Medium dpf and total denier cellulose acetate tow

Abstract

Disclosed are cellulose acetate tows, bales, and filter rods having from greater than 9 to less than 12.5 denier per filament and from 20,000 to 40,000 total denier, for use in smoking devices, including aerosol-generating devices such as an electrically heated cigarette.

We claim: 
     
         1 . A method for preparing a filter rod, the method comprising:
 forming a cellulose acetate tow band having from greater than 9 to less than 12.5 denier per filament and from 20,000 to 40,000 total denier;   baling the cellulose acetate tow band;   blooming the cellulose acetate tow band to form a bloomed tow band;   channeling the bloomed tow band to form a tow rod; and   cutting the tow rod to form a filter rod having a hardness of at least 85%;   wherein the bloomed tow band is treated with a plasticizer.   
     
     
         2 . The method of  claim 1 , wherein the bloomed tow band is treated with a plasticizer during channeling. 
     
     
         3 . The method of  claim 1 , wherein the bloomed tow band is treated by spraying plasticizer onto the bloomed tow band. 
     
     
         4 . The method of  claim 1 , wherein the bloomed tow band is treated by coating plasticizer onto the bloomed tow band. The method of  claim 1 , wherein the bloomed tow band is treated by sprinkling plasticizer onto the bloomed tow band. 
     
     
         6 . The method of  claim 1 , wherein the bloomed tow band is treated by dusting plasticizer onto the bloomed tow band. 
     
     
         7 . The method of  claim 1 , wherein the bloomed tow band is treated by affixing plasticizer onto the bloomed tow band. 
     
     
         8 . The method of  claim 1 , wherein the bloomed tow band is treated by sprinkling plasticizer onto the bloomed tow band. 
     
     
         9 . The method of  claim 1 , wherein the plasticizer is in particulate form. The method of  claim 1 , wherein at least one additive is applied to the bloomed tow band. 
     
     
         11 . The method of claim  10 , wherein the additive is at least one of active particles, active compounds, ion exchange resins, zeolites, nanoparticles, ceramic particles, softening agents, pigments, dyes, flavorants, aromas, controlled release vesicles, binders, adhesives, tackifiers, surface modification agents, lubricating agents, emulsifiers, vitamins, peroxides, biocides, antifungals, antimicrobials, antistatic agents, flame retardants, antifoaming agents, degradation agents, conductivity modifying agents, stabilizing agents, and combinations thereof. 
     
     
         12 . The method of  claim 1 , wherein the cellulose acetate tow band has from 24,000 to 35,000 total denier. 
     
     
         13 . The method of  claim 1 , wherein the cellulose acetate tow band has from 24,000 to 30,000 total denier. 
     
     
         14 . The method of  claim 1 , wherein the cellulose acetate tow band has from 10 to less than 12.5 denier per filament. The method of  claim 1 , wherein the cellulose acetate tow has a bale UCE from 200 g-cm/cm to 370 g-cm/cm. 
     
     
         16 . The method of  claim 1 , wherein filaments of the cellulose acetate tow rod have a cross-sectional shape selected from the group comprising circular, substantially circular, crenulated, ovular, substantially ovular, polygonal, substantially polygonal, dog-bone, “Y,” “X,” “K,” “C,” multi-lobe, and any combination thereof. 
     
     
         17 . The method of  claim 1 , wherein the cellulose acetate tow has a denier per filament percent coefficient of variability of less than 10%. 
     
     
         18 . The method of  claim 1 , wherein the cellulose acetate tow has a denier per filament percent coefficient of variability from 1 to 8%. 
     
     
         19 . The method of  claim 1 , further comprising:
 cutting the filter rod to a length from 20 mm to 50 mm.   
     
     
         20 . The method of  claim 1 , further comprising:
 cutting the filter rod to a filter section having a length from 3 to 15 mm.