U.S. patent application number 14/840178 was filed with the patent office on 2017-03-02 for smoking article.
The applicant listed for this patent is R. J. REYNOLDS TOBACCO COMPANY. Invention is credited to Dwayne William Beeson, Stephen Cole, Billy T. Conner, Evon Llewellyn Crooks, Michael F. Davis, Alvaro Gonzalez-Parra, Paul G. Hoertz, Matthew E. Lampe, Luis Monsalud, John-Paul Mua, Yan PU, Timothy F. Tilley, Karen Womble Wallace, Nicholas Harrison Watson, Samantha S. White, Darrell D. Williams, Karter R. Yutzy.
Application Number | 20170055576 14/840178 |
Document ID | / |
Family ID | 56926296 |
Filed Date | 2017-03-02 |
United States Patent
Application |
20170055576 |
Kind Code |
A1 |
Beeson; Dwayne William ; et
al. |
March 2, 2017 |
SMOKING ARTICLE
Abstract
A smoking article is provided and has opposed lighting and mouth
ends. A mouth end portion is disposed at the mouth end and a heat
generation portion is disposed about the lighting end. An outer
wrapping material is wrapped at least about the heat generation
portion and extends toward the mouth end portion, to define a
cylindrical rod. An aerosol-generating portion is disposed within
the outer wrapping material and between the heat generation and
mouth end portions. The aerosol-generating portion is configured to
generate an aerosol in response to heat received from the heat
generation portion. The aerosol-generating and heat generation
portions are further configured to cooperate to distribute heat
received by the aerosol-generating portion from the heat generation
portion, so as to prevent scorching of the outer wrapping material.
An associated method is also provided.
Inventors: |
Beeson; Dwayne William;
(Kernersville, NC) ; Conner; Billy T.; (Clemmons,
NC) ; Crooks; Evon Llewellyn; (Mocksville, NC)
; Hoertz; Paul G.; (Chapel Hill, NC) ; Monsalud;
Luis; (Kernersville, NC) ; Mua; John-Paul;
(Advance, NC) ; Tilley; Timothy F.; (Pinnacle,
NC) ; Cole; Stephen; (Advance, NC) ; Williams;
Darrell D.; (Winston-Salem, NC) ; White; Samantha
S.; (Thomasville, NC) ; Wallace; Karen Womble;
(Winston-Salem, NC) ; Gonzalez-Parra; Alvaro;
(Advance, NC) ; PU; Yan; (Kernersville, NC)
; Davis; Michael F.; (Clemmons, NC) ; Lampe;
Matthew E.; (Winston-Salem, NC) ; Yutzy; Karter
R.; (Kernersville, NC) ; Watson; Nicholas
Harrison; (Westfield, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R. J. REYNOLDS TOBACCO COMPANY |
Winston-Salem |
NC |
US |
|
|
Family ID: |
56926296 |
Appl. No.: |
14/840178 |
Filed: |
August 31, 2015 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24D 1/02 20130101; A24F
47/006 20130101 |
International
Class: |
A24F 47/00 20060101
A24F047/00; A24D 1/02 20060101 A24D001/02 |
Claims
1. An elongate smoking article having a lighting end and an opposed
mouth end, said smoking article comprising: a mouth end portion
disposed at the mouth end; a heat generation portion disposed about
the lighting end; an outer wrapping material wrapped at least about
the heat generation portion and extending toward the mouth end
portion, so as to define a cylindrical rod; and an
aerosol-generating portion disposed within the outer wrapping
material and between the heat generation portion and the mouth end
portion, the aerosol-generating portion being configured to
generate an aerosol in response to heat received from the heat
generation portion, the aerosol-generating portion and the heat
generation portion being further configured to cooperate to
distribute heat received by the aerosol-generating portion from the
heat generation portion, so as to prevent scorching of the outer
wrapping material.
2. The article of claim 1, wherein the aerosol-generating portion
comprises a rod member having a length and a maximum diameter, and
wherein the rod member has a surface area greater than a surface
area of a right cylinder having a length and a maximum diameter
equal to the length and the maximum diameter, respectively, of the
rod member.
3. The article of claim 1, wherein the aerosol-generating portion
comprises a fluted rod member.
4. The article of claim 3, wherein the fluted rod member defines a
channel extending longitudinally therethrough.
5. The article of claim 3, wherein the fluted rod member is
extruded from a mixture including milled tobacco, calcium
carbonate, binder, glycerin, water, and flavoring.
6. The article of claim 1, wherein the aerosol-generating portion
comprises an aerosol-generating element wrapped by a wrapping
material disposed between the aerosol-generating element and the
outer wrapping material.
7. The article of claim 6, wherein the wrapping material is elected
from the group consisting of a paper-foil sheet laminate, a
paper-foil-paper sheet laminate, a paper-foil-tobacco sheet
laminate, a non-woven graphite sheet, a graphene sheet, a
graphene-foil sheet laminate, a graphene-foil-paper sheet laminate,
a paper-graphene sheet laminate, a graphene ink imprinted on a
paper sheet, a graphene ink imprinted on a foil sheet, carbon
nanotubes engaged with a paper sheet or a foil sheet, fullerenes
engaged with a paper sheet or a foil sheet, and graphene engaged
with a paper sheet or a foil sheet.
8. The article of claim 7, wherein the graphene ink is imprinted
according to a continuous pattern or a discontinuous pattern on the
paper sheet or the foil sheet.
9. The article of claim 7, wherein the paper sheet comprises a
tobacco wrapping paper sheet, and wherein the tobacco sheet
comprises an extruded tobacco sheet, a cast tobacco sheet, or a
reconstituted tobacco sheet.
10. The article of claim 7, wherein the foil sheet comprises a
continuous foil sheet or discrete foil strips.
11. The article of claim 1, further comprising a tobacco portion
disposed within the outer wrapping material, and between the heat
generation portion and the aerosol-generating portion.
12. The article of claim 1, further comprising a tobacco portion
disposed within the outer wrapping material, and between the
aerosol-generating portion and the mouth end portion
13. The article of claim 1, further comprising a non-woven graphite
sheet or a non-woven composite sheet of graphite and graphene
wrapped about a portion of the heat generation portion and about a
portion of the aerosol-generating portion, within the outer
wrapping material, and extending toward the mouth end portion.
14. The article of claim 13, wherein the non-woven graphite sheet
is laminated with the outer wrapping material.
15. The article of claim 1, further comprising a metallic foil
sheet laminated with the outer wrapping material via an adhesive
material therebetween, the adhesive material including therein a
portion of aluminum hydroxide, and the metallic foil sheet being
wrapped about the heat generation portion and about a portion of
the aerosol-generating portion, within the outer wrapping material,
and extending toward the mouth end portion.
16. The article of claim 1, wherein the outer wrapping material
includes therein a portion of aluminum hydroxide, a portion of
magnesium hydroxide, or a portion of calcium carbonate.
17. The article of claim 1, further comprising a glass fiber sheet
wrapped about the heat generation portion and about a portion of
the aerosol-generating portion, within the outer wrapping material,
and extending toward the mouth end portion.
18. The article of claim 1, further comprising a heat conductive
material engaged with the outer wrapping material, the heat
conductive material being disposed within the outer wrapping
material and extending to wrap radially at least partially about
the heat generation portion and longitudinally from the heat
generation portion to the aerosol-generating portion.
19. The article of claim 18, wherein the heat conductive material
comprises a conductive ink imprinted on the outer wrapping
material, a metallic layer deposited on a selected portion of the
outer wrapping material, graphene engaged with the outer wrapping
material, or a carbon material engaged with a selected portion of
the outer wrapping material.
20. The article of claim 1, the aerosol-generating portion is
comprised of a material selected from the group consisting of a
cast sheet of a tobacco material in cut filler form, a sheet of a
reconstituted tobacco material in cut filler form, cut filler
tobacco material treated with glycerin, aerosol-forming beads, a
ceramic material including glycerin, a cast sheet of a non-tobacco
material in cut filler form, a glass fiber mat including a
tobacco-derived nicotine substance, a foil sheet having an aerosol
forming material applied thereto, gathered paper including a
tobacco-derived nicotine substance, a non-tobacco material
including a tobacco-derived nicotine substance, and combinations
thereof.
21. The article of claim 20, wherein the cut filler tobacco
material treated with glycerin includes between about 5% and about
25% glycerin.
22. The article of claim 20, wherein the aerosol-generating portion
includes a first portion and a second portion, the first portion
and the second portion serially disposed between the heat
generation portion and the mouth end portion.
23. The article of claim 20, wherein the aerosol-generating portion
includes a first portion and a second portion, the first portion of
the aerosol-generating portion being comprised of a different
material than the second portion of the aerosol-generating
portion.
24. The article of claim 20, wherein the aerosol-generating portion
includes a first portion and a second portion, the first and second
portions being mixed together to form a single aerosol-generating
element.
25. The article of claim 1, wherein the aerosol-generating portion
comprises a porous ceramic rod member defining at least one conduit
extending longitudinally therethrough.
26. The article of claim 25, wherein the porous ceramic rod member
includes an aerosol former, flavoring, or tobacco extract engaged
therewith.
27. The article of claim 26, wherein the aerosol former comprises
glycerin and the tobacco extract comprises tobacco derived
nicotine.
28. The article of claim 25, wherein the porous ceramic rod member
defines a plurality of longitudinally-extending open channels
angularly spaced apart about an outer surface thereof.
