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(11) | EP 4 579 008 A1 |
| (12) | EUROPEAN PATENT APPLICATION |
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| (54) | LYOCELL MATERIAL, FILTERS, SMOKING ARTICLES AND METHOD FOR PREPARING THEREOF |
| (57) The present application relates to a lyocell material, a filter for smoking articles
including the lyocell material, and a smoking article. The lyocell material and the
filter for smoking articles according to the present application may replace conventional
cellulose acetate materials and filters for smoking articles including the same. |
Technical Field
[0001] The present application relates to a lyocell material, a filter and a smoking article including the same, and a method of manufacturing the lyocell material.
Background Art
[0002] Until now, cellulose acetate fibers have been mainly used as cigarette filter materials. Cellulose acetate is known as a biodegradable material, but a filter for smoking articles, which is made of cellulose acetate, remains in its original form for one to two years after being buried in soil, and it takes a considerable amount of time until it is completely biodegraded. Considering the amount and toxicity of tobacco products that are discarded and left in the living environment as well as tobacco products that are recovered as waste and landfilled after being used for smoking, it is necessary to further improve the biodegradability of filters for smoking articles. Accordingly, recently, a more environmentally friendly lyocell has been selected as a material to replace cellulose acetate.
Disclosure of Invention
Technical Problem
[0003] An object of the present application is to provide a lyocell material that can replace commercially available cellulose acetate for filters for smoking articles.
[0004] Another object of the present application is to provide a lyocell material for filters for smoking articles of which manufacturing process is environmentally friendly and which has excellent biodegradability upon disposal.
[0005] Another object of the present application is to provide a lyocell filter for smoking articles.
[0006] Another object of the present application is to provide a smoking article (for example, cigarette) including a lyocell filter.
Solution to Problem
[0007] An aspect of the present application may provide a lyocell material, a filter including the same, a smoking article, and the like.
[0010] In particular, there may be provided a lyocell material including a lyocell multifilament to which crimps are applied and having a coefficient of variation of the number of crimps of 50% or less.
[0011] In some embodiments, the lyocell multifilament to which crimps are applied may include one or more lyocell monofilaments. The lyocell multifilament to which crimps are applied may be considered as a lyocell multifilament in the present application.
[0012] Additionally, there may be provided a filter for smoking articles, including a lyocell material having a coefficient of variation of the number of crimps of 50% or less.
[0013] Another aspect of the present application may provide a smoking article including the lyocell material or the filter.
[0014] Another aspect of the present application may provide methods of manufacturing the lyocell material, and the filter including the same, and the smoking article.
[0015] In this specification, 'smoking article' may refer to an article capable of generating aerosols, such as a cigarette, cigar, etc. In this regard, the smoking article may include an aerosol-generating material or an aerosol-forming substrate. Additionally, the smoking article may include a solid material based on a tobacco raw material, such as leaf tobacco, cut tobacco, reconstituted tobacco, etc. In addition, a smoking article may include a volatile compound.
[0016] Unless otherwise specifically defined in this specification, when characteristics of a lyocell material or a filter for smoking articles, or any component or composition thereof, are affected by temperature, the temperature at which these characteristics are determined or measured may be room temperature. In this case, the room temperature is a temperature which is not particularly decreased or increased, for example, may be a temperature of 10°C to 35°C, particularly 15°C to 35°C, 20°C to 30°C, or about 25°C.
[0018] In this specification, the "crimp" may refer to a wavy, curled or undulating configuration inherent in a material, such as a fiber, (mono)filament, multifilament and/or yarn, or imparted through mechanical, thermal and/or chemical processes. Crimp may be characterized in that it has a periodic deviation from a straight axis along the length of a material, a fiber, (mono)filament, multifilament and/or yarn. One crimp in a material, a fiber, (mono)filament, multifilament and/or yarn may be defined as one repeating unit of the periodic deviation. The presence of crimp affects the properties, such as elasticity, bulk, resilience, and texture, of a material and a fabric made of that material.
[0019] In this specification, the "standard deviation" is a measured value of the variation of variable values in a set relative to the average. A low standard deviation indicates that variable values tend to be close to the mean (also known as the expected value) in the set, whereas a high standard deviation indicates that variable values are distributed over a wider range. The standard deviation is commonly used to determine which values are abnormal values (very small or large values that are far from the range of observed data) and which values are not abnormal values. The standard deviation may be abbreviated as SD or Std Dev.
[0020] In this specification, the "breaking elongation" of a fiber or filament refers to a percentage (%) of an length to which a fiber or filament increases until it breaks with respect to the original length of the fiber. The elongation (%) is calculated by dividing a difference between the final length at which the fiber or filament was broken and the original length by the original length and multiplying this ratio by 100. In general, the elongation of a filament partially reflects degree of ease with which the filament can be stretched. It is known that a filament having higher breaking elongation than breaking strength can be easily elongated even under small loads.
[0021] In this specification, the term "degree of polymerization" (DPw) may refer to the number of monomer units and/or repeating units in a macromolecule, a polymer, or an oligomer molecule. The degree of polymerization may be expressed as Mn/M0, where Mn is a number-average molecular weight of the macromolecule, polymer or oligomer molecule and M0 is a molecular weight of the monomer unit or repeating unit.
[0022] In this specification, the "lyocell multifilament" may refer to a multifilament made of cellulose. In particular, the lyocell multifilament may be a (multi)filament and/or fiber made of cellulose derived or mainly derived from wood pulp, particularly, a semi-synthetic (multi)filament and/or fiber.
[0023] In this specification, the "lyocell tow" includes at least one lyocell multifilament or consists of at least one lyocell multifilament.
[0024] In this specification, the "opened lyocell material" refers to a lyocell material and/or a lyocell fiber and/or a lyocell multifilament that have been separated, uncoiled, unspooled, loosened or unwrapped from their original compressed and/or rolled state.
[0025] In this specification, the "non-circular cross-section" may refer to a cross-sectional shape that deviates from a standard circular shape. For example, the cross-sectional shape may have a Y-shaped cross-section, a rectangular cross-section, a star-shaped cross-section, a leaf-shaped cross-section, a hexagonal cross-section, a polygonal cross-section, etc. The non-circular cross-section may include three or more protrusions, and preferably includes three protrusions. Here, the "protrusion" may refer to a distinct and expanded segment or arm extending outward from the central core or junction point of the cross-section of a monofilament. The non-circular cross-section including three protrusions may be referred to as a "Y-shaped cross-section." The lyocell tow may have a Y-shaped cross-section for use in cigarette filters.
[0026] In some embodiments, the lyocell multifilament includes one or more monofilaments, and one or more of the monofilaments may have a non-circular cross-section.
[0027] In some embodiments, the lyocell multifilament includes one or more monofilaments, and all of the monofilaments may have a non-circular cross-section.
[0028] In this specification, the "basis weight" refers to a mass per unit area of a wrapping paper and/or a wrapper. The basis weight of a wrapping paper and/or a wrapper may be determined by measuring the mass and area of the wrapping paper and/or wrapper and dividing the mass of the wrapping paper and/or wrapper by the area.
[0029] The present application relates to a lyocell material. The lyocell material may be used in smoking articles, and, although not particularly limited, the lyocell material may be used in filters for smoking articles.
[0030] According to an example, there is provided a lyocell material including a lyocell multifilament to which crimps are applied, wherein the coefficient of variation of the number of crimps (or "first coefficient of variation") is 50% or less.
[0031] In some embodiments, the coefficient of variation of the number of crimps may be 25% or less.
[0032] In some embodiments, the coefficient of variation of the number of crimps may be 10% or more.
[0033] In some embodiments, the coefficient of variation of the number of crimps may be a value calculated according to Equation 1.
Coefficient of variation of number of crimps (%) = [standard deviation of number of
crimps/average of number of crimps] × 100
[0034] In Equation 1, the average number of crimps and the standard deviation of the number of crimps may be values calculated for two strands or more of monofilaments included in the lyocell material. Preferably, the average number of crimps and the standard deviation of the number of crimps may be values calculated for 50 strands or more of monofilaments included in the lyocell material.
[0035] In some embodiments, the coefficient of variation of the number of crimps may be a value calculated according to Equation 1-1.
Coefficient of variation of number of crimps (%) = [standard deviation of number of
crimps in central filaments and peripheral filaments/average of number of crimps in
central filaments and peripheral filaments] × 100
[0036] In Equation 1-1, with respect to an imaginary first line that is parallel to the length direction of the lyocell material and passes through the center point of the lyocell material, an imaginary second line that is parallel to the first line and passes through one end of the lyocell material, and an imaginary third line that is parallel to the second line and passes through the other end of the lyocell material, a central filament represents a monofilament that is located closer to the first line than to the second or third line, and a peripheral filament represents a monofilament that is located closer to the second or third line than to the first line.
[0037] Preferably, in Equation 1-1, the average of the number of crimps and the standard deviation of the number of crimps may be values calculated for 50 strands or more of central filaments and 50 strand or more of peripheral filaments included in the lyocell material.
[0038] In some embodiments, the number of crimps may be 3.94 ea/cm to 23.62 ea/cm (10 ea/inch to 60 ea/inch).
[0039] In some embodiments, the number of crimps may be 9.84 ea/cm to 17.72 ea/cm (25 ea/inch to 45 ea/inch).
[0040] In some embodiments, the tensile strength may be 0.026 N/tex to 0.088 N/tex (0.3 gf/d to 1.0 gf/d).
[0041] In some embodiments, the coefficient of variation of the tensile strength (or "second coefficient of variation") may be 70% or less.
[0042] In some embodiments, the coefficient of variation of the tensile strength may be 50% or less.
[0044] In some embodiments, the coefficient of variation of the tensile strength may be 30% or more.
[0045] In some embodiments, the coefficient of variation of tensile strength may be a value calculated according to Equation 2.
Coefficient of variation of tensile strength (%) = [standard deviation of tensile
strength/average of tensile strength] × 100
[0046] In Equation 2, the average of tensile strength and the standard deviation of tensile strength are values calculatedfor two strands or more of monofilaments included in the lyocell material. Preferably, the average of tensile strength and the standard deviation of tensile strength may be values calculated for 50 strands or more of monofilaments included in the lyocell material.
[0047] In some embodiments, the coefficient of variation of tensile strength may be a value calculated according to Equation 2-1.
Coefficient of variation of tensile strength (%) = [standard deviation of tensile
strength in central filaments and peripheral filaments/average of tensile strength
in central filaments and peripheral filaments] × 100
[0048] In Equation 2-1, with respect to an imaginary first line that is parallel to the length direction of the lyocell material and passes through the center point of the lyocell material, an imaginary second line that is parallel to the first line and passes through one end of the lyocell material, and an imaginary third line that is parallel to the second line and passes through the other end of the lyocell material, a central filament represents a monofilament that is located closer to the first line than to the second or third line, and a peripheral filament represents a monofilament that is located closer to the second or third line than to the first line.
[0049] In some embodiments, in Equation 2-1, the average of tensile strength and the standard deviation of tensile strength may be values calculated for 50 strands or more of central filaments and 50 strands or more of peripheral filaments included in the lyocell material.
[0055] In some embodiments, the coefficient of variation of breaking elongation (or "third coefficient of variation") may be a value calculated according to Equation 3.
Coefficient of variation of breaking elongation (%) = [standard deviation of breaking
elongation/average of breaking elongation] × 100
[0056] In Equation 3, the average of breaking elongation and the standard deviation of breaking elongation are values calculated for two strands or more of monofilaments included in the lyocell material. Preferably, the average of breaking elongation and the standard deviation of breaking elongation may be values calculated for 50 strands or more of monofilaments included in the lyocell material.
[0057] In some embodiments, the coefficient of variation of the breaking elongation may be a value calculated according to Equation 3-1.
Coefficient of variation of breaking elongation (%) = [standard deviation of breaking
elongation in central filaments and peripheral filaments/average of breaking elongation
in central filaments and peripheral filaments] × 100
[0058] In Equation 3-1, with respect to an imaginary first line that is parallel to the length direction of the lyocell material and passes through the center point of the lyocell material, an imaginary second line that is parallel to the first line and passes through one end of the lyocell material, and an imaginary third line that is parallel to the second line and passes through the other end of the lyocell material, a central filament represents a monofilament that is located closer to the first line than to the second or third line, and a peripheral filament represents a monofilament that is located closer to the second or third line than to the first line.
[0059] In some embodiments, in Equation 3-1, the average of breaking elongation and the standard deviation of breaking elongation may be values calculated for 50 strands or more of central filaments and 50 strands or more of peripheral filaments included in the lyocell material.
[0060] In some embodiments, the number of crimps may be 3.94 ea/cm to 23.62 ea/cm (10 ea/inch to 60 ea/inch), the coefficient of variation of the number of crimps may be 10% to 50%, and the coefficient of variation of the number of crimps may be a value calculated by Equation 1-1, the tensile strength may be 0.026 N/tex to 0.088 N/tex (0.3 gf/d to 1.0 gf/d), the coefficient of variation of the tensile strength may be 30% to 70%, and the coefficient of variation of the tensile strength may be a value calculated by Equation 2-1, the breaking elongation may be 2.0% to 10.0%, and the coefficient of variation of the breaking elongation may be 20% to 50%, and the coefficient of variation of the breaking elongation may be a value calculated by Equation 3-1.
[0061] In some embodiments, the single fineness of the lyocell multifilament may be 1.67 to 8.89 dtex (1.5 to 8.0 denier).
[0062] In some embodiments, the lyocell material may have a total fineness of 1,667 to 6,111 tex (15,000 to 55,000 denier).
[0065] In addition, there is provided is a filter for smoking articles, the filter including any one of the described lyocell materials.
[0066] Additionally, there is provided a smoking article including the described filter for smoking articles.
[0067] In addition, there is provided a method of manufacturing a lyocell material, the method including a lyocell dope spinning process; a coagulation and lyocell multifilament obtainment process; a washing process; an oil treatment process; and a crimp application process.
[0068] In some embodiments, the crimp application process is performed by a crimping device including one or more side plates, wherein the surface roughness of the side plate may be 1000 nm or less.
[0069] In this specification, the "surface roughness" refers to irregularity of a surface. There are several parameters to measure the roughness of a profile, and, among them, the most general parameter is a Ra value. Ra is obtained by measuring the arithmetic average of surface unevenness, including deviation from the average line within a sampling length. The measurement of surface roughness may be performed by a profilometer or a laser scanner. The larger the deviation, the rougher the surface, and the smaller the Ra, the smoother the surface. Ra is measured in nanometers (nm), micrometers (µm), or microinches (µin).
[0070] In some embodiments, when the crimping device includes two or more side plates, the surface roughness of the two or more side plates may be each independently 1000 nm or less.
[0072] In some embodiments, when the crimping device includes two or more side plates, the surface roughness of the two or more side plates may be each independently 100 nm or more.
[0073] In some embodiments, the crimping device further includes one or more blades, wherein the surface roughness of the blade may be less than 1200 nm.
[0074] In some embodiments, the crimping device further includes one or more blades, wherein the surface roughness of the blade may be 1100 nm or less.
[0075] In some embodiments, the crimping device includes a first blade and a second blade, wherein the first blade and the second blade are spaced apart from each other, and the surface roughness of the first blade and the surface roughness of the second blade may be each independently less than 1200 nm.
[0076] In some embodiments, the first coefficient of variation of the lyocell material may be 50% or less, and may be 0% or more. A lyocell material having a first coefficient of variation satisfying the above-described numerical range is expected to have uniform crimp number throughout the entire lyocell material.
