UTILITY PATENT APPLICATION for PRODUCING TRIPLE SECTION FILTERS USING A DUAL ROD FILTER MAKER by DOUGLAS R. HICKS, a United States citizen, residing at W. John Street North, Alymer, Ontario Canada N5H 2R8; and RICKY A. GONTERMAN, a United States citizen, residing at 130 Ashford Park, Macon, Georgia 31210 Attorney Dkt. No. R-03-3 (RD-B W-60)

CROSS-REFERENCE TO RELATED APPLICATIONS This international patent application is a continuation of and claims priority to and benefit from U.S. Patent Application Serial Number 10/901,889, filed 29 July 2004. STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT Not applicable. REFERENCE TO A "SEQUENTIAL LISTING," A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISC Not applicable. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to cigarette filter rods, and more particularly to a method of producing cigarette filter rods having one more filter rod section than the number of hoppers on a machine producing the cigarette filter rods. 2. Description of the Related Art Current methods of producing cigarette filter rods require a dual hopper machine to produce two-component rods, a three hopper machine to produce three-component rods, and some combination of dual hopper machines and/or three hopper machines to produce any cigarette filter rod with more than three filter rod components. See U.S. Patent No. 5.695.441. to Ikura; U.S. Patent No. 3.357. 321. to Hall; and U.S. Patent No. 3.357.320. to Sextone, et al. Prior methods of forming cigarette filter rods with two or more sections often cut through a charcoal or resin section in a filter, which is costly and unclean, as the charcoal or resin often falls out of the rod and can potentially clog machines or cause contamination, and carbide blades are required to provide equivalent runtime. A cleaner method of producing multi-component cigarette filter rods having one more section than the number of hoppers on a machine is desired. As such, a multiple hopper machine with X hoppers can conveniently produce either filters with X number of components or X+l number of components. For example, a dual hopper machine can conveniently produce either two-component filter rods or three-component filter rods, and a three hopper machine can conveniently produce either three-component filters or four-component filters.

SUMMARY OF THE INVENTION In view of known deficiencies associated with earlier methods of producing multi- component cigarette filter rods, a method is herein provided to produce multi-component cigarette filter rods having one more section than the number of hoppers on the machine producing the cigarette filter rods. For example, a dual hopper machine can produce two- component filters as well as three-component filters, and a three hopper machine can produce three-component filters as well as four-component filters. The instant method utilizes existing cigarette filter rod equipment, and only minor modifications are required to produce the new filter rods. A savings in paper plug wrap may be achieved, as well as saving one step in the production, thus reducing conversion costs. The instant method is also advantageous in that any additive material, such as charcoal or selective filtration material or reclaim of tobacco from rejected cigarettes, which, using existing methods, may fall out of the filter rod during cigarette production, is trapped in the center of the filter rod when manufactured via the instant invention. For example, the rotary knife cuts only the fibrous filter material component, such as cellulose acetate, thereby reducing the chance of charcoal, resin, and reclaim fallout, contamination, and machine clogging. As such, the method provides for much cleaner cigarette and filter rod production. For a better understanding of the present invention, together with other and further objects thereof, reference is made to the following description, taken in conjunction with the accompanying drawings, and its scope will be pointed out in the appending claims.

