 8.5 wt% or more, 9.0 wt% or more, or 9.5 wt% or more. An upper limit of the content of the emulsion may be, for example, 20.0 wt% or less, 18.0 wt% or less, 17.0 wt% or less, 16.0 wt% or less, 15.0 wt% or less, 14.5 wt% or less, 14.0 wt% or less, 13.5 wt% or less, 13.0 wt% or less, 12.5 wt% or less, 12.0 wt% or less, 11.5 wt% or less, 11.0 wt% or less, 10.5 wt% or less, 10 wt% or less, 9.5 wt% or less, 9.0 wt% or less, 8.5 wt% or less, 8.0 wt% or less, 7.8 wt% or less, or 7.6 wt% or less.

[0120] One method of measuring the content (OPU) of the emulsion may be, for example, an extrusion method. For example, a sample (weighing, for example, 2 to 5 g, specifically, about 2.5 g) is collected (here, the weight of the collected sample is referred to as a sample weight), and then, put in a syringe-type container. A material of the container is not particularly limited, but may be a stainless steel (SUS) material. Next, a solvent (e.g., methanol) is added to the container containing the sample (wherein a content of the added solvent may be 10 ml or less (e.g., about 8 ml)). When adding the solvent to the sample, a dropping method may be used, and a dropping speed may be adjusted uniformly. In addition, as described above, the solvent added to the container is allowed to fall from one end of the syringe-type container onto a plate. Here, the plate has been pre-weighed (the measured weight is referred to as plate weight X), and the plate is installed so that the solvent that has fallen onto the plate goes away (i.e., evaporates) at a temperature of 120 to 130 °C (e.g., 125 °C). The solvent is added and dropped three times, and by using a syringe-type container, a pressure is applied to the sample (e.g., 98 N / cm 2< (10 kgf / cm 2< ) or less, 49 N / cm 2< (5 kgf / cm 2< ) or less, or 20 to 39 N / cm 2< (2 to 4 kgf / cm 2< ) to press the sample once. This thoroughly extrudes the solvent and the emulsion contained in the sample. Until no more solvent comes out, the pressure is applied to squeeze the sample. Afterwards, the plate is stored in a desiccator for 5 minutes to 10 minutes, and the plate containing the sample is weighed (referred to as plate weight Y). The content of the emulsion is calculated by Equation C:

[0121] In addition, the lyocell tow, which serves as the standard of the content of the emulsion, may include a lyocell multifilament that has undergone the emulsion treatment at least once. For example, the lyocell tow may include: a lyocell multifilament that has undergone first emulsion treatment (which will be described below); a lyocell multifilament that has undergone first emulsion treatment and second emulsion treatment (which will be described later); or a lyocell multifilament that has undergone the aforementioned emulsion and further treated with a binder which will be described below. In addition, the lyocell multifilament that has undergone the emulsion and / or binder treatment may be crimpled.

[0122] Regarding the emulsion in the present application, the ingredient (a) is a compound that function as a lubricant or oil, and is an ingredient that may be harmless enough to the human body for use in food. The ingredient (a) may provide lubricity to fibers fed into a crimper. If lubricity is insufficient, the lyocell clumps together and will not able to pass through a crimper, and if lubricity if too high, crimps do not form properly. a content of the ingredient (a) may be controlled as described below, in consideration of these functions.

[0123] Regarding the ingredient (a), types of fatty acid forming this ingredient and having 16 or more carbon atoms are not particularly limited. Fatty acid having 16 or more carbon atoms and capable of providing an esterified product that may be harmless enough to humans for use in food may be used.

[0124] For example, as fatty acid having 16 or more carbon atoms, saturated fatty acid and / or unsaturated fatty acid may be used.

[0125] The saturated fatty acid may be, for example, palmitic acid (hexadecanoic acid, CH 3 (CH 2 ) 14 COOH), margaric acid (heptadecanoic acid, CH 3 (CH 2 ) 15 COOH), stearic acid (octadecanoic acid, CH 3 (CH 2 ) 16 COOH), nonadecylic acid (nanodecanoic acid, CH 3 (CH 2 ) 17 COOH), or arachidic acid (eicosanoic acid, CH 3 (CH 2 ) 18 COOH). According to certain embodiments the saturated fatty acid is selected from the group consisting of palmitic acid (hexadecanoic acid, CH 3 (CH 2 ) 14 COOH), margaric acid (heptadecanoic acid, CH 3 (CH 2 ) 15 COOH), stearic acid (octadecanoic acid, CH 3 (CH 2 ) 16 COOH), nonadecylic acid (nonadecanoic acid, CH 3 (CH 2 ) 17 COOH), arachidic acid (eicosanoic acid, CH 3 (CH 2 ) 18 COOH), or a combination thereof. However, types of the available saturated fatty acid are not limited thereto. In some embodiments, the fatty acid may be selected from the group consisting of palmitic acid, margaric acid, stearic acid, nonadecylic acid, arachidic acid, palmitoleic acid, oleic acid, linoleic acid, and arachidonic acid.

[0126] The unsaturated fatty acid may be, for example, palmitoleic acid (CH 3 (CH 2 ) 5 CH=CH(CH 2 ) 7 COOH), oleic acid (CH 3 (CH 2 ) 7 CH=CH(CH 2 ) 7 COOH), linoleic acid (C 18 H 32 O 2 ), or arachidonic acid (C 20 H 32 O 2 ). However, types of the available unsaturated fatty acid are not limited thereto. According to certain embodiments the unsaturated fatty acid is selected from the group consisting of palmitoleic acid (CH 3 (CH 2 ) 5 CH=CH(CH 2 ) 7 COOH), oleic acid (CH 3 (CH 2 ) 7 CH=CH(CH 2 ) 7 COOH), linoleic acid (C 13 H 32 O 2 ), arachidonic acid (C 20 H 32 O 2 ), or combination thereof.

[0127] An upper limit of the number of carbon atoms of the fatty acid having 16 or more carbon atoms may be, for example, 40 or less, 36 or less, 32 or less, 28 or less, 24 or less, or 20 or less.

[0128] Regarding the ingredient (a), types of aliphatic monovalent alcohol forming this ingredient are not particularly limited. Aliphatic monovalent alcohol capable of providing an esterified product that is harmless enough to humans for use in food may be used.

[0129] In some embodiments, saturated aliphatic alcohol or unsaturated aliphatic alcohol may be used, in a linear form or a branched form.

[0130] In some embodiments, the number of carbon atoms of the aliphatic monovalent alcohol may be 1 to 40. The number of carbon atoms of the aliphatic monovalent alcohol may be, for example, 4 or more, 8 or more, 12 or more, 16 or more, or 20 or more.

[0131] The aliphatic monovalent alcohol may be, for example, methanol, ethanol, butanol, lauryl alcohol, isotridecanol, or stearyl alcohol, but is not limited thereto. In some embodiments, the aliphatic monovalent alcohol may be selected from the group consisting of methanol, ethanol, butanol, lauryl alcohol, isotridecanol, and stearyl alcohol.

[0132] In some embodiments, for use as the ingredient (a), an esterified product of isotridecanol and stearic acid (e.g., isotrydecyl stearate) may be used. However, types of the available ingredient (a) are not limited thereto.

[0133] As described below, the content of the ingredient (a) included in the emulsion may be adjusted in consideration of the function of the emulsion or the function of the ingredient (a).

[0134] The ingredient (b), i.e., an esterified product of sorbitan and fatty acid having 16 or more carbon atoms, may be a compound that is able to function as an emulsifier and may be harmless enough to humans for use in food.

[0135] The ingredient (b) may have hydrophilicity and hydrophobicity at the same time due to polyols (i.e., sorbitan), and in this regard, it enables the ingredient (a), which provides lubricity to fibers, to disperse well in water as described below. In addition, the ingredient (a) and the ingredient (b) used together not only increase dispersibility of the emulsion as described above, but also lower the melting point, thereby ensuring the usability and stability of the emulsion. a content of the ingredient (b) may be controlled as described below, in consideration of these functions.

[0136] Regarding the ingredient (b), types of fatty acid forming this ingredient and having 16 or more carbon atoms are not particularly limited. Fatty acid having 16 or more carbon atoms and capable of providing an esterified product that is harmless enough to humans for use in food may be used.

[0137] For example, as fatty acid having 16 or more carbon atoms, saturated fatty acid and / or unsaturated fatty acid may be used.

[0138] The saturated fatty acid may be, for example, palmitic acid (hexadecanoic acid, CH 3 (CH 2 ) 14 COOH), margaric acid (heptadecanoic acid, CH 3 (CH 2 ) 15 COOH), stearic acid (octadecanoic acid, CH 3 (CH 2 ) 16 COOH), nonadecylic acid (nanodecanoic acid, CH 3 (CH 2 ) 17 COOH), or arachidic acid (eicosanoic acid, CH 3 (CH 2 ) 18 COOH). However, types of the available saturated fatty acid are not limited thereto. According to certain embodiments, the saturated fatty acid is selected from the group consisting of palmitic acid (hexadecanoic acid, CH 3 (CH 2 ) 14 COOH), margaric acid (heptadecanoic acid, CH 3 (CH 2 ) 15 COOH), stearic acid (octadecanoic acid, CH 3 (CH 2 ) 16 COOH), nonadecylic acid (nonadecanoic acid, CH 3 (CH 2 ) 17 COOH), arachidic acid (eicosanoic acid, CH 3 (CH 2 ) 18 COOH), or a combination thereof.