[0077] In some embodiments, the upper limit of the first coefficient of variation (i.e., the coefficient of variation of the number of crimps) may be 50 % or less, 48 % or less, 46 % or less, 44 % or less, 42 % or less, 40 % or less, 38 % or less, 36 % or less, 34 % or less, 32 % or less, 30 % or less, 28 % or less, 26 % or less, 24 % or less, 22 % or less, 20 % or less, 18 % or less, 16 % or less, 14 % or less, or 12 % or less. In addition, the lower limit of the first coefficient of variation may be 10 % or more, 12 % or more, 14 % or more, 16 % or more, 18 % or more, 20 % or more, 22 % or more, 24 % or more, 26 % or more, 28 % or more, 30 % or more, 32 % or more, 34 % or more, 36 % or more, 38 % or more, 40 % or more, 42 % or more, 44 % or more, 46 % or more, or 48 % or more. In some embodiments, the first coefficient of variation may be 10 % to 50 %, 10 % to 48 %, 10% to 46 %, 10 % to 44 %, 10 % to 42 %, 10 % to 40 %, 10 % to 38 %, 10 % to 36 %, 10 % to 34 %, 10 % to 32 %, 10 % to 30 %, 10 % to 28 %, 10 % to 26 %, 10 % to 24 %, 10 % to 22 %, 10 % to 20 %, 10 % to 18 %, 10 % to 16 %, 10 % to 14 %, 10 % to 12 %, 12 % to 50 %, 12 % to 48 %, 12 % to 46 %, 12 % to 44 %, 12 % to 42 %, 12 % to 40 %, 12 % to 38 %, 12 % to 36 %, 12 % to 34 %, 12 % to 32 %, 12 % to 30 %, 12 % to 28 %, 12% to 26 %, 12 % to 24 %, 12 % to 22 %, 12 % to 20%, 12% to 18 %, 12 % to 16 %, 12 % to 14 %, 14 % to 50 %, 14 % to 48 %, 14 % to 46 %, 14 % to 44 %, 14 % to 42 %, 14 % to 40%, 14 % to 38 %, 14 % to 36 %, 14 % to 34 %, 14 % to 32 %, 14 % to 30 %, 14 % to 28 %, 14 % to 26 %, 14 % to 24 %, 14 % to 22 %, 14 % to 20%, 14 % to 18 %, 14 % to 16 %, 16 % to 50 %, 16 % to 48 %, 16 % to 46 %, 16 % to 44 %, 16 % to 42%, 16 % to 40%, 16 % to 38 %, 16 % to 36 %, 16 % to 34 %, 16 % to 32 %, 16 % to 30 %, 16 % to 28 %, 16 % to 26 %, 16 % to 24 %, 16 % to 22 %, 16 % to 20%, 16 % to 18 %, 18 % to 50 %, 18 % to 48 %, 18 % to 46 %, 18 % to 44 %, 18 % to 42%, 18 % to 40%, 18 % to 38 %, 18 % to 36 %, 18 % to 34 %, 18 % to 32 %, 18 % to 30 %, 18 % to 28 %, 18 % to 26 %, 18 % to 24 %, 18 % to 22%, 18 % to 20%, 20 % to 50 %, 20 % to 48 %, 20% to 46 %, 20 % to 44 %, 20 % to 42 %, 20 % to 40 %, 20 % to 38 %, 20 % to 36 %, 20 % to 34 %, 20 % to 32 %, 20 % to 30 %, 20 % to 28 %, 20 % to 26 %, 20 % to 24 %, 20 % to 22%, 22 % to 50 %, 22 % to 48 %, 22 % to 46 %, 22 % to 44 %, 22 % to 42 %, 22 % to 40 %, 22 % to 38 %, 22 % to 36 %, 22 % to 34 %, 22 % to 32 %, 22 % to 30 %, 22 % to 28 %, 22 % to 26 %, 22 % to 24 %, 24 % to 50 %, 24 % to 48 %, 24 % to 46 %, 24% to 44%, 24 % to 42 %, 24 % to 40 %, 24 % to 38 %, 24 % to 36 %, 24 % to 34 %, 24 % to 32 %, 24 % to 30 %, 24 % to 28 %, 24 % to 26 %, 26 % to 50 %, 26 % to 48 %, 26 % to 46 %, 26 % to 44 %, 26 % to 42 %, 26 % to 40 %, 26 % to 38 %, 26 % to 36 %, 26 % to 34 %, 26 % to 32 %, 26 % to 30 %, 26 % to 28 %, 28 % to 50 %, 28 % to 48 %, 28 % to 46 %, 28 % to 44 %, 28 % to 42 %, 28 % to 40 %, 28 % to 38 %, 28 % to 36 %, 28 % to 34 %, 28 % to 32 %, 28 % to 30 %, 30 % to 50 %, 30 % to 48 %, 30 % to 46 %, 30 % to 44 %, 30 % to 42 %, 30 % to 40 %, 30 % to 3 8%, 30 % to 36 %, 30 % to 34 %, 30 % to 32 %, 32 % to 50 %, 32 % to 48 %, 32 % to 46 %, 32 % to 44 %, 32 % to 42 %, 32 % to 40%, 32 % to 38 %, 32 % to 36 %, 32 % to 34 %, 34 % to 50 %, 34 % to 48 %, 34 % to 46 %, 34 % to 44 %, 34 % to 42%, 34 % to 40%, 34 % to 38 %, 34 % to 36 %, 36 % to 50 %, 36 % to 48 %, 36 % to 46 %, 36 % to 44 %, 36 % to 42%, 36 % to 40 %, 36 % to 38 %, 38 % to 50 %, 38 % to 48 %, 38 % to 46 %, 38 % to 44 %, 38 % to 42 %, 38 % to 40%, 40 % to 50 %, 40 % to 48 %, 40 % to 46 %, 40 % to 44 %, 40 % to 42 %, 42 % to 50 %, 42 % to 48 %, 42 % to 46 %, 42 % to 44 %, 44 % to 50 %, 44 % to 48 %, 44 % to 46%, 46 % to 50 %, 46 % to 48 %, or 48 % to 50 %.
[0078] In some embodiments, the second coefficient of variation of the lyocell material may be 70 % or less, and may be 30 % or more. A lyocell material the above-described numerical range is expected to have uniform tensile strength throughout the entire lyocell material.
[0079] In some embodiments, the second coefficient of variation of the lyocell material may be 30 % to 70 %, 30 % to 68 %, 30 % to 66 %, 30 % to 64 %, 30 % to 62 %, 30 % to 60 %, 30 % to 58 %, 30 % to 56 %, 30 % to 54 %, 30 % to 52 %, 30 % to 50 %, 30 % to 48 %, 30 % to 46 %, 30 % to 44 %, 30 % to 42 %, 30 % to 40 %, 30 % to 38 %, 30 % to 36 %, 30 % to 34 %, 30 % to 32 %, 32 % to 70 %, 32 % to 68 %, 32 % to 66 %, 32 % to 64 %, 32 % to 62 %, 32 % to 60 %, 32 % to 58 %, 32 % to 56 %, 32 % to 54 %, 32 % to 52 %, 32 % to 50 %, 32 % to 48 %, 32 % to 46 %, 32 % to 44 %, 32 % to 42 %, 32 % to 40 %, 32 % to 38 %, 32 % to 36 %, 32 % to 34 %, 34 % to 70 %, 34 % to 68 %, 34 % to 66 %, 34 % to 64 %, 34 % to 62 %, 34 % to 60 %, 34 % to 58 %, 34 % to 56 %, 34 % to 54 %, 34 % to 52 %, 34 % to 50 %, 34 % to 48 %, 34 % to 46 %, 34 % to 44 %, 34 % to 42 %, 34 % to 40 %, 34 % to 38 %, 34 % to 36 %, 36 % to 70 %, 36 % to 68 %, 36 % to 66 %, 36 % to 64%, 36 % to 62 %, 36 % to 60 %, 36 % to 58 %, 36 % to 56 %, 36 % to 54 %, 36 % to 52 %, 36 % to 50 %, 36 % to 48 %, 36 % to 46 %, 36 % to 44 %, 36 % to 42 %, 36 % to 40 %, 36 % to 38 %, 38 % to 70 %, 38 % to 68 %, 38 % to 66 %, 38 % to 64 %, 38 % to 62 %, 38 % to 60 %, 38 % to 58 %, 38 % to 56 %, 38 % to 54 %, 38 % to 52 %, 38 % to 50 %, 38 % to 48 %, 38 % to 46 %, 38 % to 44 %, 38 % to 42 %, 38 % to 40 %, 40 % to 70 %, 40 % to 68 %, 40 % to 66 %, 40 % to 64 %, 40 % to 62 %, 40 % to 60 %, 40 % to 58 %, 40 % to 56 %, 40 % to 54 %, 40 % to 52 %, 40 % to 50 %, 40 % to 48 %, 40 % to 46 %, 40 % to 44 %, 40 % to 42 %, 42 % to 70 %, 42 % to 68 %, 42 % to 66 %, 42 % to 64 %, 42 % to 62 %, 42 % to 60 %, 42 % to 58 %, 42 % to 56 %, 42 % to 54 %, 42 % to 52 %, 42 % to 50 %, 42 % to 48 %, 42 % to 46 %, 42 % to 44 %, 44 % to 70 %, 44 % to 68 %, 44 % to 66 %, 44 % to 64 %, 44 % to 62 %, 44 % to 60 %, 44 % to 58 %, 44 % to 56 %, 44 % to 54 %, 44 % to 52 %, 44 % to 50 %, 44 % to 48 %, 44 % to 46 %, 46 % to 70 %, 46 % to 68 %, 46 % to 66 %, 46 % to 64 %, 46 % to 62 %, 46 % to 60 %, 46 % to 58 %, 46 % to 56 %, 46 % to 54 %, 46 % to 52 %, 46 % to 50 %, 46 % to 48 %, 48 % to 70 %, 48 % to 68 %, 48 % to 66 %, 48 % to 64 %, 48 % to 62 %, 48 % to 60 %, 48 % to 58 %, 48 % to 56 %, 48 % to 54 %, 48 % to 52 %, 48 % to 50 %, 50 % to 70 %, 50 % to 68 %, 50 % to 66 %, 50 % to 64 %, 50 % to 62 %, 50 % to 60 %, 50 % to 58 %, 50 % to 56 %, 50 % to 54 %, 50 % to 52 %, 52 % to 70 %, 52 % to 68 %, 52 % to 66 %, 52 % to 64 %, 52 % to 62 %, 52 % to 60 %, 52 % to 58 %, 52 % to 56 %, 52 % to 54 %, 54 % to 70 %, 54 % to 68 %, 54 % to 66 %, 54 % to 64 %, 54 % to 62 %, 54 % to 60 %, 54 % to 58 %, 54 % to 56 %, 56 % to 70 %, 56 % to 68 %, 56 % to 66 %, 56 % to 64 %, 56 % to 62 %, 56 % to 60 %, 56 % to 58 %, 58 % to 70 %, 58 % to 68 %, 58 % to 66 %, 58 % to 64 %, 58 % to 62 %, 58 % to 60 %, 60 % to 70 %, 60 % to 68 %, 60 % to 66 %, 60 % to 64 %, 60 % to 62 %, 62 % to 70 %, 62 % to 68 %, 62 % to 66 %, 62 % to 64 %, 64 % to 70%, 64 % to 68 %, 64 % to 66 %, 66 % to 70 %, 66 % to 68 %, or 68 % to 70 %. In some embodiments, the third coefficient of variation of the lyocell material may be 50 % or less, and may be 20 % or more. A lyocell material the above-described numerical range is expected to have uniform breaking elongation throughout the entire lyocell material.
[0080] In some embodiments, the third coefficient of variation of the lyocell material may be 20 % to 50 %, 20 % to 48 %, 20 % to 46 %, 20 % to 44 %, 20 % to 42 %, 20 % to 40 %, 20 % to 38 %, 20 % to 36 %, 20 % to 34 %, 20 % to 32 %, 20 % to 30 %, 20 % to 28 %, 20 % to 26 %, 20 % to 24 %, 20 % to 22 %, 22 % to 50 %, 22 % to 48 %, 22 % to 46 %, 22 % to 44 %, 22 % to 42 %, 22 % to 40 %, 22 % to 38 %, 22 % to 36 %, 22 % to 34 %, 22 % to 32 %, 22 % to 30 %, 22 % to 28 %, 22 % to 26 %, 22 % to 24 %, 24 % to 50 %, 24 % to 48 %, 24 % to 46 %, 24 % to 44 %, 24 % to 42 %, 24 % to 40 %, 24 % to 38 %, 24 % to 36 %, 24 % to 34 %, 24 % to 32 %, 24 % to 30 %, 24 % to 28 %, 24 % to 26 %, 26 % to 50 %, 26 % to 48 %, 26 % to 46 %, 26 % to 44 %, 26 % to 42 %, 26 % to 40 %, 26 % to 38 %, 26 % to 36 %, 26 % to 34 %, 26 % to 32 %, 26 % to 30 %, 26 % to 28 %, 28 % to 50 %, 28 % to 48 %, 28 % to 46 %, 28 % to 44 %, 28 % to 42 %, 28 % to 40 %, 28 % to 38 %, 28 % to 36 %, 28 % to 34 %, 28 % to 32 %, 28 % to 30 %, 30 % to 50 %, 30 % to 48 %, 30 % to 46 %, 30 % to 44 %, 30 % to 42 %, 30 % to 40 %, 30 % to 38 %, 30 % to 36 %, 30 % to 34 %, 30 % to 32 %, 32 % to 50 %, 32 % to 48 %, 32 % to 46 %, 32 % to 44 %, 32 % to 42 %, 32 % to 40 %, 32 % to 38 %, 32 % to 36 %, 32 % to 34 %, 34 % to 50 %, 34 % to 48 %, 34 % to 46 %, 34 % to 44 %, 34 % to 42 %, 34 % to 40 %, 34 % to 38 %, 34 % to 36 %, 36 % to 50 %, 36 % to 48 %, 36 % to 46 %, 36 % to 44 %, 36 % to 42 %, 36 % to 40 %, 36 % to 38 %, 38 % to 50 %, 38 % to 48 %, 38 % to 46 %, 38 % to 44 %, 38 % to 42 %, 38 % to 40 %, 40 % to 50 %, 40 % to 48 %, 40 % to 46 %, 40 % to 44 %, 40 % to 42 %, 42 % to 50 %, 42 % to 48 %, 42 % to 46 %, 42 % to 44 %, 44 % to 50 %, 44 % to 48 %, 44 % to 46 %, 46 % to 50 %, 46 % to 48 %, or 48 % to 50 %. As a means for controlling the first coefficient of variation, second coefficient of variation and/or third coefficient of variation of the lyocell material, a method of controlling the surface roughness (Ra1) of the side plate included in the crimping device may be considered. By controlling the surface roughness of the side plate, the contact area and contact strength between the side plate and the lyocell multifilament can be controlled, and the intensity of frictional force generated between the side plate and the lyocell multifilament can be controlled.
[0081] As a result, the lyocell multifilament may be provided with a preset number of crimps while preventing damage to the lyocell multifilament by the side plates. In this way, the central filament and the peripheral filament can maintain similar characteristics, and the uniformity of the lyocell material can be improved. Furthermore, the performance (e.g., filtering ability, etc.) of a filter for smoking articles, including the above lyocell material, can be improved.
[0082] As another means for controlling the first coefficient of variation, second coefficient of variation and/or third coefficient of variation of the lyocell material, a method of controlling the surface roughness (Ra2) of the blade included in the crimping device may be considered. By controlling the surface roughness of the side plate, the contact strength between the blade and the lyocell multifilament can be controlled, and the intensity of frictional force generated between the blade and the lyocell multifilament can be controlled.
[0083] As a result, during the transport process of the lyocell multifilament, damage to the lyocell multifilament by the blade can be suppressed. In this way, the uniformity of the lyocell material can be improved. Furthermore, the performance (e.g., filtering ability, etc.) of a filter for smoking articles, including the above lyocell material, can be improved.
[Non-circular cross-section]
[0084] At least one of the lyocell monofilaments included in the lyocell material of the present application may have a non-circular cross-section. The "non-circular" means that the shape of the outline of a cross-section is not circular, and the "cross-section" may be a cross-section obtained by cutting the lyocell monofilament virtually or actually perpendicular to the length direction of the filament.
[0085] The outline of the non-circular cross-section may come into contact with an imaginary first circle and an imaginary second circle, respectively. Additionally, the imaginary second circle may be within the imaginary first circle, and/or the imaginary second circle may be within the imaginary first circle. The "imaginary first circle" may also be referred to as a "imaginary circumcircle" and/or a "circumcircle", and/or the "imaginary second circle" may also be referred to as a "imaginary incircle" and/or a "incircle".
[0086] The imaginary first circle may be a circle having the smallest area value among the circles drawn to completely encompass one cross-section of a monofilament. The imaginary second circle may be a circle having the largest area value among the circles drawn within the cross section of the monofilament.
[0087] When a circumcircle including the cross section of the monofilament can be drawn, the imaginary first circle may be the above-described circumcircle. When an incircle can be drawn within the cross section of the monofilament, the imaginary second circle may be the above-described incircle.
[0088] The non-circular cross-section may have a shape including a plurality of protrusions, for example, a Y-shaped cross-section including three protrusions. It can be understood that the plurality of protrusions are formed integrally with the imaginary second circle as a center and that their ends are in contact with the imaginary first circle. The terms mentioned herein have the same meanings as described above.
[0090] Here, r1 is a radius of the imaginary first circle, and r2 is a radius of the imaginary second circle.
[0091] For example, the radius of the imaginary first circle may be 4 µm to 40 µm, the radius of the imaginary second circle may be 2 µm to 14 µm, and the non-circularity may be 1.01 to 10.
[0092] Additionally, the space occupancy of a monofilament may be defined by the following Equation 2.
[0093] Here, S1 is an area of the imaginary first circle, and S2 is a cross-sectional area of a monofilament included in a lyocell fiber.
[0094] For example, the space occupancy of a monofilament having a non-circular cross-section may be 120 % to 600 %.
[Fineness]
[0095] The lyocell material of the present application includes lyocell multifilaments, and the lyocell multifilaments may have a fineness suitable for manufacturing a filter for smoking articles and securing its function.