BRIEF DESCRIPTION OF THE DRAWINGS The aspects and advantages of the present invention will be better understood when the detailed description of the preferred embodiment is taken in conjunction with the accompanying drawings, in which: FIG. 1 is a cross-section of filter components for a cigarette embodiment having a prior art filter configuration processed via a dual hopper machine. FIG. 2 is a cross-section of filter components for the cigarette embodiment of FIG. 1 including a filter configuration of the present invention processed via a dual hopper machine. FIG. 3 is a cross-section of filter components for a second cigarette embodiment having a prior art filter configuration processed via a dual hopper machine. FIG. 4 is a cross-section of filter components for the cigarettes embodiment of FIG. 3 including a filter configuration of the present invention processed via a dual hopper machine. FIG. 5 is a cross-section of filter components for a third cigarette embodiment having a prior art filter configuration processed via a dual hopper machine. FIG. 6 is a cross section of filter components for the cigarette embodiment of FIG. 5 including a filter configuration of the present invention processed via a dual hopper machine. FIG. 7 is a cross section of filter components for a fourth cigarette embodiment having a prior art filter configuration processed via a dual hopper machine. FIG. 8 is a cross section of filter components for the cigarette embodiment of FIG. 7 including a filter configuration of the present invention processed via a dual hopper machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS While this invention is susceptible of embodiments in many different forms, there are shown in the Figures and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention, and is not intended to limit the broad aspects of the invention to the embodiments illustrated. The present invention provides a method to produce multi-component cigarette filter rods having one more filter rod section than the number of hoppers on the machine producing the cigarette filter rods. The integrity of the filter component proportions remains the same, while the configuration varies minimally to produce multi-component cigarette filter rods which have one more section than the number of hoppers on the machine producing the cigarette filter rods. Maintaining the integrity of filter components in cigarette filter rods is important because, by varying the length of the various components, such as the cellulose acetate filter plug and the various filter media, and the composition of each of the components, certain aspects of the smoking process, such as the taste, smoke constituent delivery, puff number, and draw ease, will vary. It is noted that the Figures are not drawn to scale, and the filter configuration can be comprised of any filter media known in the art, such as fibrous filter media (e.g., cellulose acetate) and pourable filter media (e.g., resin or charcoal). Referring to FIG. 1 , there is provided a cross-section of filter components for a cigarette filter rod embodiment 10, usually referred to as milds, having a prior art two-component filter configuration processed via a dual hopper machine. The total filter length for an individual milds cigarette is typically 27mm. The prior art filter configuration of FIG. 1 shows a "4 up rod," which is a cigarette filter rod 10 that is cut to make four individual cigarette filters 13, 14, 15, 16, during the cigarette manufacturing process. In this milds cigarette filter embodiment 10, a first filter media component, usually a pourable filter media component (such as for example charcoal or resin media), is 32mm in length, and a second filter media component, usually a fibrous filter material component (such as for example cellulose acetate), is 22mm in length, alternate along the cigarette filter rod, for a total of five components. A joint 11 is located between each alternating component. To obtain a milds configuration of 27mm, via a dual hopper using the prior art method, the cigarette filter rod 10 must receive a slice 12 via a rotary knife halfway through each first filter media component and through each second filter media component, resulting in four individual cigarette filters 13, 14, 15, 16, each having an adjoined 16mm first filter media component length (half of 32 mm is 16mm) and 1 lmm second filter media component length (half of 22mm is 11mm), which total 27mm (16mm plus 11mm is 27mm). In the instant invention, a dual hopper machine will not only be able to produce the two component filters as previously described, but also three component cigarette filters 24, 25, 26, 27, as shown in FIG. 2. The method utilizes the existing cigarette filter rod equipment with minor modifications to the milds cigarette filter rods 20. Referring to FIG. 2, there is shown a cross- section of filter components for the milds cigarette filter rod 20 having the new three-component filter configuration using a dual hopper machine. The 27mm milds configuration is maintained by varying the position of each component of the cigarette filter rod. In such a configuration, the first filter media component is 16mm in length and the second filter media component