[0139] The unsaturated fatty acid may be, for example, palmitoleic acid (CH 3 (CH 2 ) 5 CH=CH(CH 2 ) 7 COOH), oleic acid (CH 3 (CH 2 ) 7 CH=CH(CH 2 ) 7 COOH), linoleic acid (C 18 H 32 O 2 ), or arachidonic acid (C 20 H 32 O 2 ). In certain embodiments, the unsaturated fatty acid is selected from the group consisting of palmitoleic acid (CH 3 (CH 2 ) 5 CH=CH(CH 2 ) 7 COOH), oleic acid (CH 3 (CH 2 ) 7 CH=CH(CH 2 ) 7 COOH), linoleic acid (C 13 H 32 O 2 ), arachidonic acid (C 20 H 32 O 2 ), or a combination thereof. However, types of the available unsaturated fatty acid are not limited thereto. In some embodiments, the fatty acid may be selected from the group consisting of palmitic acid, margaric acid, stearic acid, nonadecylic acid, arachidic acid, palmitoleic acid, oleic acid, linoleic acid, and arachidonic acid.

[0140] An upper limit of the number of carbon atoms of the fatty acid having 16 or more carbon atoms may be, for example, 40 or less, 36 or less, 32 or less, 28 or less, 24 or less, or 20 or less.

[0141] In some embodiments of the present application, for use as the ingredient (b), an esterified product of sorbitan and oleic acid (e.g., sorbitan monooleate) may be used. However, types of the available ingredient (b) are not limited thereto.

[0142] The content of the ingredient (b) may be adjusted in consideration of the aforementioned function of the ingredient (b) and the function of the emulsion.

[0143] In some embodiments, the emulsion may include, based on 100 parts by weight of the esterified product (a) of fatty acid having 16 or more carbon atoms and aliphatic monovalent alcohol, 20 to 60 parts by weight of the esterified product (b) of sorbitan and fatty acid having 16 or more carbon atoms.

[0144] For example, in the emulsion of the present application, the content of the ingredient (b) may be 25 parts by weight or more, 30 parts by weight or more, 35 parts by weight or more, 40 parts by weight or more, 45 parts by weight or more, or 50 parts by weight or more, based on 100 parts by weight of the ingredient (a). In addition, an upper limit of the content of the ingredient (b) based on the 100 parts by weight of the ingredient (a) may be, for example, 55 parts by weight or less, 50 parts by weight or less, 45 parts by weight or less, 40 parts by weight or less, 35 parts by weight or less, 30 parts by weight or less, or 25 parts by weight or less. When the content is satisfied within the ranges above, the surface of the emulsion-treated lyocell multifilament or the emulsion-treated lyocell tow may be hydrophobic.

[0145] In some embodiments, the emulsion may include, based on 100 wt% of the total weight of the emulsion, 40 to 80 wt% of the esterified product (a) of fatty acid having 16 or more carbon atoms and aliphatic monovalent alcohol. Specifically, based on 100 wt% of the total weight of the emulsion, the content of the ingredient (a) may be 45 wt% or more, 50 wt% or more, 55 wt% or more, 60 wt% or more or 65 wt% or more, 70 wt% or more, or 75 wt% or more. In addition, an upper limit of the content may be, for example, 75 wt% or less, 70 wt% or less, 65 wt% or less, 60 wt% or less, 55 wt% or less, 50 wt% or less, or 45 wt% or less.

[0146] In some embodiments, the emulsion may include an excessive content of the ingredient (a).

[0147] In some embodiments, the emulsion may include, based on 100 wt% of the total weight of the emulsion, 15 to 55 wt% of the esterified product (b) of sorbitan fatty acid having 16 or more carbon atoms. Specifically, based on 100 wt% of the total weight of the emulsion, the content of the ingredient (b) may be 20 wt% or more, 25 wt% or more, 30 wt% or more, 35 wt% or more, 40 wt% or more, 45 wt% or more, or 50 wt% or more. In addition, an upper limit of the content may be, for example, 50 wt% or less, 45 wt% or less, 40 wt% or less, 35 wt% or less, 30 wt% or less, or 25 wt% or less.

[0148] In some embodiments, the emulsion may further include water. Water in a small content may assist emulsification.

[0149] A content of the water is not particularly limited, but may be equal to the residual content after subtracting the sum of the contents of the ingredients (a) and (b) from total 100 wt% of the emulsion. The content of the water included in the emulsion (i.e., the residual content after subtracting the sum of ingredients other than water) may be, for example, 10 wt% or less, 9 wt% or less, 8 wt% or less, 7 wt% or less, 6 wt% or less, 5 wt% or less, 4 wt% or less, 3 wt% or less, 2 wt% or less, or 1 wt% or less. In addition, a lower limit of the content may be, for example, 0 wt% or more, 0.1 wt% or more, 0.5 wt% or more, or 1 wt% or more.[Method of manufacturing bale of lyocell tow]

[0150] The present application relates to a method of manufacturing a bale of lyocell tow. Using the method described herein, a bale of lyocell tow may be manufactured. The lyocell tow included in the bale may be used in a smoking article.

[0151] In some embodiments, the method of manufacturing a bale of lyocell tow includes: spinning a lyocell dope; coagulating; obtaining a lyocell multifilament; water-washing; performing first emulsion treatment; crimp-imparting; performing second emulsion treatment; drying; plaiting; and wrapping a lyocell tow. The method of manufacturing a bale of lyocell tow may further include: performing binder treatment; and other processes (steps). Crimp imparting can be referred to crimping.

[0152] During transfer of the lyocell tow from the drying to the plaiting, a dry gas with a moisture content of 30 mg / m3 or less is supplied to the surrounding of the lyocell tow. A dry atmosphere is formed around the lyocell tow by the dry gas.

[0153] The emulsion treatment may be performed before the crimp-imparting, after the crimp-imparting, or before and after the crimp-imparting as described above.

[0154] The emulsion treatment may each independently performed by, for example, spraying the emulsion with the aforementioned composition to the lyocell multifilament or immersing the lyocell multifilament in the emulsion. The emulsion treatment may be performed such that the content of the emulsion (e.g., OPU (wt%)) in a lyocell material is within a predetermined range.

[0155] The crimp-imparting may be performed by, for example, applying steam and / or pressure to the lyocell multifilament.

[0156] The method of manufacturing a bale of lyocell tow according to an embodiment of the present application including the performing of emulsion treatment and crimp-imparting will be described in detail below. The method of the present application may be performed by including one or more of the following processes.<Spinning lyocell dope>

[0157] The spinning a lyocell dope is a process of spinning a lyocell spinning dope including a pulp and an N-methylmorpholine-N-oxide (NMMO).

[0158] A cellulose acetate filter is being blamed for the occurrence of microplastics which are pollutants. In contrast, an amine oxide-based solvent used in the manufacture of a lyocell multifilament is recyclable and biodegradable when discarded. A lyocell tow does not generate any pollutant during the manufacturing process. A lyocell tow may be biodegraded and removed within a relatively short period of time. A lyocell tow is a more eco-friendly tow than a cellulose acetate tow.

[0159] In some embodiments, a content of cellulose in a spinning dope may be, based on 100 wt% of a total weight of the dope, 5 to 15 wt%. When the content of cellulose is excessively small, it is difficult to implement the properties of lyocell fibers, and when the content of cellulose exceeds the range above, it is difficult to dissolve cellulose in a solvent. A lower limit of the content of cellulose may be, for example, 6 wt% or more, 7 wt% or more, 8 wt% or more, 9 wt% or more, or 10 wt% or more. An upper limit of the content of cellulose may be, for example, 14 wt% or less, 13 wt% or less, 12 wt% or less, 11 wt% or less, 10 wt% or less, or 9 wt% or less. The term "cellulose" may refer to "lyocell cellulose".

[0160] In some embodiments, the spinning dope may include an NMMO aqueous solution. The NMMO aqueous solution may contain, for example, based on 100 parts by weight of the NMMO aqueous solution, 80 to 95 parts by weight of NMMO and 5 to 20 parts by weight of water, in consideration of the degree of cellulose solubility and process temperature.

[0161] Shapes of spinneret for discharging the spinning dope are not particularly limited. For example, a doughnut-shaped spinneret may be used.

[0162] A nozzle temperature of the spinneret, specifically, a spinning temperature may be appropriately selected by those skilled in the art. Considering that discharging may not be easily done due to viscosity of the spinning dope that varies depending on the spinning temperature, the spinning may be performed at a temperature of, for example, 100 °C to 120 °C or 100 °C to 110 °C.

[0163] For example, the spinning of the spinning dope may be performed under conditions where the single fiber fineness of a filament is controlled to be in a range of 1.67 dtex to 8.89 dtex (1.5 denier to 8.0 denier). For example, under the spinning conditions where one or more of the discharge content and the spinning rate of the spinning dope are appropriately controlled, the single fiber fineness of a filament included in a lyocell material may be satisfied in a range of 1.67 dtex to 8.89 dtex (1.5 to 8.0 denier). Herein, the single fiber fineness of the filament refers to fineness of a single monofilament separated from the multifilament.

[0164] For example, an upper limit of the single fiber fineness of the filament may be, for example, 8.33 dtex (7.5 denier) or less, 7.78 dtex (7.0 denier) or less, 7.22 dtex (6.5 denier) or less, 6.67 dtex (6.0 denier) or less, 6.11 dtex (5.5 denier) or less, 5.56 dtex (5.0 denier) or less, 5.00 dtex (4.5 denier) or less, 3.89 dtex (3.5 denier) or less, 3.33 dtex (3.0 denier) or less, or 2.78 dtex (2.5 denier) or less. A lower limit of the single fiber fineness of the filament may be 2.22 dtex (2.0 denier) or more, 2.78 dtex (2.5 denier) or more, 3.33 dtex (3.0 denier) or more, 3.89 dtex (3.5 denier) or more, 4.44 dtex (4.0 denier) or more, 5.00 dtex (4.5 denier) or more, 5.56 dtex (5.0 denier) or more, 6.11 dtex (5.5 denier) or more, 6.67 dtex (6.0 denier) or more, 7.22 dtex (6.5 denier) or more, or 7.78 dtex (7.0 denier) or more. The filament satisfying the fineness within the ranges above may be more advantageous for achieving stable suction resistance and processability in the filter for a smoking article.

