U.S. patent application number 10/909040 was filed with the patent office on 2005-03-17 for modified reconstituted tobacco sheet.
Invention is credited to Hicks, Douglas R., Monsalud, Luis JR., Mua, John-Paul, Wanna, Joseph T..
Application Number | 20050056294 10/909040 |
Document ID | / |
Family ID | 35432750 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050056294 |
Kind Code |
A1 |
Wanna, Joseph T. ; et
al. |
March 17, 2005 |
Modified reconstituted tobacco sheet
Abstract
A reconstituted tobacco sheet for use in a cigarette includes up
to about 80% by weight of wood pulp, up to about 30% by weight of a
binder, and up to about 80% by weight of tobacco. A humectant and a
flavor may be included. The reconstituted tobacco sheet is used in
elongated strips along the outer surface of a tobacco rod between
the tobacco rod and an inner surface of an outer wrap of cigarette
paper
Inventors: |
Wanna, Joseph T.; (Macon,
GA) ; Hicks, Douglas R.; (Alymer, CA) ;
Monsalud, Luis JR.; (Macon, GA) ; Mua, John-Paul;
(Macon, GA) |
Correspondence
Address: |
MIDDLETON & REUTLINGER
2500 BROWN & WILLIAMSON TOWER
LOUISVILLE
KY
40202
|
Family ID: |
35432750 |
Appl. No.: |
10/909040 |
Filed: |
July 30, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10909040 |
Jul 30, 2004 |
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10811270 |
Mar 26, 2004 |
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10811270 |
Mar 26, 2004 |
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10299231 |
Nov 19, 2002 |
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6827087 |
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Current U.S.
Class: |
131/372 ;
131/370 |
Current CPC
Class: |
A24B 15/14 20130101;
A24B 3/14 20130101; A24D 1/025 20130101 |
Class at
Publication: |
131/372 ;
131/370 |
International
Class: |
A24B 015/00 |
Claims
What is claimed is:
1. A process for making a reconstituted tobacco sheet having a
binder, comprising the steps of: preparing a slurry containing a
mixture of up to about 80% by weight tobacco, and up to about 30%
by weight of said binder; and coating a preformed reconstituted
tobacco sheet, wherein said sheet contains up to about 80% wood
pulp, with said slurry.
2. The process of claim 1, wherein said reconstituted sheet
contains up to about 60% by weight of said wood pulp.
3. The process of claim 1, wherein said slurry contains up to about
20% by weight of said binder.
4. The process of claim 1, including the addition of up to about
30% by weight of a flavor in said solid mixture.
5. The process of claim 4, wherein said solid mixture contains from
about 3% to about 5% by weight of said flavor.
6. The process of claim 1, said tobacco being firstly added to an
aqueous solvent to from said slurry, and said binder being added to
said slurry secondly, each of said tobacco and said binder being
dispersed before adding to said preformed reconstituted tobacco
sheet.
7. The process of claim 1, said binder being selected from the
group consisting of alginate, guar, xanthan, acacia, pectin, other
gums, modified cellulose compounds, and hydrocolloid based
compounds.
8. The process of claim 7, wherein said alginate is sodium
alginate.
9. The process of claim 1, including the addition of a
humectant.
10. The process of claim 9, said humectant being selected from the
group consisting of glycerin and propylene glycol.
11. The process of claim 10, said glycerin being up to 30% by
weight of said mixture.
12. The process of claim 1, further comprising: cutting said sheet
of reconstituted tobacco into longitudinal strips; inserting a
plurality of said longitudinal strips of said reconstituted tobacco
into a cigarette adjacent a column of tobacco.
13. A process for making a reconstituted tobacco sheet comprising
the steps of: preparing a slurry including a binder, a humectant,
tobacco, and a flavoring, said tobacco being up to about 80% by
weight and dispersed in an aqueous solvent into said slurry, said
binder being up to about 30% by weight and dispersed secondly into
said slurry, said humectant being up to about 30% by weight and
dispersed thirdly into said slurry, and then up to about 30% by
weight of flavor being dispersed lastly into said slurry; coating a
preformed reconstituted tobacco sheet with said slurry; cutting
said sheet of reconstituted tobacco into longitudinal strips; and
inserting a plurality of said longitudinal strips of said
reconstituted tobacco into a cigarette adjacent a column of
tobacco.
14. The process of claim 13, said binder being selected from the
group consisting of alginate, guar, xanthan, acacia, pectin, other
gums, modified cellulose compounds, and hydrocolloid based
compounds.
15. The process of claim 14, wherein said alginate is sodium
alginate
16. The process of claim 13, said humectant being selected from the
group consisting of glycerin and propylene glycol.