[0096] For example, the single fineness of filaments forming the above-described lyocell multifilament may be 1.67 to 8.89 dtex (1.5 to 8.0 denier). In this case, the single fineness of a filament refers to a fineness of one monofilament separated from a multifilament.
[0097] In particular, the single fineness of the filament may be, for example, 8.33 dtex (7.5 denier) or less, 7.78 dtex (7.0 denier) or less, 7.22 dtex (6.5 denier) or less, 6.67 dtex (6.0 denier) or less, 6.11 dtex (5.5 denier) or less, 5.56 dtex (5.0 denier) or less, 5.00 dtex (4.5 denier) or less, 3.89 dtex (3.5 denier) or less, 3.33 dtex (3.0 denier) or less, 2.78 dtex (2.5 denier) or less, or 2.22 dtex (2.0 denier) or less. Further, the lower limit thereof may be, for example, 2.22 dtex (2.0 denier) or more, 2.78 dtex (2.5 denier) or more, 3.33 dtex (3.0 denier) or more, 3.89 dtex (3.5 denier) or more, 4.44 dtex (4.0 denier) or more, 5.00 dtex (4.5 denier) or more, 5.56 dtex (5.0 denier) or more, 6.11 dtex (5.5 denier) or more, 6.67 dtex (6.0 denier) or more, 7.22 dtex (6.5 denier) or more, or 7.78 dtex (7.0 denier) or more. Satisfying the above range may be more advantageous in securing stable physical properties (e.g., hardness or draw resistance implementation, etc.) and processability of a filter for smoking articles.
[0098] For example, the lyocell multifilament may have a total fineness of 1,667 to 6,111 tex (15,000 to 55,000 denier). For example, the lower limit of the total fineness may be, for example, 1,778 tex (16,000 denier) or more, 1,833 tex (16,500 denier) or more, 1,889 tex (17,000 denier) or more, 1,944 tex (17,500 denier) or more, 2,000 tex (18,000 denier) or more, 2,056 tex (18,500 denier) or more, 2,111 tex (19,000 denier) or more, 2,167 tex (19,500 denier) or more, 2,222 tex (20,000 denier) or more, 2,278 tex (20,500 denier) or more, 2,333 tex (21,000 denier) or more, 2,389 tex(21,500 denier) or more, 2,444 tex(22,000 denier) or more, 2,500 tex(22,500 denier) or more, 2,556 tex(23,000 denier) or more, 2,611 tex(23,500 denier) or more, 2,667 tex(24,000 denier) or more, 2,722 tex(24,500 denier) or more, 2,778 tex(25,000 denier) or more, 2,833 tex(25,500 denier) or more, 2,889 tex(26,000 denier) or more, 2,944 tex(26,500 denier) or more, 3,000 tex(27,000 denier) or more, 3,056 tex(27,500 denier) or more, 3,111 tex(28,000 denier) or more, 3,167 tex(28,500 denier) or more, 3,222 tex(29,000 denier) or more, 3,287 tex(29,500 denier) or more, 3,333 tex(30,000 denier) or more, 3,389 tex(30,500 denier) or more, 3,444 tex(31,000 denier) or more, 3,500 tex(31,500 denier) or more, 3,556 tex(32,000 denier) or more, 3,611 tex(32,500 denier) or more, 3,667 tex(33,000 denier) or more, 3,722 tex(33,500 denier) or more, 3,778 tex(34,000 denier) or more, 3,833 tex(34,500 denier) or more, 3,889 tex(35,000 denier) or more, 3,944 tex(35,500 denier) or more, 4,000 tex(36,000 denier) or more, 4,056 tex(36,500 denier) or more, 4,111 tex(37,000 denier) or more, 4,167 tex(37,500 denier) or more, 4,222 tex(38,000 denier) or more, 4,278 tex(38,500 denier) or more, 4,333 tex(39,000 denier) or more, 4,389 tex(39,500 denier) or more, 4,444 tex(40,000 denier) or more, 4,500 tex(40,500 denier) or more, 4,556 tex(41,000 denier) or more, 4,611 tex(41,500 denier) or more, 4,667 tex(42,000 denier) or more, 4,722 tex(42,500 denier) or more, 4,778 tex(43,000 denier) or more, 4,833 tex(43,500 denier) or more, 4,889 tex(44,000 denier) or more, 4,944 tex(44,500 denier) or more, 5,000 tex(45,000 denier) or more, 5,056 tex(45,500 denier) or more, 5,111 tex(46,000 denier) or more, 5,167 tex(46,500 denier) or more, 5,222 tex(47,000 denier) or more, 5,278 tex(47,500 denier) or more, 5,333 tex(48,000 denier) or more, 5,389 tex(48,500 denier) or more, 5,444 tex(49,000 denier) or more, 5,500 tex(49,500 denier) or more, 5,556 tex(50,000 denier) or more, 5,611 tex(50,500 denier) or more, 5,667 tex(51,000 denier) or more, 5,722 It can be 51,500 denier or more, 5,778 tex (52,000 denier) or more, 5,833 tex (52,500 denier) or more, 5,889 tex (53,000 denier) or more, 5,944 tex (53,500 denier) or more, 6,000 tex (54,000 denier) or more, or 6,056 tex (54,500 denier) or more. And, the upper limit thereof may be, for example, 6,056 tex (54,500 denier) or less, 6,000 tex (54,000 denier) or less, 5,944 tex (53,500 denier) or less, 5,889 tex (53,000 denier) or less, 5,833 tex (52,500 denier) or less, 5,778 tex (52,000 denier) or less, 5,722 tex (51,500 denier) or less, 5,667 tex (51,000 denier) or less, 5,611 tex (50,500 denier) or less, 5,556 tex (50,000 denier) or less, 5,500 tex (49,500 denier) or less, 5,444 tex(49,000 denier) or less, 5,389 tex(48,500 denier) or less, 5,333 tex(48,000 denier) or less, 5,278 tex(47,500 denier) or less, 5,222 tex(47,000 denier) or less, 5,167 tex(46,500 denier) or less, 5,111 tex(46,000 denier) or less, 5,056 tex(45,500 denier) or less, 5,000 tex(45,000 denier) or less, 4,944 tex(44,500 denier) or less, 4,889 tex(44,000 denier) or less, 4,833 tex(43,500 denier) or less, 4,778 tex (43,000 denier) or less, 4,722 tex (42,500 denier) or less, 4,667 tex (42,000 denier) or less, 4,611 tex (41,500 denier) or less, 4,556 tex (41,000 denier) or less, 4,500 tex (40,500 denier) or less, 4,444 tex (40,000 denier) or less, 4,389 tex (39,500 denier) or less, 4,333 tex (39,000 denier) or less, 4,278 tex (38,500 denier) or less, 4,222 tex (38,000 denier) or less, 4,167 tex (37,500 denier) or less, 4,111 tex (37,000 denier) or less, 4,056 tex (36,500 denier) or less, 4,000 tex (36,000 denier) or less, 3,944 tex (35,500 denier) or less, 3,889 tex (35,000 denier) or less, 3,833 tex (34,500 denier) or less, 3,778 tex (34,000 denier) or less, 3,722 tex (33,500 denier) or less, 3,667 tex (33,000 denier) or less, 3,611 tex (32,500 denier) or less, 3,556 tex (32,000 denier) or less, 3,500 tex (31,500 denier) or less, 3,444 tex (31,000 denier) or less, 3,389 tex (30,500 denier) or less, 3,333 tex (30,000 denier) or less, 3,278 tex (29,500 denier) or less, 3,222 tex (29,000 denier) or less, 3,167 tex (28,500 denier) or less, 3,111 tex (28,000 denier) or less, 3,056 tex (27,500 denier) or less, 3,000 tex (27,000 denier) or less, 2,944 tex (26,500 denier) or less, 2,889 tex (26,000 denier) or less, 2,833 tex (25,500 denier) or less, 2,778 tex (25,000 denier) or less, 2,722 tex (24,500 denier) or less, 2,667 tex (24,000 denier) or less, 2,611 tex (23,500 denier) or less, 2,556 tex (23,000 denier) or less, 2,500 tex (22,500 denier) or less, 2,444 tex (22,000 denier) or less, 2,389 tex (21,500 denier) or less, 2,333 tex (21,000 denier) or less, 2,278 tex (20,500 denier) or less, 2,222 tex (20,000 denier) or less, 2,167 tex (19,500 denier) or less, 2,111 tex (19,000 denier) or less, 2,056 tex (18,500 denier) or less, 2,000 tex (18,000 denier) or less, 1,944 tex (17,500 denier) or less, 1,889 tex (17,000 denier) or less, 1,833 tex (16,500 denier) or less, 1,778 tex (16,000 denier) or less, or 1,722 tex (15,500 denier) or less. When the total fineness is outside the above range, the processability of manufacturing a filter for smoking articles may not be good (continuous process by cutting is impossible), and when the amount of tow filling a filter wrapper during a process of manufacturing a filter for smoking articles is too small or too large, it may be difficult to secure sufficient properties (e.g., hardness or draw resistance, etc.) of the filter.
[0099] Although there are no particular restrictions on the method of measuring fineness, for example, lyocell tow to be measured is collected as a 2 m sample and left in a room with a constant temperature and humidity at a temperature of 20°C and a humidity of 65% for 24 hours and is stabilized. One end of the stabilized lyocell tow is fixed, and a 2 kg of weight is mounted on the other end of the lyocell tow. The tow in an extended state due to a load is maintained (stabilized) for 5 seconds, and is then cut into 90 cm pieces to obtain a sample, and the weight (total fineness) of the sample is measured. The fineness, which is denier according to a denier conversion method, is converted into the measured weight × 10000. When the total fineness is divided by the number of strands of monofilaments in the sample, single fineness of the monofilaments in the sample is calculated.
[0100] The total fineness of the above lyocell multifilament may be determined by the single fineness of monofilaments and the number of crimps. In the present application, the single fineness and the number of crimps may be controlled, and the total fineness of the lyocell material suitable for manufacturing a filter for smoking articles and securing its function may be secured.
[0101] Although not specifically limited, the lyocell material produced to satisfy the above-described single fineness and/or total fineness may be used in smoking articles.
[Crimp]
[0102] In some embodiments, the lyocell multifilament may have crimps of 3.94 to 23.62 per centimeter (10 to 60 per inch). For example, the lower limit of the number of crimps may be 5.91 ea/cm (15 ea/inch) or more, 7.87 ea/cm (20 ea/inch) or more, 9.84 ea/cm (25 ea/inch) or more, 11.81 ea/cm (30 ea/inch) or more, 13.78 ea/cm (35 ea/inch) or more, 15.75 ea/cm (40 ea/inch) or more, or 17.72 ea/cm (45 ea/inch) or more, 19.69 ea/cm (50 ea/inch) or more, or 21.65 ea/cm (55 ea/inch) or more, and the upper limit thereof may be, for example, 17.72 ea/cm (45 ea/inch) or less, 15.75 ea/cm (40 ea/inch) or less, It may be 13.78 ea/cm(35 ea/inch) or less, 11.81 ea/cm(30 ea/inch) or less, or 9.84 ea/cm(25 ea/inch) or less. The number of crimps and the uniformity thereof may be controlled through pressure and temperature conditions, etc., in the crimping process to be described below.
[0103] Additionally, in some embodiments, the coefficient of variation of the number of crimps (or the "first coefficient of variation") may be 50 % or less, and may be 0 % or more. Preferably, the upper limit of the first coefficient of variation may be 50 %, 45 %, 40 %, 35 %, 30 %, 25 %, 20 %, or 15 %, and the lower limit of the first coefficient of variation may be 0 %, 5 %, 10 %, 15 %, 20 %, 25 %, 30 %, 35 %, 40 %, or 45%. A lyocell material satisfying the above-described numerical range is expected to have a uniform crimp number throughout the entire lyocell material.
[0104] Additionally, the first coefficient of variation may be a value calculated according to Equation 1 below.
Coefficient of variation of number of crimps (%) = [standard deviation of number of
crimps/average of number of crimps] × 100
[0105] In Equation 1, the average number of crimps and the standard deviation of the number of crimps may be values calculated for two strands or more of monofilaments included in the lyocell material. Preferably, the average number of crimps and the standard deviation of the number of crimps may be values calculated for 50 strands or more of monofilaments included in the lyocell material.
[0106] Additionally, monofilaments may be arbitrarily unspun from the lyocell material for calculation according to Equation 1. By calculating the first coefficient of variation from the arbitrarily unspun monofilaments according to Equation 1, the first coefficient of variation may provide information on the uniformity of crimps applied to the lyocell material, and. preferably, may provide information related to the number of crimps.
[0107] In particular, the coefficient of variation of the number of crimps may be a value calculated according to Equation 1-1.
Coefficient of variation of number of crimps (%) = [standard deviation of number of
crimps in central filaments and peripheral filaments/average of number of crimps in
central filaments and peripheral filaments] × 100
[0108] In Equation 1-1, with respect to an imaginary first line that is parallel to the length direction of the lyocell material and passes through the center point of the lyocell material, an imaginary second line that is parallel to the first line and passes through one end of the lyocell material, and an imaginary third line that is parallel to the second line and passes through the other end of the lyocell material, a central filament represents a monofilament that is located closer to the first line than to the second or third line, and a peripheral filament represents a monofilament that is located closer to the second or third line than to the first line.
[0109] Preferably, in Equation 1-1, the average number of crimps and the standard deviation of the number of crimps may be values calculated for 50 strands or more of central filaments and 50 strands or more of peripheral filaments included in the lyocell material.
[0110] More preferably, in Equation 1-1, the average number of crimps and the standard deviation of the number of crimps in may be values calculated for 100 strands or more of central filaments and 200 strands or more of peripheral filaments. Additionally, some (e.g., 50 strands) of 100 strands of central filaments and others (e.g., residual 50 strands) of 100 strands of central filaments may be collected at locations equidistant from the first line, respectively. Similarly, some (e.g., 100 strands) of 200 strands of peripheral filaments and others (e.g., residual 100 strands) of 200 strands of peripheral filaments may be collected at locations equidistant from the second line and the third line, respectively. In particular, 50 strands of 100 strands of peripheral filaments may be collected at locations closer to the second line than residual 50 strands of 100 strands of peripheral filaments, and 50 strands of 100 strands of peripheral filaments may be collected at locations closer to the third line than residual 50 strands of 100 peripheral filaments.
[0111] For example, when the x-coordinate of the second line is 0, the x-coordinate of the first line is 50, and the x-coordinate of the third line is 100, the central filaments may be collected at points where the x-coordinates are 40 and/or 60, and the peripheral filaments may be taken at points where the x-coordinates are 5, 20, 80, and/or 95.
[0112] Additionally, for the calculation of Equation 1-1, monofilaments may be arbitrarily unspun from the center of the lyocell material and the periphery of the lyocell material, respectively. By calculating the first coefficient of variation using the monofilaments arbitrarily unspun from the center and periphery of the lyocell material, the first coefficient of variation may provide information on the uniformity of crimps applied to the center and periphery of the lyocell material, and. preferably, may provide information related to the number of crimps.
[0113] The number of crimps and the coefficient of variation of the number of crimps may be measured using a physical property evaluation apparatus. Although not particularly limited, FAVIMAT+ of Textechno Inc. may be considered as an example of a physical property evaluation apparatus. In using the physical property evaluation apparatus, a dedicated jig may be used, and a sample (preferably, monofilaments) collected from the lyocell material is mounted on the dedicated jig and evaluated by the physical property evaluation apparatus. The sample may be mounted on a dedicated jig with a length (gauge length) of 10 to 30 mm.
[0114] Although not particularly limited, an initial load may be applied to the monofilaments to enable easy physical property evaluation. For example, the initial load may be 0.009 N/tex (0.1 g/d), 0.0066 N/tex (0.075 g/d), 0.0044 N/tex (0.05 g/d), 0.0022 N/tex (0.025 g/d), or 0.0009 N/tex (0.01 g/d). Additionally, evaluation conditions for the number of crimps may be set. As examples of evaluation conditions, crimp sensitivity and loading speed may be considered. In general, the smaller the crimp sensitivity and loading speed, the more crimps may be measured. For example, the crimp sensitivity may be set to 0.03 mm, 0.02 mm, 0.01 mm, or 0.005 mm. The loading speed may be set to 20 mm/min, 15 mm/min, 10 mm/min, or 5 mm/min.
[0115] Although not particularly limited, stabilization of the lyocell material and/or the monofilaments may be performed prior to measurement of the number of crimps and the first coefficient of variation. The stabilization may be performed under constant temperature and humidity conditions. For example, the constant temperature condition may be a temperature of 20±2°C, and the constant humidity condition may be a humidity of 65±4%RH. Additionally, the stabilization may be performed for 24 hours or more.
[0116] Although not particularly limited, a lyocell material prepared to satisfy the number of crimps and/or coefficient of variation of the number of crimps, described above, may be used in smoking articles.