[0165] The spinning dope discharged from the spinneret may undergo coagulation described below.<Coagulating, and obtaining multifilament>

[0166] The coagulating and the obtaining of a multifilament refer to a process that the lyocell spinning dope is spun and coagulated to obtain a lyocell multifilament.

[0167] For the coagulation, a method of contacting the spinning dope with air and / or a coagulation solution may be used.

[0168] For example, the coagulating may include: a first coagulation process of supplying cold air to the spun lyocell dope; and a second coagulation process of adding the spinning dope resulting from the first coagulation to a coagulation solution for coagulation.

[0169] In some embodiments, the lyocell dope discharged from the spinneret may undergo first coagulation in a space, i.e., an air gap zone, between the spinneret and a coagulation tank. In the air gap zone, for example, cold air may be supplied outwards from the inside of the spinneret, starting from an air-cooling part positioned inside the spinneret. Alternatively, the first coagulation may be achieved by air-quenching or other means.

[0170] In some embodiments, an upper limit of the temperature of cold air in the first coagulation may be, for example, 15 °C or less. The cold air may be, for example, air at a temperature of 14 °C or less, 13 °C or less, 12 °C or less, 11 °C or less, or 10 °C or less. When the temperature exceeds the ranges above, the spinning dope is not coagulated by air sufficiently, resulting in degradation in the spinning-related processability.

[0171] A lower limit of the cold air may be determined in consideration of spinning processability and / or cross-sectional uniformity of the filament. When the temperature of the cold air is lower than 4 °C, the surface of the spinneret may be cooled, the surface of the filament may become non-uniform, and the spinning processability may also deteriorate. The temperature of the cold air may be, for example 5 °C or more, 6 °C or more, 7 °C or more, 8°C or more, or 9 °C or more.

[0172] The degree to which the cold air is supplied may be adjusted in consideration of sufficient coagulation, spinning processability, and effects on the physical properties of the filament. The cold air may be supplied to the discharged spinning dope at an airflow rate of 70 to 400 Nm 3< / h. A lower limit of the airflow rate of the cold air may be, for example, 100 Nm 3< / h or more, 150 Nm 3< / h or more, 200 Nm 3< / h or more, or 250 Nm 3< / h or more. An upper limit of the airflow rate of the cold air may be, for example, 350 Nm 3< / h or less, 300 Nm 3< / h or less, 250 Nm 3< / h or less, 200 Nm 3< / h or less, or 150 Nm 3< / h or less.

[0173] Following the first coagulation as described above, the cooled spinning dope may be provided into a coagulation tank or bath containing a coagulation solution for the second coagulation. For appropriate coagulation, an upper limit of the temperature of the coagulation solution may be, for example, 30 °C or less, or 25 °C or less. A lower limit of the temperature of the coagulation solution may be, for example, 10 °C or more, 15 °C or more, or 20 °C or more. When the temperature is maintained within the ranges above, the coagulation rate may be appropriately maintained.

[0174] Types of the coagulation solution for the second coagulation are not particularly limited. For example, the coagulation solution may contain one or more of water and NMMO.

[0175] In the coagulation solution containing water and NMMO, for example, based on a total weight of the coagulation solution, an amount of water may be 60 to 90 wt% and an amount of NMMO may be 10 to 40 wt%. The coagulation solution may contain, for example, based on a total weight of the coagulation solution, water in the amount of 70 to 80 wt% and NMMO in the amount of 20 to 30 wt%. A concentration of the coagulation solution may be controlled to be maintained during the manufacturing process using a sensor or the like.<Water-washing>

[0176] The water-washing is a process of water-washing the lyocell multifilament after the coagulating and the obtaining of the multifilament. By this water-washing, any residual NMMO and / or other impurities present in the filament may be removed.

[0177] Methods of the water-washing are not particularly limited. For example, the water-washing may be performed by introducing the coagulated lyocell multifilament into a washing bath by using a draw roller. Alternatively, the water-washing may be performed by spraying a water-washing solution during the transfer to the next process by the draw roller.

[0178] Here, ingredients of the water-washing solution are not particularly limited. The water-washing solution may contain, for example, water, and may further contain other additives known in the art.

[0179] Considering reuse after the water-washing, the water-washing solution may be used at a temperature of 100 °C or less.

[0180] For example, the obtaining of the lyocell multifilament may further include drawing the lyocell multifilament into a first roller, and the water-washing may further include drawing the lyocell multifilament into a second roller. For example, a moisture regain of the lyocell multifilament may be adjusted by a ratio of the rotational speed of the second roller to the rotational speed of the first roller. In the water-washing, the drawing of the lyocell multifilament may be performed by one or more rollers. When the drawing of the lyocell multifilament is performed by two or more rollers in the water-washing, the second roller may be the last roller among the two or more rollers.

[0181] By adjusting the ratio of the rotational speed of the second roller to the rotational speed of the first roller, the time for the water-washing of the lyocell multifilament and dehydration upon elongation of the lyocell multifilament may be adjusted. The ratio of the rotational speed of the second roller to the rotational speed of the first roller may be, for example, 1.00 to 1.15. When the ratio of the rotational speed of the second roller to the rotational speed of the first roller is less than 1.00, transport of the lyocell multifilament and production of the lyocell tow may not proceed. When the ratio of the rotational speed of the second roller to the rotational speed of the first roller exceeds 1.15, the strength of the lyocell monofilament may decrease and the shape stability of the lyocell multifilament may be accordingly reduced.

[0182] The method of manufacturing a bale of lyocell tow according to an example may further include pressing the lyocell multifilament. The pressing of the lyocell multifilament may be included between the water-washing and the crimp-imparting. The pressing of the lyocell multifilament may be, for example, performed with a pressure of 3.0 kgf / cm 2< to 3.5 kgf / cm 2< By performing the pressing of the lyocell multifilament, the moisture regain of the lyocell multifilament may be adjusted.<Performing emulsion treatment>

[0183] The performing of emulsion treatment is a process of treating the lyocell multifilament with an emulsion. The performing of emulsion treatment is a process of applying the emulsion of the aforementioned ingredients to the surface of the filament. The emulsion treatment reduces friction on the filament, and accordingly, crimps may be formed properly during the crimp-imparting. When the emulsion treatment is performed twice or more, it may be distinguished as first emulsion treatment and second emulsion treatment depending on the order of the performance.

[0184] The emulsion treatment may be performed by, for example, immersing the lyocell multifilament in a bath filled with the emulsion such that the lyocell multifilament may be completely immersed in the emulsion. Alternatively, the emulsion treatment may be performed by spraying an emulsion solution during the transfer to the next process by the draw roller. For example, the first emulsion treatment may be performed by an immersion method, and the second emulsion treatment may be performed by a spray method. For example, between the first emulsion treatment and the second emulsion treatment, the crimp-imparting may be performed.

[0185] After the performing of emulsion treatment, the method may further include adjusting an amount of the emulsion applied to the lyocell multifilament. For example, before the performing of emulsion treatment and / or after the performing of emulsion treatment, the method may further include removing the emulsion by compressing the surface of the lyocell multifilament using a roll or the like.

[0186] In an example, the emulsion treatment may be performed such that the emulsion content (oil pick up ratio (OPU) (wt%)) satisfies 1.0 wt% or more based on 100 wt% of the lyocell multifilament that has undergone the emulsion treatment at least once. The emulsion-treated lyocell multifilament may be, for example, a lyocell multifilament that has undergone the first emulsion treatment, a lyocell multifilament that has undergone the first emulsion treatment and the second emulsion treatment, or a lyocell multifilament that has undergone the aforementioned emulsion treatment and binder treatment. The lyocell multifilament that has undergone the emulsion treatment and / or binder treatment may be crimped lyocell multifilament.

[0187] A lower limit of the emulsion content in the emulsion-treated lyocell multifilament may be, for example, based on the total weight of the emulsion-treated lyocell multifilament, 0.5 wt% or more, 1.0 wt% or more, 1.5 wt% or more, 2.0 wt% or more, 2.5 wt% or more, 3.0 wt% or more, 3.5 wt% or more, 4.0 wt% or more, 4.2 wt% or more, 4.5 wt% or more, 5.0 wt% or more, 5.5 wt% or more, 6.0 wt% or more, 6.5 wt% or more, 7.0 wt% or more, 7.5 wt% or more, 8.0 wt% or more, 8.5 wt% or more, 9.0 wt% or more, or 9.5 wt% or more. An upper limit of the emulsion content in the emulsion-treated lyocell multifilament may be, for example, based on the total weight of the emulsion-treated lyocell multifilament, 20.0 wt% or less, 18.0 wt% or less, 17.0 wt% or less, 16.0 wt% or less, 15.0 wt% or less, 14.5 wt% or less, 14.0 wt% or less, 13.5 wt% or less, 13.0 wt% or less, 12.5 wt% or less, 12.0 wt% or less, 11.5 wt% or less, 11.0 wt% or less, 10.5 wt% or less, 10 wt% or less, 9.5 wt% or less, 9.0 wt% or less, 8.5 wt% or less, 8.0 wt% or less, 7.8 wt%, or 7.6 wt% or less. The emulsion content in the lyocell multifilament may refer to the dry weight after volatile ingredients, such as solvents, contained in the emulsion have evaporated.