is 1 lmm in length, which alternate along the cigarette filter rod, for a total of nine components. A first joint 21 and a second joint 22 are now present in each resulting individual cigarette filter 24, 25, 26, 27. The new inventive method provides for a slice 23 with a rotary knife halfway through each 1 lmm second filter media component only. The first filter media components are not cut. Referring to FIG. 2, the result is individual cigarette filters 24, 25, 26, 27, each having a first filter media componentlόmm in length positioned between second filter media components 5.5mm in length (half of 1 lmm is 5.5mm) on each side, separated by the two joints 21, 22. The two 5.5mm second filter media components, totaling 11mm, positioned on either side of the 16mm first filter media component, result in the 27mm milds cigarette filter configuration 24, 25, 26, 27 (5.5mm plus 16mm plus 5.5mm is 27mm). The first and last sections of each cigarette filter 24, 25, 26, 27 have the same first filter media component, such as cellulose acetate. The first filter media component and the second filter media component are in a different configuration, but the total amount of the first filter media component and the second filter media component will remain the same; that is, the first filter media component will remain at a length of 16mm and the second filter media component will remain at a length of 11mm, as in the original configuration (FIG. 1). The lengths of the components may change if desired, but will most likely stay the same to give similar filter functions as the original filter design. FIGS. 3-8 are for illustrative purposes only, and show that the instant invention could be used to produce any number of varying filter designs, each having one more filter than the number of hoppers on the machine. Additionally, each filter design would have the same filter component at both the mouth end and the tobacco end of the filter. The length and components of the filter rods may change. Referring now to FIG. 3, there is provided a cross-section of filter components for a cigarette filter rod embodiment 30, usually referred to as milds, having a prior art two-component filter configuration processed via a dual hopper machine. Again, the total filter length for the milds cigarette is typically 27mm. The prior art filter configuration of FIG. 3 shows a "4 up rod," which is a cigarette filter rod 30 that is cut to make four individual filters 33, 34, 35, 36, during the cigarette manufacturing process. This milds cigarette filter rod embodiment 30 has a first filter media component, such as a pourable filter media component, 28mm in length in the middle of the filter rod, a second filter media component, such as a fibrous filter media component 26mm in length on either side of the pourable filter media component (first filter media component), and the pourable filter media (first filter media component) component 14mm in length on the outer ends of the filter rod, for a total of five components. A joint 31 is located between each alternating component. To obtain a milds configuration of 27mm, via a dual hopper machine using a prior art method, the filter rod must receive a slice 32 halfway through the 28mm-length pourable filter media component (first filter media component) and halfway through each of the fibrous filter media components, resulting in four individual cigarette filters 33, 34, 35, 36, each having an adjoined 14mm-length pourable filter media component (first filter media component) (half of 28 is 14) and a 13mm length of fibrous filter media component (half of 26mm is 13mm), which total 27mm (14mm plus 13mm is 27mm). In the instant invention, a dual hopper machine will not only be able to produce the two component filters as just described, but also three component cigarette filters 44, 45, 46, 47, as shown in FIG. 4. The method utilizes the existing cigarette filter rod equipment with minor modifications to the milds cigarette filter rods 40. Referring to FIG. 4, there is shown a cross- section of filter components for milds cigarettes filter rod 40 having the new three-component filter configuration using a dual hopper machine. The 27mm-length milds configuration is maintained by varying the position of each component of the cigarette filter rod. In such a configuration, the pourable filter media component (first filter media component) is 14mm in length and the fibrous filter media component (second filter media component) is 13mm in length, with 6.5mm fibrous filter media components (second filter media component) on each end of the cigarette filter rod, for a total of nine components. A first joint 41 and a second joint 42 are now present in each resulting cigarette filter 44, 45, 46, 47. The new inventive method provides for a slice 43 with a rotary knife halfway through each 13mm length of fibrous filter media component (second filter media component) only. The pourable filter media components (first filter media component) are not cut. Referring to FIG. 4, the result is individual cigarette filters 44, 45, 46, 47, each having a 14mm length of pourable filter media component (first filter media component) positioned between a 6.5mm length of fibrous filter media