Abstract: A method for forming a filter rod may include providing a bale of crimped tow band having about 10 denier per filament or greater and about 20,000 total denier or less, the crimped tow band comprising a plurality of cellulose acetate filaments; and placing the crimped tow band in an apparatus so as to form a filter rod.

Abstract: A method for forming a filter rod may include providing a bale of crimped tow band having about 10 denier per filament or greater and about 20,000 total denier or less, the crimped tow band comprising a plurality of cellulose acetate filaments; and placing the crimped tow band in an apparatus so as to form a filter rod.

Abstract: A method for forming a filter rod may include providing a bale of crimped tow band having about 10 denier per filament or greater and about 20,000 total denier or less, the crimped tow band comprising a plurality of cellulose acetate filaments; and placing the crimped tow band in an apparatus so as to form a filter rod.

Abstract: High-throughput production apparatuses, systems, and associated methods may include pneumatic dense phase feeding. For example, a method may involve feeding via pneumatic dense phase feeding a matrix material into a mold cavity to form a desired cross-sectional shape, the matrix material comprising a binder particle and an active particle; heating (e.g., via microwave irradiation) at least a portion of the matrix material so as to bind the matrix material at a plurality of contact points thereby forming a porous mass length; cooling the porous mass length; and cutting the porous mass length radially thereby producing a porous mass. In some instances, the matrix material may include a plurality of active particles, a plurality of binder particles (optionally having a hydrophilic surface modification), and optionally a microwave enhancement additive.

Abstract: High-throughput production apparatuses, systems, and associated methods may include pneumatic dense phase feeding. For example, a method may involve feeding via pneumatic dense phase feeding a matrix material into a mold cavity to form a desired cross-sectional shape, the matrix material comprising a binder particle and an active particle; heating (e.g., via microwave irradiation) at least a portion of the matrix material so as to bind the matrix material at a plurality of contact points thereby forming a porous mass length; cooling the porous mass length; and cutting the porous mass length radially thereby producing a porous mass. In some instances, the matrix material may include a plurality of active particles, a plurality of binder particles (optionally having a hydrophilic surface modification), and optionally a microwave enhancement additive.

Abstract: A method for producing a bale of crimped tow band may include providing a tow band having about 10 denier per filament or greater and about 20,000 total denier or less, the tow band comprising a plurality of cellulose acetate filaments; crimping the tow band thereby yielding a crimped tow band; conditioning the crimped tow band; and baling the crimped tow band to form a bale.

Abstract: A method for forming a filter rod may include providing a bale of crimped tow band having about 10 denier per filament or greater and about 20,000 total denier or less, the crimped tow band comprising a plurality of cellulose acetate filaments; and placing the crimped tow band in an apparatus so as to form a filter rod.

Abstract: A process for making a cigarette tow comprising: spinning a dope; taking-up the as-spun cellulose acetate filaments; lubricating the filaments; forming a tow from the filaments; crimping the tow with a stuffer box crimper; drying the crimped tow; and baling the dried crimped tow. The process further comprises at least two of the following: A. crimping further comprising one roller of the pair of nip rollers being adapted to induce crimp into the tow; B. crimping further comprising one roller of the pair of nip rollers being made of a solid ceramic material; C. crimping further comprising a pair of tow edge lubricators; D. crimping further comprising a steam injector; E. further comprising plasticizing the tow; F. lubricating the filaments further comprises a finish consisting of a water emulsion.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, the tow is plasticized prior to entry into the crimper. The preferred plasticizer is water.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has a steam injector in communication with the stuffer channel of the crimper. The steam injector consists of a single pair of injectors vertically aligned with one another above and below the stuffer channel of the crimper.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has a pair of tow edge lubricators adapted to lubricate the lateral edges of the tow immediately prior to contact with the nip rollers of the crimper.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has one roller adapted to induce crimp into the tow. This roller induces crimp by preferentially weakening a portion of the tow. This roller has an axially grooved surface. This roller may be located in the stuffer box crimper or before the stuffer box crimper.

Abstract: The instant application relates to a fiber bale and a method for producing the same. The instant fiber bale includes a highly compressed hexahedral fibrous material substantially free of disrupting curvatures on a top side or a bottom side. The highly compressed hexahedral fibrous material has a packing density of at least 300 kg/m3. The method for producing a fiber bale according to instant invention includes the following steps: (1) providing a press for producing a highly compressed hexahedral fibrous material comprising at least one convex bale platen; (2) filling the press with the fibrous material; (3) pressing the fibrous material via the press; (4) thereby forming the highly compressed hexahedral fibrous material; (5) packaging the highly compressed hexahedral fibrous material with a wrapping material; and (6) securing the wrapping material thereby producing the fiber bale.

Abstract: In the manufacture of a fiber tow, particularly cellulose acetate tow, a stuffer box crimper has a pair of nip rollers, at least one, made of a solid ceramic material.

Abstract: The instant invention is a stuffer box crimper and a method for crimping. The stuffer box crimper according to instant invention includes a pair of nip rollers, a pair of doctor blades, and a stuffer box. The pair of doctor blades is adjacent to an exit end of the pair of nip rollers. The stuffer box includes a stuffer box channel adjacent to the pair of doctor blades, and the stuffer box channel includes a surface consisting of a hard material having a hardness of at least 60 Rc. The method of crimping according to instant invention includes the steps of (1) providing a stuffer box crimper including a stuffer box having a stuffer box channel including a surface consisting of a hard material having a hardness of at least 60 Rc; and (2) crimping via the stuffer box crimper.

Abstract: A cigarette filter tow is a cellulose acetate tow having a high uncrimping energy (UCE) and a low fly. In one embodiment, the average UCE is greater than 280 and the average fly is less than or equal to 0.030 grams per 30 minutes. In another embodiment, the average UCE is greater than 265 and the average fly is less than or equal to 0.023 grams per 30 minutes. In another embodiment, the average UCE is greater than 250 and the average fly is less than or equal to 0.017 grams per 30 minutes.

Abstract: A method for wrapping a bale of compressed, resilient fibers comprises the steps of: providing a reusable bale wrap kit. The kit includes at least two pieces. Each piece, when joined with the other piece, is adapted for substantially enclosing and containing the bale of compressed, resilient fibers. Mushroom and loop fasteners are located along an edge portion of each piece and are adapted for joining the pieces to one another. Uncompressed, resilient fibers are provided. A portion of the uncompressed, resilient fibers are surrounded with the kit. Those fibers are compressed, and the mushroom and loop fasteners are engaged.