[0188] When the emulsion is treated within the content ranges above, the hydrophilic properties of lyocell tow may be alleviated. Following the emulsion treatment, drying the emulsion may be performed.

[0189] In some embodiments, the single fiber fineness of the filament constituting the lyocell multifilament may be controlled within a range of 1.67 dtex to 8.89 dtex (1.5 to 8.0 denier). The single fiber fineness of the filament refers to fineness of a single monofilament separated from the multifilament, as described above. An upper limit of the single fiber fineness of the filament may be, for example, 8.33 dtex (7.5 denier) or less, 7.78 dtex (7.0 denier) or less, 7.22 dtex (6.5 denier) or less, 6.67 dtex (6.0 denier) or less, 6.11 dtex (5.5 denier) or less, 5.56 dtex (5.0 denier) or less, 5.00 dtex (4.5 denier) or less, 3.89 dtex (3.5 denier) or less, 3.33 dtex (3.0 denier) or less, or 2.78 dtex (2.5 denier) or less. A lower limit of the single fiber fineness of the filament may be 2.22 dtex (2.0 denier) or more, 2.78 dtex (2.5 denier) or more, 3.33 dtex (3.0 denier) or more, 3.89 dtex (3.5 denier) or more, 4.44 dtex (4.0 denier) or more, 5.00 dtex (4.5 denier) or more, 5.56 dtex (5.0 denier) or more, 6.11 dtex (5.5 denier) or more, 6.67 dtex (6.0 denier) or more, 7.22 dtex (6.5 denier) or more, or 7.78 dtex (7.0 denier) or more. When the single fiber fineness of the filament is satisfied within the ranges above, the filter for a smoking article may easily achieve stable suction resistance and ensure processability.

[0190] To ensure the single fiber fineness ranges above, the spinning conditions of the spinning may be controlled. Alternatively, to ensure the single fiber fineness ranges above, one or more of the processing conditions of the spinning, the coagulating, the water-washing, and the performing of emulsion treatment may be controlled.<crimp-imparting>

[0191] The crimp-imparting is a process of preparing crimped lyocell multifilament, preferably, a crimped lyocell tow, by applying steam and / or pressure through a press roller, to the emulsion-treated lyocell multifilament. The crimp-imparting may be referred to as crimping.

[0192] The crimping imparts waves to the lyocell multifilament, and the lyocell multifilament may accordingly have bulky properties. The crimping may be performed by using a known crimp machine, such as a stuffer box and / or a steam box. The crimp machine may be, for example, any machine without particular limitation, as long as it is capable of applying one or more of pressures described below.

[0193] The crimp-imparting may be performed on the lyocell multifilament in which the moisture regain has been controlled by the water-washing and the performing of the emulsion treatment.

[0194] The crimp-imparting may be, for example, performed by simultaneously applying steam and pressure through a press roller, to the multifilament.

[0195] The crimp-imparting may be, for example, performed by applying steam of 0.98 to 19.61 N / cm 2< (0.1 to 2.0 kgf / cm 2< ) to the lyocell multifilament before introducing into the crimp machine (specifically, a press roller).

[0196] The crimp-imparting may be, for example, performed by pressing the lyocell multifilament with a press roller to form pleats in the lyocell multifilament.

[0197] The crimp-imparting may be, for example, performed by applying a pressure of 14.7 to 39.2 N / cm 2< (1.5 to 4.0 kgf / cm 2< ) to the lyocell multifilament that has been introduced into the crimp machine by using a press roller.

[0198] A lower limit of the pressure applied to the lyocell multifilament may be, for example, 15.69 N / cm 2< (1.6 kgf / cm 2< ) or more, 16.67 N / cm 2< (1.7 kgf / cm 2< ) or more, 17.65 N / cm 2< (1.8 kgf / cm 2< ) or more, 18.63 N / cm 2< (1.9 kgf / cm 2< ) or more, 19.61 N / cm 2< (2.0 kgf / cm 2< ) or more, 20.60 N / cm 2< (2.1 kgf / cm 2< ) or more, 21.58 N / cm 2< (2.2 kgf / cm 2< ) or more, 22.56 N / cm 2< (2.3 kgf / cm 2< ) or more, 23.54 N / cm 2< (2.4 kgf / cm 2< ) or more, or 24.52 N / cm 2< (2.5 kgf / cm 2< ). An upper limit of the pressure applied to the lyocell multifilament may be, for example, 38.25 N / cm 2< (3.9 kgf / cm 2< ) or less, 37.27 N / cm 2< (3.8 kgf / cm 2< ) or less, 36.29 N / cm 2< (3.7 kgf / cm 2< ) or less, 35.31 N / cm 2< (3.6 kgf / cm 2< ) or less, 34.33 N / cm 2< (3.5 kgf / cm 2< ) or less, 33.35 N / cm 2< (3.4 kgf / cm 2< ) or less, 32.37 N / cm 2< (3.3 kgf / cm 2< ) or less, 31.39 N / cm 2< (3.2 kgf / cm 2< ) or less, 30.41 N / cm 2< (3.1 kgf / cm 2< ) or less, 29.42 N / cm 2< (3.0 kgf / cm 2< ) or less, 28.44 N / cm 2< (2.9 kgf / cm 2< ) or less, 27.46 N / cm 2< (2.8 kgf / cm 2< ) or less, 26.48 N / cm 2< (2.7 kgf / cm 2< ) or less, 25.50 N / cm 2< (2.6 kgf / cm 2< ) or less, or 24.52 N / cm 2< (2.5 kgf / cm 2< ) or less. When the pressure of the press roller is less than the ranges above, the number of formed crimps may be insufficient. When the pressure of the press roller exceeds the ranges above, the filament may not be fed smoothly into the crimp machine or may not pass through the stuffer box. When the pressure of the pressure roller is within the ranges above, pleats may be formed in the lyocell multifilament.

[0199] In some embodiments, the pressure of 0.98 to 19.61 N / cm 2< (0.1 to 2 kgf / cm 2< ) may be applied using a upper plate to the lyocell multifilament. The upper plate may, for example, apply pressure to the lyocell multifilament while the lyocell multifilament passes through or is passing through the press roller.

[0200] The pressure applied by the upper plate may be, for example, 1.96 N / cm 2< (0.2 kgf / cm 2< ) or more, 2.94 N / cm 2< (0.3 kgf / cm 2< ) or more, 3.92 N / cm 2< (0.4 kgf / cm 2< ) or more, or 4.90 N / cm 2< (0.5 kgf / cm 2< ) or more. The pressure applied by the upper plate may be, for example, 14.71 N / cm 2< (1.5 kgf / cm 2< ) or less, 13.73 N / cm 2< (1.4 kgf / cm 2< ) or less, 12.75 N / cm 2< (1.3 kgf / cm 2< ) or less, 11.77 N / cm 2< (1.2 kgf / cm 2< ) or less, 10.79 N / cm 2< (1.1 kgf / cm 2< ) or less, or 9.81 N / cm 2< (1.0 kgf / cm 2< ) or less.

[0201] The upper plate may move up and down to ensure uniform crimping after passing through the press roller. When the pressure applied by the upper plate is less than 0.1 kgf / cm 2< , the upper plate may not be fixed due to the pressure inside the stuffer box, and consequently, the lyocell tow remain in the stuffer box for a long time and the process continuity may not be maintained. When the pressure of the upper plate exceeds 3 kgf / cm 2< , steam may not be discharged smoothly from the stuffer box, and consequently, the shape of crimps may be irregular.

[0202] In the crimp-imparting, for example, a doctor blade applying a predetermined pressure to the lyocell multifilament may be used. The doctor blade may contribute to controlling the number of crimps by adjusting the retention time of the filament introduced into a stuffer box crimper. The doctor blade may be, for example, located in the path of the lyocell multifilament discharged from the point where the press roller applies pressure after being pressed by the press roller.

[0203] The crimp-imparting may be, for example, performed by applying a pressure of 0.98 to 19.61 N / cm 2< (0.1 to 2 kgf / cm 2< ) to the lyocell multifilament that has passed through the press roller of a crimp machine using the doctor blade.

[0204] The lower limit of the pressure applied by the doctor blade may be, for example, 1.96 N / cm 2< (0.2 kgf / cm 2< ) or more, 2.94 N / cm 2< (0.3 kgf / cm 2< ) or more, 3.92 N / cm 2< (0.4 kgf / cm 2< ) or more, or 4.90 N / cm 2< (0.5 kgf / cm 2< ) or more. The upper limit of the pressure applied by the doctor blade may be, for example, 14.71 N / cm 2< (1.5 kgf / cm 2< ) or less, 13.73 N / cm 2< (1.4 kgf / cm 2< ) or less, 12.75 N / cm 2< (1.3 kgf / cm 2< ) or less, 11.77 N / cm 2< (1.2 kgf / cm 2< ) or less, 10.79 N / cm 2< (1.1 kgf / cm 2< ) or less, or 9.81 N / cm 2< (1.0 kgf / cm 2< ) or less.

[0205] The crimp-imparting may be, for example, performed at a temperature in a range of 120 to 250 °C. When the temperature is too low, the shape stability of the crimps may deteriorate. When the temperature is too high, it may be difficult to form crimps. Considering the steam pressure or the like, the crimp-imparting may be, for example, performed at a temperature of 130 °C or more, 140 °C or more, or 150 °C or more, 200 °C or less, 180 °C or less, or 160 °C or less.<Performing binder treatment>

[0206] The performing binder treatment is a process of treating a binder to the emulsion-treated lyocell multifilament or the lyocell multifilament obtained by the crimp-imparting. The performing of binder treatment may be omitted.