[Tensile strength]
[0117] In some embodiments, tensile strength may be 0.026 N/tex to 0.106 N/tex (0.30 gf/d to 1.2 gf/d). Preferably, the upper limit of the tensile strength may be 0.097 N/tex (1.1 gf/d), 0.088 N/tex (1.0 gf/d), 0.0794 N/tex (0.9 gf/d), 0.0706 N/tex (0.8 gf/d), 0.0618 N/tex (0.7 gf/d) or 0.0530 N/tex (0.6 gf/d), and the lower limit of the tensile strength can be 0.0265 N/tex (0.30 gf/d), 0.0353 N/tex (0.40 gf/d), 0.0397 N/tex (0.45 gf/d), 0.0441 N/tex (0.5 gf/d), or 0.0485 N/tex (0.55 gf/d).
[0118] In some embodiments, the coefficient of variation of the tensile strength of the lyocell material (or "second coefficient of variation") may be 70% or less, and may be 30% or more. Preferably, the upper limit of the second coefficient of variation may be 60%, 50%, 45%, 40%, 35%, 30%, or 25%, and the lower limit of the second coefficient of variation may be 0%, 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, or 45%. A lyocell material satisfying the above-described numerical range is expected to have uniform tensile strength throughout the entire lyocell material.
[0119] Additionally, the second coefficient of variation may be a value calculated according to Equation 2.
Coefficient of variation of tensile strength (%) = [standard deviation of tensile
strength/average of tensile strength] × 100
[0120] In Equation 2, the average of tensile strength and the standard deviation of tensile strength are values calculated for two strands or more of monofilaments included in the lyocell material. Preferably, the average of tensile strength and the standard deviation of tensile strength may be values calculated for 50 strands or more of monofilaments included in the lyocell material.
[0121] Additionally, monofilaments may be arbitrarily unspun from the lyocell material for calculation according to Equation 2. By calculating the second coefficient of variation from the arbitrarily unspun monofilaments according to Equation 2, the second coefficient of variation may provide information on the tensile strength of the lyocell material, and, preferably, may provide information related to the uniformity of tensile strength.
[0122] In particular, the second coefficient of variation may be a value calculated according to Equation 2-1.
Coefficient of variation of tensile strength (%) = [standard deviation of tensile
strength in central filaments and peripheral filaments/average of tensile strength
in central filaments and peripheral filaments] × 100
[0123] In Equation 2-1, with respect to an imaginary first line that is parallel to the length direction of the lyocell material and passes through the center point of the lyocell material, an imaginary second line that is parallel to the first line and passes through one end of the lyocell material, and an imaginary third line that is parallel to the second line and passes through the other end of the lyocell material, a central filament represents a monofilament that is located closer to the first line than to the second or third line, and a peripheral filament represents a monofilament that is located closer to the second or third line than to the first line.
[0124] In some embodiments, in Equation 2-1, the average of tensile strength and the standard deviation of tensile strength may be values calculated for 50 strands or more of central filaments and 50 strand or more of peripheral filaments included in the lyocell material.
[0125] More preferably, the average of tensile strength and the standard deviation of tensile strength in Equation 2-1 may be values calculated for 100 strands or more of central filaments and 200 strands or more of peripheral filaments. Additionally, some (e.g., 50 strands) of 100 strands of central filaments and others (e.g., residual 50 strands) of 100 strands of peripheral filaments may be collected at locations equidistant from the first line, respectively. Similarly, some (e.g., 100 strands) of 200 strands of peripheral filaments and others (e.g., residual 100 strands) of 200 strands of peripheral filaments may be collected at locations equidistant from the second line and the third line, respectively. In particular, 50 strands of 100 strands of peripheral filaments may be collected at locations closer to the second line than residual 50 strands of 100 peripheral filaments, and 50 strands of 100 strands of peripheral filaments may be collected at locations closer to the third line than residual 50 strand of 100 strands of peripheral filaments.
[0126] For example, when the x-coordinate of the second line is 0, the x-coordinate of the first line is 50, and the x-coordinate of the third line is 100, the central filaments may be collected d at points where the x-coordinates are 40 and/or 60, and the peripheral filaments may be collected at points where the x-coordinates are 5, 20, 80, and/or 95.
[0127] Additionally, for the calculation of Equation 2-1, monofilaments may be arbitrarily unspun from the center of the lyocell material and the periphery of the lyocell material, respectively. By calculating the second coefficient of variation using the monofilaments arbitrarily unspun from the center and periphery of the lyocell material, the second coefficient of variation may provide information on the tensile strength of the monofilaments included in the center and periphery of the lyocell material, and, preferably, may provide information related to the uniformity between the tensile strength of the monofilaments included in the center of the lyocell material and the tensile strength of the monofilaments included in the periphery of the lyocell material.
[0128] The tensile strength and second coefficient of variation of the lyocell material may be measured using a physical property evaluation apparatus. Although not particularly limited, FAVIMAT+ of Textechno Inc. may be considered as an example of the physical property evaluation apparatus. In using the physical property evaluation apparatus, a dedicated jig may be used, and a sample (preferably, monofilaments) collected from the lyocell material is mounted on the dedicated jig and evaluated by the physical property evaluation apparatus. The sample may be mounted on a dedicated jig with a length (gauge length) of 10 to 30 mm.
[0129] Additionally, the sample may be stretched at a constant tension rate to measure tensile strength. For example, the tension rate may be 100 mm/min, 90 mm/min, 80 mm/min, 70 mm/min, 60 mm/min, 50 mm/min, 40 mm/min, 30 mm/min, 20 mm/min, or 10 mm/min, and preferably 20 mm/min.
[0130] Additionally, the lyocell material and/or monofilament may be stabilized under constant temperature and humidity conditions prior to measurement of the tensile strength and the second coefficient of variation. For example, the constant temperature condition may be a temperature of 20±2°C, and the constant humidity condition may be a humidity of 65±4%RH. Additionally, the stabilization may be performed for 24 hours or more.
[0131] Although not particularly limited, a lyocell material prepared to satisfy the tensile strength and/or coefficient of variation of tensile strength, described above, may be used in smoking articles.
[Breaking elongation]
[0132] In some embodiments, breaking elongation may be 2.0% to 10.0%. Preferably, the upper limit of the breaking elongation may be 9.5%, 9.0%, 8.5%, 8.0% 7.5%, 7.0%, 6.5%, 6.0%, 5.5%, 5.0%, 4.5%, 4.0%, 3.5%, or 3.0%, and the lower limit of the breaking elongation may be 2.5%, 3.0%, 3.5%, 4.0%, 4.5%, or 5.0%.
[0133] In some embodiments, the coefficient of variation of the breaking elongation (or "third coefficient of variation") may be 50% or less, and may be 20% or more. The upper limit of the third coefficient of variation may be 45%, 40%, 35%, 30%, or 25%, and the lower limit of the first coefficient of variation may be 0%, 5%, 10%, or 15%. A lyocell material satisfying the above-described numerical range is expected to have a uniform breaking elongation throughout the entire lyocell material.
[0134] Additionally, the third coefficient of variation may be a value calculated according to Equation 3.
Coefficient of variation of breaking elongation (%) = [standard deviation of breaking
elongation/average of breaking elongation] × 100
[0135] In Equation 3, the average of breaking elongation and the standard deviation of breaking elongation are values calculated for two strands or more of monofilaments included in the lyocell material. Preferably, the average of breaking elongation and the standard deviation of breaking elongation may be values calculated for 50 strand or more of monofilaments included in the lyocell material.
[0136] Additionally, monofilaments may be arbitrarily unspun from the lyocell material for calculation according to Equation 3. By calculating the third coefficient of variation from the arbitrarily unspun monofilaments according to Equation 3, the third coefficient of variation may provide information on the breaking elongation of the lyocell material, and, preferably, information related to the uniformity of the breaking elongation.
[0137] In particular, the coefficient of variation of breaking elongation may be a value calculated according to Equation 3-1.
Coefficient of variation of breaking elongation (%) = [standard deviation of breaking
elongation in central filaments and peripheral filaments/average of breaking elongation
in central filaments and peripheral filaments] × 100
[0138] In Equation 3-1, with respect to an imaginary first line that is parallel to the length direction of the lyocell material and passes through the center point of the lyocell material, an imaginary second line that is parallel to the first line and passes through one end of the lyocell material, and an imaginary third line that is parallel to the second line and passes through the other end of the lyocell material, a central filament represents a monofilament that is located closer to the first line than to the second or third line, and a peripheral filament represents a monofilament that is located closer to the second or third line than to the first line.
[0139] In some embodiments, in Equation 3-1, the average of breaking elongation and the standard deviation of breaking elongation may be values calculated for 50 strands or more of central filaments and 50 strands or more of peripheral filaments included in the lyocell material.
[0140] More preferably, in Equation 3-1, the average of the breaking elongation and the standard deviation of the breaking elongation may be values calculated for 100 strands or more of central filaments and 200 strands or more of peripheral filaments. Additionally, some (e.g., 50 strands) of 100 strands of central filaments and others (e.g., residual 50 strands) of 100 strands of central filaments may be collected at locations equidistant from the first line, respectively. Similarly, some (e.g., 100 strands) of 200 strands of peripheral filaments and others (e.g., residual 100 strands) of 200 strands of peripheral filaments may be collected at locations equidistant from the second line and the third line, respectively. In particular, 50 strands of 100 strands of peripheral filaments may be collected at locations closer to the second line than residual 50 strands of 100 strands of peripheral filaments, and 50 strands of 100 strands of peripheral filaments may be collected at locations closer to the third line than residual 50 strands of 100 strands of peripheral filaments.
[0141] For example, when the x-coordinate of the second line is 0, the x-coordinate of the first line is 50, and the x-coordinate of the third line is 100, the central filaments may be collected at points where the x-coordinates are 40 and/or 60, and the peripheral filaments may be taken at points where the x-coordinates are 5, 20, 80, and/or 95.
[0142] Additionally, for the calculation of Equation 3-1, monofilaments may be arbitrarily unspun from the center of the lyocell material and the periphery of the lyocell material, respectively. By calculating the third coefficient of variation using the monofilaments arbitrarily unspun from the center and periphery of the lyocell material, the third coefficient of variation may provide information on the breaking elongation of the monofilaments included in the center and periphery of the lyocell material, and, preferably, may provide information related to the uniformity between the breaking elongation of the monofilaments included in the center of the lyocell material and the breaking elongation of the monofilaments included in the periphery of the lyocell material.
[0143] The breaking elongation and third coefficient of variation of the lyocell material may be measured using a physical property evaluation apparatus. Although not particularly limited, FAVIMAT+ of Textechno Inc. may be considered as an example of the physical property evaluation apparatus. In using the material property evaluation apparatus, a dedicated jig may be used, and a sample (preferably, monofilaments) collected from the lyocell material is mounted on the dedicated jig and evaluated by the physical property evaluation apparatus. The sample may be mounted on the dedicated jig with a length (gauge length) of 10 mm to 30 mm.
[0144] Additionally, the sample may be stretched at a constant tension rate to measure breaking elongation. For example, the tension rate may be 100 mm/min, 90 mm/min, 80 mm/min, 70 mm/min, 60 mm/min, 50 mm/min, 40 mm/min, 30 mm/min, 20 mm/min, or 10 mm/min, and, preferably, may be 20 mm/min.
[0145] Additionally, the lyocell material and/or monofilaments may be stabilized under constant temperature and humidity conditions prior to measurement of the breaking elongation and the third coefficient of variation. For example, the constant temperature condition may be a temperature of 20±2°C, and the constant humidity condition may be a humidity of 65±4%RH. Additionally, the stabilization may be performed for 24 hours or more.
[0146] Although not particularly limited, a lyocell material prepared to satisfy the breaking elongation and/or coefficient of variation of breaking elongation, described above, may be used in smoking articles.
[Binder]
[0147] In an non-limiting example, the lyocell material may further include a binder. The binder may be present, for example, on the surface of the lyocell multifilaments, or between the lyocell multifilaments (or monofilaments). The binder may increase the hardness of a filter for smoking articles, thereby preventing a filter from being caught during a process of manufacturing a filter or a process of manufacturing a smoking article (e.g. cigarette).
[0148] The type of a usable binder is not particularly limited, and any known binder may be used as long as it does not hinder the purpose of the present invention. For example, a binder providing sufficient compatibility with an oil used in the present application, improving the hardness of a filter, and providing excellent binding force may be used.
[0149] In an non-limiting example, the binder may include a polyester-based binder, a cellulosic-based binder, and/or a vinyl-based binder.
[0150] Although not particularly limited, a polyester-based binder including at least one selected from the group consisting of alkylene, arylene and heteroarylene, each having 5 to 12 carbon atoms, may be used.
[0151] Examples of the cellulose-based binder may include, but are not limited to, hydroxypropyl methyl cellulose (HPMC), ethyl cellulose (EC), methyl cellulose (MC), and/or carboxymethyl cellulose (CMC).
[0152] In some embodiments, the cellulose-based binder is selected from the group consisting of hydroxypropylmethylcellulose, ethylcellulose, methylcellulose, carboxymethylcellulose, and combinations thereof.
[0153] Examples of the vinyl-based binder may include, but are not limited to, polyvinylpyrrolidone (PVP), polyvinyl alcohol (PVA), and/or ethylene vinyl acetate (EVAc).
[0154] In some embodiments, the vinyl-based binder is selected from the group consisting of polyvinylpyrrolidone, polyvinyl alcohol, ethylene vinyl acetate, and combinations thereof.
[Oil]
[0156] The lyocell material may include a lyocell multifilament; and an oil applied on the lyocell multifilament. The oil includes (a) an esterification product of a fatty acid having 16 or more carbon atoms and an aliphatic monohydric alcohol; and (b) an esterification product of sorbitan and a fatty acid having 16 or more carbon atoms. This oil may be applied to some or all of monofilaments or multifilaments constituting the lyocell material. Additionally, the oil may penetrate among filaments.
[0157] The oil including at least the component (a) and the component (b) may have hydrophobicity. As a result, the lyocell material treated with the oil has excellent spreading properties.
[0158] In a specific example of the present application, the lyocell material may include a preset content of the oil. In this case, the content of the oil may refer to OPU (wt%) to be described later. OPU may refer to "oil pick up ratio". For example, the lyocell material may include an oil in a content of 0.1 wt% or more based on 100 wt% of the total lyocell material. Specifically, the content of the oil may be 0.5 wt% or more, 1.0 wt% or more, 1.5 wt% or more, 2.0 wt% or more, 2.5 wt% or more, 3.0 wt% or more, specifically, 3.5 wt% or more, 4.0 wt% or more, 4.2 wt% or more, 4.5 wt% or more, 5.0 wt% or more, 5.5 wt% or more, 6.0 wt% or more, 6.5 wt% or more, 7.0 wt% or more, 7.5 wt% or more, 8.0 wt% or more, 8.5 wt% or more, 9.0 wt% or more, or 9.5 wt% or more. The upper limit thereof may be, for example, 20.0 wt% or less, 18.0 wt% or less, 17.0 wt% or less, 16.0 wt% or less, 15.0 wt% or less, 14.5 wt% or less, 14.0 wt% or less, 13.5 wt% or less, 13.0 wt% or less, 12.5 wt% or less, 12.0 wt% or less, 11.5 wt% or less, 11.0 wt% or less, 10.5 wt% or less, 10 wt% or less, 9.5 wt% or less, 9.0 wt% or less, 8.5 wt% or less, 8.0 wt% or less, 7.8 wt% or less, or 7.6 wt% or less.
[0159] As a method of measuring the content (OPU) of the oil, for example, an extrusion method may be used. For example, a sample (e.g., 2 to 5 g, specifically about 2.5 g) is collected (in this case, the weight of the collected sample is referred to as a sample weight), and is introduced into a syringe-shaped container. The material of the container is not particularly limited, but may be SUS (stainless steel). Subsequently, a solvent (e.g., methanol) is introduce into the container containing the sample (the amount of the introduced solvent may be 10 ml or less (e.g., about 8 ml)). When adding the solvent to the sample, a dropping method may be used, and a dropping speed may be adjusted uniformly. And, as described above, the solvent introduced into the container is allowed to drop from one end of the syringe-shaped container onto a plate. In this case, the plate is pre-weighed (the weighed weight is referred to as plate weight A), and the plate is mounted so that the solvent dropped onto the plate can fly away (i.e., evaporate) at a temperature of 120°C to 130°C (e.g., 125°C). The introduction and dropping of the solvent are performed three times, and the sample is pressed once using a syringe-shaped container to apply pressure (e.g., 98 N/cm2 (10 kgf/cm2) or less, 49 N/cm2 (5 kgf/cm2) or less, or 18-39 N/cm2 (2-4 kgf/cm2)) to the sample. This process allows the solvent and oil present in the sample to be sufficiently extruded. The sample is squeezed under pressure until no solvent comes out. Then, the plate is stored in a desiccator for 5 to 10 minutes, and the weight of the plate containing the sample (plate weight B) is measured. Then, the content of the oil is calculated according to Equation below.