29. The article of claim 1, wherein the aerosol-generating portion
is comprised of aerosol-forming beads serially disposed in relation
to the heat generation portion, and includes a non-tobacco plug
member disposed between the beads and the mouth end portion.
30. The article of claim 1, wherein the aerosol-generating portion
comprises a plurality of rod members extending in parallel with
each other, the rod members being comprised of a tobacco material,
a non-tobacco material, or a ceramic material.
31. The article of claim 1, wherein the heat generation portion
includes a heating element comprised of a carbonized material or a
pyrolyzed material, including an ignitability-enhancing material
selected from the group consisting of carbon, cotton linters, glass
microspheres, a catalyst, and combinations thereof.
32. The article of claim 1, further comprising an overwrap material
wrapped at least about the outer wrapping material wrapped at least
about the heat generation portion, the overwrap material being
embossed so as to be at least partially spaced apart from the outer
wrapping material.
33. The article of claim 1, further comprising a thermochromic ink
material interacted with the outer wrapping material, the
thermochromic ink being configured to provide a visual indicium is
response to the outer wrapping material exceeding a temperature
threshold.
Description
BACKGROUND
[0001] Field of the Disclosure
[0002] The present disclosure relates to products made or derived
from tobacco, or that otherwise incorporate tobacco, and are
intended for human consumption; and more particularly, to
segmented-type smoking articles that yield aerosols having
considerably reduced quantities of incomplete combustion and
pyrolysis products relative to tobacco products that produce smoke
by burning tobacco.
[0003] Disclosure of Related Art
[0004] Popular smoking articles, such as cigarettes, have a
substantially cylindrical rod-shaped structure and include a
charge, roll or column of smokable material, such as shredded
tobacco (e.g., in cut filler form), surrounded by a paper wrapper,
thereby forming a so-called "smokable rod", "tobacco rod" or
"cigarette rod." Normally, a cigarette has a cylindrical filter
element aligned in an end-to-end relationship with the tobacco rod.
Preferably, a filter element comprises plasticized cellulose
acetate tow circumscribed by a paper material known as "plug wrap."
Preferably, the filter element is attached to one end of the
tobacco rod using a circumscribing wrapping material known as
"tipping paper." It also has become desirable to perforate the
tipping material and plug wrap, in order to provide dilution of
drawn mainstream smoke with ambient air. Descriptions of cigarettes
and the various components thereof are set forth in Tobacco
Production, Chemistry and Technology, Davis et al. (Eds.) (1999);
which is incorporated herein by reference. A traditional type of
cigarette is employed by a smoker by lighting one end thereof and
burning the tobacco rod. The smoker then receives mainstream smoke
into his/her mouth by drawing on the opposite end (e.g., the filter
end or mouth end) of the cigarette. Through the years, efforts have
been made to improve upon the components, construction and
performance of smoking articles. See, for example, the background
art discussed in U.S. Pat. No. 7,753,056 to Borschke et al.; which
is incorporated herein by reference.
[0005] Certain types of cigarettes that employ carbonaceous fuel
elements have been commercially marketed under the brand names
"Premier" and "Eclipse" by R. J. Reynolds Tobacco Company. See, for
example, those types of cigarettes described in Chemical and
Biological Studies on New Cigarette Prototypes that Heat Instead of
Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) and
Inhalation Toxicology, 12:5, p. 1-58 (2000). Additionally, a
similar type of cigarette recently has been marketed in Japan by
Japan Tobacco Inc. under the brand name "Steam Hot One."
[0006] Various types of smoking products incorporating carbonaceous
fuel elements for heat generation and aerosol formation recently
have been set forth in the patent literature; and several patent
documents provide a historical perspective of the technology
related to smoking products that deliver aerosols having chemical
compositions that are relatively simple compared to that of
mainstream smoke produced by burning tobacco. See, for example, the
types of smoking products and associated technologies proposed in
U.S. Pat. No. 7,647,932 to Cantrell et al.; U.S. Pat. No. 7,836,897
to Borschke et al.; U.S. Pat. No. 8,469,035 to Banerjee et al.;
U.S. Pat. No. 8,464,726 to Sebastian et al.; U.S. Pat. No.
8,616,217 to Tsuruizumi et al; U.S. Pat. No. 8,678,013 Crooks, et
al.; and U.S. Pat. No. 8,915,255 to Poget et al.; US Pat. Pub. Nos.
2012/0042885 to Stone et al.; and 2013/0133675 to Shinozaki et al.;
PCT WO Nos. 2012/0164077 to Gladden et al.; 2013/098380 to Raether
et al.; 2013/098405 to Zuber et al.; 2013/098410 to Zuber et al.;
2013/104914 to Woodcock; 2013/120849 to Roudier et al.; 2013/120854
to Mironov; WO 2013/162028 to Azegami et al. and 20132/1600112 to
Saleem et al.; EP 1808087 to Baba et al. and EP 2550879 to
Tsuruizumi et al.; which are incorporated herein by reference.
[0007] It would be highly desirable to provide smoking articles
that demonstrate the ability to provide to a smoker much of the
enjoyment of conventional cigarette smoking, without delivering
aerosol that incorporates considerable quantities of incomplete
combustion and pyrolysis products.
BRIEF SUMMARY OF THE DISCLOSURE
[0008] The above and other needs are met by aspects of the present
disclosure which, in one aspect, provides an elongate smoking
article having a lighting end and an opposed mouth end, wherein
such a smoking article comprises a mouth end portion disposed at
the mouth end, and a heat generation portion disposed about the
lighting end. An outer wrapping material is wrapped at least about
the heat generation portion and extends toward the mouth end
portion, so as to define a cylindrical rod. An aerosol-generating
portion is disposed within the outer wrapping material and between
the heat generation portion and the mouth end portion, wherein the
aerosol-generating portion is configured to generate an aerosol in
response to heat received from the heat generation portion, and
wherein the aerosol-generating portion and the heat generation
portion are further configured to cooperate to distribute heat
received by the aerosol-generating portion from the heat generation
portion, so as to prevent scorching of the outer wrapping
material.
[0009] As such, aspects of the present disclosure provide a smoking
article, and in particular, a rod-shaped or elongate smoking
article, such as a cigarette. The smoking article includes a
lighting end (i.e., an upstream end) and a mouth end (i.e., a
downstream end), each positioned at opposite ends thereof. The
smoking article also includes an aerosol-generating system that
comprises: (i) a heat generation region, portion, or segment, and
(ii) an aerosol-generating region, portion, or segment located
downstream from the heat generation segment. The heat generation
segment incorporates a relatively short (longitudinally-extending)
heat source or fuel element (i.e., a heat generation element);
comprised of a material such as, for example, a relatively clean
burning carbonaceous material. The aerosol-generating segment most
preferably includes a substrate region, and in certain embodiments
the substrate region incorporates pellets or beads formed from
tobacco that are disposed within a substrate cavity. Alternatively,
for example, the substrate region incorporates material that
includes reconstituted type tobacco (e.g., a shredded cast sheet
type of material). The substrate cavity or substrate region where
the substrate material is located is preferably circumscribed along
the longitudinally extending length of the smoking article by a
metal foil (e.g., heat conducting) layer or strip laminated to a
paper-type wrapping material. A substrate that is comprised, at
least in part of tobacco, acts as a carrier and source of
aerosol-forming materials.
[0010] In certain aspects, the present disclosure provides an
elongate smoking article that comprises a mouth end segment,
region, or portion disposed at the mouth end, and a tobacco rod
segment, region, or portion (or other suitably configured segment)
disposed between the lighting end and the mouth end portion. An
aerosol-generating system is located as a segment disposed between
the heat generation segment and the mouth end portion. That is, the
aerosol-generating segment is longitudinally disposed adjacent to a
heat generation portion or segment disposed at the lighting end;
and those two segments are in a heat exchange relationship such
that heat produced by combustion of components of the heat
generation segment acts upon aerosol forming components of the
aerosol-generating segment, and results in the production of
aerosol. The longitudinally extending outer surfaces of the heat
generation and aerosol-generating segments are circumscribed by an
outer wrapping material so as to provide a rod that is in turn
attached to the mouth end segment. A layer of heat conductive
material is disposed beneath the outer wrapping material so as to
provide an outer internal surface of the aerosol-generating
segment. The heat conductive layer most preferably overlies the
outer longitudinal surface of heat generation segment in the region
thereof adjacent to the aerosol-generating segment; and the heat
conductive layer optionally can overlie the outer longitudinal
surface of the tobacco rod segment in the region thereof adjacent
the aerosol-generating segment. Certain materials within the
aerosol-generating segment generate aerosol upon the action of and
in response to heat produced by a burning fuel element of the heat
generation segment.
[0011] In certain aspects, the fuel element or heat source of the
heat generation segment may incorporate a material that may be
characterized as a carbonized or pyrolyzed material derived from
the carbonization or pyrolysis of cotton material. In this regard,
it may be preferable and/or desirable for the fuel element/heat
source to be ignited and remain burning (i.e., smoldering), but
without emitting a flame, during consumption of the smoking
article, while producing sufficient heat for actuating the
aerosol-generating segment to produce the aerosol. As such, aspects
of the present disclosure may be directed to, for example, a fuel
element/heat source configured or arranged to facilitate ready
ignition or lightability thereof. In some instances, existing fuel
elements/heat sources comprised of conventional materials may be
optimized to produce the desired ignition/lightability
characteristics for the smoking article. In other instances, other
substances, such as additives (i.e., test carbons or cotton
linters) and/or catalysts may be included in existing fuel
elements/heat sources comprised of conventional materials in order
to enhance the ignition/lightability characteristics thereof.