[0207] When the lyocell tow is used to manufacture a filter for a smoking article, a binder may be additionally used in the manufacturing process of the lyocell tow. The binder increases the hardness of a filter for a smoking article including a lyocell material, and thus defects in the filter manufacturing process or tobacco manufacturing process may be prevented.

[0208] Methods of coating the lyocell tow with the binder are not particularly limited. For example, the binder treatment may be performed by immersing the lyocell multifilament in a bath filled with the binder or binder solution such that the lyocell multifilament is completely immersed in the binder. Alternatively, binder coating may be performed by spraying the binder or binder solution onto the lyocell multifilament by using a nozzle.

[0209] The types or ingredients of the binder are the same as described above, and thus descriptions thereof will be omitted.

[0210] The binder or binder solution may further include a solvent in addition to the aforementioned ingredients. The solvent may include, for example, water, ethanol, propylene glycol, and / or glycerin, but is not limited thereto. In some embodiments, the solvent is selected from the group consisting of water, ethanol, propylene glycol, glycerin, or a combination thereof. In the binder including the solvent or in the binder solution including the solvent, the content of the solvent may be, for example, based on total 100 wt% of the binder or binder solution, about 20 to 80 wt% or 40 to 60 wt%.

[0211] The binder treatment may be performed at a level sufficient to achieve the aforementioned purpose of the binder treatment. In the binder treatment, the content of the binder may be, for example, based on total 100 wt% of the lyocell multifilament treated with the emulsion and the binder, 20 wt% or less, or 8 to 15 wt%. The content of the binder may refer to the dry weight after volatilization of volatile components that may be included in the binder.

[0212] After the lyocell multifilament has been coated with the binder, drying may be performed on the binder. The temperature for the drying is not particularly limited, but the drying may be performed at room temperature, for example, 10 to 35 °C.<Performing second emulsion treatment>

[0213] The second emulsion treatment refers to a process of additionally treating the crimped lyocell tow with an emulsion. The second emulsion treatment is a part of the aforementioned emulsion treatment.

[0214] For example, as described above, the second emulsion treatment may be additionally performed after the crimp-imparting. By the second emulsion treatment, the tow may become more flexible. The second emulsion treatment may be performed in the same manner or similar to the aforementioned emulsion treatment.

[0215] The second emulsion treatment may be, for example, performed by applying an emulsion to the lyocell tow that has undergone a process using a crimper. Accordingly, it may be advantageous in various processes used in the manufacture of the filter for a smoking article. The emulsion treatment may, for example, not only allow fibers and filters to spread well in the air during a spreading process, but also limit fiber cutting during an elongation process.

[0216] The second emulsion treatment may be, for example, performed before or after the binder treatment. Alternatively, it may be performed regardless of the binder treatment.

[0217] Even when the second emulsion treatment is performed, the second emulsion treatment may be performed to satisfy the content or OPU content of the emulsion in the material within the same ranges as those described in the aforementioned emulsion treatment.

[0218] The second emulsion treatment may include spraying an emulsion-containing composition to the lyocell multifilament. The spraying may be, for example, performed using a sprayer.

[0219] The emulsion-containing composition may be, for example, an aqueous solution. The content of water may be, for example, 50 to 80 wt% based on the total weight of the emulsion-containing composition. When the content of water in the emulsion-containing composition is excessively low, the dispersibility of the emulsion may be reduced. When the content of water in the emulsion-containing composition is excessively high, the moisture regain of the lyocell tow may increase, resulting in an increase in the moisture regain of the lyocell tow included in the bale.<Drying>

[0220] The drying is a process of removing moisture from the lyocell tow that has undergone the second emulsion treatment.

[0221] For example, after the crimp-imparting or the second emulsion treatment, the drying may be additionally performed. The drying may be, for example, performed at a temperature in a range of 100 to 130 °C. Types or methods of the drying are not particularly limited, and known techniques may be used. The drying may be performed by, for example, applying hot air to the lyocell tow, passing the lyocell tow through a temperature-controlled room for a certain period of time, or leaving the lyocell tow unattended. The drying may be performed by, for example, passing the lyocell tow through a dehumidifier.

[0222] The moisture regain of the lyocell tow dried in the drying may be, for example, 4 % or less, 3.8 % or less, 3.6 % or less, 3.4 % or less, 3.2 % or less, or 3.0 % or less. The moisture regain is determined as described with regard to the other aspects.<Plaiting>

[0223] The plaiting refers to a process in which the lyocell tow dried in the drying is laminated and compressed in the space of a can, box, container, or the like.

[0224] The plaiting may be performed in a plaiting machine. The plaiting refers to a process of preparing a laminated and / or compressed lyocell tow in the plaiting machine by sequentially storing the lyocell tow that has been transferred from the drying in, for example, the spaces inside a can, box, container, or the like. The dry atmosphere may be kept in the plaiting machine.

[0225] The upper limit of the moisture regain of the lyocell tow that has been compressed in the plaiting may be, for example, 8 % or less, 7.5 % or less, 7 % or less, 6.5 % or less, 6 % or less, 5.5 % or less, 5 % or less, or 4.5 % or less. The lower limit of the moisture regain of the lyocell tow that has been compressed in the plaiting may be, for example, 0.1 % or more, 0.5 % or more, 1 % or more, 1.5 % or more, or 2 % or more. The moisture regain of the lyocell tow that has been compressed may be, for example, from 1 % to 7.2 %. As described below, by maintaining the dry atmosphere between the drying and the plaiting, the moisture regain of the lyocell tow that has been compressed in the plaiting may be kept low. The lower the moisture regain of the lyocell tow that has been compressed in the plaiting, the lower the moisture regain of the lyocell tow included in the bale of lyocell tow. The moisture regain is determined as described with regard to the other aspects.<Wrapping lyocell tow>

[0226] The wrapping of the lyocell tow is a process of wrapping the lyocell tow, which has been laminated and / or compressed into a certain shape, using a packaging wrapper.

[0227] The wrapping of the lyocell tow may include, for example: providing the lyocell tow in a compressed form using a press device with a load; releasing the load of the press device that has been applied to the compressed lyocell tow; wrapping each of the upper part and the lower part of the compressed lyocell tow using one or more of a packaging paper box and a packaging wrapper; sealing the side surfaces of the compressed lyocell tow using a packaging wrapper; and obtaining bale of lyocell tow.

[0228] When the lyocell tow is compressed using such a press device, the volume of the lyocell tow may be reduced.

[0229] By releasing the load of the press device that has been applied to the compressed lyocell tow may be released to prepare the compressed lyocell tow.

[0230] Each of the upper part and the lower part of the compressed lyocell tow may be wrapped using one or more of a wrapping paper box and a packaging wrapper. For example, the upper part of the compressed lyocell tow may be wrapped using a packaging paper box, and the lower part of the compressed lyocell tow may be wrapped using a packaging wrapper. For example, the upper part of the compressed lyocell tow may be wrapped using a packaging wrapper, and the lower part of the compressed lyocell tow may be wrapped using a packaging wrapper paper box. For example, both the upper part and the lower part of the compressed lyocell tow may be wrapped using a packaging paper box. For example, both the upper part and the lower part of the compressed lyocell tow may be wrapped using a packaging wrapper.

[0231] In the process of wrapping the upper part and / or the lower part of the compressed lyocell tow using a packaging wrapper, the packaging wrapper wraps the compressed lyocell tow. The packaging wrapper may be, for example, a moisture-impermeable polymer film.

[0232] In the process of sealing the side surfaces of the compressed lyocell tow using a packaging wrapper, a connection part of the packaging wrapper may be sealed by an air-tight connection. By sealing with the packaging wrapper, a bale of lyocell tow may be obtained, and the bale of lyocell tow may block moisture penetration.

[0233] The pressure inside the packaging wrapper, i.e., the pressure inside the bale of lyocell tow may be, for example, a negative pressure that is lower than the external pressure. The negative pressure inside the bale of lyocell tow may suppress the increase in volume of the bale of lyocell tow caused by natural expansion of the lyocell tow.

[0234] The moisture regain of the lyocell tow included in the bale may be 2 times or less, 1.8 times or less, 1.5 times or less, or 1.3 times or less than the moisture regain of the lyocell tow dried in the aforementioned drying. The moisture regain is determined as described with regard to the other aspects.

[0235] By maintaining the drying atmosphere from the drying to the plaiting, an increase in the moisture regain of the lyocell tow during the manufacture of the bale of lyocell tow may be suppressed.<Drying atmosphere between drying and plaiting>

[0236] During the transfer of the lyocell tow from the aforementioned drying to the plaiting, dry gas is supplied to the surrounding of the lyocell tow to form a drying atmosphere, thereby suppressing an increase in the moisture regain of the lyocell tow.

[0237] The dry gas having a moisture content of 30 mg / m 3< or less may be supplied to the surrounding of the lyocell tow. By supplying the dry gas having a moisture content of 30 mg / m 3< or less to the surrounding of the lyocell tow, the drying atmosphere around the lyocell tow may be kept. Consequently, the moisture regain of the lyocell tow included in the bale of lyocell tow may be kept low. The filter manufactured from the lyocell tow included in the bale may provide improved strength and suppressed strength reduction.

[0238] The upper limit of the moisture content in the dry gas may be, for example, 30 mg / m 3< or less, 25 mg / m 3< or less, 20 mg / m 3< or less, 15 mg / m 3< or less, 10 mg / m 3< or less, or 5 mg / m 3< or less. The lower limit of the moisture content in the dry gas may be, for example, 0.1 mg / m 3< or more, 0.5 mg / m 3< or more, or 1 mg / m 3< or more. The moisture content in the dry gas may be, for example 0.1 to 25 mg / m 3< . By providing the dry air having a moisture content within the ranges above to the surrounding of the lyocell tow transferred from the drying to the plaiting, an increase in the moisture regain of the lyocell tow caused by the external environment may be suppressed.