[0160] In addition, the lyocell material that serves as the standard for the content of the oil may be at least an oil-treated lyocell multifilament. For example, the lyocell material may be a lyocell multifilament to which a first oil treatment (as described below) has been applied, a lyocell multifilament to which a first oil treatment and a second oil treatment (as described below) have been applied, or a lyocell multifilament to which a binder treatment to be described below has been applied together with the above-described oil treatment. Additionally, the lyocell multifilament treated with an oil and/or a binder may be a lyocell multifilament to which crimps are applied.
[0161] In relation to the oil of the present application, the component (a) may be a compound that can function as a type of lubricant or oil, and may be a component that is harmless to the human body enough to be used in food. The component (a) provides lubricity to fibers introduced into a crimper. When lubricity is insufficient, lyocells may clump together and not pass through the crimper, and when lubricity is too high, crimps may not form properly. Taking these functions into consideration, the content of the component (a) may be controlled as described below,
[0162] In relation to the component (a), the type of fatty acid having 16 or more carbon atoms forming the esterification product is not particularly limited. Fatty acids having 16 or more carbon atoms may be used as long as they provide esterification products that are harmless to the human body to such a degree of being used in foods.
[0163] For example, as the fatty acids having 16 or more carbon atoms, saturated fatty acids and/or unsaturated fatty acids may be used.
[0164] Examples of saturated fatty acids may include palmitic acid (hexadecanoic acid, CH3(CH2)14COOH), margaric acid (heptadecanoic acid, CH3(CH2)15COOH), stearic acid (octadecanoic acid, CH3(CH2)16COOH), nonadecylic acid (nonadecanoic acid, CH3(CH2)17COOH), and arachidic acid (eicosanoic acid, CH3(CH2)18COOH). However, the types of available saturated fatty acids are not limited thereto.
[0165] Examples of unsaturated fatty acids may include palmitoleic acid (CH3(CH2)5CH=CH(CH2)7COOH), oleic acid (CH3(CH2)7CH=CH(CH2)7COOH), linoleic acid (C18H32O2), and arachidonic acid (C20H32O2). However, the types of available unsaturated fatty acids are not limited thereto.
[0166] In some embodiments, the fatty acid is selected from the group consisting of palmitic acid, margaric acid, stearic acid, nonadecylic acid, arachidic acid, palmitoleic acid, oleic acid, linoleic acid, arachidonic acid, and combinations thereof.
[0167] The upper limit of the number of carbons of the fatty acid having 16 or more carbon atoms is not particularly limited, but may be, for example, 40 or less, 36 or less, 32 or less, 28 or less, 24 or less, or 20 or less.
[0168] In relation to the component (a), the type of aliphatic monohydric alcohol forming it is also not particularly limited. Aliphatic monohydric alcohols capable of providing esterification products that are harmless to the human body to such a degree of being used in foods may be used.
[0169] For example, saturated fatty alcohols or unsaturated fatty alcohols may be used, and they may have a linear or branched form.
[0170] For example, the number of carbon atoms of the aliphatic monohydric alcohol may be 1 to 40. Specifically, the number of carbon atoms of the aliphatic monohydric alcohol may be, for example, 4 or more, 8 or more, 12 or more, 16 or more, or 20 or more.
[0171] Examples of the aliphatic monohydric alcohols may include, but are not limited to, methanol, ethanol, butanol, lauryl alcohol, isotridecanol, and stearyl alcohol.
[0172] In some embodiments, the aliphatic monohydric alcohol is selected from the group consisting of methanol, ethanol, butanol, lauryl alcohol, isotridecanol, stearyl alcohol, and combinations thereof.
[0173] In a specific example of the present application, as the component (a), an esterification product of isotridecanol and stearic acid (e.g., isotridecyl stearate) may be used. However, the types of available component (a) are not limited thereto.
[0174] As will be described below, the content of the component (a) included in the oil may be adjusted in consideration of the function of the oil or the function of the component (a).
[0175] The component (b), i.e., an ester of sorbitan and fatty acid having 16 or more carbon atoms, is a compound that can function as a type of emulsifier, and may be a component that is harmless to the human body to such a degree of being used in foods.
[0176] Since this component (b) has both hydrophilicity and hydrophobicity due to polyhydric alcohol (i.e., sorbitan), it enables the component (a) providing lubricity to fibers to be well dispersed in water to be described below. In addition, the components (a) and (b) used together not only increase the dispersibility of the oil as described above, but also lower the melting point of the oil, thereby ensuring the handling easiness and stability of the oil. Taking these functions into consideration, the content of the component (b) may be controlled as will be described below.
[0177] In relation to the component (b), the type of fatty acid having 16 or more carbon atoms forming it is not particularly limited. Fatty acids having 16 or more carbon atoms capable of providing esterification products that are harmless to the human body to such a degree of being used in foods may be used.
[0178] For example, as the fatty acids having 16 or more carbon atoms, saturated fatty acids and/or unsaturated fatty acids may be used.
[0179] Examples of saturated fatty acids may include palmitic acid (hexadecanoic acid, CH3(CH2)14COOH), margaric acid (heptadecanoic acid, CH3(CH2)15COOH), stearic acid (octadecanoic acid, CH3(CH2)16COOH), nonadecylic acid (nonadecanoic acid, CH3(CH2)17COOH), and arachidic acid (eicosanoic acid, CH3(CH2)18COOH). However, the types of available saturated fatty acids are not limited thereto.
[0180] Examples of unsaturated fatty acids may include palmitoleic acid (CH3(CH2)5CH=CH(CH2)7COOH), oleic acid (CH3(CH2)7CH=CH(CH2)7COOH), linoleic acid (C18H32O2), and arachidonic acid (C20H32O2). However, the types of available unsaturated fatty acids are not limited thereto.
[0181] In some embodiments, the fatty acid is selected from the group consisting of palmitic acid, margaric acid, stearic acid, nonadecylic acid, arachidic acid, palmitoleic acid, oleic acid, linoleic acid, arachidonic acid, and combinations thereof.
[0182] The upper limit of the number of carbons of the fatty acid having 16 or more carbon atoms is not particularly limited, but may be, for example, 40 or less, 36 or less, 32 or less, 28 or less, 24 or less, or 20 or less.
[0183] In a specific example of the present application, as the component (b), an esterification product of sorbitan and oleic acid (e.g., sorbitan monooleate) may be used. However, the type of the available component (b) is not limited thereto.
[0184] The content of the component (b) may be adjusted in consideration of the function of the component (b) and the function of the oil as described above.
[0185] For example, the oil may include 20 to 60 parts by weight of an ester esterification product (b) of sorbitan and a fatty acid having 16 or more carbon atoms with respect to 100 parts by weight of an esterification product (a) of a fatty acid having 16 or more carbon atoms and an aliphatic monohydric alcohol.
[0186] Specifically, the oil of the present application may include the component (b) in a content of 25 parts by weight or more, 30 parts by weight or more, 35 parts by weight or more, 40 parts by weight or more, 45 parts by weight or more, or 50 parts by weight or more with respect to 100 parts by weight of the component (a). And, the upper limit of the content of the component (b) with respect to 100 parts by weight of the component (a) may be, for example, 55 parts by weight or less, 50 parts by weight or less, 45 parts by weight or less, 40 parts by weight or less, 35 parts by weight or less, 30 parts by weight or less, or 25 parts by weight or less. When the above content range is satisfied, the surface of the lyocell multifilament or lyocell tow treated with the oil may have hydrophobicity.
[0187] For example, the oil may include 40 to 80 wt% of an esterification product (a) of a fatty acid having 16 or more carbon atoms and an aliphatic monohydric alcohol, based on 100 wt% of the total weight of the oil. Specifically, the content of the component (a) may be 45 wt% or more, 50 wt% or more, 55 wt% or more, 60 wt% or more, or 65 wt% or more, 70 wt% or more, or 75 wt% or more, based on 100 wt% of the total weight of the oil, And, the upper limit of the content thereof may be, for example, 75 wt% or less, 70 wt% or less, 65 wt% or less, 60 wt% or less, 55 wt% or less, 50 wt% or less, or 45 wt% or less.
[0189] For example, the oil may include 15 to 55 wt% of an esterification product (b) of sorbitan and a fatty acid having 16 or more carbon atoms, based on 100 wt% of the total weight of the oil. Specifically, the content of the component (b) may be 20 wt% or more, 25 wt% or more, 30 wt% or more, 35 wt% or more, 40 wt% or more, 45 wt% or more, or 50 wt% or more, based on 100 wt% of the total weight of the oil, And, the upper limit of the content thereof may be, for example, 50 wt% or less, 45 wt% or less, 40 wt% or less, 35 wt% or less, 30 wt% or less, or 25 wt% or less.
[0190] For example, the oil may further include water. A small amount of water may help emulsification.
[0191] The content of water is not particularly limited, but water may be included in the amount remaining after excluding the total content of components (a) and (b) from 100 wt% of the entire oil. The content of water in the oil (i.e., the remaining amount excluding the total content of the remaining components excluding water) may be, for example, 10 wt% or less, 9 wt% or less, 8 wt% or less, 7 wt% or less, 6 wt% or less, 5 wt% or less, 4 wt% or less, 3 wt% or less, 2 wt% or less, or 1 wt% or less. And, the lower limit thereof may be, for example, 0 wt% or more, 0.1 wt% or more, 0.5 wt% or more, or 1 wt% or more.
[Method of manufacturing lyocell material]
[0192] This application relates to a method of manufacturing a lyocell material. By this method, a lyocell material may be manufactured, and this lyocell may be used in smoking articles.
[0193] Specifically, the method of manufacturing a lyocell material includes a lyocell dope spinning process; a coagulation and multifilament obtainment process; a washing process; an oil treatment process; and a crimp application process. The method of manufacturing a lyocell material may further include a binder treatment process; and other processes. In some embodiments, these processes are performed in the mentioned order.
[0194] The oil treatment process may be performed before the crimp application process, after the crimp application process, or before and after the crimp application process.
[0195] The oil treatment may be performed independently, for example, by spraying an oil of the above-described composition onto lyocell multifilaments or by immersing the lyocell multifilaments in the oil. As described above, the oil treatment may be performed so that the content (e.g., OPU (wt%)) of the oil in the lyocell material satisfies a preset range.
[0196] The crimp application process may be performed, for example, by applying steam and/or pressure to the lyocell multifilaments.
[0197] A method of manufacturing a lyocell material according to a specific embodiment of the present application, including an oil treatment process and a crimp application process, will be described in more detail below. The method of the present application may be performed by including one or more of the processes to be described below.
<(a) Lyocell dope spinning process>
[0198] This process is a process of spinning a lyocell spinning dope including lyocell cellulose (or cellulose pulp) and N-methylmorpholine-N-oxide (NMMO).
[0199] Commercially available cellulose acetate filters are pointed out as a major cause of microplastics. However, just as an amine oxide solvent used in the production of lyocell fibers is recyclable and is biodegradable even when it is discarded, a lyocell material does not generate any pollutants during its production process. Furthermore, since a lyocell tow is biodegraded within a relatively short period of time and is removed, lyocell is a more environmentally friendly material than cellulose acetate.
[0200] For example, the content of cellulose in the spinning dope may be 5 to 15 wt% based on 100 wt% of the total weight of the lyocell dope. When the content of cellulose is too small, it is difficult to implement the characteristics of lyocell fibers, and when the content of cellulose exceeds the above range, it is difficult to dissolve in a solvent. Considering this, the content of cellulose in the spinning dope may be 6 wt% or more, 7 wt% or more, 8 wt% or more, 9 wt% or more, or 10 wt% or more, based on 100 wt% of the total weight of the lyocell dope, and the upper limit thereof may be, for example, 14 wt% or less, 13 wt% or less, 12 wt% or less, 11 wt% or less, 10 wt% or less, or 9 wt% or less, based on 100 wt% of the total weight of the lyocell dope. The term "cellulose" may refer to "lyocell cellulose".
[0201] For example, the spinning dope may include an aqueous solution of N-methylmorpholine-N-oxide (NMMO). Taking into consideration degree of dissolution of cellulose and process temperature, the aqueous solution may include, for example, a weight ratio of 80 to 95 of N-methylmorpholine-N-oxide and a weight ratio of 5 to 20 of water, .
[0202] For example, the content of alpha-cellulose in the cellulose or cellulose pulp may be 85 to 97 wt% with respect to 100 wt% of the total cellulose and/or cellulose pulp.
[0203] For example, the content of hemicellulose in the cellulose or cellulose pulp may be 3 to 15 wt% with respect to 100 wt% of the total cellulose and/or cellulose pulp. By controlling the content of hemicellulose within the above range, stable physical properties (e.g., hardness or suction resistance implementation) and processability of the lyocell material can be more easily secured.
[0204] Additionally, in a specific example of the present application, the degree of polymerization (DPw) of the cellulose may be 600 to 1700.
[0205] In some embodiments, the degree of polymerization of the cellulose refers to the number of repeating units and/or monomers of cellulose, alpha-cellulose and/or hemicellulose in the cellulose or cellulose pulp.
[0206] In the spinning process, the shape of a spinneret for discharging the spinning dope is not particularly limited. For example, a donut-shaped spinneret may be used.
[0207] The nozzle temperature, particularly, spinning temperature of a spinneret may be appropriately selected by those skilled in the art. Considering that the viscosity of the spinning dope may vary depending on the spinning temperature to result in poor discharging, the spinning temperature may be, for example, 100°C or lower to 120°C or lower, or 100°C or lower to 110°C or lower.
[0208] For example, the process of spinning the spinning dope may be performed under controlled spinning conditions so that the single fineness of a filament is 1.67 dtex to 8.89 dtex (1.5 denier to 8.0 denier) or less. For example, at least one spinning condition of the discharge amount and spinning speed of the spinning dope may be appropriately controlled so that the single fineness of the filament included in the lyocell material satisfies 1.67 to 8.89 dtex (1.5 to 8.0 denier). In this case, the single fineness of a filament refers to the fineness of a single monofilament separated from a multifilament.
[0209] In particular, the single fineness of the filament may be, for example, 8.33 dtex (7.5 denier) or less, 7.78 dtex (7.0 denier) or less, 7.22 dtex (6.5 denier) or less, 6.67 dtex (6.0 denier) or less, 6.11 dtex (5.5 denier) or less, 5.56 dtex (5.0 denier) or less, 5.00 dtex (4.5 denier) or less, 3.89 dtex (3.5 denier) or less, 3.33 dtex (3.0 denier) or less, 2.78 dtex (2.5 denier) or less, or 2.22 dtex (2.0 denier) or less. Additionally, the lower limit therof may be, for example, 2.22 dtex (2.0 denier) or more, 2.78 dtex (2.5 denier) or more, 3.33 dtex (3.0 denier) or more, 3.89 dtex (3.5 denier) or more, 4.44 dtex (4.0 denier) or more, 5.00 dtex (4.5 denier) or more, 5.56 dtex (5.0 denier) or more, 6.11 dtex (5.5 denier) or more, 6.67 dtex (6.0 denier) or more, 7.22 dtex (6.5 denier) or more, or 7.78 dtex (7.0 denier) or more. When the above range is satisfied, it may be more advantageous in implementing the stable draw resistance of a filter for smoking articles and ensuring the processibility of a filter for smoking articles.
[0210] The spinning dope discharged through the spinneret may undergo a coagulating process to be described later.
<(b) Coagulation and multifilament obtainment process>
[0211] In this process, the spun lyocell spinning dope is coagulated, and lyocell multifilaments may be obtained.
[0212] For the coagulation, a method in which the spinning dope comes into contact with air and/or a coagulation liquid may be used.
[0213] For example, the coagulation may include a first coagulation process of supplying cooling air to the spun lyocell dope; and a second coagulation process of coagulating the first-coagulated spinning dope by adding the same to a coagulation liquid.
[0214] According to the coagulation method, the lyocell dope discharged from the spinneret may be first coagulated in the space (air gap section) between the spinneret and a coagulation tank. This air gap section may be supplied with cooling air from an air-cooling unit located inside the spinneret to the inside to outside of the spinneret. In addition, the first coagulation may be achieved by the so-called air quenching method or means known in the related field.
[0215] For example, the upper temperature limit of the cooling air used for the first coagulation may be, for example, 15°C or less. In particular, the cooling air may be air having a temperature of 14°C or less, 13°C or less, 12°C or less, 11°C or less, or 10°C or less. When the temperature is exceeded, the coagulation of the spinning dope by air may not be sufficient, and the spinning-related processability may not be good.