17. A cigarette comprising: a tobacco column surrounded by an outer
wrap paper; and, a partial inner wrap material extending
longitudinally of said tobacco column and disposed between said
outer wrap, said partial inner wrap being one or more strips of a
reconstituted tobacco sheet which is comprised of up to about 80%
by weight of wood pulp, up to about 30% by weight of a binder, and
up to about 80% by weight of tobacco, said partial inner wrap being
coated with a coating comprising up to about 80% by weight tobacco
and up to about 30% by weight of a binder.
18. The cigarette of claim 17, including up to about 30% by weight
of flavor in said inner wrap.
19. The cigarette of claim 18, wherein said flavor is from about 3%
to about 5% by weight of said inner wrap.
20. The cigarette of claim 17, including up to about 30% by weight
of a humectant in said inner wrap.
21. The cigarette of claim 20, said humectant being selected from
the group consisting of glycerin and propylene glycol.
22. The cigarette of claim 17, said binder being selected from the
group consisting of alginate, guar, xanthan, acacia, pectin, other
gums, modified cellulose compounds, and hydrocolloid based
compounds.
23. The cigarette of claim 22, said alginate being sodium
alginate.
24. The cigarette of claim 17, wherein said wood pulp is up to
about 60% by weight of said reconstituted tobacco sheet.
25. The cigarette of claim 17, wherein said binder is up to about
20% by weight of said reconstituted tobacco sheet.
26. A reconstituted tobacco sheet, comprised of up to about 80% by
weight of wood pulp, up to about 30% by weight of binder, and up to
about 80% by weight of tobacco.
27. The sheet of claim 26, wherein said wood pulp is up to about
60% by weight.
28. The sheet of claim 26, wherein said binder is up to about 20%
by weight.
29. The sheet of claim 26, including up to about 30% by weight of
flavor.
30. The sheet of claim 29, wherein said flavor is from about 3% to
about 5% by weight.
31. The sheet of claim 26, including up to about 30% by weight of a
humectant.
32. The sheet of claim 26, said humectant being selected from the
group consisting of glycerin and propylene glycol.
33. The sheet of claim 26, said binder being selected from the
group consisting of alginate, guar, xanthan, acacia, pectin, other
gums, modified cellulose compounds, and hydrocolloid based
compounds.
34. The sheet of claim 33, said alginate being sodium alginate.
35. The sheet of claim 26, wherein said reconstituted tobacco sheet
is formed in a plurality of longitudinal strips, said strips
inserted into a cigarette adjacent a column of tobacco.
36. The sheet of claim 35, wherein said plurality of longitudinal
strips are a first and a second strip positioned equidistant from
each other.
37. A process for making a modified reconstituted tobacco sheet,
comprising the steps of: preparing a slurry containing tobacco
particles and an aqueous solvent; extracting said slurry at about
160.degree. F. for about 30 minutes; separating said slurry into an
extract with water soluble compounds and solid portion; mixing said
solid portion with wood pulp, wherein said wood is up to about 80%
by weight; forming said solid portion into a reconstituted tobacco
sheet over a Fourdriner paper machine wire; centrifuging and
concentrating said extract; adding a first binder to said extract,
wherein said first binder is up to about 30% by weight; adding a
humectant to said extract, wherein said humectant is up to about
30% by weight; applying said extract to said reconstituted tobacco
sheet and drying; slitting said reconstituted tobacco sheet into
elongated strips; and inserting a plurality of said elongated
strips into a cigarette adjacent a column of tobacco.
38. The process of claim 37, said tobacco particles and said
aqueous solvent being in a ratio of from about 1:11 to about
1:20.
39. The process of claim 37, wherein said solid portion and said
wood pulp are further mixed with a second binder, said second
binder being up to about 30% by weight.
40. The process of claim 39, said second binder being selected from
the group consisting of alginate, guar, xanthan, acacia, pectin,
other gums, modified cellulose compounds, and hydrocolloid
compounds.
41. The process of claim 40, wherein said alginate is sodium
alginate.
42. The process of claim 37, wherein said extract is treated with
adsorbents.
43. The process of claim 37, said first binder being selected from
the group consisting of alginate, guar, xanthan, acacia, pectin,
other gums, modified cellulose compounds, and hydrocolloid
compounds.
44. The process of claim 43, wherein said alginate is sodium
alginate.
45. The process of claim 37, said humectant being selected from the
group consisting of glycerin and propylene glycol.
46. The process of claim 37, including the addition of up to about
30% by weight of a flavor to said extract.
47. The process of claim 46, wherein said extract contains from
about 3% to about 5% by weight of said flavor.
48. The process of claim 37, including the addition of an inert
filler to said solid portion before forming said reconstituted
tobacco sheet over said Fourdriner paper machine wire.