[0239] The dry gas may include, for example, air or inert gas. The inert gas may include, for example, nitrogen, argon, helium, or a combination thereof.

[0240] The dry gas may be, for example, provided by a dehumidifier. The relative humidity inside the dehumidifier may be, for example, lower than the relative humidity outside the dehumidifier. The relative humidity inside the dehumidifier may be, for example, 90 % or less, 80 % or less, 70 % or less, 60 % or less, 50 % or less, 40 % or less, 30 % or less, 20 % or less, or 10 % or less of the relative humidity outside the dehumidifier. By having such low relative humidity inside the dehumidifier, the drying atmosphere may be kept.

[0241] The lyocell tow may be transferred through the dehumidifier from the drying to the plaiting. For example, the lyocell tow dried and discharged from the dehumidifier in the drying may be fed into the dehumidifier, transferred through the dehumidifier, and then discharged from the dehumidifier to be fed into the plaiting machine. The dry gas is supplied into the dehumidifier, and thus the drying atmosphere may be kept therein. The dehumidifier may be, for example, a moisture regain-maintaining device.

[0242] The dehumidifier may include, for example: a housing; an inlet located on one side of the housing; and an outlet located on another side of the housing. The housing may extend from the inlet to the outlet and surrounds the interior space.

[0243] The dehumidifier may include, for example, one or more through-holes on a surface, for example, on a side surface of the housing. The dry gas may be supplied into the housing through these through-holes.

[0244] The lyocell tow may be, for example, fed into the housing through the inlet of the dehumidifier. The lyocell tow may be transferred along the longitudinal axis of the housing. The lyocell tow may be, for example, transferred in the longitudinal axis of the housing in the direction from the inlet to the outlet of the housing. The lyocell tow may be, for example, discharged from the housing through the outlet of the dehumidifier.

[0245] The housing of the dehumidifier may be, for example, impermeable to moisture. The housing of the dehumidifier may be, for example, formed of a metal material. The housing of the dehumidifier may be, for example, formed of a metal sheet.

[0246] The lyocell tow may be, for example, transferred from the inlet of the housing to the outlet of the housing by a conveyor belt within the housing of the dehumidifier.

[0247] The inlet of the dehumidifier may be, for example, located adjacent to the dehumidifier used in the drying. The dried lyocell tow discharged from the dehumidifier may be fed into the inlet of the dehumidifier while minimizing exposure to the external environment. The outlet of the dehumidifier may be, for example, located adjacent to the plaiting machine used in the plaiting. The lyocell tow discharged from the dehumidifier may be fed into the inlet of the plaiting machine while minimizing exposure to the external environment.[Filter for a smoking article]

[0248] The lyocell tow may be used in a filter for a smoking article. The lyocell material may be the lyocell tow. In an example, the lyocell tow includes a crimped lyocell multifilament.

[0249] For example, the present application relates to a filter for a smoking article. The filter for a smoking article may include a lyocell material, and the lyocell material may be the same as described above. In addition, the filter for a smoking article may include a lyocell tow, and the lyocell tow may be the same as described above.

[0250] In addition, the lyocell material may include the emulsion in a content of 0.1 wt% or more based on total 100 wt% of the lyocell material. For the rests, descriptions of the emulsion ingredients and contents thereof are the same as described above.

[0251] In some embodiments, the single fiber fineness of the monofilament constituting the lyocell multifilament may be 1.5 denier to 8.0 denier. Such specific values are the same as described above.

[0252] In some embodiments, the crimped lyocell multifilament may be a lyocell material having a total fineness of 15,000 to 55,000 denier, and may preferably be a lyocell tow. Such specific values are the same as described above.

[0253] In some embodiments, the crimped lyocell multifilament may have 10 to 50 crimps per inch. Such specific values are the same as described above.

[0254] In some embodiments, the filter for a smoking article may further include a binder on the surface of the crimped lyocell multifilament or between the crimped lyocell multifilaments. The binder increases the hardness of the filter for a smoking article made of the tow, and thus may prevent problems such as filter jamming during a manufacturing process of the filter or a manufacturing process of a cigarette. Descriptions of the types, ingredients, and contents of available binders are the same as described above.

[0255] In some embodiments, the filter for a smoking article may further include a wrapping paper (which may be referred to as a rolling paper, a filter paper, or a filter wrapping paper). For example, the wrapping paper wrapper may be a porous paper or a non-porous paper that wraps the aforementioned lyocell tow and maintains a filter shape (e.g., a cylinder or a rube).

[0256] In some embodiments, the hardness of the filter for a smoking article may be, for example, 80 % or more, 83 % or more, 85 % or more, 87 % or more, or 89 % or more. When the hardness of the filter is low, consumer satisfaction may decrease.

[0257] The hardness of the filter may be a value measured by Equation 2: Hardness of filter % = DA − a / DA × 100 wherein, in the equation, DA represents a diameter of an initial filter, and a represents a distance reduced by 300 g of weight from the diameter of the initial filter as described above.

[0258] In some embodiments, the moisture-induced hardness reduction of the filter for a smoking article may be, for example, less than 7 %, 6 % or less, 5 % or less, 4 % or less, or 3 % or less. The lower the moisture-induced hardness reduction, the more effectively the filter may be prevented from softening caused by saliva or the like, when used.

[0259] The moisture-induced hardness reduction of the filter may be a value measured by Equation 3: Hardness reduction % of filter by addition of moisture = H 1 − H 2 wherein, in the equation, H1 represents a filter hardness before injection of water, and H2 represents a filter hardness measured 5 minutes after injection of 20 µl of water into the filter.

[0260] In some embodiments of the present application, the filter for a smoking article may have a predetermined shape and a predetermined size.

[0261] For example, the filter may have a rod shape. More specifically, the filter for a smoking article may have a cylinder-like shape.

[0262] In addition, the filter may have, for example, a length of 10 mm to 50 mm. Specifically, the lower limit of the length of the filter may be 15 mm or more, 20 mm or more, 25 mm or more, 30 mm or more, 35 mm or more, 40 mm or more, or 45 mm or more. The upper limit of the length of the filter may be 45 mm or less, 40 mm or less, 35 mm or less, 30 mm or less, 25 mm or less, 20 mm or less, or 15 mm or less.

[0263] In some embodiments of the present application, the filter having the length within the ranges above may have a circular cross section, and the circular cross section may have a circumference of 10 to 40 mm. For example, the lower limit of the circumference of the filter may be 15 mm or more, 20 mm or more, 25 mm or more, 30 mm or more, or 35 mm or more. The upper limit of the circumference of the filter may be 35 mm or less, 30 mm or less, 25 mm or less, 20 mm or less, or 15 mm or less.

[0264] In some embodiments, the filter for a smoking article may include a lyocell tow and a filter wrapper. Descriptions of the lyocell tow and the filter wrapper are the same as described above, and thus will be omitted.

[0265] The wrapping paper wrapper may be a porous paper or a non-porous paper that wraps the aforementioned lyocell tow and maintains a filter shape (e.g., a cylinder or a rube).

[0266] In some embodiments, when a porous wrapper is used, the wrapping paper may have a porosity of 10 to 50,000 Coresta unit (CU). Coresta Unit is defined as the volume flow (cm 3< min -1< ) of the air passing through a 1 cm 2< substrate sample (i.e., a porous wrapper) at a pressure difference of 1 kPa. Specifically, the lower limit of the porosity of the wrapping paper may be, for example, 1000 CU or more, 5000 CU or more, 10000 CU or more, 15000 CU or more, 20000 CU or more, 25000 CU or more, 30000 CU or more, 35000 CU or more, 40000 CU or more, or 45000 CU or more. The upper limit of the porosity of the wrapping paper may be, for example, 45000 CU or less, 40000 CU or less, 35000 CU or less, 30000 CU or less, 25000 CU or less, or 20000 CU or less. In an embodiment of the present application, the porosity of the wrapping paper may be in a range of 22,000 to 26,000 CU or 23,000 to 25,000 CU.

[0267] In some embodiments, the wrapping paper may have a basis weight of 15 to 60 g / m 2< . Specifically, the lower limit of the basis weight of the wrapping paper may be, for example, 20 g / m 2< or more, 25 g / m 2< or more, 30 g / m 2< or more, 35 g / m 2< or more, 40 g / m 2< or more, 45 g / m 2< or more, 50 g / m 2< or more, or 55 g / m 2< or more, and the upper limit of the basis weight of the wrapping paper may be, for example, 55 g / m 2< or less, 50 g / m 2< or less, 45 g / m 2< or less, 40 g / m 2< or less, 35 g / m 2< or less, 30 g / m 2< or less, 25 g / m 2< or less, or 20 g / m 2< or less. In some embodiments, the basis weight of the wrapping paper may be 16 g / m 2< or more, 17 g / m 2< or more, 18 g / m 2< or more, 19 g / m 2< or more, 20 g / m 2< or more, or 21 g / m 2< or more, and may be 25 g / m 2< or less, 24 g / m 2< or less, 23 g / m 2< or less, 22 g / m 2< or less, or 21 g / m 2< or less.

[0268] Although not particularly limited, the weight of the rod-shaped filter may be 50 mg or more. For example, the lower limit of the weight of the filter may be, for example, 100 mg or more, 150 mg or more, or 200 mg or more. The upper limit of the filter may be 500 mg or less, 450 mg or less, 400 mg or less, 350 mg or less, 300 mg or less, 250 mg or less, or 200 mg or less.