Representative aspects of such fuel elements/heat sources are
disclosed, for example, in U.S. patent application Ser. No.
14/755,205 to Nordskog et al., which is incorporated herein by
reference in its entirety.
[0012] In certain aspects, the substrate region (aerosol-generating
system) incorporates a form of tobacco that forms tobacco smoke
exhibiting desirable sensory attributes. For example, the substrate
region can be comprised of a mixture of: (i) pellets or beads
comprised of tobacco, which pellets and beads act as carriers for
an aerosol forming material, such as glycerin (i.e., the aerosol
forming material may be included or otherwise incorporated into the
beads/pellets or brought into contact with the beads/pellets and
sealed thereto by a gelling agent/sealant for maintaining the
integrity of the aerosol forming material with the bead/pellet
until exposed to heat during use); and (ii) a form of tobacco that
forms tobacco smoke exhibiting desirable sensory attributes.
Alternatively, for example, the substrate region can be comprised
of a mixture of: (i) pieces or parts of a cast sheet type of
reconstituted tobacco material that act as carriers for an aerosol
forming material, such as glycerin; and (ii) a form of tobacco that
forms tobacco smoke exhibiting desirable sensory attributes. In
particular aspects, the substrate region/aerosol-generating system,
discretely or in cooperation with the heat generation segment, may
be configured to more uniformly or efficiently transfer and
distribute the heat directed from the heat generation segment to
the substrate region/aerosol-generating system. Preferably, such
increased uniformity or efficiency in the transfer and distribution
of the heat directed from the heat generation segment to the
substrate region/aerosol-generating system also advantageously
reduces, minimizes or eliminates scorching of the outer wrapping
material of the smoking article. In addition, such increased
uniformity or efficiency in the transfer and distribution of the
heat directed from the heat generation segment to the substrate
region/aerosol-generating system may also reduce scorching of the
substrate region/aerosol-generating system itself, or at least
facilitate a reduction or minimization of adverse sensory effects,
caused by scorching of the substrate, on the aerosol inhaled and
experienced by the user.
[0013] Further features and advantages of the present disclosure
are set forth in more detail in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0015] FIG. 1 schematically illustrates a longitudinal
cross-sectional view of a representative smoking article, according
to one aspect of the disclosure;
[0016] FIG. 2 schematically illustrates a longitudinal
cross-sectional view of a representative deconstructed smoking
article, according to another aspect of the disclosure;
[0017] FIG. 3 schematically illustrates a longitudinal
cross-sectional view of a representative deconstructed smoking
article, according to yet another aspect of the disclosure; and
[0018] FIGS. 4 and 5 schematically illustrate aerosol-generating
substrate elements, according to alternate aspects of the
disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0019] The present disclosure now will be described more fully
hereinafter with reference to the accompanying drawings, in which
some, but not all aspects of the disclosure are shown. Indeed, the
disclosure may be embodied in many different forms and should not
be construed as limited to the aspects set forth herein; rather,
these aspects are provided so that this disclosure will satisfy
applicable legal requirements. Like numbers refer to like elements
throughout.
[0020] FIG. 1 illustrates a representative smoking article 10 in
the form of a cigarette, according to one aspect of the present
disclosure. Preferably, the smoking article 10 has the overall
size, shape and general appearance of a filtered cigarette. The
smoking article 10 has a rod-like shape, and includes a lighting
end 14 and a mouth end 18. At the lighting end 14 is positioned a
longitudinally-extending, generally cylindrical, heat generation
segment 35. The heat generation segment 35 includes a heat source
40 circumscribed by insulation 42, which most preferably is
coaxially encircled by an outer wrapping material 45. The heat
source 40 preferably is configured to be activated by direct
ignition of the lighting end 14. That is, the heat source or fuel
element is designed to be lit so as to burn or smolder, and hence
produce heat. The smoking article 10 also includes a filter segment
55 located at the opposing end (i.e., mouth end 18), and an
aerosol-generating segment 61 that is located in between the filter
segment and the heat source.
[0021] The heat generation segment 35 most preferably includes a
combustible fuel element 40 that has a generally cylindrical shape
and incorporates a combustible carbonaceous material. Such
combustible carbonaceous materials generally have high carbon
content. Preferred carbonaceous materials are comprised
predominantly of carbon, typically have carbon contents of greater
than about 60 percent, generally greater than about 70 percent,
often greater than about 80 percent, and frequently greater than
about 90 percent, on a dry weight basis. Such combustible fuel
elements can incorporate components other than combustible
carbonaceous materials (e.g., tobacco components, such as powdered
tobaccos or tobacco extracts; flavoring agents; salts, such as
sodium chloride, potassium chloride and sodium carbonate; heat
stable graphite fibers; iron oxide powder; glass filaments;
powdered calcium carbonate; alumina granules; ammonia sources, such
as ammonia salts; and/or binding agents, such as guar gum, ammonium
alginate and sodium alginate). A representative fuel element, for
example, has a length of about 12 mm and an overall outside
diameter of about 4.2 mm. A representative fuel element can be
extruded or compounded using a ground or powdered carbonaceous
material, and has a density that is greater than about 0.5
g/cm.sup.3, often greater than about 0.7 g/cm.sup.3, and frequently
greater than about 1 g/cm.sup.3, on a dry weight basis.
[0022] Layered insulation 42 can be comprised of glass filaments or
fibers. The insulation 42 can act as a jacket that assists in
maintaining the heat source 40 firmly in place within the smoking
article 10 (i.e., disposed between the heat source and the outer
wrapping material so as to secure the heat source within the outer
wrapping material). Preferably, the insulation is provided in the
form of a non-woven mat of glass filaments. The insulation 42 can
be provided as a multi-layer component, for example, including an
inner layer or mat 67 of non-woven glass filaments, an intermediate
layer of reconstituted tobacco paper 68, and an outer layer of
non-woven glass filaments 69. These layers may be concentrically
oriented or each overwrapping and/or circumscribing the heat source
in a continuous overlapping manner.
[0023] Preferably, both ends of the heat generation segment 35 are
open to expose at least the heat source 40 and insulation 42 at the
lighting end 14. The heat source 40 and the surrounding insulation
42 can be configured so that the length of both materials is
co-extensive (i.e., the ends of the insulation 42 are flush with
the respective ends of the heat source 40, and particularly at the
downstream end of the heat generation segment). Optionally, though
not necessarily preferably, the insulation 42 can extend slightly
beyond (e.g., from about 0.5 mm to about 2 mm beyond) either or
both ends of the heat source 40. Moreover, heat and/or heated air
produced when the lighting end 14 is ignited during use of the
smoking article 10 can readily pass through the heat generation
segment 35 during draw by the smoker on the mouth end 18, through
the heat source 40 itself (i.e., through a longitudinal channel
extending through the heat source 40) and/or longitudinally through
the insulation 42.
[0024] Preferably, an outer wrapping material 75 circumscribes the
insulation 42 over the longitudinally extending outermost surface
of the lighting end 14 of the smoking article 10. That outer
wrapping material 75 typically is a paper wrapping material, such
as, for example, the type of paper wrapping materials used to as
the circumscribing wrapping materials of the insulation regions of
the heat source segments of the cigarettes marketed under the trade
names "Premier" and "Eclipse" by R. J. Reynolds Tobacco Company. As
such, the "outer wrapping material 75" may also be referred to as
the "outer wrapping paper 75" to indicate such aspects, but without
limiting the outer wrapping material 75 to a paper wrapping
material.
[0025] The heat generation segment 35 preferably is positioned with
one end disposed at or very near the extreme lighting end 14, and
is axially aligned in an end-to-end serial relationship with a
downstream aerosol-generating segment 61, preferably abutting one
another, and preferably with no barrier (other than open air-space)
therebetween. The close proximity of the heat generation segment 35
to the lighting end 14 provides for direct ignition of the heat
source 40 of the heat generation segment 35.
[0026] The cross-sectional shape and dimensions of the heat
generation segment 35, prior to burning during use, can vary.
Preferably, the cross-sectional area of the fuel element/heat
source 40 makes up about 10 percent to about 35 percent, often
about 15 percent to about 25 percent of the total cross-sectional
area of the heat generation segment 35; while the cross-sectional
area of the outer or circumscribing region (comprising the
insulation 42 and relevant outer wrapping materials) makes up about
65 percent to about 90 percent, often about 75 percent to about 85
percent of the total cross-sectional area of the heat generation
segment 35. For example, for a cylindrical smoking article 10
having a circumference of about 24 mm to about 26 mm, a
representative fuel element/heat source 40 has a generally circular
cross-sectional shape with an outer diameter of about 2.5 mm to
about 5 mm, often about 3 mm to about 4.5 mm.
[0027] The components of the heat generation segment can vary. One
component of the heat generation segment is the fuel element.
Suitable fuel elements typically comprise carbonaceous materials
that possess high carbon contents, and also can include ingredients
such as graphite and/or alumina. Carbonaceous fuel elements include
those types of components and configurations that have been
incorporated within those cigarettes commercially marketed under
the trade names "Premier," "Eclipse" and "Steam Hot One."
Additionally, representative types of heat generation segments,
fuel element features, and representative components, designs and
configurations thereof, as well as manners and methods for
producing those heat generation segments and fuel elements
therefor, are set forth in U.S. Pat. No. 4,714,082 to Banerjee et
al.; U.S. Pat. No. 4,756,318 to Clearman et al.; U.S. Pat. No.