49. The process of claim 48, wherein said inert filler is selected
from the group consisting of chalk, chitosan, liposan, or
combinations thereof.
50. The process of claim 37, including the step of applying a third
binder solution to said reconstituted tobacco sheet subsequent,
wherein said binder is selected from the group consisting of
alginate, guar, xanthan, acacia, pectin, other gums, modified
cellulose compounds, and hydrocolloid based compounds.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This continuation-in-part application claims priority to and
benefit from currently pending U.S. application Ser. No.
10/811,270, filed Mar. 26, 2004, which is a continuation-in-part of
and claims priority to and benefit from currently pending U.S.
application Ser. No. 10/299,231, filed Nov. 19, 2002, which are
incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A "SEQUENTIAL LISTING," A TABLE, OR A COMPUTER PROGRAM
LISTING APPENDIX SUBMITTED ON A COMPACT DISC
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] The present invention relates to a process for making a
reconstituted tobacco sheet and more particularly to a process for
making a reconstituted tobacco sheet including a flavoring compound
contained in a gel matrix within the reconstituted tobacco sheet
and even more particularly to a paper process for making a
reconstituted tobacco sheet including an alginate based
compound.
[0005] In the manufacturing of smoking articles and particularly
cigarettes, it is common to use in the tobacco blend a percentage
of strips of reconstituted tobacco. The reconstituted tobacco is
generally prepared from tobacco fines, veins, stems and other waste
tobacco products which are further processed and formed into
sheets, cut into strips and blended in with fresh cut tobacco. The
amount of reconstituted tobacco used in a tobacco blend for a
smoking article varies, but is generally less than 20%. Usually,
reconstituted tobacco sheets made via the paper process are absent
of additional binders, such as alginate, guar, xanthan, acacia,
pectin, other gums, and modified cellulose compounds.
[0006] Additionally, there has been great concern for the reduction
of the ignition propensity of smoking articles as there have been a
substantial number of fires which have been attributed to burning
cigarettes coming into contact with combustible or flammable
materials. Therefore, there is a considerable effort being expended
in the industry to provide smoking articles which provide a low
ignition propensity smoking article. Many of these proposals
include a modification of the wrapper for the smoking article.
Particularly, coatings or additives have been made to wrappers for
the smoking articles to reduce the porosity or to change the
chemical properties of the wrapper.
SUMMARY OF THE INVENTION
[0007] It is an object of the present invention to provide a novel
formulation for a reconstituted tobacco sheet and the process for
making same.
[0008] It is also an object of the present invention to provide a
smoking article, including a novel reconstituted tobacco sheet in
one layer of a wrapper for the smoking article.
[0009] It is a further object of the present invention to provide a
novel formulation for a reconstituted tobacco sheet having an
alginate based coating and the process or making same.
[0010] It is yet a further object of the present invention to
provide a smoking article, including a novel reconstituted tobacco
sheet having an alginate based coating in one layer of a wrapper
for the smoking article.
[0011] The present invention provides a reconstituted tobacco sheet
which includes up to about 80% by weight of tobacco; up to about
80% by weight of wood pulp, preferably up to about 60% by weight of
wood pulp; up to about 30% by weight of a binder (e.g., alginate,
guar, xanthan, acacia, pectin, other gums, and modified cellulose
compounds), preferably up to about 20% by weight of a binder; and
up to about 30% by weight of flavoring compounds, preferably about
3% to about 5% by weight of flavoring compounds.
[0012] Processes for making a reconstituted tobacco sheet are known
in the art. The present invention provides a process for making a
reconstituted tobacco sheet having a binder applied to the sheet to
decrease sheet porosity, thereby lowering ignition propensity and
cigarette burn rate. The binder may be alginate, guar, xanthum,
acacia, pectin, other gums, and modified cellulose compounds. The
resulting tobacco sheet with the applied binder is cut into lengths
of preselected widths for use in a smoking article. In one
embodiment, the strips are positioned longitudinally of the tobacco
rod between the tobacco rod and an outer cigarette or smoking
article wrapper.
[0013] Additional objects and advantages of the present invention
will become apparent to those skilled in the art upon consideration
of the following detailed description including examples of the
preparation of the reconstituted tobacco sheet of the present
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The aspects and advantages of the present invention will be
better understood when the detailed description of the preferred
embodiments is taken in conjunction with the accompanying drawings,
in which:
[0015] FIG. 1 is perspective view of a partial cigarette of the
present invention using the reconstituted tobacco sheet of the
instant invention;
[0016] FIG. 2 is a perspective view of an unrolled cigarette
wrapper including the reconstituted tobacco sheet of the instant
invention;
[0017] FIG. 3 is an end view of the cigarette of FIG. 1;
[0018] FIG. 4 is a perspective view of the cigarette paper of an
alternative embodiment of the instant invention including the
reconstituted tobacco sheet;
[0019] FIG. 5 is a perspective view of the cigarette paper of an
alternative embodiment of the instant invention including the
reconstituted tobacco sheet;
[0020] FIG. 6 is an end view of FIG. 5; and,
[0021] FIG. 7 is a partial cut away view of a cigarette with the
cigarette paper of an alternative embodiment of the instant
invention including the reconstituted tobacco sheet.