[0269] For the rest, a description of the filter for a smoking article or materials included therein is the same as described above, and thus will be omitted.[Method of manufacturing filter for smoking article]

[0270] For example, the present application relates to a method of manufacturing a filter for a smoking article. The method refers to a method of manufacturing method the aforementioned the lyocell filter for a smoking article, and in this regard, may include a method of manufacturing the aforementioned lyocell material.

[0271] Regarding the method of manufacturing a filter for a smoking article, the processes other than a process of manufacturing a filter are the same as those described in connection with the lyocell material, and thus descriptions of these processes will be omitted. For the rest, descriptions that overlap with the aforementioned descriptions will also be omitted.

[0272] The process of manufacturing a filter may be appropriately performed by those skilled in the art according to the disclosed methods. For example, a filter may be manufactured by forming a wrapping paper filled with the lyocell material into a rod shape. Alternatively, a filter may be manufactured by cutting a rod-shaped filter paper filled with the lyocell material to an appropriate length. A description of the wrapping paper is as follows.

[0273] Although not particularly limited, processing such as disentanglement or plasticizer treatment may be additionally performed, before filling the filter paper with the lyocell material. By disentanglement of the lyocell material, the surface area of the lyocell material may be increased. For example, disentanglement of the lyocell material may be performed by applying external forces in the lengthwise direction, widthwise direction, and / or thickness direction.

[0274] Preferably, the lyocell material used in the manufacture of the filter for a smoking article may be a lyocell tow.

[0275] Although not particularly limited, the filter for a smoking article may further include a known cellulose acetate multifilament to the extent that it does not impair the purpose of the present disclosure. The cellulose acetate multifilament may be mixed with a lyocell multifilament. The cellulose acetate multifilament may be included in a segment that is distinct from a segment including the lyocell multifilament.[Smoking article]

[0276] Although not particularly limited, the lyocell tow manufactured by the method may be included in a smoking article. The smoking article may be an aerosol-generating article. The aerosol-generating article may be an aerosol-generating substance or an aerosol-forming substrate.

[0277] For example, the lyocell tow may be included in a combustible cigarette. In another example, the lyocell tow may be included in a heat-not-burn cigarette, and the heat-not-burn cigarette may be used with an aerosol-generating device (not shown).

[0278] For example, when used as a heat-not-burn smoking article, the smoking article may be separately inserted into the aerosol-generating device. Here, aerosol-generating device includes an accommodation groove that accommodates the aerosol-generating article, and further includes: a heater for heating the aerosol-generating article to generate aerosol; a controller for controlling the overall operation of the aerosol-generating device; a battery for supplying power used for the operation of the aerosol-generating device; and a detector for detecting that the aerosol-generating article has been inserted into the aerosol-generating device.

[0279] The smoking article may include a tobacco medium part, a filter for the smoking article, a wrapper. The filter for a smoking article may be located at one end, for example, rear end or front end, of the tobacco medium part. The tobacco medium part and the filter for a smoking article may each include a single segment, or may each independently include a plurality of segments.

[0280] The tobacco medium part may include a tobacco material, and the tobacco material may include nicotine. In addition, the tobacco medium part may further include an excipient.

[0281] The excipient may include a binder, a filler, and other additives. For example, a tobacco medium included in the tobacco medium part may be prepared in the form of granules including a tobacco material and an excipient.

[0282] For example, to maintain the shape, strength, and mass of the tobacco medium part, a filler may be further included. For example, the lyocell material may be included in the tobacco medium part. In addition, the lyocell material may be used as a filler.

[0283] The wrapper may be further divided into: a cigarette paper that wraps a tobacco medium part; a filter paper that wraps a filter; and a tipping wrapper that combines the tobacco medium part and the filter.Advantageous Effects of Invention

[0284] According to the present application, provided are a bale of lyocell tow that can replace the commercially available bale of cellulose acetate (CA) tow and a filter for a smoking article. Specifically, by using a lyocell tow prepared from the bale of lyocell tow having a low moisture regain, the performance of the filter for a smoking article may be improved.Mode for the Invention

[0285] Hereinafter, the present disclosure will be described in more detail with reference to the following examples. However, the following examples are merely presented to exemplify the present disclosure, and the scope of the present disclosure is not limited thereto.

[0286] Lyocell tow bales were manufactured by the following processes described in the manufacturing examples below. Conditions not specifically mentioned herein are within the scope of the descriptions above.Example 1

[0287] Cellulose pulps having a degree of polymerization (DPw) of 820 and including 93.9 wt% of alpha-cellulose were mixed with a NMMO / H 2 O solvent containing 0.01 wt% of propyl gallate to prepare a spinning dope for manufacturing a tow with a concentration of 11 wt%. The polymerization degree of polymerization refers to the number of repeating units and / or monomeric units of the components (cellulose, hemicellulose, etc.) contained in the cellulose pulp. The polymerization degree (DPw) is given by DPw = Mn / M0 wherein Mn is the number-average molecular weight of the macromolecule or polymer or oligomer molecule and M0 is the molecular weight of the monomeric unit.

[0288] Under the conditions where the discharge amount and spinning speed were appropriately controlled while maintaining the spinning temperature at 110 °C in a spinning nozzle, the spinning dope was spun.

[0289] The spinning dope in the form of filaments discharged from the spinning nozzle was provided to a coagulation solution (a coagulation solution containing 75 wt% of water and 25 wt% of NMMO and being used at a temperature of about 25 °C) contained in a coagulation tank through an air gap zone.

[0290] In the air gap zone, the spinning dope was subjected to first coagulation at a temperature of 8 °C using cold air at an airflow rate of 120 N m' / h. The spinning dope that has undergone the first coagulation was immersed in a coagulation solution to proceed second coagulation, thereby preparing a lyocell multifilament. The lyocell multifilament contained in the coagulation solution was then transported by a draw roller. Using a sensor and a refractometer, the concentration of the coagulation solution was continuously monitored.

[0291] The coagulated lyocell multifilament was then water-washed. The lyocell multifilament was introduced into a water-washing machine by the draw roller, and NMMO remaining in the lyocell multifilament was removed with a water-washing solution sprayed from the water-washing machine. The water-washed lyocell multifilament was immersed in a bath designed with a predetermined emulsion concentration to proceed first emulsion treatment.

[0292] The lyocell multifilament was treated at a pressure of 3.0 kgf / cm 2< using a nip roll installed in a discharge portion of the bath, thereby preparing an uncrimped lyocell multifilament with a controlled moisture regain.

[0293] Then, to impart crimps, the lyocell multifilament was introduced into a crimp machine. Specifically, the pressure of the press roller was set at 24.52 N / cm 2< (2.5 kgf / cm 2< ) and the pressure of the doctor blade was set at 4.90 N / cm 2< (0.5 kgf / cm 2< ) to manufacture a lyocell tow. The lyocell tow consists of the crimped lyocell multifilament.

[0294] In terms of antistatic and flexibility properties, the lyocell tow thus manufactures was subjected to second emulsion treatment. The second emulsion treatment was performed by spraying an emulsion-containing composition to the lyocell tow. The emulsion-containing composition was an aqueous solution containing 25 wt% of emulsion and 75 wt% of water.

[0295] Emulsion compounds used in the first emulsion treatment and the second emulsion treatment include an esterified product of aliphatic monovalent alcohol and fatty acid having 16 or more carbon atoms and an esterified product of sorbitan and fatty acid having 16 or more carbon atoms.

[0296] Drying treatment was carried out to dry the manufactured lyocell tow. Immediately after the second emulsion treatment, the lyocell tow was passed through a continuous dehumidifier set at 120 °C to proceed drying treatment. The dried lyocell tow then had a moisture regain of 3.42 %.

[0297] Plaiting treatment was carried out to laminate and compress the dried lyocell tow. Immediately after the drying treatment, the dried lyocell tow was fed into a plaiting machine through a dehumidifier, and laminated in a full can.

[0298] The laminated lyocell tow was then wrapped to manufacture a bale. Specifically, the laminated lyocell tow was compressed with a compressor. The lyocell tow was compressed to reduce the volume of the laminated tow, and then decompressed. The compressed lyocell tow was wrapped with a packaging wrapper to manufacture a bale of lyocell tow.

[0299] A dehumidifier was placed between the dehumidifier and the plaiting machine such that, during transfer of the dried lyocell tow to the plaiting machine through the dehumidifier, an increase in the moisture regain of the lyocell tow due to external moisture was suppressed. Dry air was supplied to the surrounding of the lyocell tow in the dehumidifier, and thus the dry atmosphere was maintained. The dry air was supplied into the dehumidifier, and the moisture content of the dry air was maintained at 5.0 mg / m 3< . The dehumidifier corresponds to a moisture regain-maintaining machine. The lyocell tow was fed into a housing of the dehumidifier through an inlet of the dehumidifier, transferred by a conveyor belt within the housing, discharged to the outside the housing through an outlet of the dehumidifier, and then fed into the plaiting machine.

[0300] The lyocell tow included in the bale had a single fiber fineness of 2.22 dtex to 3.885 dtex (2.0 to 3.5 denier(denier)) and a total fineness of 33,333 dtex to 61,110 dtex (30,000 to 45,000 denier), and the number of crimps therein was 9.84 to 11.8 crimps / cm (25 to 30 crimps / inch).

[0301] During the manufacturing process of the bale of lyocell tow, the external environment had a temperature of 25 °C and a relative humidity of 50 %.

[0302] Using the lyocell tow included in the bale of lyocell tow, a filter for a smoking article was manufactured. The filter for a smoking article was manufactured in a cylinder shape.

