Mixed Fiber Sliver for Biodegradable Cigarette Filters

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Solution Overview

Problem

Conventional cigarette filter elements made from cellulose acetate are not biodegradable and have a detrimental environmental impact, while alternatives like cellulose fibers result in poor taste due to the lack of acetate groups on their surface.

Innovation Solution

A method involving blending cellulose acetate staple fibers with degradable polymeric staple fibers, such as aliphatic polyesters or cellulose, to create a mixed fiber sliver with enhanced biodegradability and desirable taste properties, which is then processed into a filter element with improved degradation rates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If conventional cellulose acetate is used for filter elements, then taste and filtration efficiency are maintained, but biodegradability is poor and environmental impact is detrimental

Engineering Contradiction:

Improveenvironmental impactVSAvoiddegradation time

Core Design Contradiction:

Object-affected harmful factorsVSDuration of action of stationary object

Solution Approach 1:

The patent applies composite materials by combining cellulose acetate fibers with degradable polymeric fibers (such as aliphatic polyesters or cellulose) to create a mixed fiber sliver. This composite structure allows the filter element to maintain the taste and filtration properties of cellulose acetate while incorporating biodegradable components that accelerate environmental degradation, thus resolving the contradiction between maintaining performance and improving biodegradability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the compositional parameters of the filter material by blending cellulose acetate with degradable polymers in specific ratios (e.g., 20-80 wt% degradable polymeric fibers). This parameter modification enables the filter to achieve enhanced biodegradability (at least 50% faster degradation) while preserving the essential functional properties of cellulose acetate, thereby addressing the environmental persistence issue without sacrificing performance.

Inventive Principle:

Principle #35Parameter changes

2Duration of action of stationary object

If cellulose fibers are used instead of cellulose acetate, then biodegradability is improved, but taste quality deteriorates due to lack of acetate groups

Engineering Contradiction:

Improvedegradation rateVSAvoidtaste quality

Core Design Contradiction:

Duration of action of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent uses composite materials to combine the biodegradability advantage of cellulose fibers with the taste-enhancing acetate groups of cellulose acetate. The mixed fiber sliver contains both cellulose (or other degradable polymeric) fibers and cellulose acetate fibers, creating a synergistic effect where the cellulose provides rapid degradation while the cellulose acetate maintains taste quality, thus resolving the contradiction between biodegradability and taste.

Inventive Principle:

Principle #40Composite materials

3Strength

If filter elements are tightly-compacted and highly crimped for structural integrity, then mechanical strength is improved, but biodegradation rate decreases due to reduced fiber exposure

Engineering Contradiction:

Improvestructural integrityVSAvoidbiodegradation rate

Core Design Contradiction:

StrengthVSDuration of action of stationary object

Solution Approach 1:

The patent applies composite materials where degradable polymeric fibers are blended with cellulose acetate fibers in a mixed fiber sliver. These composite fibers, when incorporated into the filter structure, provide inherent biodegradability that compensates for the reduced fiber exposure caused by tight compaction. The degradable polymers break down more readily even in the compacted structure, maintaining both structural integrity during use and enhanced biodegradation after disposal.

Inventive Principle:

Principle #40Composite materials

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 filter element exhibits at least 50% faster degradation compared to traditional cellulose acetate filters while maintaining the taste and filtration efficiency of cellulose acetate-based filters.

Implementation Method 1

Cellulose is a known biodegradable fiber which is capable of aerobic and/or anaerobic degradation in a variety of environments

Methodology Applied

Scientific EffectBiodegradation: Decomposition (biological)

Data Source

PatentUS9833017B2Mixed fiber sliver for use in the manufacture of cigarette filter elements

Publication Date: 2017.12.05 R J REYNOLDS TOBACCO COMPANY

AI summary

Smoking articles including filter elements formed from two or more fibrous inputs with different physical properties are provided. The two or more fibrous inputs are provided in the form of staple fibers, which are at least partially entangled with each other to form a mixed fiber sliver. The mixed fiber sliver includes a first plurality of cellulose acetate staple fibers blended with a second plurality of staple fibers comprising a polymeric material different from the first plurality of staple fibers, such as staple fibers of a degradable polymeric material. The entangled fibers of the mixed fiber sliver may be sufficiently separated from one another such that blooming operations typically required in filter element production may not be necessary prior to incorporating the mixed fiber sliver into a filter element. Related methods, apparatuses and mixed fiber products are also provided by the disclosure.