[0022] FIG. 8 is a flow chart showing the modified paper
reconstituted process for making split inner wrap.
DETAILED DESCRIPTION OF THE PREFERRED EMBDIMENTS
[0023] A cigarette with burn rate modification is shown in FIG. 1
and may be described as a partial double wrap cigarette 10. As seen
therein, the partial double wrap cigarette 10 of the present
invention incorporates a standard column of tobacco 13 which
extends from an exposed end to the filter 15. Circumscribing the
tobacco column 13 is the outer wrap of the cigarette paper 12.
Interior of the outer wrap cigarette paper 12 is a separate partial
inner wrap layer or strip 14a and 14b. The separate partial inner
wrap layer 14a and 14b acts as a burn rate modifier for the tobacco
column 13 by altering the burn characteristics of the cigarette 10.
As can be seen from the embodiment shown in FIG. 1, the inner wrap
layer strips may be co-axial to the tobacco column 13 and may
extend substantially the length of the tobacco column from the
exposed end to the filter 15. By insertion of the separate partial
inner wrap layer 14a and 14b which in this embodiment extends
co-axial to the tobacco column 13, modification may be made to the
burn rate of the cigarette in such a manner that the burn rate may
be adjusted depending upon the packing density of the tobacco,
porosity of the outer wrap paper 12 and additives to the outer
wrap, width of the separate partial inner wrap layer 14a and 14b,
porosity of the inner wrap layers 14a and 14b, and additives to the
inner wrap strips. Alternatively, the inner wrap layer may be
shortened to not extend the full length of the tobacco column 13 or
may extend in varying directions. Thus, many alterations to the
burn rate of the partial double wrap cigarette 10 of the present
invention may be established based upon the combination of factors
noted herein, among others.
[0024] As depicted in FIG. 1, the partial double wrap cigarette 10
of the present invention which has a modified burn rate
characteristic incorporates an outer wrap paper 12 with a first and
a second separate partial inner wrap strip 14a and 14b. The outer
wrap cigarette paper 12 may be a normal porosity paper which
typically exhibits a porosity of 15-80 CORESTA units. In
combination with the outer wrap cigarette paper 12 is positioned at
least one partial inner wrap layer which can modify the burn rate
characteristics of the cigarette 10. As shown, a first and a second
partial inner wrap layer 14a and 14b are provided on opposite sides
of the tobacco column 13. In order to provide substantially
equivalent burn rate characteristics along the entirety of the
tobacco column 13, the partial inner wrap strips 14a and 14b may
substantially extend and be co-axial with the tobacco column 13 to
the filter 15.
[0025] As depicted in the embodiment of FIG. 4, the partial inner
wrap layers 14a and 14b extend from end to end of the tobacco
column 13 and may be positioned such that they are either equal
distant from each other or may be placed in alternative positions
based upon the desired burn rate characteristics.
[0026] Turning to FIG. 3, it is apparent that the partial double
wrap cigarette 10 of the present invention has alternating high
diffusion areas 21 and low diffusion areas 22 based upon the
placement of the inner wrap layers or strips 14a and 14b. As can be
seen, the high diffusion areas 21 of which there is at least one,
allow for increased permeation of CO and oxygen gases through the
barrier formed by the outer wrap 12 while maintaining normal
deliveries. In combination, low diffusion areas 22 which are
defined by the circumferential extent of each of the partial inner
wrap layers 14a and 14b may potentially block a significant portion
or all of the inflow and outflow of gases therethrough related
directly to the porosity of the inner wrap layer 14a and 14b in
combination with the outer wrap layer 12. The co-linear zones of
high diffusion area 21 and low diffusion area 22 may exhibit a
porosity of greater than 14 CORESTA for the co-linear high
diffusion areas and less than 8 CORESTA for the co-linear low
diffusion areas.