4,881,556 to Clearman et al.; U.S. Pat. No. 4,989,619 to Clearman
et al.; U.S. Pat. No. 5,020,548 to Farrier et al.; U.S. Pat. No.
5,027,837 to Clearman et al.; U.S. Pat. No. 5,067,499 to Banerjee
et al.; U.S. Pat. No. 5,076,297 to Farrier et al.; U.S. Pat. No.
5,099,861 to Clearman et al.; U.S. Pat. No. 5,105,831 to Banerjee
et al.; U.S. Pat. No. 5,129,409 to White et al.; U.S. Pat. No.
5,148,821 to Best et al.; U.S. Pat. No. 5,156,170 to Clearman et
al.; U.S. Pat. No. 5,178,167 to Riggs et al.; U.S. Pat. No.
5,211,684 to Shannon et al.; U.S. Pat. No. 5,247,947 to Clearman et
al.; U.S. Pat. No. 5,345,955 to Clearman et al.; U.S. Pat. No.
5,461,879 to Barnes et al.; U.S. Pat. No. 5,469,871 to Barnes et
al.; U.S. Pat. No. 5,551,451 to Riggs; U.S. Pat. No. 5,560,376 to
Meiring et al.; U.S. Pat. No. 5,706,834 to Meiring et al.; U.S.
Pat. No. 5,727,571 to Meiring et al.; U.S. Pat. No. 7,836,897 to
Borschke et al.; U.S. Pat. No. 8,617,263 to Banerjee et al. and
U.S. Pat. No. 8,678,013 to Crooks; and U.S. Pat. App. Pub. Nos.
2005/0274390 to Banerjee et al.; 2007/0215168 to Banerjee et al.;
2012/0042885 to Stone et al.; 2013/0269720 to Stone et al.; and
2015/0083150 to Conner et al.; which are incorporated herein by
reference. See also, the types of fuel element configurations and
components thereof that are described in U.S. Pat. No. 4,819,655 to
Roberts et al. and U.S. Pat. App. Pub. No. 2009/0044818 to Takeuchi
et al.; which are incorporated herein by reference.
[0028] Certain fuel elements can contain high carbon content
carbonaceous material that is obtained from cotton-containing fiber
(e.g., cotton linters) that have been carbonized or pyrolyzed. For
descriptions of cotton linter materials that have been carbonized
or pyrolyzed, and manners and methods that those materials have
been incorporated into smoking articles, carbonized smoking
materials, and fuel elements, see for example, U.S. Pat. No.
4,219,031 to Rainer et al.; U.S. Pat. No. 4,920,990 to Lawrence et
al.; U.S. Pat. No. 5,007,440 to Robinson et al.; U.S. Pat. No.
5,060,673 to Lehman; U.S. Pat. No. 5,129,409 to White et al.; U.S.
Pat. No. 5,211,684 to Shannon et al.; and U.S. Pat. No. 8,119,555
to Banerjee et al.; which are incorporated herein by reference. The
fuel element of the heat generation segment most preferably is
circumscribed or otherwise jacketed by insulation, or other
suitable material. The insulation can be configured and employed so
as to support, maintain and retain the fuel element in place within
the smoking article. The insulation may additionally be configured
such that drawn air and aerosol can pass readily therethrough.
Suitable insulation assemblies have been incorporated within those
types of cigarettes commercially marketed under the trade names
"Premier," "Eclipse" "Steam Hot One." Examples of insulation
materials, components of insulation assemblies, configurations of
representative insulation assemblies within heat generation
segments, wrapping materials for insulation assemblies, and manners
and methods for producing those components and assemblies,
additionally are set forth in U.S. Pat. No. 4,807,809 to Pryor et
al.; U.S. Pat. No. 4,893,637 to Hancock et al.; U.S. Pat. No.
4,938,238 to Barnes et al.; U.S. Pat. No. 5,027,836 to Shannon et
al.; U.S. Pat. No. 5,065,776 to Lawson et al.; U.S. Pat. No.
5,105,838 to White et al.; U.S. Pat. No. 5,119,837 to Banerjee et
al.; U.S. Pat. No. 5,247,947 to Clearman et al.; U.S. Pat. No.
5,303,720 to Banerjee et al.; U.S. Pat. No. 5,345,955 to Clearman
et al.; U.S. Pat. No. 5,396,911 to Casey, III et al.; U.S. Pat. No.
5,546,965 to White; U.S. Pat. No. 5,727,571 to Meiring et al.; U.S.
Pat. No. 5,902,431 to Wilkinson et al.; U.S. Pat. No. 5,944,025 to
Cook et al.; U.S. Pat. No. 8,424,538 to Thomas et al.; U.S. Pat.
No. 8,464,726 to Sebastian et al. and U.S. Pat. No. 8,678,013
Crooks et al.; which are incorporated herein by reference.
[0029] A longitudinally extending, generally cylindrical
aerosol-generating segment 61 is located downstream from the heat
generation segment 35. The aerosol-generating segment 61 includes a
substrate element 85 comprising a material that is itself an
aerosol-forming agent or aerosol-forming substance, or otherwise
acts as a carrier for an aerosol-forming agent or material (not
shown). For example, the aerosol-generating segment can include a
reconstituted tobacco material that includes processing aids,
flavoring agents, and/or glycerin. The foregoing components of the
aerosol-generating segment can be disposed within, and
circumscribed by, a wrapping material 90. The wrapping material 90
can be configured to facilitate the transfer of heat from the
lighting end 14 of the smoking article 10 (e.g., from the heat
generation segment 35) to components of the aerosol-generating
segment 61. That is, the aerosol-generating segment and the heat
generation segment can be configured in a heat exchange
relationship with one another, wherein such a heat exchange
relationship can be facilitated by the wrapping material 90. The
heat exchange relationship is such that sufficient heat from the
heat source 40 is supplied to the aerosol-generating segment 61 to
volatilize aerosol-forming material (i.e., associated with the
substrate element 85) for aerosol formation and generation. In some
instances, the wrapping material 90 may be a discrete component in
relation to the outer wrapping material 75, or may be engaged with
the outer wrapping material 75 in various manners. In other
instances, the wrapping material 90 may comprise an insulating
material for insulating the substrate element 85 from the outer
wrapping material 75. For example, the wrapping material 90 may
comprise a glass fiber mat having a thickness of between about 50
.mu.m and about 500 .mu.m.
[0030] In one aspect of the present disclosure, the heat exchange
relationship is achieved by serially positioning the heat
generation and aerosol-generating segments 35, 61 in proximity to
one another. In some instances, those segments may be serially
arranged in end-to-end contact with each other. A heat exchange
relationship also can be achieved by extending a heat conductive
material from the vicinity of the heat source 40 into and/or around
the region occupied by the aerosol-generating segment 61. For
example, in one aspect, a representative wrapping material 90 for
the substrate element 85 can include heat conductive elements or
properties for conducting heat from the heat generation segment 35
to the aerosol-generating segment 61 (and/or maintaining the heat
in interaction with the aerosol-generating segment 61 along a
length thereof), in order to provide for the volatilization of the
aerosol forming components contained therein (i.e., in association
with the substrate element 85). In other aspects, the
representative wrapping material 90 and/or the outer wrapping
material 75 may include heat conductive properties for dissipating
heat not directed from the heat generation segment 35 to the
aerosol-generating segment 61, and/or for uniformly or more
consistently distributing heat between the heat generation segment
35 and the aerosol-generating segment 61, while still providing for
the volatilization of the aerosol forming components contained in
the aerosol-generating segment 61 or associated with the substrate
element 85. Such a wrapping material 90 can be provided by a
laminated paper/foil sheet, for example, comprised of an outer
layer 94 of a paper-type material sheet and an inner layer 96 of a
heat conductive metallic foil sheet. The metal foil sheet 96 can,
for instance, extend from a region downstream from the heat source
40, and along at least a portion of the length of the
aerosol-generating segment 61. The metal foil/inner layer 96
laminate can be associated with the outer layer 94 in the form of
one or more discrete, longitudinally-extending strips affixed to
the outer layer 94, or in the form of a continuous sheet that
cooperates with the outer layer 94 to circumscribe the noted region
overlapping the heat generation and aerosol-generating segments 35,
61.
[0031] In aspects of the disclosure implementing the wrapping
material 90, the heat conductive provision thereof may be
accomplished in various manners. Generally, the wrapping material
90, in the form of a laminated paper/foil sheet, may have a typical
length (i.e., along the aerosol-generating segment 61) of between
about 8 mm and about 50 mm for a representative smoking article of
the type described herein. The laminated paper/foil sheet can be
perforated, etched, embossed or primed, for example, to enhance
ease of manufacturing. In some instances, the thickness of the foil
used in the laminate can be varied or increased/decreased as
necessary or desired, for example, between about 0.0001 inches and
0.005 inches, in order to alter performance of the laminated
paper/foil sheet and/or to reduce visual scorching of the paper
sheet portion (i.e., outer layer 94) of the laminate and/or the
outer wrapping paper 75 wrapped about the wrapping paper 90 and/or
the aerosol-generating segment 61.