[0216] The lower temperature limit of the cooling air may be determined in consideration of spinning processability and/or cross-sectional uniformity of a filament. For example, when the temperature of the cooling air is lower than 4°C, the surface of the spinneret may cool, the surface of the filament may become uneven, and the spinning processability may also deteriorate. In consideration of this, the temperature of the cooling air may be 5°C or higher, 6°C or higher, 7°C or higher, 8°C or higher, or 9°C or higher.
[0217] The degree to which the cooling air is supplied may be controlled in consideration of sufficient coagulation, spinning processability, and influence on the physical properties of the filament. For example, the cooling air may be supplied to the discharged spinning dope at an air flow rate of 70 to 400 Nm3/h. More particularly, the air flow rate may be 100 Nm3/h or more, 150 Nm3/h or more, 200 Nm3/h or more or 250 Nm3/h or more, and the upper limit of the air flow rate can be, for example, 350 Nm3/h or less, 300 Nm3/h or less, 250 Nm3/h or less, 200 Nm3/h or less or 150 Nm3/h or less.
[0218] After the first coagulation process, the cooled spinning dope may be supplied to a coagulation tank or bath containing a coagulation liquid (second coagulation process). For appropriate coagulation to proceed, the temperature of the coagulation liquid may be, for example, 30°C or lower or 25°C or lower. Additionally, the temperature of the coagulation liquid may be 10°C or higher, 15°C or higher, or 20°C or higher. If the temperature is maintained, a coagulation rate may be appropriately maintained.
[0219] The type of the coagulation liquid for the second coagulation as described above is not particularly limited. For example, the coagulation liquid may include at least one of water and N-methylmorpholine-N-oxide (NMMO).
[0220] Although not particularly limited, when the coagulation liquid includes water and NMMO, based on 100 wt% of the total weight of the coagulation liquid, the content of water in the coagulation liquid may be 60 to 90 wt%, and the content of NMMO in the coagulation liquid may be 10 to 40 wt%. Alternatively, the coagulation liquid may include 70 to 80 wt% of water and 20 to 30 wt% of NMMO based on 100 wt% of the total weight of the coagulation liquid. The concentration of this coagulation liquid may be controlled to be maintained during the manufacturing process using sensors, etc.
<(c) Washing process>
[0221] If necessary, the lyocell multifilament may be washed after the above-described coagulation and obtaining multifilament process. NMMO and/or other impurities remaining in the filament may be removed by this washing.
[0222] The method of performing the washing is not particularly limited. For example, the washing may be performed by introducing the coagulated lyocell multifilaments into a washing tank using a towing roller. Alternatively, the washing may be performed by spraying a washing liquid during the procedure of moving to the next process by a towing roller.
[0223] The components of the washing liquid is not particularly limited. For example, the washing liquid may include water, and may further include known additives.
[0224] Additionally, in consideration of reuse after washing, the washing liquid may be used by adjusting the temperature to 100°C or lower.
<(d) Oil treatment process>
[0225] If necessary, a process of treating the lyocell multifilaments with an oil may be performed. This process is a process of applying the above-described oil to the surface of a filament. Through the oil treatment, friction applied to the filament may be reduced, and crimps may be formed well in the crimp application process to be described later. When the oil treatment is performed twice or more as described below, it may be called first oil treatment and second oil treatment depending on the order.
[0226] Although not particularly limited, the oil treatment may be performed by immersing the lyocell multifilament in a bath filled with the oil so that the lyocell multifilaments are completely immersed in the oil. Alternatively, the oil may be treated by spraying an oil liquid during the procedure of moving to the next process by a towing roller.
[0227] In order to ensure that the amount of the oil applied to the lyocell multifilament after the oil treatment as described above is constant, an additional process may be performed in which a roll or the like positioned before and/or after the oil treatment process squeezes out the oil from the surface of the lyocell multifilament.
[0228] For example, the oil treatment may be performed such that the content of the oil (OPU: oil pick up ratio (weight %)) is 1.0 weight % or more based on 100 wt % of the at least oil-treated lyocell multifilament. In this case, the at least oil-treated lyocell multifilament may be, for example, a lyocell multifilament to which first oil treatment has been applied, a lyocell multifilament to which first oil treatment and second oil treatment (refer to the description below) have been applied, or a lyocell multifilament to which a binder to be described below has been applied together with the above-described oil treatment. Additionally, the lyocell multifilament treated with an oil and/or a binder as described above may be a lyocell multifilament to which crimps are applied.
[0229] In particular, the content of the oil in the at least oil-treated lyocell multifilament may be 0.5 wt% or more, 1.0 wt% or more, 1.5 wt% or more, 2.0 wt% or more, 2.5 wt% or more, 3.0 wt% or more, particularly 3.5 wt% or more, 4.0 wt% or more, 4.2 wt% or more, 4.5 wt% or more, 5.0 wt% or more, 5.5 wt% or more, 6.0 wt% or more, 6.5 wt% or more, 7.0 wt% or more, 7.5 wt% or more, 8.0 wt% or more, 8.5 wt% or more, 9.0 wt% or more or 9.5 wt% or more, based on 100 wt% of the total weight of the at least oil-treated lyocell multifilament. And, the upper limit thereof may be, for example, 20.0 wt% or less, 18.0 wt% or less, 17.0 wt% or less, 16.0 wt% or less, 15.0 wt% or less, 14.5 wt% or less, 14.0 wt% or less, 13.5 wt% or less, 13.0 wt% or less, 12.5 wt% or less, 12.0 wt% or less, 11.5 wt% or less, 11.0 wt% or less, 10.5 wt% or less, 10 wt% or less, 9.5 wt% or less, 9.0 wt% or less, 8.5 wt% or less, 8.0 wt% or less, 7.8 wt% or less, or 7.6 wt% or less, based on 100 wt% of the total weight of the at least oil-treated lyocell multifilament. In this case, the above content may refer to a dry weight after a solvent (e.g., water) or liquid component that may be included in the oil has evaporated.
[0230] When the above-described oil is treated within the above content range, the hydrophilic properties of the lyocell material can be supplemented.
[0232] In specific embodiments of the present application, one or more of the above-described processes may be controlled so that the single fineness of filaments forming the lyocell multifilament may be 1.67 to 8.89 dtex (1.5 to 8.0 denier). The single fineness of the filament refers to a fineness of a single monofilament separated from a multifilament.
[0233] In particular, the single fineness of the filament may be, for example, 8.33 dtex (7.5 denier) or less, 7.78 dtex (7.0 denier) or less, 7.22 dtex (6.5 denier) or less, 6.67 dtex (6.0 denier) or less, 6.11 dtex (5.5 denier) or less, 5.56 dtex (5.0 denier) or less, 5.00 dtex (4.5 denier) or less, 3.89 dtex (3.5 denier) or less, 3.33 dtex (3.0 denier) or less, 2.78 dtex (2.5 denier) or less, or 2.22 dtex (2.0 denier) or less. And, the lower limit thereof may be, for example, 2.22 dtex (2.0 denier) or more, 2.78 dtex (2.5 denier) or more, 3.33 dtex (3.0 denier) or more, 3.89 dtex (3.5 denier) or more, 4.44 dtex (4.0 denier) or more, 5.00 dtex (4.5 denier) or more, 5.56 dtex (5.0 denier) or more, 6.11 dtex (5.5 denier) or more, 6.67 dtex (6.0 denier) or more, 7.22 dtex (6.5 denier) or more, or 7.78 dtex (7.0 denier) or more. Satisfying the above range may be more advantageous in implementing stable draw resistance of a filter for smoking articles and ensuring processability of a filter for smoking articles.
[0234] Although not particularly limited, the process controlled to ensure the above-described single fineness range may be the above-described spinning process. Alternatively, the above-described spinning, coagulation, washing and oil treatment processes may all be controlled to ensure the above-described single fineness range.
<(e) Crimp application process>
[0235] The crimp application process is a process of applying pressure to the oil-treated lyocell multifilament through steam and/or a press roller to obtain a crimped multifilament, preferably, a crimped tow. The crimp application process may be referred to as a crimping process. In this specification, the terms "oil-treated" and "emulsified" may be used interchangeably.
[0236] Through the crimping, lyocell multifilaments may be imparted with waves, and fibers may have bulky characteristics. The crimping may be performed using a known crimping device, such as one including a stuffer box and/or a steam box, and the usable crimping device is not particularly limited as long as it is a device capable of applying one or more of the pressures to be described below.
[0237] For example, the crimp application process may be performed by first supplying steam to the lyocell multifilament to preheat and swell the lyocell multifilament and then pressing the lyocell multifilament with a press roller to form wrinkles in the lyocell multifilament. In this case, a steam box may be used for steam supply, and this steam box may be located at the front end of the crimping device.
[0238] For example, the crimp application process may be performed in a manner in which pressurization of the lyocell multifilament by a press roller and steam supply are performed simultaneously.
[0239] For example, the crimp application process may be performed by first supplying steam to the lyocell multifilament to preheat and swell the lyocell multifilament and then simultaneously applying pressure and steam to the lyocell multifilament by a press roller.
[0240] For example, the crimp application process may be performed by applying steam of 0.98 to 19.61 N/cm2 (0.1 to 2.0 kgf/cm2) to the lyocell multifilament before introducing it into the crimping device (specifically, press roller).
[0241] For example, steam of 1.96 N/cm2 (0.2 kgf/cm2) or more, 2.94 N/cm2 (0.3 kgf/cm2) or more, 3.92 N/cm2 (0.4 kgf/cm2) or more, 4.90 N/cm2 (0.5 kgf/cm2) or more or 5.88 N/cm2 (0.6 kgf/cm2) or more may be supplied by the steam box. Additionally, steam of 14.71 N/cm2 (1.5 kgf/cm2) or less, 13.73 N/cm2 (1.4 kgf/cm2) or less, 12.75 N/cm2 (1.3 kgf/cm2) or less, 11.77 N/cm2 (1.2 kgf/cm2) or less, 10.79 N/cm2 (1.1 kgf/cm2) or less, or 9.81 N/cm2 (1.0 kgf/cm2) or less may be supplied. When the steam supply or pressure is below the above range, crimps may not be formed easily. In addition, when the steam supply or pressure exceeds the above range, the flexibility of the filament increases to apply excessive crimps within the crimping device, and thus the filament may not pass through the crimping device.
[0242] For example, the crimp application process may be performed by pressing the lyocell multifilament with a press roller to form wrinkles in the lyocell multifilament. Additionally, steam supply may not be performed prior to pressurization, steam supply may not be performed simultaneously with pressurization, or steam supply may not be performed both prior to pressurization and simultaneously with pressurization.
[0243] For example, the crimp application process may be performed by applying a pressure of 14.71 to 39.23 N/cm2 (1.5 to 4.0 kgf/cm2) to the lyocell multifilament introduced into the crimping device using a press roller.
[0244] For example, a pressure of 15.69 N/cm2(1.6 kgf/cm2) or more, 16.67 N/cm2(1.7 kgf/cm2) or more, 17.65 N/cm2(1.8 kgf/cm2) or more, 18.63 N/cm2(1.9 kgf/cm2) or more, 19.61 N/cm2(2.0 kgf/cm2) or more, 20.60 N/cm2(2.1 kgf/cm2) or more, 21.58 N/cm2(2.2 kgf/cm2) or more, 22.56 N/cm2(2.3 kgf/cm2) or more, 23.54 N/cm2(2.4 kgf/cm2) or more, or 24.52 N/cm2(2.5 kgf/cm2) or more may be applied to the lyocell multifilament through the press roller. Also, 38.25 N/cm2(3.9 kgf/cm2) or less, 37.27 N/cm2(3.8 kgf/cm2) or less, 36.29 N/cm2(3.7 kgf/cm2) or less, 35.31 N/cm2(3.6 kgf/cm2) or less, 34.33 N/cm2(3.5 kgf/cm2) or less, 33.35 N/cm2(3.4 kgf/cm2) or less, 32.37 N/cm2(3.3 kgf/cm2) or less, 31.39 N/cm2(3.2 kgf/cm2) or less, 30.41 N/cm2(3.1 kgf/cm2) or less, 29.42 N/cm2(3.0 kgf/cm2) or less, 28.44 N/cm2(2.9 kgf/cm2) Below, a pressure of 27.46 N/cm2 (2.8 kgf/cm2) or less, 26.48 N/cm2 (2.7 kgf/cm2) or less, 25.50 N/cm2 (2.6 kgf/cm2) or less, or 24.52 N/cm2 (2.5 kgf/cm2) or less may be applied by the press roller.
[0245] When the pressure of the press roller is below the above range, the desired number of crimps may not be formed sufficiently. Additionally, when the pressure of the press roller exceeds the above range, pressing force may be too strong, so that the filament may not be smoothly introduced into the crimping device or may not pass through the crimping device. Wrinkles may be formed in the lyocell multifilament by the press roller providing the above pressure.
[0246] For example, a pressure of 0.98 to 19.61 N/cm2 (0.1 to 2 kgf/cm2) may be applied to the lyocell multifilament using an upper plate. Additionally, the upper plate may apply pressure to the lyocell multifilament when the lyocell multifilament passes through the press roller or is passing through the press roller.
[0247] For example, the pressure applied by the upper plate may be 1.96 N/cm2 (0.2 kgf/cm2) or more, 2.94 N/cm2 (0.3 kgf/cm2) or more, 3.92 N/cm2 (0.4 kgf/cm2) or more, or 4.90 N/cm2 (0.5 kgf/cm2) or more. Additionally, a pressure of 14.71 N/cm2 (1.5 kgf/cm2) or less, 13.73 N/cm2 (1.4 kgf/cm2) or less, 12.75 N/cm2 (1.3 kgf/cm2) or less, 11.77 N/cm2 (1.2 kgf/cm2) or less, 10.79 N/cm2 (1.1 kgf/cm2) or less, or 9.81 N/cm2 (1.0 kgf/cm2) or less may be applied by the upper plate.
[0248] Furthermore, when the pressure of the upper plate, serving to move up and down to provide uniform crimps after passing through the press roller, is less than 0.98 N/cm2 (0.1 kgf/cm2), the upper plate cannot be fixed due to the pressure inside the crimping device, thereby causing the tow to stay in the crimping device for a long time to prevent the continuity of a process from being maintained. When the pressure of the upper plate exceeds 19.61 N/cm2 (2 kgf/cm2), steam cannot be easily discharged inside the crimping device, thereby causing the shape of crimps to become irregular.
[0249] In an exemplary method of manufacturing a lyocell material, the crimp application process is performed by a crimping device including one or more side plates, and the surface roughness (Ra1) of the side plates may be 1000 nm or less, and may be 100 nm or more.
[0250] Preferably, the upper limit of the surface roughness (Ra1) may be 950 nm, 900 nm, 850 nm, 800 nm, 750 nm, 700 nm, 650 nm, 600 nm, 550 nm, 500 nm, 450 nm, 400 nm, 350 nm, or 300 nm, and the lower limit thereof may be 100 nm, 125 nm, 150 nm, 175 nm, 200 nm, 225 nm, or 250 nm.
[0251] When the surface roughness of the side plate exceeds 1000 nm, the side plate may cause excessive physical deformation to the lyocell multifilament contacting the side plate. As a result, at least a portion of the lyocell multifilament may be damaged, or its properties may deteriorate.
[0252] Conversely, when the surface roughness of the side plate is less than 100 nm, the contact area between the side plate and the lyocell multifilament may excessively increase. As a result, excessive friction may occur between the side plates and the lyocell multifilament. As a result, the area of the lyocell multifilament subject to physical deformation may be excessive, the uniformity of the lyocell multifilament may deteriorate, and its properties may deteriorate.
[0253] In particular, during the process of applying crimps to the lyocell multifilament, at least a portion of the lyocell multifilament may come into contact with the surface of the side plate. In particular, at least some of the peripheral filaments included in the lyocell multifilament may come into contact with the surface of the side plate. The definition of the peripheral filament is as described above.
[0254] Since the side plate and at least a portion of the lyocell multifilament come into contact with each other, a frictional force occurs between the side plate and the lyocell multifilament during the crimp application process. Additionally, at least a portion of the lyocell multifilament is physically deformed by the frictional force.
[0255] As a result, a difference may occur between a portion deformed by the friction force and a portion not deformed by the friction force. In particular, differences may occur between peripheral filaments and residual portions excluding the peripheral filaments. In particular, a difference may occur between a peripheral filament and a central filament. For example, the peripheral filament and the central filament may have different crimp numbers, different tensile strengths, and/or different breaking elongations.
[0256] When the frictional force generated between the side plate and the lyocell multifilament is excessive, an excessive difference may occur between a portion deformed by the frictional force and a portion not deformed by the frictional force. For example, the number of crimps of the peripheral filament may be excessively different from the number of crimps of the central filament, the tensile strength of the peripheral filament may be excessively different from the tensile strength of the central filament, and the breaking elongation of the peripheral filament may be excessively different from the breaking elongation of the central filament. As a result, the properties (e.g., filtering ability, etc.) of the lyocell material including both the peripheral filament and the central filament may be deteriorated due to a difference between the peripheral filament and the central filament.