[0303] Specifically, 15 g of a polyester binder (a copolymer of phthalic acid, sebasic acid, and ethylene glycol) and 85 g of distilled water were mixed to prepare a binder solution. 15 parts by weight of the binder solution was sprayed to 100 parts by weight of the lyocell tow, and then dried. The dried lyocell tow was wrapped with a wrapper to prepare a filter in a cylindrical shape. The filter has an axial length of about 110 mm and a diameter of about 8 mm.

[0304] The manufacturing conditions for a bale of lyocell tow, the moisture regain of the lyocell tow, and the filter properties are shown in Tables 1 and 2.Examples 2 to 7

[0305] Bales of lyocell tow and filters were manufactured in the same manner as in Example 1, except that the manufacturing conditions for the bale of lyocell tow were changed. The manufacturing conditions for the bale of lyocell tow, the moisture regain of lyocell tow, and properties of filters in Examples 2 to 7 are shown in Tables 1 and 2.Comparative Examples 1 and 2

[0306] Lyocell materials and filters were manufactured in the same manner as in Example 1, except that the manufacturing conditions for the bale of lyocell tow were changed. The manufacturing conditions for the bale of lyocell tow, the moisture regain of lyocell tow, and the filter properties in Comparative Examples 1 and 2 are shown in Tables 1 and 2.

[0307] In Comparative Examples 1 and 2, the dehumidifier was not placed between the dehumidifier and the plaiting machine. Thus, during transfer of the dried lyocell tow to the plaiting machine, an increase in the moisture regain of the lyocell tow caused by the external moisture could not be suppressed.Evaluation Example 1: Manufacturing conditions for lyocell tow and measurement of moisture regain

[0308] The temperature and relative humidity of the surrounding environment during the manufacturing process of the lyocell tow bales in Examples 1 to 7 and Comparative Examples 1 and 2 are shown in Table 1.

[0309] The constituents of the emulsion-containing compositions used in the second emulsion treatment during the manufacturing processes of the lyocell tow bales in Examples 1 to 7 and Comparative Examples 1 and 2 are shown in Table 1.

[0310] The moisture regain of the lyocell tow dried in a dehumidifier during the manufacturing processes of the bale of lyocell tow in each of Examples 1 to 7 and Comparative Examples 1 and 2 was measured and shown in Table 1. The moisture regain of the dried lyocell tow was measured within three minutes after the lyocell tow was discharged from the dehumidifier.

[0311] The moisture content of the air inside the dehumidifier used during the manufacturing processes of the lyocell tow bales in Examples 1 to 7 was shown in Table 1. During the manufacturing processes of the lyocell tow bales in Comparative Examples 1 and 2, the dehumidifier was not used.

[0312] The moisture regain of the lyocell tow manufactured in each of Examples 1 to 7 and Comparative Examples 1 and 2 was measured within three minutes after opening the bale of lyocell tow.

[0313] The moisture regain was measured according to Equation 1: Results of the measurement were shown in Table 1. Moisture regain % = W − D / D × 100 wherein, in the equation, W represents the weight of a sample measured before drying, and D represents the weight of a sample measured after drying.

[0314] The moisture regain was measured using an automatic moisture regain meter, Precisa XM 60 Moisture Analyzer. Such an automatic moisture regain meter includes a scale for measuring the weight of a sample and a drying system. The weight of a sample measured before drying refers to the initial weight of a sample placed in the moisture regain meter. The weight of a sample measured after drying refers to the weight at which the weight change is less than 1 mg when the weight of a sample measured every 30 seconds at 120 °C in the drying system. [Table 1]PulpExam ple 1Exam ple 2Exam ple 3Exam ple 4Exam ple 5Exam ple 6Exam ple 7Compar ative Exampl e 1Compar ative Exampl e 2Temperat ure (°C)252525353535352525Relative humidity [%]505050808090905090Weight ratio of emulsion: water25:7525:7535:6525:7525:7535:6545:555:9510:90Moisture content of air in dehumidifi er [mg / m 3< ]5.025.01.05.025.05.00.1--Moisture regain of dried lyocell tow [%]3.423.483.053.823.772.982.753.383.88Moisture regain of bale-derived lyocell tow [%]4.184.853.545.227.155.545.129.5711.52

[0315] As shown in Table 1, the moisture regain of the lyocell tow of Examples 1 to 7 dried in the drying was similar to that of the lyocell tow of Comparative Examples 1 and 2 dried in the drying.

[0316] In contrast, as shown in Table 2, the lyocell tow included in the bales manufactured in Examples 1 to 7 showed a lower moisture regain than the lyocell tow included in the bales manufactured in Comparative Examples 1 and 2.

[0317] In the case of the lyocell tow included in the bales manufactured in Examples 1 to 7, the dry atmosphere provided around the lyocell tow during the transfer of the lyocell tow from the drying to the plaiting blocked the moisture provided to the lyocell tow from the external environment, and thus an increase in the moisture regain could be suppressed.

[0318] In contrast, in the case of the lyocell tow included in the bales manufactured in Comparative Examples 1 and 2, the moisture provided to the lyocell tow from the external environment during the transfer the lyocell tow from the drying to the plaiting was not blocked, and thus an increase in the moisture regain could not be suppressed.Evaluation Example 2: Measurement of filter hardness

[0319] The filters manufactured using the lyocell tow included in the bale manufactured in Examples 1 to 7 and Comparative Examples 1 and 2 were subjected to measurement of hardness and hardness reduction. Results of the measurement are shown in Table 2.

[0320] The hardness of the filter is measured according to Equation 2: Hardness of filter % = DA − a / DA × 100 wherein, in the equation, DA represents a diameter of an initial filter, and a represents a distance reduced by 300 g of weight from the diameter of the initial filter (i.e., a distance pressed by a filter).

[0321] The hardness reduction of the filter is measured according to Equation 3, provided that the hardness reduction of the filter is the difference in hardness before and after injection of distilled water into the filter. Hardness reduction % of filter by addition of moisture = H 1 − H 2 wherein, in the equation, H1 represents a filter hardness before injection of distilled water, and H2 represents a filter hardness measured 5 minutes after injection of 20 µl of distilled water into the filter.

[0322] The values used for measuring the hardness of the filter were measured using a DHT 200 ™< hardness tester, Filtrona Instruments. [Table 2]PulpExam ple 1Exam ple 2Exam ple 3Exam ple 4Exam ple 5Exam ple 6Exam ple 7Compar ative Example 1Compar ative Example 2Filter hardn ess before injecti on of distille d water [%]90.589.192.388.787.489.489.785.483.7Filter hardn ess after injecti on of distille d water [%]87.785.988.584.882.885.886.276.272.4Filter hardn ess reduct ion [%]2.83.23.83.94.63.63.59.211.3

[0323] As shown in Table 2, the filters manufactured in Examples 1 to 7 showed the hardness reduction of less than 7 %. In contrast, the filters manufactured in Comparative Examples 1 and 2 showed the hardness reduction of 7 % or more.

[0324] The filters manufactured in Examples 1 to 7 showed improved hardness and reduced hardness reduction by using the lyocell tow prepared from the bale of lyocell tow with a moisture regain of 8 % or less.

[0325] The filters manufactured in Comparative Examples 1 and 2 showed significant hardness reduction by using the lyocell tow prepared from the bale of lyocell tow with a moisture regain of greater than 8 %.

[0326] The filters manufactured in Comparative Examples 1 and 2 were unsuitable for use as products because the filters became brittle during use due to the hardness reduction of 7 % or more.

Claims

1. A bale of lyocell tow comprising: a compressed lyocell tow; and a packaging wrapper wrapping the compressed lyocell tow, wherein a moisture regain of the lyocell tow is 8 % or less.

2. The bale of claim 1, wherein the moisture regain of the lyocell tow is a value measured from the lyocell tow after opening the bale, preferably wherein the moisture regain of the lyocell tow is a value measured from the lyocell tow within 10 minutes after opening the bale.

3. The bale of claim 1, wherein the lyocell tow comprises a crimped lyocell multifilament, and / or wherein the packaging wrapper seals the lyocell tow, and / or wherein the packaging wrapper is impermeable to moisture.

4. A filter for a smoking article, the filter comprising the lyocell tow provided from the bale of any one of claims 1 to 3.

5. The filter of claim 4, wherein a hardness of the filter is 80 % or more, and / or wherein a hardness reduction of the filter is less than 7 %.

6. A smoking article comprising the filter of claim 4.

7. A method of manufacturing a bale of lyocell tow, the method comprising: spinning a lyocell dope; coagulating; obtaining a lyocell multifilament; water-washing; performing first emulsion treatment; crimp-imparting; performing second emulsion treatment; drying; plaiting; and wrapping a lyocell tow, wherein, during transfer of the lyocell tow from the drying to the plaiting, dry gas having a moisture content of 30 mg / m3 or less is supplied to the surrounding of the lyocell tow.

8. The method of claim 7, wherein the dry gas includes air or inert gas, and / or wherein the dry gas is supplied by a dehumidifier.

9. The method of claim 7, wherein relative humidity inside the dehumidifier is lower than relative humidity outside the dehumidifier.

10. The method of claim 7, wherein the performing of the second emulsion treatment comprises spraying an emulsion-containing composition to a lyocell multifilament.

11. The method of claim 10, wherein the emulsion-containing composition is an aqueous solution, and has a water content of 50 to 80 wt% based on a total weight of the emulsion-containing composition.

12. The method of claim 7, wherein a moisture regain of a lyocell tow included in the bale is 2 times or less than a moisture regain of a lyocell tow dried in the drying.

13. The method of claim 7, wherein a moisture regain of a lyocell tow dried in the drying is 4 % or less.

14. The method of claim 7, wherein a moisture regain of a lyocell tow compressed in the plaiting is 8 % or less.

15. The method of claim 7, wherein a moisture regain of a lyocell tow included in the bale is 8 % or less.

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