[0027] As shown in the drawings, the construction of the cigarette
with burn rate modification is a partial double wrap cigarette 10
depicted herein and utilizes a standard outer wrap cigarette paper
12 which, in a typical cigarette, is 27 mm wide. Placed along the
interior of the outer wrap, as shown in FIG. 2 and in FIG. 4 in an
alternative embodiment, is located the separate partial inner wrap
layer 14a and 14b which may substantially extend along the length
of the outer wrap 12. While the outer wrap of the cigarette paper
may be standard porosity and construction, the partial inner wrap
of this embodiment has a first and a second strip 14a and 14b each
of which may be 4 mm in width and which may have a porosity of less
than 8 CORESTA units. Therefore, combined, the two inner wrap
layers or strips 14a and 14b may circumscribe about 8 mm of the
circumference of the partial double wrap cigarette 10 of the
present invention but may extend around a circumference of up to 15
mm of the tobacco column in relation to a standard cigarette
dimension. Any combination of the partial inner wrap and outer wrap
may work depending on the variables noted, such as porosity of each
paper, but it is felt that good burn rate characteristics as well
as limited effects to smoke characteristics and flavor may be
achieved by incorporating an inner wrap which covers less than
about 75% or preferably less than about 60% and even more
preferably less than about 35% of the circumference of the outer
wrap. This is a function of the overall cigarette and may vary
depending on the circumference of the outer wrap. However,
variations are available to achieve the same favorable results
utilizing the inventive aspects of the present design and such
descriptions are not felt to be limiting and are exemplary
only.
[0028] Alternatively, many different constructions may be utilized
to provide the cigarette with burn rate modification as set forth
herein. As may be understood, a single inner wrap layer or a
plurality of inner wrap layers may be provided based upon the
desired characteristics and burn rate modification. Thus, as
previously mentioned, combinations of low porosity inner wrap
segments and higher porosity outer wrap segments may be utilized to
provide various linear burn rates which may be desirable. Thus, a
typical linear burn rate of 6.0 mm per minute may be reduced as
desired based upon a combination of porosity of outer wrap and
partial inner wrap strips among other factors and may readily be
reduced to below 4 mm/minute if needed. This includes formulation
of single inner wrap strips of lower porosity or replacement of the
inner wrap strips with various construction material including
reconstituted tobacco, low porosity paper, reconstituted tobacco, a
polymer based material, other paper or material. The inner wrap
strips are coated with binders, such as alginates (e.g., sodium
alginate), guar, xanthum, acacia, pectin, other gums, modified
cellulose compounds or hydrocolloid-based compounds, which act as
burn modifiers or inhibitors and which create at least one low
diffusion area along the tobacco column. The binders decrease the
porosity of the coated reconstituted tobacco sheet, which are used
as inner strips, and provide adequate characteristics such that the
entire combination of outer wrap porosity, tobacco packing density,
inner strip burning characteristics, inner strip porosity, and
other factors cause the cigarette to exhibit a desired burn
rate.
[0029] As shown in FIGS. 4-7, various embodiments may be utilized
in order to create the low porosity zone. As depicted in FIG. 4,
the opened standard outer wrap 12 is lined with a plurality of
inner wrap or inner layer strips 16a, 16b, 16c and 16d. These
strips may be placed equidistantly apart along the interior of the
outer wrap 12 and positioned away from the edges or seam where the
outer wrap is adhered to itself during rolling within the garniture
of the cigarette maker. As depicted, the strips 16a-16d may all be
fed into the garniture and incorporated on the interior of the
outer wrap adjacent the tobacco column. Placement of the partial
inner wrap strips coated with an alginate based compound modifies
the burn rate to a desired level such that the rate may be
decreased sufficiently to cause either a significantly reduced
static burn rate or self-extinguishment at a desired interval.
[0030] As shown in FIG. 5, an inner layer with non-linear sides 17
as compared to the edges of the outer wrap 12 may be utilized as
the partial inner wrap in order to create the low porosity zone. As
shown therein, the inner wrap layer 17 may have be a wave form so
that the placement of the low porosity zone changes in position
along the tobacco column axis. Such non-linear placement of the low
porosity zone may allow for different positioning of the cigarette
during static burn and insure that the desired static burn rate
takes effect regardless of the position of the cigarette.
[0031] Depicted in FIG. 6 is another embodiment of the cigarette
with burn rate modification of the present invention. As seen
therein, a high diffusion area 21 and low diffusion area 22 is
defined by addition of a partial double wrap inner wrap layer 18
which circumscribes a portion of the tobacco column 13 on the
interior of outer wrap 12. The partial inner wrap layer 18, as
depicted in the FIG. 6, extends approximately halfway around the
perimeter of the tobacco column 13. However, many different
configurations may be utilized in order to achieve the appropriate
linear burn rate through the burn rate modification set forth. The
partial double wrap inner wrap layer 18 may be comprised of
standard cigarette paper which has a low porosity of less than 7
CORESTA units or cigarette paper coated with burn rate modifiers,
or may be alternative construction such as a reconstituted tobacco
sheet with or without additives and which typically has a low
CORESTA unit value, typically less than 5 and more preferably less
than 3. A secondary benefit of utilizing reconstituted or
reconstituted tobacco sheets as the partial double wrap inner wrap
layer 18 is that the coloring of the inner wrap may be such that it
is similar to the tobacco column 13 and does not provide a
contrasting whitened area which extends along the low diffusion
area 22. Additionally, a polymer film or other material may be used
as the partial double wrap inner wrap layer 18. It may be
preferable for the partial double wrap inner layer displayed in
FIG. 6 to be 2-14 mm in width or alternatively, less than 75% of
the circumference of the outer wrap in order to obtain the
appropriate burn rate modification desired wherein the linear burn
rate is sustained at a low enough level, preferably below 4.0 mm
per minute.