[0032] The laminated paper/foil sheet can be formed in different
manners. For example, a heat conductive ink (in some instances, a
heat conductive metallic ink) may be used to print on the paper
portion such that the printed ink forms a foil layer (sheet or
strip) on the paper portion (and/or may be at least partially
absorbed into/integrated with the paper portion). Such a heat
conductive ink may include, for example, carbon, graphite,
graphene, silver, or any other suitable heat or thermally
conductive material or combinations thereof, to conduct heat along
the paper portion, with the conducted heat, in turn, heating the
substrate element to generate an aerosol therefrom. Preferably,
such heat conductive inks can be printed according to a continuous
pattern or a discontinuous pattern on foil sheets or conventional
cigarette papers, with basis weights of the cigarette paper ranging
from about 20 gsm to about 100 gsm.
[0033] In other instances, a heat or thermally conductive material
such as, for example, a metallic foil (i.e., silver), a conductive
carbon material (i.e., graphene), or any other suitable heat
conductive material or combinations thereof, may be deposited on or
otherwise attached in various configurations (i.e., discrete strip,
full sheet, complete coating, etc.) to a conventional cigarette
paper, e.g., using a "island placement" or selective
deposition/engagement technology, for example, to facilitate ease
of manufacturing and to enhance functionality. In any instance, the
implementation of the laminated paper/foil sheet as the wrapping
paper 90 may, in some cases, dissipate or redirect heat produced by
the heat generation segment 35 to reduce scorching of the outer
wrapping paper 75 and/or other components of the smoking article.
As such, the elimination of scorching may improve the taste or
sensory perception of the generated aerosol to the user. That is,
scorched materials may impart an undesirable taste or sensory
perception to the generated aerosol, and reduction, minimization,
or elimination of such scorching may, for example, improve the
taste of the aerosol to the user, and remove undesirable visual
effects caused by such scorching. Accordingly, aspects of the
present disclosure involve arrangements for more completely and
efficiently directing and distributing the heat generated by the
heat generation segment 35 and directed to the aerosol-generating
segment 61, without scorching the substrate element 85, the outer
wrapping paper 90, or other components that contribute to or
otherwise affect the aerosol drawn and experienced by the user. In
addition, since the aerosol-generating segment 61 may, in some
instances, include glycerin or other leachable substances, the
various aspects of the wrapping material 90 disclosed herein may
also be directed to preventing or minimizing leaching of the
glycerin or other leachable substances from the aerosol-generating
segment 61 to the outer wrapping paper 75. That is, aspects of the
present disclosure may include a wrapping material 90 configured to
prevent or minimize discoloration of the outer wrapping paper 75
which may be caused by glycerin or another leachable substance
leaching from the aerosol-generating segment 61.
[0034] In some aspects, the wrapping paper 90 may comprise a
cigarette paper/foil/tobacco paper in a tri-laminate sheet form,
wherein such a tri-laminate sheet configuration may further
facilitate improvement in the taste or sensory perception of the
generated aerosol experienced by the user, for example, by
reducing, minimizing or eliminating scorching or charring of
particular components of the smoking article, and by directing more
of the heat toward the aerosol-generating segment 61. The tobacco
paper/sheet composition may vary and can be comprised of and
include different ratios, for example, of burley tobacco, flue
cured tobacco, oriental tobacco, or any other suitable type of
tobacco or combinations thereof. The tobacco inclusion in the
tobacco paper/sheet may be up to about 85% tobacco, and the tobacco
paper/sheet may have a basis weight ranging from about 20 gsm to
about 100 gsm. In some instances, the tri-laminate form of the
wrapping paper 90 may be comprised of tobacco paper/foil/tobacco
paper, as necessary or desired. In other instances, a bi-laminate
of tobacco paper/foil may be implemented, wherein the tobacco sheet
can be laminated to an aluminum or other heat-conductive foil
having a thickness ranging from about 0.0005 inches to about 0.002
inches, wherein such a bi-laminate sheet may exhibit a basis weight
of between about 60 gsm and about 100 gsm.
[0035] According to yet further aspects, wrapping paper 90 may be
configured as any of a paper-foil sheet laminate, a
paper-foil-paper sheet laminate, a paper-foil-tobacco sheet
laminate, a non-woven graphite sheet, a non-woven graphite and
graphene composite sheet, a graphene sheet, a graphene-foil sheet
laminate, a graphene-foil-paper sheet laminate, a paper-graphene
sheet laminate, a graphene ink imprinted on a paper sheet, a
graphene ink imprinted on a foil sheet, carbon nanotubes engaged
with a paper sheet or a foil sheet, fullerenes engaged with a paper
sheet or a foil sheet, and graphene engaged with a paper sheet or a
foil sheet. In such instances, for example where graphene comprises
one of the outer layers of the laminate, it may be desirable for
the graphene layer of the laminate to provide the initial layer of
the laminate closest to the substrate element 85. In other
instances, for example, in the case of a graphene-foil sheet
laminate, it may be desirable for the foil sheet layer of the
laminate to provide the initial layer of the laminate closest to
the substrate element 85, while the graphene layer functions as a
heat shield between the substrate element 85 and the outer wrapping
material 75, or the order could be reversed, wherein the graphene
layer of the laminate is the initial layer of the laminate closest
to the substrate element 85, while the foil sheet layer functions
as a heat shield between the substrate element 85 and the outer
wrapping material 75. In instances where the wrapping paper 90
comprises a heat conducting layer and a paper sheet or foil sheet,
an insulating layer or thermal layer may be disposed
therebetween.
[0036] In aspects implementing the imprinting, for example, of a
graphene ink, the ink may be applied using a variety of printing
processes such as, for instance, gravure printing, flexographic
printing, off-set printing, screen printed, ink-jet printing, or
other appropriate printing method, in order to provide varying
thicknesses, patterns, surface coverage, and composition
gradients.
[0037] In other aspects, a graphene foil or graphene conductive
sheet can be placed between the cigarette paper (i.e., the outer
wrapping material 75) and the aluminum foil (i.e., the foil sheet
layer associated with the wrapping paper 90) to create a
paper/graphene/foil laminate structure encompassing the outer
wrapping material 75 and the wrapping paper 90. In such an
instance, the graphene portion could be entirely encased (i.e.,
between inner and outer layers) to prevent or minimize material
transfer or migration therefrom during product manufacturing and
usage, which may also prevent or minimize any leaching of glycerin
from the substrate element 85 to the outer wrapping material 75.
One skilled in the art will appreciate, however, that the wrapping
material 90 configured to accomplish the purposes herein may be
structured and composed in many different manners in addition to
the various configurations disclosed herein, and that these
exemplary configurations are not intended to be limiting in this
regard.
[0038] The outer wrapping paper 75 is generally configured to wrap
around the heat generation segment 35 and to extend longitudinally
(downstream) so as to wrap about the aerosol-generating segment 61
and along at least a portion of the length thereof. In so being
engaged to wrap about the noted components of the smoking article,
the outer wrapping paper 75 also extends over the interface between
the heat generation segment 35 and the aerosol-generating segment
61 and, as such, may also desirably exhibit no scorching or minimal
scorching propensities (as well as anti-leaching propensities). As
such, in some aspects of the present disclosure, the outer wrapping
paper 75 may be treated with, interacted with, or otherwise exposed
to, for example, calcium carbonate (CaCO.sub.3), aluminum
hydroxide, magnesium hydroxide, and/or combinations thereof as
fillers in the paper matrix of the outer wrapping paper 75 at least
as anti-scorching agents.
[0039] One skilled in the art will also appreciate that the
wrapping paper 90 and/or the outer wrapping material 75, when
wrapped about the appropriate components of the smoking article,
may have the opposing ends thereof (i.e., the angularly overlapping
ends forming a longitudinally extending seam along the smoking
article) sealed together, for example, by an adhesive material.
Accordingly, in some aspects of the disclosure, the adhesive
material may also include a filler such as, for example, calcium
carbonate (CaCO.sub.3), aluminum hydroxide, magnesium hydroxide,
and/or combinations thereof, in order to reduce, minimize or
eliminate scorching or charring of the adhesive material and/or the
outer wrapping material 75 along the longitudinally-extending seam
of the outer wrapping material 75 wrapped about the components of
the smoking article.
[0040] The substrate element 85 forming part of the
aerosol-generating segment 61 can incorporate tobacco. More
particularly, if incorporating tobacco, the substrate element 85
can be comprised of a blend of flavorful and aromatic tobaccos, for
example, in cut filler form. Those tobaccos, in turn, can be
treated with an aerosol-forming material and/or at least one
flavoring agent. The substrate element 85 can also be comprised of
a processed tobacco (e.g., a reconstituted tobacco manufactured
using cast sheet or papermaking types of processes) in cut filler
form. Certain cast sheet constructions may include about 270 mg to
about 300 mg of tobacco per 10 mm of linear length of the cast
sheet. In other instances, the substrate element 85 can be
comprised of a mixture of formed tobacco pellets. In particular
aspects of the disclosure, the substrate element 85 comprised of a
form of tobacco, in turn, can be treated with, or processed to
incorporate, an aerosol-forming material and/or at least one
flavoring agent, as well as a burn retardant (e.g., diammonium
phosphate, other similar type of salt, and/or other suitable burn
retardant materials). The inclusion of the burn retardant material
in the substrate element may be configured to prevent ignition of
the material forming the substrate and/or to prevent scorching of
the substrate element by the heat-generation segment. Additionally,
the metallic inner layer or surface 96 of the wrapping
material/outer layer 94 of the aerosol-generating segment 61 can
act as a carrier for aerosol-forming material, tobacco components
and/or at least one flavoring agent.