component (second filter media component) (half of 13mm is 6.5mm) on each side, separated by the two joints 41, 42. The two 6.5mm fibrous filter media components (second filter media component), totaling 13mm, positioned on either side of the 14mm length of pourable filter media component (first filter media component) results in the 27mm milds cigarette filter configuration 44, 45, 46, 47 (6.5mm plus 14mm plus 6.5mm is 27mm). The first and last sections of each cigarette filter 44, 45, 46, 47, have the same fibrous filter media component (second filter media component), such as cellulose acetate. The positions of the pourable filter media components (first filter media component) and the length of the fibrous filter media components(second filter media component) are in a different configuration, but the total amount of the pourable filter media component (first filter media component) and the fibrous filter media component (second filter media component) will preferably remain the same; that is, the pourable filter media component (first filter media component) will remain at 14mm in length and the fibrous filter media component (second filter media component) will remain at 13mm in length, as in the original configuration (FIG. 3). Referring to FIG. 5, there is provided a cross-section of filter components for a cigarette filter rod embodiment 50, usually referred to as full flavor, having a prior art two-component filter configuration processed via a dual hopper machine. The total filter length for a full flavor cigarette is typically 21mm. The prior art filter configuration of FIG. 5 shows a "4 up rod," which is a cigarette filter rod 50 that is cut to make four individual filters 53, 54, 55, 56, during the cigarette manufacturing process. In this full flavor cigarette embodiment 50, the pourable filter media component (first filter media component) is 26mm in length in the middle of the filter rod, has a 16mm-length of fibrous filter media component on either side (second filter media component), and a 13mm length of the pourable filter media component (first filter media component) on the outer ends of the filter rod, for a total of five components. A joint 51 is located between each alternating component. To obtain the full flavor configuration of 21 mm in length, via a dual hopper using the prior art method, the filter rod must receive a slice 52 halfway through the 26mm length of pourable filter media component (first filter media component) and halfway through each of the 16mm lengths of fibrous filter media components (second filter media component), resulting in four cigarette filters 53, 54, 55, 56, each having an adjoined 13mm length of pourable filter media component (first filter media component) (half of 26mm is 13mm) and 8mm length of fibrous filter media component (second filter media component) (half of 16mm is 8mm), which total 21mm (13mm plus 8mm is 21mm). In the instant invention, a dual hopper machine will not only be able to produce the two- component filters as just described, but also three-component filters 64, 65, 66, 67, as shown in FIG. 6. The method utilizes' the existing cigarette filter rod equipment with minor modifications to the full flavor cigarette filter rods 60. Referring to FIG. 6, there is shown a cross-section of filter components for full flavor cigarette filter rods 60 having the new three-component filter configuration using a dual hopper machine. The 21mm-length full flavor configuration is maintained by varying the position of the components of the cigarette filter rod. In such a configuration, the pourable filter media component (first filter media component) is 13mm in length and the fibrous filter media component (second filter media component) is 8mm in length, with 4mm fibrous filter media components (second filter media component) on each end of the cigarette filter rod, for a total of nine components. A first joint 61 and a second joint 62 are now present in each resulting cigarette filter 64, 65, 66, 67. The new inventive method provides for a slice 63 with a rotary knife halfway through each 8mm fibrous filter media component (second filter media component) only. The pourable filter media component (first filter media component) is not cut. Referring to FIG. 6, the result is individual cigarette filter 64, 65, 66, 67, each having a 13mm length of pourable filter media component (first filter media component) positioned between a 4mm length of fibrous filter media component (second filter media component) (half of 8mm is 4mm) on each side, separated by the two joints 61, 62. The two 4mm fibrous filter media components (second filter media component), totaling 8mm, positioned on either side of the 13mm pourable filter media components (first filter media component) results in the 2 lmm full flavor cigarette filter configuration 64, 65, 66, 67 (4mm plus 13mm plus 4mm is 2 lmm). The first and last sections of each cigarette filter 64, 65, 66, 67, preferably have the same fibrous filter media component (second filter media component), such as cellulose acetate. The positions of the pourable filter media components (first filter media component) and the length of the fibrous filter media components (second filter media