[0032] As depicted in FIG. 7, an alternative embodiment is
disclosed wherein a plurality of inner wrap strips 19 are utilized
substantially surrounding the tobacco column 13 on the interior of
the outer wrap 12. The plurality of inner wrap strips 19 may be fed
into the garniture adjacent the outer wrap 12 and encircling the
tobacco column 13 as it is formed within the cigarette maker. The
plurality of strips 19 may be comprised of a low porosity cigarette
paper individually fed into the cigarette maker or by a single or
multiple strips fed into the cigarette maker adjacent to the
garniture and cut to the appropriate strip widths. As depicted in
FIG. 7, a plurality of inner wrap strips 19 are utilized and extend
co-axially substantially along the length of the tobacco column 13.
Preferably, the plurality of strips 19 extends along the entire
tobacco column length such as to modify the burn rate along the
entire tobacco column regardless of cigarette positioning. It is
felt that by providing a plurality of strips 19 as depicted in FIG.
7, a more even modification of the burn rate of the cigarette may
be produced.
[0033] As may be appreciated, extending the inner wrap layer
substantially along the length of the tobacco column 13 such that
they are co-axial provides a significant benefit over alternating
rings which are perpendicular to the axis of the tobacco column 13.
Such perpendicular rings which alternate along the length of the
tobacco column may provide a non-linear burn rate of the tobacco
column 13. Thus, in such a design where there are circumscribing
rings around the tobacco column, the linear burn rate becomes
variable between a low linear burn rate to a high linear burn rate
depending upon the porosity of the paper at the point of the rings
as opposed to the porosity of the non-adjusted paper between the
rings. Such non-linear burn rate may in fact be undesirable in that
continued free burning of the tobacco column between the rings for
significant periods of time does not produce an appropriate burn
rate modification which can be depended upon through the entire
tobacco column length. Further, at points where the low porosity
rings are present, a smoker may puff on the cigarette as the
burning of the tobacco column passes over a low porosity ring. At
such a point, it is thought that the deliveries of the cigarette
may be altered significantly to increase the CO and other compounds
provided as the cigarette burns over one of these rings. Thus, the
partial double wrap inner layer of the present invention overcomes
these problems by providing known standard deliveries over the
entire length of the tobacco column while also modifying the burn
rate along the entire co-axial length.
[0034] In the design of the cigarette with the burn rate
modification 10 of the present invention, it may be desirable to
incorporate the inner wrap layers, whether a plurality of strips or
a single layer, away from the seam of the outer wrap 12. As is
known in cigarette manufacturing, the seam 23, depicted in FIG. 1,
is formed by the maker by over-wrapping the side edges 24 of the
outer wrap 12. In typical cigarette manufacturing, an adhesive is
applied along one of the edges 24 prior to folding of the outer
wrap and formation of the tobacco column 13. During manufacturing
of the cigarette with burn rate modification 10 of the present
invention, it is desirable to maintain the partial inner wrap layer
away from the seam portion to assure that the outer wrap 12 is
properly formed and the partial inner wrap layer does not intercede
in the formation of the tobacco column or adhesive of the outer
wrap layer. Thus, as depicted in the embodiments, the partial inner
wrap layers are shown to be placed away from the side edges 24 so
that the inner wrap portions will not interfere with the seam of
the outer wrap 12 nor interfere with the formation of the tobacco
column within the garniture in a typical cigarette manufacturing
machine. Thus, the cigarette with burn rate modification of the
present invention may be implemented on standard cigarette making
machines with only minor modifications made to the paper feeding
devices and no modifications therefore will necessarily be required
within the garniture. It is also apparent that in any of the
embodiments shown herein the strips may be alternatively placed on
the exterior of the cigarette and retained on the wrapper by
adhesives or other means so that there are still formed co-linear
zones of high and low porosity.