[0041] As used herein, the term "tobacco pellets" is meant to
include beads, pellets, or other discrete small units of tobacco
that has been formed, shaped, compressed, extruded, or otherwise
fashioned into a desired shape. For example, tobacco pellets can be
formed using a so-called marumarizing process. Tobacco pellets may
have smooth, regular outer shapes (e.g., spheres, cylinders,
ovoids, etc.) and/or they may have irregular outer shapes. In one
example, the diameter of each tobacco pellet may range from less
than about 1 mm to about 2 mm. The tobacco pellets may at least
partially fill a substrate cavity of a smoking article, as
described herein. That is, the substrate element 85 may take the
form of pellets or other loose objects that occupy a space within
the aerosol-generating segment 61 adjacent to and downstream of the
heat generation segment 35. In one example, the volume of the
substrate cavity may range from about 500 mm.sup.3 to about 700
mm.sup.3 (e.g., a substrate cavity of a smoking article where the
cavity diameter is about 7.5 to about 7.8 mm, and the cavity length
is about 11 to about 15 mm, with the cavity having a generally
cylindrical geometry). In one example, the mass of the tobacco
pellets within the substrate cavity may range from about 200 mg to
about 500 mg. For example, the tobacco pellets can be employed so
as to fill the appropriate section of the aerosol-generating
segment 61 (e.g., the cylindrical region within the wrapping
material thereof and bound by the ends of the heat generation
segment 35 and the filter segment 55) at a packing density of about
100 to about 400 mg/cm.sup.3.
[0042] The configuration and arrangement of the substrate element
85 can vary according to various aspects of the present disclosure.
In one aspect, the substrate element 85 may be formed as a
monolithic or integrated structure via, for instance, an extrusion,
molding, or casting process. In some preferred aspects, the
monolithic substrate element 85 may include tobacco or products of
tobacco. For example, in one aspect, the monolithic substrate
element 85, formed in an extrusion process, may include glycerin,
milled tobacco, calcium carbonate, binder, flavorings, and water.
More particularly, on a dry weight basis, the extrudate material
may comprise about 37.86% milled tobacco, about 39.82% calcium
carbonate, about 1.00% binder such as carboxymethyl cellulose (CMC)
or cellulose gum, and about 21.32% glycerin and flavoring (with
.about.20% being glycerin).
[0043] Monolithic substrate elements 85 formed by an extrusion,
molding, or casting process can have different final forms and
shapes, wherein the form/shape may facilitate improved heat
transfer from the heat generation segment 35 and/or more efficient
and effective distribution of heat to the substrate element 85
instead of other proximal components of the smoking article so as
to reduce, minimize, or eliminate scorching or charring thereof.
For example, an extruded substrate element 85 may have the form and
configuration of a monolithic fluted rod member 300 (see, e.g.,
FIG. 4). That is, the rod member may include a plurality of
angularly spaced-apart lobes 310 about the circumference of the rod
member, with adjacent lobes defining a longitudinally-extending
open channel 320 therebetween. In some instances, the fluted rod
member may further define one or more conduits 330 extending
longitudinally through a central portion of the cross section
thereof, or through one or more of the lobes. The locations,
dimensions and/or configurations of the open channels and/or the
conduits can be varied, as necessary or desired, to obtain
particular performance characteristics. For example, one effect of
the open channels and/or is to increase the exposed surface area as
compared to a solid cylindrical rod member which, in turn, has such
effects as increased cigarette yield (i.e., increased operational
life) and decreased pressure drop along the smoking article (i.e.,
less resistance to draw).
[0044] The effective diameter (i.e., the maximum outside diameter)
of the fluted rod member can vary, for example, from about 5.8 mm
to about 7.3 mm. In order to incorporate the fluted rod member into
the aerosol-generating segment 61, the larger diameter extrusion
may be wrapped, for example, with a paper/foil laminate or
paper/foil/paper laminate, while the smaller diameter extrusion may
be wrapped, for example, with a single layer of glass fiber mat and
then further overwrapped with either a paper/foil laminate or a
paper/foil/paper laminate, prior to the aerosol-generating segment
being wrapped with the outer wrapping material 75 (though any of
the configurations of the wrapping material 90 disclosed herein may
be implemented as necessary or desired). The increased surface area
of the fluted rod member would result in less surface area of the
rod member in contact with the wrapping disposed between the rod
member and the outer wrapping material 75 which, in turn, causes
less heat to be transferred to the outer wrapping material 75
during use of the smoking article. The internal conduits may
further provide additional surface area of the rod member that is
heated by the heat generation segment, and may serve to draw some
of the heat away from the outermost surfaces of the fluted rod
member (i.e., the outermost portions of the lobes). As such, visual
scorching of the outer wrapping material 75 may be reduced. In
addition, the increased surface area of the fluted rod member as
compared to a solid cylindrical rod member, which increase in
surface area may be further enhanced by the additional conduit(s),
may provide additional capacity (i.e., proportional to the surface
area of the substrate element 85) of the aerosol forming material
incorporated into the substrate element 85 and exposed to the heat
from the heat generation segment 35, as well as a reduction in the
draw required to be imparted to the smoking article by the user.
Accordingly, such a smoking article may exhibit an enhanced service
life as compared to a smoking article incorporating a solid
cylindrical substrate element 85.
[0045] In the alternative to either a paper/foil laminate or a
paper/foil/paper laminate forming an overwrap of the substrate
element 85 directly, or with a single layer of glass fiber mat
disposed therebetween, a tobacco paper bi-laminate or tri-laminate
could be used as the overwrap. In such instances, should the
overwrap experience heat from the heat generation segment
sufficient to char or scorch the overwrap, the initial layer of the
overwrap laminate may preferably comprise a tobacco paper. In such
a manner, the scorching or charring of the tobacco paper layer may
provide a tobacco flavor to the formed aerosol, and thus have
little or no adverse effect upon the taste or sensory perception of
the formed aerosol. More particularly, a tobacco paper, such as a
cast sheet or extruded tobacco paper, can be laminated to a
paper/foil bi-laminate to form a paper/foil/tobacco paper
tri-laminate, with the tobacco paper providing the initial layer of
the laminate closest to the substrate element 85. Such a
tri-laminate arrangement may be applied, for example to both
tobacco-containing and non-tobacco substrate elements and may, for
example, facilitate improved adhesion along the seam formed by
wrapping the tri-laminate about the substrate element (i.e., the
seam would be formed between the tobacco paper and the cigarette
paper forming the outer layer of the tri-laminate), and may add
positive aspects to the taste and/or sensory perception
characteristics of the aerosol experienced by the user. One skilled
in the art, in appreciation of the inventive aspects of the present
disclosure, will also appreciate that the paper/foil/tobacco paper
tri-laminate of the type disclosed herein can also be applied to
any of the various tobacco-containing or tobacco-free substrate
elements and aerosol-generating segments set forth in the present
disclosure.
[0046] In another aspect of the present disclosure, the substrate
element 85 may take the form of a plurality of solid cylindrical
rod members 400 (see, e.g., FIG. 5) extending in parallel to each
other from the interface of the heat generation segment 35 and the
aerosol-generating segment 61. Such solid cylindrical rod members
may be formed using an extrusion process, or by molding or casting,
as appropriate, and may be comprised of, for example, glycerin,
milled tobacco, calcium carbonate, binder, flavorings, and water.
In some instances, a solid cylindrical rod member may have a
diameter of about 2.9 mm, wherein a plurality of such rods may be
bundled or stacked for insertion into the aerosol-generating
segment 61 as the substrate element 85. The collective solid
cylindrical rod members can subsequently be overwrapped in a
similar manner, under similar conditions, as the fluted rod member
configuration disclosed herein
[0047] In still other aspects, the material composition used for
the extruded rods, namely, for example, glycerin, milled tobacco,
calcium carbonate, binder, flavorings, and water, may instead be
used to form a flat sheet having a thickness of between about 0.3
mm to about 1.7 mm. In some instances, the sheet can also be formed
by an extrusion process (or molded or cast, as appropriate),
wherein the sheet is then dried to form the substrate material. The
dried sheet can then be deconstructed, for example, by cutting the
sheet into strips, or shredding the sheet. The cut/shredded
portions of the formed sheet may then be stacked or gathered, and
deposited in the aerosol-generating segment 61 as the substrate
element 85, in a manner similar to cut filler tobacco (i.e.,
deposited instead of, but in a similar manner to, cut filler
tobacco).
[0048] In some aspects, the substrate element 85 may be comprised,
for example, of cast sheets including a tobacco material. Such cast
sheets can be formed in a process whereby a selected
tobacco-containing mixture is cast, dried, and cut into strips or
shredded. In some instances, the cut strips or shredded portions of
the cast sheet can be mixed with other cut fillers (i.e., a
traditional cut filler tobacco, with or without an additional
aerosol former) to provide desired taste and sensory perception of
the user, as well as to facilitate the manufacturing process. In
one example, the selected tobacco-containing mixture may be
characterized as a pectin release mixture comprising, for example,
(on a dry weight basis) about 66.60% milled tobacco, about 3.75%
diammonium phosphate, about 4.65% ammonium hydroxide, and about 25%
glycerin and flavoring. To process the pectin release mixture, the
milled tobacco, diammonium phosphate, ammonium hydroxide, and water
may be heated to about 160.degree. F. for about 1.5 hours, for
example, to improve or enhance sensory qualities of the resulting
mixture. The glycerin and flavorings may then be added to the
remainder of the mixture upon cooling following the heating step.
