Apparatus and associated method for forming a filter component of a smoking article

Abstract

An apparatus and associated method are provided for forming a rod member for use in the manufacture of cigarette filter elements. A fibrillation unit is configured to fibrillate a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith. A rod-forming unit is operably engaged with the fibrillation unit and is configured to form the fibrillated sheet material into a continuous filter rod member.

1 . An apparatus for forming a rod member for use in the manufacture of cigarette filter elements, the rod member defining a longitudinal axis, the apparatus comprising:
 a fibrillation unit configured to fibrillate a sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith; and   a rod-forming unit operably engaged with the fibrillation unit and configured to form the fibrillated sheet material into a continuous filter rod member.   
     
     
         2 . An apparatus according to  claim 1 , further comprising a rod-dividing unit configured to subdivide the continuous filter rod member, at selected intervals along the longitudinal axis thereof, into a plurality of filter rod portions each having a portion of the fibrillated sheet material therein. 
     
     
         3 . An apparatus according to  claim 1 , further comprising an applicator unit configured to apply a material layer to the sheet material prior to the fibrillation unit fibrillating the sheet material. 
     
     
         4 . An apparatus according to  claim 1 , wherein the applicator unit is configured to apply a plurality of successive layers to the sheet material prior to the fibrillation unit fibrillating the sheet material. 
     
     
         5 . An apparatus according to  claim 1 , wherein the fibrillating unit is configured to fibrillate the sheet material to form a plurality of fibrous elements, the fibrous elements being at least partially interconnected. 
     
     
         6 . An apparatus according to  claim 1 , further comprising a crimping unit configured to crimp the sheet material prior to the fibrillation unit fibrillating the sheet material. 
     
     
         7 . An apparatus according to  claim 1 , further comprising an embossing unit configured to emboss the sheet material prior to the fibrillation unit fibrillating the sheet material. 
     
     
         8 . An apparatus according to  claim 1 , further comprising an applicator unit configured to apply at least one material layer to the sheet material as one of a coating, a co-extrusion, and a laminate, prior to the fibrillation unit fibrillating the sheet material. 
     
     
         9 . An apparatus according to  claim 1 , wherein the fibrillation unit is further configured to fibrillate a sheet material comprising cellulose acetate. 
     
     
         10 . An apparatus according to  claim 1 , wherein the rod forming unit is further configured to gather the fibrillated sheet material into a cylindrical composite prior to forming the continuous filter rod member. 
     
     
         11 . A method of forming a rod member for use in the manufacture of cigarette filter elements, the rod member defining a longitudinal axis, the method comprising:
 fibrillating a sheet material with a fibrillation unit, the sheet material having one of a biodegradability-enhancing substance and a compostability-enhancing substance associated therewith; and   forming the fibrillated sheet material into a continuous filter rod member with a rod-forming unit operably engaged with the fibrillation unit.   
     
     
         12 . A method according to  claim 11 , further comprising subdividing the continuous filter rod member, at selected intervals along the longitudinal axis thereof, into a plurality of filter rod portions each having a portion of the fibrillated sheet material therein with a rod-dividing unit. 
     
     
         13 . A method according to  claim 11 , further comprising applying a material layer to the sheet material, prior to fibrillating the sheet material, with an applicator unit. 
     
     
         14 . A method according to  claim 11 , further comprising applying a plurality of successive layers to the sheet material, prior to fibrillating the sheet material, with an applicator unit. 
     
     
         15 . A method according to  claim 11 , wherein fibrillating a sheet material further comprises fibrillating the sheet material to form a plurality of fibrous elements, the fibrous elements being at least partially interconnected. 
     
     
         16 . A method according to  claim 11 , further comprising crimping the sheet material, prior to fibrillating the sheet material, with a crimping unit. 
     
     
         17 . A method according to  claim 11 , further comprising embossing the sheet material, prior to fibrillating the sheet material, with an embossing unit. 
     
     
         18 . A method according to  claim 11 , further comprising applying at least one material layer to the sheet material, with an applicator unit, as one of a coating, a co-extrusion, and a laminate, prior to fibrillating the sheet material. 
     
     
         19 . A method according to  claim 11 , wherein fibrillating a sheet material further comprises fibrillating a sheet material comprising cellulose acetate. 
     
     
         20 . A method according to  claim 11 , further comprising gathering the fibrillated sheet material into a cylindrical composite prior to forming the continuous filter rod member.