[0035] The cigarette with burn rate modification of the present
invention may be designed with variations in outer wrap and inner
wrap paper characteristics. As previously explained, standard outer
wrap designs are such that the typical outer wrap has a linear laid
out width of 27 mm and generally a porosity of between 15 and 80
CORESTA units. As is generally understood, significantly decreasing
the outer wrap porosity changes the deliveries and linear burn rate
of the cigarette. Modification of the standard burn rate for a
normal or typical cigarette may be obtained through addition of a
partial inner wrap to the cigarette. The partial inner wrap may be
a single inner wrap portion or may be a plurality of inner wrap
strips as shown in the various figures. The partial inner wrap may
have paper characteristics with a significantly reduced porosity
such that the inner wrap paper exhibits a porosity of less than 8
CORESTA units. If a single inner wrap strip is utilized, the inner
wrap layer may have a width of between 2-15 mm. The porosity of the
inner wrap layer may be adjusted from any where to 0 to 8 CORESTA
units.
EXAMPLES
[0036] A more comprehensive understanding of the invention can be
obtained by considering the following examples. However, it should
be understood that the examples are not intended to be unduly
limitative of the invention.
Example 1
[0037] Several product examples were made using the construction of
a partial strip wrap or partial inner wrap cigarette using the
inventive techniques and construction described herein. In the
examples, a control cigarette was used having no partial inner wrap
strips which exhibited a linear burn rate of between 4.3-4.7
mm/min. Different materials were utilized, as detailed in the chart
below, for the partial inner wrap strips ranging from standard
treated paper to band cast tobacco material.
[0038] Examples of cigarettes with two band cast inner wrap strips
having a porosity of band cast material less than 5 CORESTA
units:
1 Outer Outer Self Wrapper Wrap Inner Inner Strip Linear Burn
Extinguishment Porosity Citrate Strips Width Rate (LBR) On 10
layers Cig. CORESTA % Number mm mm/min % 1 50 0.5 0 0 4.3 0 2 50
0.5 2 4 3.1 100 3 50 0.5 2 5 2.6 100 4 50 0.5 2 6 2.7 100 5 40 0.7
0 0 4.7 0 6 40 0.7 2 3 3.8 48 7 30 0.6 0 0 4.3 0 8 30 0.6 2 4 3.1
100
[0039] Examples of cigarettes with two cigarette paper strips
treated or covered with sodium alginate having a porosity of inner
strip paper less than 5 CORESTA units:
2 Outer Outer Inner Self Wrapper Wrap Strip Linear Burn
Extinguishment Porosity Citrate Inner Strips Width Rate (LBR) On 10
layers Cig. CORESTA % Number mm mm/min % 9 70 0.6 0 0 4.4 0 10 70
0.6 2 2 3.8 25
[0040] Examples of cigarettes detailing smoke deliveries of two
samples with band cast strips:
3 Outer Outer Inner Self Nico- Wrapper Wrap Inner Strip Linear Burn
Extinguishment tar tine CO Puff Porosity Citrate Strip Width Rate
(LBR) On 10 layers mg/ mg/ mg/ Num- Cig CORESTA % Number mm mm/min
% cig cig cig ber 11 70 0.6 2 4 3.9 90 15.5 1.4 12.2 10.3 12 50 0.5
2 4 3.8 90 14.5 0.9 14.6 7.3
[0041] In the examples presented, it is apparent that the addition
of the partial inner wrap to the cigarette had a definite impact on
linear burn rate and self extinguishment as compared to the control
cigarette. The linear burn rate for the cigarettes using the
present invention was directly affected and evidenced a reduction
in linear burn rate by up to 40 percent. Where inner wrap strips
were utilized having a width of at least 4 mm, all test samples
self extinguished. Narrower width strips had differing results
which could be modified by using alternative additives or
increasing the number of strips. References to the
self-extinguishment of the cigarette on 10 layers are related to
the NIST test for cigarette ignition propensity.
[0042] Smoking Article Including Strips of Reconstituted
Tobacco
[0043] The separate partial inner wrap strips 14 may be strips of
reconstituted tobacco made in accordance with the specific formula
and process for making same as discussed hereinafter. The outer
wrap cigarette paper 12 may be a normal porosity paper which
typically exhibits a porosity of 15-80 CORESTA units. As shown, two
strips 14 of a reconstituted tobacco sheet are provided on opposite
sides of the tobacco column 13 to provide a partial inner wrap
layer. The partial inner wrap layer including the reconstituted
tobacco strips 14 may extend substantially the length of and be
co-axial with the tobacco column 13. In one embodiment, the strips
are placed equidistant from each other such that the resulting
cigarette burns evenly.