The resulting mixture may then be used to form the cast sheet.
[0049] In another example, the selected tobacco-containing mixture
may be characterized as a non-ammoniated mixture comprising, for
example, (on a dry weight basis) about 65.62% milled tobacco, about
4.50% sodium alginate, about 1.13% sodium hydroxide or other pH
adjuster, about 25% glycerin, and about 3.75% wood pulp. To process
the non-ammoniated mixture, the milled tobacco, sodium alginate,
and water may heated to about 160.degree. F. for about 1.5 hours,
for example, to improve or enhance sensory qualities of the
resulting mixture. Hydrated wood pulp, the binder, glycerin and
flavorings may then be added to the remainder of the mixture upon
cooling following the heating step. The resulting mixture may then
be used to form the cast sheet.
[0050] In another example, the selected tobacco-containing mixture
may be characterized as a tobacco-containing reconstituted material
comprising, for example, (on a dry weight basis) about 51.8%
tobacco pulp, about 4.2% wood pulp, about 22.0% concentrated
tobacco extract, and about 22.0% glycerin and flavorings. A sheet
may be formed from the tobacco-containing reconstituted material in
a similar manner to conventional reconstituted sheet. For example,
water soluble elements are first removed from the tobacco pulp
lamina and the remaining tobacco pulp concentrated to about 25%
solids content. The wood pulp may then be added to the tobacco pulp
to form a base sheet that can vary in basis weight from between
about 120 grams per square meter (gsm) to about 240 gsm. Glycerin
is then mixed with concentrated tobacco derived nicotine (TDN)
extract (i.e., in a 1:1 ratio) and added to the base sheet. The
formed base sheet can then be dried, and cut into strips or
shredded. Similar to cast sheets, the cut strips or shredded
reconstituted sheets can be mixed with other cut fillers (i.e., a
traditional cut filler tobacco, with or without an additional
aerosol former) (i.e., a traditional cut filler tobacco, with or
without an additional aerosol former).
[0051] In another example, the selected tobacco-containing mixture
may be characterized as a traditional cut filler tobacco material
with elevated glycerin content. In such instances, the cut filler
tobacco can be loaded or interacted with between about 5% and about
30% glycerin. The cut filler tobacco material with elevated
glycerin content can subsequently be used as the primary substrate
(i.e., the substrate material forming the substrate element), or
can be mixed with cast sheet material, such that the resulting
mixture forms the substrate material of the substrate element.
Based on amount of glycerin necessary or desired, the glycerin can
be applied to the cut filler tobacco, for example, as a casing for
cutting (i.e., applied to individual strips of tobacco), as a top
dressing, or as both. Such cut filler tobacco with elevated
glycerin content can be, for example, mixed with various cast
sheets, reconstituted sheets, and/or tobacco beads, as necessary or
desired, to form the substrate material for the substrate element
85. In such instances of a substrate element 85 having elevated
glycerin levels, it may be desirable to include overwrapping of the
substrate element 85 that will minimize or eliminate any leaching
of the incorporated glycerin onto the outer wrapping material
75.
[0052] In yet another example, the selected tobacco-containing
mixture may be characterized as a non-tobacco material. For
example, a cast sheet used to form a substrate element, an extruded
substrate element, or a substrate element in bead (marumerized)
form, may include calcium carbonate, rice flour, a binder,
diammonium phosphate, glycerin, flavorings, tobacco derived
nicotine (TDN), and water. More particularly, such a non-tobacco
cast sheet may be comprised of, for instance, about 41.25% calcium
carbonate, about 13.75% rice flour, about 6% ammonium alginate,
about 5.5% wood pulp, about 3.5% diammonium phosphate, and about
30% glycerin. In addition, tobacco derived nicotine (TDN), certain
acids (i.e., levulinic acid and/or citric acid), and flavorings can
be incorporated in the glycerin. An extruded substrate element, or
a substrate element in bead (marumerized) form can be comprised of,
for example, about 51.94% calcium carbonate, about 17.15% rice
flour, about 1% TDN, about 1% carboxymethyl cellulose (CMC), about
0.66% levulinic acid, about 0.44% lactic acid, about 20% glycerin,
and about 9.41% flavorings. In some instances, the cast sheet may
be processed into cut strips, shredded, or processed into cut
filler form. In other instances, if the substrate element 85
includes beads, the beads may be positioned to abut the heat
generation segment, to be adjacent to the heat generation segment,
or to be closest to the heat generation segment. In those
instances, a selected component may be implemented opposite to the
heat generation segment from the beads, in order to secure the
beads in place. For example, such a selected component could
include, a folded paper filter material or other non-tobacco paper
plug.
[0053] In another example of a substrate element 85 formed of a
non-tobacco material, tobacco derived nicotine (TDN), glycerin
(i.e., an aerosol former), and flavorings can be added to an
extruded ceramic substrate of relatively high porosity (i.e., a
high porosity extruded ceramic rod member). In such instances, the
ceramic rod member may be extruded so as to define one or more
longitudinally-extending channels (i.e., open channels or slots
disposed about the outer surface and/or conduits extending through
the central portion of the rod member). In a similar manner to the
fluted rod member previously disclosed, the increased surface area
of the ceramic rod member (i.e., due to the open channels about the
surface thereof) would result in less surface area of the rod
member in contact with the wrapping disposed between the rod member
and the outer wrapping material 75 which, in turn, causes less heat
to be transferred to the outer wrapping material 75 during use of
the smoking article. The internal conduits may further provide
additional surface area of the rod member that is heated by the
heat generation segment, and may serve to draw some of the heat
away from the outermost surfaces of the fluted ceramic rod member
(i.e., the outermost portions of the lobes). As such, visual
scorching of the outer wrapping material 75 may be reduced. In
addition, the increased surface area of the fluted ceramic rod
member as compared to a solid cylindrical rod member, which
increase in surface area may be further enhanced by the additional
conduit(s), may provide additional capacity (i.e., proportional to
the surface area of the substrate element 85) of the aerosol
forming material incorporated into the substrate element 85 and
exposed to the heat from the heat generation segment 35, as well as
a reduction in the draw required to be imparted to the smoking
article by the user. Accordingly, such a smoking article may
exhibit an enhanced service life as compared to a smoking article
incorporating a solid cylindrical substrate element 85. In
addition, the open channels/conduits may provide less resistance to
draw.
[0054] In some aspects of the present disclosure, the substrate
element 85 may be segmented (i.e., the substrate element 85 may
include a plurality of serially-disposed components or a plurality
of components disposed in parallel), or may include combinations of
two or more substrate materials. For example, the substrate element
may comprise a combination of cast sheet and/or reconstituted
sheet, each shredded or cut into strips, mixed with cut filler
tobacco treated with glycerin. The cut filler tobacco can have
various levels of glycerin ranging, for example, from about 5% to
about 25%. In another example, cast sheet, shredded or cut into
strips, may be mixed with tobacco-containing beads. In addition to
an extruded substrate element being wrapped with glass fiber mat,
the extruded substrate element 85 may alternatively be wrapped with
tobacco paper or a laminate including a tobacco paper layer,
wherein the substrate element 85 may be comprised of, for example,
a bundle of smaller diameter rod members arranged in parallel, or
strips of a cast sheet, extruded sheet or reconstituted tobacco
sheet processed in a similar manner to cut filler tobacco, or
rolled together to form a substantially cylindrical substrate
element.
[0055] In addition to the components disclosed herein, the
substrate element 85 may be comprised of many different
combinations of such components. In particular aspects, such
components may also be additionally selected from the group
consisting of, for example, a glass fiber mat having a TDN/glycerin
(B3) solution applied thereto, a porous ceramic element having an
aerosol former such as glycerin applied thereto, a cast sheet
including a pectin release material, a non-ammoniated cast sheet, a
non-tobacco cast sheet, a gathered or shredded foil sheet having an
aerosol former applied thereto or strips formed therefrom, a
non-tobacco product such as gathered paper treated with an extract
such as TDN, beads, or gathered carbon or non-carbon paper.
[0056] The components of the aerosol-generating segment can vary.
The aerosol-generating segment incorporates components that can be
vaporized, aerosolized or entrained in air drawn through the
smoking article during use. Most preferably, those components,
separately or in combination, provide sensory and organoleptic
effects, such as aroma, flavor, mouth feel, visible aerosol
sensations, and the like. Examples of components of the
aerosol-generating segment that are drawn into the mouth of the
smoker during draw include water (e.g., as water vapor), visible
aerosol forming materials (e.g., glycerin), various volatile
flavors (e.g., vanillin or menthol), volatile components of tobacco
(e.g., nicotine), and the like.
[0057] A preferred aerosol-forming material produces a visible
aerosol upon the application of sufficient heat thereto, or
otherwise through the action of aerosol forming conditions brought
about by components of the smoking article. A highly preferred
aerosol-forming material produces a visible aerosol that can be
considered to be "smoke-like." A preferred aerosol-forming material
is chemically simple, relative to the chemical nature of the smoke
produced by burning tobacco. A preferred visible aerosol-forming
material is a polyol, and exemplary preferred aerosol forming
materials include glycerin, propylene glycol, and mixtures thereof.
If desired, aerosol forming materials can be combined with other
liquid materials, such as water. For example, aerosol forming
material formulations can incorporate mixtures of glycerin and
water, or mixtures of propylene glycol and water. See, for example,
the various aerosol forming materials referenced in U.S. Pat. No.
