Cigarette filter rod manufacturing process

Abstract

A cigarette filter rod comprising a filter substrate with a single-structured body having a multi-orientation distribution of fibers, the filter substrate including a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder, wherein the multi-orientation distribution of fibers inhibits laminar airflow and the creation of adverse linear axial channels.

We claim: 
     
         1 . A cigarette filter rod, comprising:
 a filter substrate with a single-structured body having a multi-orientation distribution of fibers,   the filter substrate including a fiber blend of at least one of abaca, sisal, and wood pulp, and 0-50% hemp, 0-50% flax, 0-95% abaca, 0-95% sisal, 0-50% wood pulp, 0-50% cotton, 0-50% regenerated cellulose, 0-30% natural binder,   wherein the multi-orientation distribution of fibers inhibits laminar airflow and the creation of adverse linear axial channels.   
     
     
         2 . A method of manufacturing the cigarette filter rod of  claim 1 , comprising:
 receiving natural or synthetic fibers, water and/or solvent, raw materials, and ingredients and/or processing aids;   mixing and blending the received materials until a homogenous slurry is produced;   enriching the homogenous slurry with aeration, binder, flavoring, coloring, and/or other add-ons, targeting a specific density, porosity, and air permeability;   shaping the enriched homogenous slurry into a specific shape and/or diameter;   drying the shaped enriched homogenous slurry to a dried or semi-dried stable matter according to specific density, hardness, and air permeability;   cutting the dried or semi-dried stable matter into filter rods in a semi-format.   
     
     
         3 . The method of  claim 2 , wherein shaping the enriched homogenous slurry into a filter rod of a specific shape and/or diameter includes extruding the enriched homogenous slurry into a filter rod of a specific shape and/or diameter. 
     
     
         4 . The method of  claim 2 , wherein shaping the enriched homogenous slurry into a filter rod of a specific shape and/or diameter includes molding the enriched homogenous slurry into a filter rod of a specific shape and/or diameter. 
     
     
         5 . The method of  claim 2 , wherein cutting includes cutting the dried or semi-dried stable matter into filter rods in a semi-format for storage and then cutting depending on application. 
     
     
         6 . The method of  claim 2 , further including packaging the filter rods for transport and/or sale. 
     
     
         7 . The method of  claim 1 , wherein the fiber blend includes a fiber of at least one of Abaca, Tencel, Cotton Flock and Hemp.