[0044] Preparation of a Reconstituted Tobacco Sheet Having
Binder
[0045] FIG. 8 is a flowchart illustrating the modified
reconstituted tobacco process for making split inner wraps. In the
preparation of a reconstituted tobacco sheet for use in a
cigarette, tobacco particles, such as tobacco fines, stems, scraps,
cut lamina, shredded stems, or combinations thereof are slurried in
an aqueous solvent, such as water, wherein the ratio is one part
tobacco to 11-20 parts aqueous solvent. The solution is extracted
at about 160.degree. F. for about 30 minutes. The solution is then
separated into an extract with water soluble compounds and
solid/fibrous portion via separation techniques known in the art,
such as centrifugation or filtration. The solid/fibrous portion is
refined and mixed with over 10% wood pulp, made from wood fibers
that have been refined to a pulp, and an optional second binder,
such as alginate (e.g., sodium alginate), guar, xanthum, acacia,
pectin, other gums, modified cellulose compounds, and hydrocolloid
based compounds. This mixture of solid/fibrous tobacco, wood pulp,
and optional second binder is then made into a reconstituted
tobacco sheet via a paper process known in the art.
[0046] The extract, meanwhile, can optionally be treated with
particular adsorbents to selectively remove undesired constituents.
The extract is then centrifuged and the adsorbent now containing
the constituents is discarded. The extract is then concentrated. A
first binder, such as alginate (e.g. sodium alginate), guar,
xanthum, acacia, pectin, other gums, modified cellulose compounds,
and hydrocolloid-based compounds is added to the extract. Also, a
humectant, such as glycerin, can be added for sheet pliability and
is generally added before the binder and before any additional
flavorant. A desired flavoring can also be added to the
extract.
[0047] The new extract mixture is then reapplied to the preformed
reconstituted tobacco sheet. Optionally, a third binder mix
solution, such as alginate (e.g., sodium alginate), guar, xanthum,
acacia, pectin, other gums, modified cellulose compounds, and
hydrocolloid-based compounds, can be size pressed and/or sprayed
onto the reconstituted tobacco sheet. The reconstituted tobacco
sheet can then be dried and slit into elongated strips of a desired
width and wound onto a bobbin. The elongated strips can be used as
longitudinally extending strips along the outer periphery of a
tobacco rod and the inner surface of an outer paper wrap.
[0048] In a preferred mix, the tobacco is up to about 80% by
weight; the wood pulp is up to about 80% by weight, preferably up
to about 60% by weight; the binder is up to about 30% by weight,
preferably up to about 20% by weight; and, if a flavoring is added,
the flavoring will be up to about 30% by weight, preferably from
about 3% to about 5% by weight.
[0049] The following examples demonstrate the procedure that was
followed in preparing the reconstituted tobacco sheet having a
binder for use in a smoking article.
Example 2
[0050] In the process of making a reconstituted tobacco sheet, 500
pounds of a combination of tobacco and wood pulp (1:3 to 3:1 ratio)
was extracted with 750 gallons of water in a mixing vessel, at
140.degree. C. to 190.degree. C. for 30 to 45 minutes. Following
extraction, the mixture was separated into solids (fiber) and
liquid (extract) streams via centrifugation, filtration, or
pressing.
[0051] The liquid extract was concentrated by vacuum evaporation
and mixed thoroughly with 60 pounds of glycerin. In a separate
vessel, an alginate solution was prepared by thoroughly dispersing
40 pounds of sodium alginate in 135 gallons of water. The
concentrated extract with glycerin was then thoroughly mixed with
the alginate solution. Optionally, the liquid extract was gently
agitated for 20 to 45 minutes with 75 pounds of a powdered solid
adsorbent, such as bentonite (diatomaceous earth), carbon,
cyclodextrin, cellulose acetate, or combinations thereof, to
selectively remove nitrogen and other undesired components. After
agitation, the adsorbent was separated and discarded from the
extract via centrifugation. The extract was then concentrated and
treated with glycerin and alginate as described above.
[0052] Meanwhile, the solid stream was put through a refiner to
fibrillate the fibers into a tobacco-wood pulp. The pulp was then
used to make base sheets over a Fourdriner paper machine wire and
dried. Any of the two concentrated extracts as prepared above were
then added back to the base sheets either via size pressing or
spraying. The finished sheet was finally dried and slit into strips
and wound onto bobbins to be used as split inner wraps.
Example 3
[0053] Sheets were prepared and slit as described in Example 2,
except that the alginate solution was added directly to the base
sheet, instead of being mixed with the concentrated extract. Also,
25 pounds of precipitated chalk or chitosan (inorganic or organic
inert fillers) were added to the refined pulp mixture before making
base sheet over the Fourdriner machine wire. Other inert fillers
include liposan and combinations of chalk, chitosan, and
liposan.
[0054] It is to be understood that the invention is not to be
limited to the specific examples shown, because the parameters set
forth in the examples may be varied by appropriate changes of the
amounts of the constituents within the reconstituted tobacco sheet
mix used in the examples.
* * * * *