component) are in a different configuration, but the total amount of the pourable filter material component (first filter media component) and the fibrous filter media component (second filter media component) will remain the same; that is, the pourable filter media component (first filter media component) will remain at 13mm in length and the fibrous filter media component (second filter media component) will remain at 8mm in length, as in the original configuration (FIG. 5). Referring to FIG. 7, there is provided a cross-section of filter components for a cigarette embodiment 70, usually referred to as full flavor, having a prior art two-component filter configuration processed via a dual hopper machine. As previously discussed, the total filter length for a full flavor cigarette is typically 21mm. The prior art filter configuration of FIG. 7 shows a "4 up rod," which is a cigarette filter rod that is cut to make four individual filters 73, 74, 75, 76, during the cigarette manufacturing process. In this full flavor cigarette embodiment 70, the pourable filter media component (first filter media component) is 18mm in length in the middle of the filter rod, has a 24mm-length of fibrous filter media component (second filter media component) on either side, and 9mm-length of the pourable filter media component (first filter media component) on the outer ends of the filter rod, for a total of five components. A joint 71 is located between each alternating component. To obtain a full flavor configuration of 21 mm, via a dual hopper using the prior art method, the filter rod receives a slice 72 halfway through the pourable filter media component (first filter media component) and halfway through each of the fibrous filter media components (second filter media component), resulting in four cigarette filters 73, 74, 75, 76, each having an adjoined 9mm length of pourable filter media component (first filter media component) (half of 18mm is 9mm) and a 12mm length of fibrous filter media component (second filter media component) (half of 24mm is 12mm), which total 21mm (9mm plus 12mm is 21mm). In the instant invention, a dual hopper machine will not only be able to produce the two- component filters as just described, but also three-component filters 84, 85, 86, 87, as shown in FIG. 8. The method utilizes the existing cigarette filter rod equipment with minor modifications to the cigarette filter rods 80. Referring to FIG. 8, there is shown a cross-section of filter components for full flavor cigarette filter rods 80 having the new three-component filter configuration using a dual hopper machine. The 21mm-length full flavor configuration is maintained by varying the position of the components of the cigarette filter rod. In such a configuration, the pourable filter media component (first filter media component) is 9mm in length and the fibrous filter media components (second filter media component) are 12mm in length, with 6mm lengths of fibrous filter media components (second filter media component) on each end of the cigarette filter rod, for a total of nine components. A first joint 81 and a second joint 82 are now present in each resulting cigarette filter plug 84, 85, 86, 87. The new method provides for a slice 83 with a rotary knife halfway through each 12mm fibrous filter media component (second filter media component) only. The pourable filter media components (first filter media component) are not cut. Referring to FIG.8, the result is four individual cigarette filter plugs 84, 85, 86, 87, each having a 9mm length of pourable filter media component (first filter media component) positioned between a 6mm (half of 12mm is 6mm) length of fibrous filter media component (second filter media component) on each side, separated by the two joints 81, 82. The two 6mm fibrous filter media components (second filter media component), totaling 12mm, positioned on either side of the 9mm pourable filter media component (first filter media component) results in the 21mm full flavor cigarette filter configuration 84, 85, 86, 87 (6mm plus 9m plus 6mm is 21 mm). The first and last sections of the cigarette filter 84, 85, 87, 87, have the same fibrous filter media component (second filter media component), such as cellulose acetate. The positions of the pourable filter media components (first filter media component) and the length of the fibrous filter media components (second filter media component) are in a different configuration, but the length will always remain the same; that is, the pourable filter media components (first filter media component) will remain at 9mmin length and the fibrous filter media components (second filter media component) will remain at 12mm in length. The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art upon reading this disclosure, and may be made without departing from the spirit of the invention and scope of the appended claims. For example, the configuration of the components of the cigarette filter rod are the essence of the invention. The pourable filter media component (first filter media component) may be charcoal, resin, charcoal and resin, etc. The fibrous material may be cellulose acetate or any other fiber which acts as a filter and is non pourable.