Lyocell Cigarette Filter Tow Crimping Process
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Solution Overview
Problem
Current methods for manufacturing cigarette filters using cellulose acetate fibers are not biodegradable enough, leading to environmental hazards, and existing lyocell fibers lack sufficient crimping properties required for effective cigarette filters.
Innovation Solution
A method involving spinning a lyocell spinning dope with 8-13 wt% cellulose pulp and 87-92 wt% N-methylmorpholine-N-oxide aqueous solution, followed by coagulation, water-washing, oil-treating, and applying steam and pressure using a stuffer box to achieve a crimped tow with 12-16 crimps per centimeter, enhancing biodegradability and crimping properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If cellulose acetate fiber is used for cigarette filter, then the filter structure is maintained, but biodegradation takes 1-2 years which is too slow
Solution Approach 1:
The invention changes the chemical composition parameters of the filter material by using cellulose with low acetylation degree (few substitutions) instead of conventional cellulose acetate. This parameter change enables the filter to maintain its structure during use while allowing rapid biodegradation (within days) after disposal, thus resolving the contradiction between structure maintenance and environmental harm.
Solution Approach 2:
The invention applies the principle of disposable short-living objects by designing a filter that is intended to be short-lived in the environment. The filter is made from materials that rapidly biodegrade after use, transforming the filter from a long-lasting pollutant into a temporary protective barrier that quickly returns to nature.
2Object-affected harmful factors
If lyocell fiber is used for cigarette filter, then biodegradability is improved, but crimping properties are insufficient
Solution Approach 1:
The invention applies preliminary action by pre-treating the lyocell fibers with oil before crimping. This oil treatment prepares the fibers by adjusting their surface properties and flexibility, enabling them to accept and maintain crimps effectively. The preliminary oil treatment resolves the contradiction by preparing the material in advance to achieve both biodegradability and crimping properties.
Solution Approach 2:
The invention uses composite materials by combining lyocell fibers with oil treatment to create a material that possesses both the biodegradability of lyocell and the crimping properties needed for filter application. The oil-lyocell composite achieves properties that neither component alone could provide.
3Object-affected harmful factors
If additives are added to increase biodegradation rate, then decomposition speed improves, but filter performance during smoking may be compromised
Solution Approach 1:
The invention applies the principle of taking out by removing the need for harmful additives entirely. Instead of adding substances to accelerate biodegradation, the invention extracts the essential property (biodegradability) from the material selection itself by using natural cellulose or lyocell fibers that inherently biodegrade rapidly without requiring any additive intervention.
Solution Approach 2:
The invention applies self-service by allowing the filter material to biodegrade through its own inherent properties without external assistance from additives. The cellulose or lyocell fibers naturally decompose through microbial action in the environment, making the biodegradation process self-driven and eliminating the need for performance-compromising additives.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting lyocell crimped tow exhibits high biodegradability and improved crimping properties, suitable for cigarette filters, enhancing smoking preference and absorption while ensuring environmental sustainability.
Implementation Method 1
spinning a lyocell spinning dope comprising 8 to 13 wt% of a cellulose pulp and 87 to 92 wt% of an N-methylmorpholine-N-oxide (NMMO) aqueous solution
Implementation Method 2
coagulating the lyocell spinning dope spun in (S1), thus obtaining a lyocell multifilament
Implementation Method 3
applying steam and pressure to the lyocell multifilament obtained in (S4) using a stuffer box, wherein the stuffer box is controlled so that a steam pressure is 0.01 to 0.3 mPa (0.1 to 3 kgf/cm2)
Data Source
AI summary
This invention relates to a method of manufacturing a lyocell material for a cigarette filter, including (S1) spinning a lyocell spinning dope composed of 8 to 13 wt% of a cellulose pulp and 87 to 92 wt% of an N-methylmorpholine-N-oxide (NMMO) aqueous solution; (S2) coagulating the lyocell spinning dope spun in (S1), thus obtaining a lyocell multifilament; (S3) water-washing the lyocell multifilament obtained in (S2); (S4) oiling the lyocell multifilament water-washed in (S3); and (S5) applying steam and pressure to the lyocell multifilament obtained in (S4), thus obtaining a crimped tow having 30 to 40 crimps per inch.