[0257] In an exemplary method of manufacturing a lyocell material, when the crimping device includes two or more side plates, the surface roughness of the two or more side plates may be independently 1000 nm or less, and may be 100 nm or more.
[0258] As described above, by controlling the surface roughness of the side plated to satisfy a preset range, an exemplary lyocell material may have a first coefficient of variation of 10% to 50%, a second coefficient of variation of 30% to 70%, and a third coefficient of variation of 20% to 50%. Based on the fact that the first coefficient of variation, the second coefficient of variation, and the third coefficient of variation satisfy the above-described ranges, those skilled in the art will appreciate that the exemplary lyocell material has improved uniformity compared to conventional lyocell materials Additionally, based on the improved uniformity of the lyocell material, those skilled in the art will appreciate that a filter for smoking articles including the lyocell material may provide improved filtering performance.
[0259] For example, in the crimp application process, a blade applying a preset pressure to the lyocell multifilament may be used. The blade controls the residence time of the filaments introduced into the crimping apparatus, thereby contributing to the control of the number of crimps. This blade may be located in the path of the lyocell multifilament pressed by the roller and then discharged at the roller pressure point. Preferably, the blade may be a doctor blade.
[0260] For example, the crimp application process may be performed by applying a pressure of 0.98 to 19.61 N/cm2 (0.1 to 2.0 kgf/cm2) to the lyocell multifilament passing through the roller of the crimping apparatus using at least one blade (doctor blade).
[0261] For example, the pressure applied by the blade may be 1.96 N/cm2 (0.2 kgf/cm2) or more, 2.94 N/cm2 (0.3 kgf/cm2) or more, 3.92 N/cm2 (0.4 kgf/cm2) or more, or 4.90 N/cm2 (0.5 kgf/cm2) or more. Additionally, a pressure of 14.71 N/cm2 (1.5 kgf/cm2) or less, 13.73 N/cm2 (1.4 kgf/cm2) or less, 12.75 N/cm2 (1.3 kgf/cm2) or less, 11.77 N/cm2 (1.2 kgf/cm2) or less, 10.79 N/cm2 (1.1 kgf/cm2) or less, or 9.81 N/cm2 (1.0 kgf/cm2) or less may be applied by the blade.
[0262] In an exemplary method of manufacturing a lyocell material, the surface roughness (Ra2) of the blade may be less than 1200 nm. Preferably, the surface roughness (Ra2) may be 1150 nm or less, 1100 nm or less, 1050 nm or less, 1100 nm or less, 950 nm or less, 900 nm or less, 850 nm or less, 800 nm or less, 750 nm or less, 700 nm or less, 650 nm or less, 600 nm or less, 550 nm or less, 500 nm or less, or 450 nm or less.
[0263] When the surface roughness of the blade is 1200 nm or more, excessive physical deformation may be caused to the lyocell multifilament contacting the blade during the transport procedure of the lyocell multifilament. As a result, at least a portion of the lyocell multifilament may be damaged or its properties may be deteriorated.
[0264] In an exemplary method of manufacturing a lyocell material, the crimping apparatus includes a first blade and a second blade, the first blade and the second blade are spaced apart from each other, and the surface roughness of the first blade and the surface roughness of the second blade may be each independently less than 1200 nm.
[0265] As described above, by controlling the surface roughness of the first blade and the surface roughness of the second blade to satisfy a preset range, an exemplary lyocell material may have a first coefficient of variation of 10% to 50%, a second coefficient of variation of 30% to 70%, and a third coefficient of variation of 20% to 50%. Based on the fact that the first coefficient of variation, the second coefficient of variation, and the third coefficient of variation satisfy the above-described ranges, those skilled in the art will appreciate that the exemplary lyocell material has improved uniformity compared to conventional lyocell materials Additionally, based on the improved uniformity of the lyocell material, those skilled in the art will appreciate that a filter for smoking articles including the lyocell material may provide improved filtering performance.
[0266] For example, the crimp application process may be performed at a temperature in the range of 120°C to 250°C. When the temperature is too low, the shape stabilization effect of crimps is not good, and when the temperature is too high, the concentration of oil in the crimping apparatus increases, thus making it difficult to form crimps. Therefore, considering the above-described steam pressure or the like, the temperature may be appropriately controlled in a range of 130°C or higher, 140°C or higher, or 150°C or higher, and 200°C or lower, 180°C or lower, or 160°C or lower.
<(f) Binder treatment process>
[0267] For example, the method may further include a process of treating the oil-treated lyocell multifilamet or the lyocell multifilament obtained by the crimp application process with a binder.
[0268] When a filter for smoking articles is manufactured using a lyocell material (e.g., lyocell tow), a binder may be used additionally. The binder may increase the hardness of a filter for smoking articles including a lyocell material, thereby preventing a filter from being caught during a filter manufacturing process or a cigarette manufacturing process.
[0269] A method of coating a lyocell material with a binder is not particularly limited. For example, the oil treatment may be carried out by immersing the lyocell multifilaments in a bath filled with a binder (or a binder solution) so that the lyocell multifilaments are completely immersed in the binder. Alternatively, binder coating on the lyocell multifilament may be achieved by spraying (or injecting) a binder (or binder solution) through a nozzle.
[0270] Since the types and components of available binders are as described above, a detailed description thereof will be omitted.
[0271] For example, the binder (or binder solution) may further include a solvent in addition to the above-described components. Examples of the solvent may include, but are not limited to, water, ethanol, propylene glycol, and/or glycerin. When the binder (or binder solution) includes a solvent, the content of the solvent may be, for example, about 20 to 80 wt% or about 40 to 60 wt% based on 100 wt% of the total weight of the binder (or binder solution).
[0272] The binder treatment may be performed at a level that can achieve the purpose of the above-described binder treatment. For example, the binder treatment may be performed so that the content of the binder satisfies a range of 20 wt% or less, for example, 8 to 15 wt%, based on 100 wt% of the oil and binder-treated lyocell multifilament. In this case, the content may refer to a dry weight after the solvent or liquid component that may be included in the binder has evaporated.
[0273] After the lyocell multifilament is coated with the binder, drying of the binder may proceed. Although drying temperature is not particularly limited, for example, drying may be performed at room temperature (approximately 10 to 35 ° C).
<(g) Other processes>
[0275] For example, second oil treatment (g1) may be additionally performed. The second oil treatment may provide more flexibility to a tow. The second oil treatment may be performed in the same manner as or in accordance with (d) the above-described oil treatment process.
[0276] In particular, the second oil treatment may be performed by applying an oil to a lyocell tow that has undergone a process using a crimper. This treatment may be advantageously utilized in various processes performed during the manufacturing of filters for smoking articles. For example, the second oil treatment may allow fibers and filters to be easily spread by air during a spreading process, while also restricting the breakage of fibers during a stretching process.
[0277] The above-described second oil treatment may be performed before or after the binder treatment. Alternatively, the second oil treatment may be performed regardless of the binder treatment.
[0278] Even in cases where the above-described second oil treatment is performed, a second oil treatment process may be performed so that the content of oil or OPU in the material satisfies the above-described range.
[0279] For example, drying treatment (g2) may be performed additionally. The drying may be carried out, for example, at a temperature ranging from 100 to 130° C. The drying treatment method or process is not particularly limited, and known technologies may be used. For example, this drying treatment may be achieved by applying hot air to the tow or passing the tow through or leaving the tow in a temperature-controlled room for a certain period of time.
[0280] In an aspect, the present disclosure provides a lyocell material obtained by the above-described method of manufacturing a lyocell material.
[0281] In an aspect, the present disclosure provides a lyocell material capable of being obtained by the above-described method of manufacturing a lyocell material.
[Smoking articles]
[0282] Although not particularly limited, the lyocell material manufactured by the above method may be included in a smoking article. Smoking articles may be aerosol-generating articles. An aerosol-generating article may include an aerosol-generating material or an aerosol-forming substrate.
[0283] For example, a lyocell material may be included in a combustible cigarette. As another example, the lyocell material may be included in a heating cigarette, and the heating cigarette may be used in conjunction with an aerosol generating device.
[0284] For example, when a smoking article is used as a heating smoking article, the smoking article may be inserted separately into the aerosol generating device. Here, the aerosol generating device includes a receiving groove capable of receiving an aerosol generating article, and, in addition, may include a heater for heating the aerosol generating article so as to generate an aerosol, a control unit for generally controlling the operation of the aerosol generating device, a battery for providing power used for operating the aerosol generating device, and a detector for recognizing that the aerosol generating article has been inserted into the aerosol generating device.
[0285] The smoking article may include a tobacco medium unit, a filter for the smoking article, and a wrapper, wherein the filter for the smoking article may be located at one end of the tobacco medium unit, for example at the rear end or front end of the tobacco medium unit. The tobacco medium unit and the filter for the smoking article may each include a single segment, or may each independently include a plurality of segments.
[0286] The tobacco medium unit includes a tobacco material, and the tobacco material includes nicotine. In addition, the tobacco medium unit may additionally include one or more excipients.
[0287] The excipients may include a binder, a filler, and other additives. For example, a tobacco medium included in the tobacco medium unit may be manufactured in the form of granules including a tobacco material, an excipient, etc.
[0288] For example, a filler may be additionally included to maintain the shape, strength and mass of the tobacco medium unit constant. For example, the lyocell material may be included in the tobacco medium unit. Additionally, the lyocell material may be used as a filler.
[0289] The wrapper may be subdivided into a cigarette paper wrapping the tobacco medium unit, a filter paper wrapping the filter, and a tipping wrapper combining the tobacco medium unit and the filter.
[Filter for smoking articles]
[0290] A lyocell material may be used in a filter for smoking articles. The lyocell material may be a lyocell tow. For example, the lyocell tow includes a lyocell multifilament to which crimps are applied.
[0291] For example, the present application relates to a filter for smoking articles. The filter for smoking article includes a lyocell material, and the lyocell material may be the same as that described above. Additionally, the filter for smoking articles may include a lyocell tow, and the lyocell tow may be the same as that described above.
[0292] In addition, the lyocell material includes the oil in an amount of 0.1 wt% or more with respect to 100 wt% of the total weight of the lyocell material. Besides, the description of the oil component and content according to a specific example of the present application is the same as those described above.
[0293] For example, the single fineness of filaments forming the lyocell multifilament may be 1.67 to 8.89 dtex (1.5 to 8.0 denier). Specific figures are the same as those described above.
[0294] For example, the lyocell multifilament to which crimps are applied may be a lyocell material having a total fineness of 1,667 to 6,111 tex (15,000 to 55,000 denier), and, preferably, may be a lyocell tow. Specific figures are the same as those described above.
[0295] For example, the lyocell multifilament to which crimps are applied may have crimps of 3.94 to 19.69 per centimeter (10 to 50 per inch). Specific figures are the same as those described above.
[0296] For example, the filter for smoking articles may further include a binder on the surface of the lyocell multifilament to which crimps are applied or between the lyocell multifilament to which crimps are applied. The binder may increase the hardness of a filter for smoking articles manufactured from tow, thereby preventing a filter from being caught during a filter manufacturing process or a cigarette manufacturing process. The description of the types, components and contents of available binders is the same as those described above.
[0297] For example, the filter for smoking articles may further include a wrapper (referred to as wrapper paper, filter paper or filter wrapper). For example, the wrapper may be a porous paper or non-porous paper capable of wrapping the above-described lyocell tow and maintaining the shape of a filter (e.g., a column or cylinder).
[0298] In a specific example of the present application, the filter for smoking articles may have a preset shape and size.
[0299] For example, the filter may have a rod shape. In particular, the filter for smoking articles may have a cylindrical shape.
[0300] Additionally, the filter may have a length of, for example, 10 mm to 50 mm. In particular, the length of the filter may have a lower limit of 15 mm or more, 20 mm or more, 25 mm or more, 30 mm or more, 35 mm or more, 40 mm or more, or 45 mm or more, and may have an upper limit of 45 mm or less, 40 mm or less, 35 mm or less, 30 mm or less, 25 mm or less, 20 mm or less, or 15 mm or less.
[0301] In a specific example of the present application, the filter having the above length may have a circular cross-section, and the circular cross-section may be a circumference of 10 mm to 40 mm. For example, the circumference of the filter may have a lower limit of 15 mm or more, 20 mm or more, 25 mm or more, 30 mm or more, or 35 mm or more, and may have an upper limit of 35 mm or less, 30 mm or less, 25 mm or less, 20 mm or less, or 15 mm or less.
[0302] For example, the filter for smoking articles may include a lyocell tow and a filter wrapper. Since the description of the lyocell tow and the filter wrapper is the same as that described above, it will be omitted.
[0303] The wrapper may be a porous paper or non-porous paper capable of wrapping the above-described lyocell tow and maintaining the shape of a filter (e.g., a column or cylinder).
[0304] For example, when a porous wrapper is used, the wrapper may have a porosity of 10 to 50,000 CU (Coresta Units). Coresta Unit may be defined as a volume flow rate (cm3min-1) of air passing through 1 cm2 of a substrate sample (i.e. porous wrapper) at a pressure difference of 1 kPa. In particular, the lower limit of the porosity of the wrapper may be, for example, 1000 CU or more, 5000 CU or more, 10000 CU or more, 15000 CU or more, 20000 CU or more, 25000 CU or more, 30000 CU or more, 35000 CU or more, 40000 CU or more, or 45000 CU or more, and the upper limit thereof may be, for example, 45000 CU or less, 40000 CU or less, 35000 CU or less, 30000 CU or less, 25000 CU or less, or 20000 CU or less. In specific embodiments of the present application, the wrapper may have a porosity within a range of 22,000 to 26,000 CU or 23,000 to 25,000 CU.
[0305] For example, the basis weight of the wrapper may be 15 to 60 g/cm2. In particular, the lower limit of the basis weight of the wrapper may be, for example, 20 g/cm2 or more, 25 g/cm2 or more, 30 g/cm2 or more, 35 g/cm2 or more, 40 g/cm2 or more, 45 g/cm2 or more, 50 g/cm2 or more, or 55 g/cm2 or more, and the upper limit thereof may be, for example, 55 g/cm2 or less, 50 g/cm2 or less, 45 g/cm2 or less, 40 g/cm2 or less, 35 g/cm2 or less, 30 g/cm2 or less, 25 g/cm2 or less, or 20 g/cm2 or less. In specific embodiments of the present application, the wrapper may have a basis weight of 16 g/cm2 or more, 17 g/cm2 or more, 18 g/cm2 or more, 19 g/cm2 or more, 20 g/cm2 or more, or 21 g/cm2 or more, and 25 g/cm2 or less, 24 g/cm2 or less, 23 g/cm2 or less, 22 g/cm2 or less, or 21 g/cm2 or less.
[0306] Although not particularly limited, the weight of the rod-shaped filter may be 50 mg or more. In particular, the weight of the filter may have, for example, a lower limit of 100 mg or more, 150 mg or more, or 200 mg or more, and may have an upper limit of 500 mg or less, 450 mg or less, 400 mg or less, 350 mg or less, 300 mg or less, 250 mg or less, or 200 mg or less.
[0307] Since descriptions of other filters for smoking articles and materials included therein are the same as those described above, they will be omitted.
[Method of manufacturing filter for smoking articles]
[0308] For example, the present application relates to a method of manufacturing a filter for smoking articles. This method is a method of manufacturing the above-described filter for lyocell smoking articles, and may be a method including a method of manufacturing the above-described lyocell material.
[0309] With regard to the method of manufacturing a filter for smoking articles, residual processes except for the process of manufacturing the filter are the same as those described for the above-described lyocell material, and therefore, a description thereof will be omitted. In addition, any description that overlaps with those described above will also be omitted.
[0310] The process of manufacturing a filter may be appropriately performed by those skilled in the art according to a known method. For example, a filter may be manufactured by forming a wrapper filled with a lyocell material into a rod shape. Alternatively, a filter may be manufactured by cutting a filter paper filled with a lyocell material having a rod shape to an appropriate length. A description of the wrapper is as the same as that described above.
[0311] Although not particularly limited, prior to filling a filter paper with a lyocell material, opening of the lyocell material or treatment with a plasticizer may be additionally performed. The surface area of the lyocell material may be increased by opening the lyocell material. For example, opening of the lyocell material may be performed by applying an external force in a length direction, width direction, and/or thickness direction.
[0312] Preferably, the lyocell material used in manufacturing a filter for smoking articles may be a lyocell tow.
[0313] Although not particularly limited, the filter for smoking articles may additionally include known cellulose acetate multifilaments at a level that does not hinder the purpose of the present disclosure. Cellulose acetate multifilaments may be blended with lyocell multifilaments. Cellulose acetate multifilaments may be included in a segment distinct from the segment including lyocell multifilaments.
Advantageous Effects of Invention
[0314] According to the present application, there are provided a lyocell material for a filter of smoking articles that can replace commercialized cellulose acetate (CA), and a filter for smoking articles including the same. In particular, there are provided a lyocell material having improved uniformity, and a filter for smoking articles having improved performance (e.g., filtering ability) by including the same.
Mode for the Invention
[0315] Hereinafter, the operation and effects of the invention will be described in more detail through specific examples of the invention. However, this is presented as an example of the invention and the scope of the invention is not limited thereto in any way.
[0316] A lyocell material was prepared through the same process as those described in the following preparation example. Any conditions not specifically mentioned were made within the scope of the above description.
[Preparation Example]
[0317] Cellulose pulp having an alpha-cellulose content of 93.9% and a degree of polymerization (DPw) of 820 was mixed with an NMMO/H2O solvent having a propyl gallate content of 0.01 wt% to prepare a spinning dope for producing a tow with a concentration of 11 wt%. Then, while maintaining a spinning temperature at 110°C in a spinning nozzle, a discharge amount and a spinning rate were appropriately adjusted, and the spinning dope was spun.
[0318] The filament-phase spinning dope discharged from the spinning nozzle was supplied through an air gap section to a coagulation liquid (a coagulation liquid having a concentration of 75 wt% water and 25 wt% NMMO based on 100% of the total weight of the coagulation liquid and a temperature of about 25°C) in a coagulation tank. In this case, cooling air in the air gap section first coagulates the spinning dope at a temperature of 8 °C and an air flow rate of 100 N m'/h. Additionally, the concentration of the coagulation liquid was continuously monitored using a sensor and a refractometer.
[0319] Then, the coagulated lyocell filaments were washed. In particular, filaments were introduced into a towing roller, and NMMO remaining in the filaments was removed using a washing liquid sprayed from a washing device. Then, the washed filaments were immersed inside a bath designed to have a preset oil concentration.
[0320] The filaments were treated with a pressure of 19.61 N/cm2 (2 kgf/cm2) by a nip roll installed in the discharge unit of the bath, and were introduced into a crimping machine to provide wrinkles. The crimping machine included a side plate, a first blade and a second blade. The first blade and the second blade are arranged to be parallel to each other and spaced apart from each other. In particular, the pressure of a press roller was set to 14.71 to 39.23 N/cm2 (1.5 to 4.5 kgf/cm2), and the pressures of the first blade and the second blade were set to 4.90 N/cm2 (0.5 kgf/cm2), respectively, to prepare a tow.
[0321] In order to prevent static electricity and provide flexibility to the prepared tow, a second oil treatment was performed, and immediately after the treatment, the tow passed through a continuous drying device set to 120°C to obtain a dried tow product.
[0322] The prepared tow has a single fineness of 2.22 to 4.44 dtex (2.0 to 4.0 denier), a total fineness of 3,333 to 5,000 tex (30,000 to 45,000 denier), and a crimp number of 9.84 to 15.75 ea/cm (25 to 45 ea/inch).
[Examples]
Examples 1 to 15
[0323] Lyocell materials were manufactured according to Preparation Example, and roughness (Ra1) of the side plate, roughness (Ra2) of the first blade and the second blade, pressure of the press roller, and a draft ratio were as shown in Table 1.
Comparative Examples 1 to 6
[0324] Lyocell materials were manufactured according to Preparation Example, and roughness (Ra1) of the side plate, roughness (Ra2) of the first blade and the second blade, pressure of the press roller, and a draft ratio were as shown in Table 1.
[0325] All of the lyocell materials of Comparative Examples 1 to 4 to 6 had uneven crimps. In particular, under the conditions of Comparative Examples 2 and 3, production of lyocell materials was impossible, and under the conditions of Comparative Examples 5 and 6, continuous production of lyocell materials was impossible.
[0326] Meanwhile, the roughness (Ra1) of the side plate, the roughness (Ra2) of the first blade, and the roughness (Ra2) of the second blade were measured using NPFLEX of Bruker Inc., and measurement conditions and analysis conditions of measured values were as follows.
Measurement conditions: VSI/VXI mode, measurement area 4648 µm x 3486 µm, Backscan/Length 50 µm, Threshold 1%
Analysis Conditions: Gaussian Short Wavelength Cutoff 0.25 mm, n=5 times
[Table 1]
| Ra1 (nm) | Ra2 (nm) | Pressure of press roller (N/cm2(kgf/cm2)) | Draft ratio | ||
| 1 | 250 | 350 | 27.46 (2.8) | 1.16 | |
| 2 | 250 | 500 | 27.46 (2.8) | 1.16 | |
| 3 | 250 | 650 | 27.46 (2.8) | 1.16 | |
| 4 | 250 | 800 | 27.46 (2.8) | 1.16 | |
| 5 | 250 | 950 | 27.46 (2.8) | 1.16 | |
| 6 | 650 | 350 | 34.33 (3.5) | 1.19 | |
| 7 | 650 | 500 | 34.33 (3.5) | 1.19 | |
| Example | 8 | 650 | 650 | 34.33 (3.5) | 1.19 |
| 9 | 650 | 800 | 34.33 (3.5) | 1.10 | |
| 10 | 650 | 950 | 34.33 (3.5) | 1.10 | |
| 11 | 650 | 350 | 29.42 (3.0) | 1.16 | |
| 12 | 650 | 500 | 29.42 (3.0) | 1.16 | |
| 13 | 650 | 650 | 29.42 (3.0) | 1.16 | |
| 14 | 650 | 800 | 29.42 (3.0) | 1.12 | |
| 15 | 650 | 950 | 29.42 (3.0) | 1.12 | |
| Comparative Example | 1 | 650 | 1200 | 27.46 (2.8) | 1.10 |
| 2 | 1100 | 1200 | 27.46 (2.8) | 1.10 | |
| 3 | 1100 | 1200 | 19.61 (2.0) | 1.05 | |
| 4 | 50 | 1200 | 29.42 (3.0) | 1.10 | |
| 5 | 1100 | 500 | 29.42 (3.0) | 1.10 | |
| 6 | 50 | 650 | 29.42 (3.0) | 1.10 | |
[Evaluation Example]
<Experiment 1: Evaluation of characteristics of Lyocell materials>
[0327] Regarding the characteristics of the lyocell materials manufactured in Examples 1 to 15 and Comparative Examples 1 to 6, the number of crimps, the coefficient of variation of the number of crimps, the tensile strength of the lyocell materials, the coefficient of variation of the tensile strength, the breaking elongation of the lyocell materials, and the coefficient of variation of the breaking elongation were measured, respectively.
[0328] The number of crimps and the coefficient of variation of the number of crimps were measured using FAVIMAT+, a monofilament property evaluation apparatus. In particular, monofilaments unspun from the lyocell material was mounted on a jig of a preset length. An initial load was 0.0044 N/tex (0.05 g/d) and sensitivity of crimps was 0.01 mm.
[0329] Meanwhile, in order to measure the coefficient of variation of the number of crimps, central filaments and peripheral filaments were unspun, respectively. A total of 200 strands of peripheral filaments were prepared, and a total of 100 strands of central filaments were prepared. Additionally, the coefficient of variation of the number of crimps was calculated according to Equation 1-1 below. The measurement and calculation results are shown in Table 2 below.
Coefficient of variation of number of crimps (%) = [standard deviation of number of
crimps in central filaments and peripheral filaments/average of number of crimps in
central filaments and peripheral filaments] × 100
[0330] The tensile strength, coefficient of variation of tensile strength, breaking elongation, and coefficient of variation of breaking elongation of the lyocell material were measured using FAVIMAT+, a material property evaluation device from Textechno Inc.. In particular, a tensile speed was 20 mm/min. Prior to measurement, samples collected from the lyocell materials were pre-dried for 2 hours at a temperature of 110°C, and left for 24 hours or more under a constant temperature condition of 20±2°C and a constant humidity condition of 65±4%RH.
[0331] Meanwhile, in order to measure the coefficient of variation of tensile strength and the coefficient of variation of breaking elongation, central filaments and peripheral filaments were each unspun from the specimens. A total of 200 strands of peripheral filaments were prepared, and a total of 100 strands of central filaments were prepared. In addition, the coefficient of variation of tensile strength was calculated according to Equation 2-1 below, and the coefficient of variation of breaking elongation was calculated according to Equation 3-1 below. The measurement and calculation results are shown in Table 2 below.
Coefficient of variation of tensile strength (%) = [standard deviation of tensile
strength in central filaments and peripheral filaments/average of tensile strength
in central filaments and peripheral filaments] × 100
Coefficient of variation of breaking elongation (%) = [standard deviation of breaking
elongation in central filaments and peripheral filaments/average of breaking elongation
in central filaments and peripheral filaments] × 100
[Table 2[
| Number of crimps (ea/cm(ea/in ch)) | Coefficie nt of variation of number of crimps (%) | Tensile strength N/tex((gf/ d)) | Coefficie nt of variation of tensile strength (%) | Breakin 9 elongati on (%) | Coefficie nt of variation of breaking elongati on (%) | ||
| Example | 1 | 12.60 (32) | 17.6 | 0.054(0.6 1) | 35.0 | 4.9 | 25.8 |
| 2 | 11.81 (30) | 14.2 | 0.071 0.81) | 33.7 | 9.4 | 21.1 | |
| 3 | 13.39 (34) | 18.7 | 0.047(0.5 3) | 32.4 | 7.3 | 21.5 | |
| 4 | 11.81 (30) | 15.3 | 0.050(0.5 7) | 38.3 | 5.7 | 25.7 | |
| 5 | 14.96 (38) | 11.2 | 0.065(0.7 4) | 39.2 | 9.6 | 22.0 | |
| 6 | 13.78 (35) | 17.8 | 0.084(0.9 5) | 41.9 | 2.9 | 23.5 | |
| 7 | 13.78 (35) | 16.3 | 0.063(0.7 1) | 47.9 | 6.2 | 26.6 | |
| 8 | 13.39 (34) | 22.8 | 0.074(0.8 4) | 45.6 | 5.5 | 30.1 | |
| 9 | 12.99 (33) | 13.4 | 0.076(0.8 6) | 42.2 | 8.8 | 20.5 | |
| 1 0 | 16.54 (42) | 22.3 | 0.056(0.6 4) | 43.5 | 4.3 | 28.2 | |
| 11 | 11.02 (28) | 17.0 | 0.049(0.5 6) | 38.4 | 5.7 | 24.2 | |
| 1 2 | 11.81 (30) | 18.2 | 0.073(0.8 3) | 39.4 | 8.8 | 24.3 | |
| 1 3 | 13.78 (35) | 20.4 | 0.069(0.7 8) | 34.3 | 5.9 | 27.8 | |
| 1 4 | 16.14 (41) | 15.9 | 0.086(0.9 8) | 36.7 | 4.6 | 24.2 | |
| 1 5 | 13.39 (34) | 11.3 | 0.057(0.6 5) | 45.7 | 4.2 | 21.9 | |
| Comparati ve Example | 1 | 14.17 (36) | 65.5 | 0.029(0.3 3) | 63.2 | 4.6 | 66.4 |
| 2 | - | - | - | - | - | - | |
| 3 | - | - | - | - | - | - | |
| 4 | 12.60 (32) | 61.2 | 0.023(0.2 6) | 71.2 | 4.9 | 71.5 | |
| 5 | 15.35 (39) | 56.0 | 0.021 (0.2 4) | 58.2 | 3.2 | 75.2 | |
| 6 | 14.57 (37) | 52.0 | 0.026(0.2 9) | 69.3 | 3.0 | 71.3 | |
[0332] Referring to Table 2, it was found that all of the lyocell materials of Examples 1 to 15 had a low coefficient of variation of number of crimps, a low coefficient of variation of tensile strength, and a low coefficient of variation of breaking elongation.
[0333] Therefore, it was confirmed that the central filaments and peripheral filaments included in the lyocell materials of Examples 1 to 15 had relatively uniform crimp numbers, tensile strengths, and breaking elongations. Furthermore, due to the uniformity of the central filaments and peripheral filaments, the lyocell materials of Examples 1 to 15 are expected to provide uniform quality (e.g., filtering ability) as filters for smoking articles.
[0334] On the other hand, it was confirmed that the lyocell materials of Comparative Examples 1 and 4 had large deviations in the number of crimps, tensile strength, and breaking elongation, to such a degree that the coefficient of variation of the number of crimps, the coefficient of variation of the tensile strength, and the coefficient of variation of the breaking elongation each exceeds 60 or 70. Under the conditions of Comparative Examples 2 and 3, as described above, lyocell materials were not manufactured. From the evaluation results of Comparative Examples 1 to 4, it can be confirmed that when the Ra2 value of the second blade is 1200 nm or more, the uniformity of the lyocell material manufactured using the second blade is significantly deteriorated.
In addition, it was found that the lyocell materials of Comparative Examples 5 and 6 had significantly poor processability because continuous manufacturing was impossible.
1. A lyocell material comprising: a lyocell multifilament to which crimps are applied,
wherein a coefficient of variation of the number of the crimps is 50 % or less.
wherein a coefficient of variation of the number of the crimps is 50 % or less.
2. The lyocell material of claim 1,
wherein the coefficient of variation of the number of the crimps is a value calculated
according to Equation 1 below:
Coefficient of variation of number of crimps (%) = [standard deviation of number of
crimps /average of number of crimps] × 100
wherein, in Equation 1,
an average of the number of the crimps and a standard deviation of the number of the crimps are values calculated for 50 strands or more of monofilaments included in the lyocell material.
3. The lyocell material of claim 1,
wherein the coefficient of variation of the number of the crimps is a value calculated
according to Equation 1-1 below:
Coefficient of variation of number of crimps (%) = [standard deviation of number of
crimps in central filaments and peripheral filaments/average of number of crimps in
central filaments and peripheral filaments] × 100
wherein, in Equation 1-1,
with respect to an imaginary first line parallel to a length direction of the lyocell material and passing through a center point of the lyocell material, an imaginary second line parallel to the first line and passing through one end of the lyocell material, and an imaginary third line parallel to the second line and passing through the other end of the lyocell material,
a central filament represents a monofilament located closer to the first line than to the second line or the third line, and
a peripheral filament represents a monofilament located closer to the second line or the third line than to the first line.
4. The lyocell material of claim 1,
wherein the number of the crimps is 10 ea/inch to 60 ea/inch, and/or
a tensile strength of the lyocell material is 0.3gf/d to 1.0 gf/d.
5. The lyocell material of claim 1,
wherein a coefficient of variation of tensile strength is 70 % or less, and, preferably,
the coefficient of variation of tensile strength is a value calculated according to
Equation 2 below:
Coefficient of variation of tensile strength (%) = [standard deviation of tensile
strength/ average of tensile strength] × 100
wherein, in Equation 2,
an average of the tensile strength and a standard deviation of the tensile strength are values calculated for 50 strands or more of monofilaments included in the lyocell material.
6. The lyocell material of claim 1,
wherein a breaking elongation of the lyocell material is 2.0% to 10.0%.
wherein a breaking elongation of the lyocell material is 2.0% to 10.0%.
7. The lyocell material of claim 1,
wherein a coefficient of variation of breaking elongation of the lyocell material is 50 % or less, and,
preferably, the coefficient of variation of the breaking elongation is a value calculated
according to Equation 3 below:
Coefficient of variation of breaking elongation (%) = [standard deviation of breaking
elongation/average of breaking elongation] × 100
wherein, in Equation 3,
an average of the breaking elongation and a standard deviation of the breaking elongation are values calculated for 50 strands or more of monofilaments included in the lyocell material.
8. The lyocell material of claim 1,
wherein a single fineness of the lyocell multifilament is 1.5 to 8.0 denier, and/or
the lyocell multifilament has a total fineness of 15,000 to 55,000 denier, and/or
the lyocell material is a lyocell tow.
9. The lyocell material of claim 1,
wherein the lyocell material is used for a filter for a smoking article.
wherein the lyocell material is used for a filter for a smoking article.
10. A filter for a smoking article, the filter comprising the lyocell material of any
one of claims 1 to 9.
11. A smoking article comprising the filter for a smoking article of claim 10.
12. A method of manufacturing a lyocell material, the method comprising: a lyocell dope
spinning process; a coagulation and lyocell multifilament obtainment process; a washing
process; an oil treatment process; and a crimp application process,
wherein the crimp application process is performed by a crimping device including at least one side plate, and
a surface roughness of the side plate is 1000 nm or less.
13. The method of claim 12,
wherein a surface roughness of the side plate is 100 nm or more.
wherein a surface roughness of the side plate is 100 nm or more.
14. The method of claim 12,
wherein the crimping device further comprises at least one blade, and a surface roughness of the blade is less than 1200 nm.
wherein the crimping device further comprises at least one blade, and a surface roughness of the blade is less than 1200 nm.
15. The method of claim 14,
wherein the crimping device comprises a first blade and a second blade, the first blade and the second blade are spaced apart from each other, and
a surface roughness of the first blade and a surface roughness of the second blade are each independently less than 1200 nm.