4,793,365 to Sensabaugh, Jr. et al.; U.S. Pat. No. 5,101,839 to
Jakob et al. and U.S. Pat. No. 8,678,013 Crooks, et al.; as well as
PCT WO 98/57556 to Biggs et al.; which are incorporated herein by
reference.
[0058] The materials that can be used to provide the substrates for
the aerosol-forming materials within the aerosol-generating region
can vary. Suitable substrate elements and associated
aerosol-forming materials have been incorporated within those types
of cigarettes commercially marketed under the trade names
"Premier," "Eclipse" "Steam Hot One." The substrate element can
incorporate tobacco of some form, normally is composed
predominantly of tobacco, and can be provided by virtually all
tobacco material. For example, in some embodiments, at least a
portion of the overall substrate material is employed in an
essentially traditional filler form (e.g., as cut filler). Suitable
substrate materials, and substrate formulations incorporating
aerosol-forming materials (including cast sheet and paper type
reconstituted tobacco materials), also are set forth in U.S. Pat.
No. 4,793,365 to Sensabaugh et al.; U.S. Pat. No. 4,893,639 to
White; U.S. Pat. No. 5,099,861 to Clearman et al.; U.S. Pat. No.
5,101,839 to Jakob et al.; U.S. Pat. No. 5,105,836 to Gentry et
al.; U.S. Pat. No. 5,109,122 to Clearman et al.; U.S. Pat. No.
5,159,942 to Brinkley et al.; U.S. Pat. No. 5,203,355 to Clearman
et al.; U.S. Pat. No. 5,271,419 to Arzonico et al.; U.S. Pat. No.
5,327,917 to Lekwauwa et al.; U.S. Pat. No. 5,396,911 to Casey, III
et al.; U.S. Pat. No. 5,533,530 to Young et al.; U.S. Pat. No.
5,588,446 to Clearman; U.S. Pat. No. 5,598,868 to Jakob et al.;
U.S. Pat. No. 5,715,844 to Young et al.; U.S. Pat. No. 6,378,528 to
Beeson et al. and U.S. Pat. No. 8,678,013 Crooks, et al.; and U.S.
Pat. App. Pub. Nos. 2005/0066986 to Nestor et al.; US 2012/0067360
to Conner et al.; and 2015/0157052 to Ademe et al.; which are
incorporated herein by reference. Additionally, substrate materials
can have the types of forms or configurations set forth in U.S.
Pat. No. 8,839,799 to Conner et al.; as a gathered web or sheet,
using the types of techniques generally set forth in U.S. Pat. No.
4,807,809 to Pryor et al., or in the form of a web or sheet that is
shredded into a plurality of longitudinally extending strands,
using the types of techniques generally set forth in U.S. Pat. No.
5,025,814 to Raker; each of which is incorporated herein by
reference.
[0059] The manner by which the aerosol-forming material is
contacted with the substrate material (e.g., the tobacco material)
can vary. The aerosol-forming material can be applied to a formed
tobacco material, or can be incorporated into processed tobacco
materials during manufacture of those materials. The aerosol
forming material can be dissolved or dispersed in an aqueous
liquid, or other suitable solvent or liquid carrier, and sprayed
onto that substrate material. See, for example, U.S. Patent
Application Pub. No. 2005/0066986 to Nestor et al, which is
incorporated herein by reference in its entirety. The amount of
aerosol-forming material employed relative to the dry weight of
substrate material can vary. Materials including exceedingly high
levels of aerosol-forming material can be difficult to process into
cigarette rods using conventional types of automated cigarette
manufacturing equipment.
[0060] Cast sheet types of materials may incorporate relatively
high levels of aerosol-forming material. Reconstituted tobaccos
manufactured using paper-making types of processes may incorporate
moderate levels of aerosol-forming material. Tobacco strip and cut
filler tobacco can incorporate lower amounts of aerosol-forming
material. Various paper and non-paper substrates including
gathered, laminated, laminated metal/metallic, strips, beads such
as alumina beads, open cell foam, foamed monolith, air permeable
matrices, and other materials can be used within the scope of the
disclosure. See, for example, U.S. Pat. Nos. 5,183,062; 5,203,355;
and 5,588,446; each to Clearman, and each of which is incorporated
herein by reference.
[0061] The laminated paper or other wrapping material may be
constructed in accordance with the disclosure of U.S. Pat. No.
6,849,085 to Marton, which is incorporated herein by reference in
its entirety, or in accordance with other appropriate methods
and/or materials.
[0062] In some preferred smoking articles, both ends of the
aerosol-generating segment 61 are open to expose the substrate
element 85 thereof. Together, the heat generating segment 35 and
the aerosol-generating segment 61 form an aerosol generation system
99. The aerosol-generating segment is positioned adjacent to the
downstream end of the heat generation segment such that those
segments are axially aligned in an end-to-end relationship. Those
segments can abut one another, or be positioned in a slightly
spaced apart relationship, which may include an optional buffer
region 110 (which may, in some instances, include a heat conductive
and air-porous spacer element). The outer cross-sectional shapes
and dimensions of those segments, when viewed transversely to the
longitudinal axis of the smoking article 10, can be essentially
identical to one another. The physical arrangement of those
components preferably is such that heat is transferred (e.g., by
mechanisms that includes conductive and convective heat transfer)
from the heat source 40 to the adjacent substrate element 85,
throughout the time that the heat source is actuated (e.g., burned)
during use of the smoking article 10.
[0063] A buffer region 110 may reduce potential scorching or other
thermal degradation of portions of the aerosol-generating segment
61. The buffer region may mainly include empty air space, or it may
be partially or substantially completely filled with a
non-combustible material such as, for example, metal, organic,
inorganic, ceramic, or polymeric materials, or any combination
thereof. The buffer regions may be from about 1 mm to about 10 mm
or more in thickness (length), but often will be about 2 mm to
about 5 mm in thickness (length). If desired, the buffer region or
spacer segment 110 can incorporate catalytic materials, such as
materials incorporating cerium or copper ions or oxides and/or
salts of cerium and copper ions. See, for example, U.S. Pat. No.
8,469,035 to Banerjee et al. and U.S. Pat. No. 8,617,263 to
Banerjee et al.; and U. S. Pat. Appl. Pub. Nos. 2007/0215168 to
Banerjee et al.; which are incorporated herein by reference.
[0064] The components of the aerosol generation system 99
preferably are attached to one another, and secured in place using
an overwrap material 118. For example, the overwrap material can
include a paper wrapping material or a laminated paper-type
material that circumscribes a downstream portion of the heat
generation segment 35, and at least a portion of outer
longitudinally extending surface of the aerosol-generating segment
61. The inner surface of the overwrap material 118 may be secured
to the outer surfaces of the components it circumscribes by a
suitable adhesive. One skilled in the art will appreciate that the
aspects disclosed herein directed to the reduction, minimization,
or elimination of scorching or charring of the outer wrapping
material 75 or wrapping paper 90 may thus also be applicable to the
overwrap material 118, to the extent that the overwrap material 118
overlaps the outer wrapping material 75 or extends over the
interface between the heat generation segment 35 and the
aerosol-generating segment 61.
[0065] The smoking article 10 preferably includes a suitable
mouthpiece such as, for example, a filter element 135, positioned
at the mouth end 18 thereof. The filter element 135 preferably is
positioned at one end of the aerosol generation system 99, such
that the filter element 135 and the aerosol-generating segment 99
are axially aligned in an end-to-end relationship, abutting one
another and without any barrier therebetween. Preferably, the
general cross-sectional shapes and dimensions of those segments
99,135 are essentially identical to one another when viewed
transversely to the longitudinal axis of the smoking article. The
filter element 135 can include filter material 140 that is
overwrapped along the longitudinally extending surface thereof with
circumscribing plug wrap material 142. In one example, the filter
material 140 includes plasticized cellulose acetate tow, or other
suitable cigarette-type filter material. Both ends of the filter
element 135 preferably are open to permit the passage of aerosol
therethrough. In some instances, the filter element 135 may be
configured to include any combination of paper plug, void, and
conventional cigarette filter material (i.e., cellulose acetate
tow), as necessary or desired.
[0066] The filter element may also include a crushable flavor
capsule of the type described in U.S. Pat. No. 7,479,098 to Thomas
et al. and U.S. Pat. No. 7,793,665 to Dube et al.; and U.S. Pat.
No. 8,186,359 to Ademe et al., which are incorporated herein by
reference.
[0067] The aerosol-generating system 99 preferably is attached to
the filter element 135 using tipping material 150. Examples of
tipping materials are described, for example, in U.S. Pat. No.
7,789,089 to Dube et al., and in U.S. Pat. App. Publ. Nos.
2007/0215167 to Crooks et al., 2010/0108081 to Joyce et al.,
2010/0108084 to Norman et al., and 2013/0167849 to Ademe et al.;
and PCT Pat. App. Pub. No. 2013/160671 to Dittrich et al., each of
which is incorporated by reference herein.
[0068] The smoking article 10 may include an air dilution
provision, such as a series of perforations 160, each of which may
extend through the filter element tipping material 150 and plug
wrap material 142. Alternatively, the various perforations can
extend around the smoking article as a ring in a region upstream
from that shown.
[0069] A representative smoking article 10 has a length of between
about 80 mm and about 100 mm. For example, for a smoking article 10
having a length of about 85 mm, a representative heat generation
segment 35 can have a length of between about 10 mm and about 15
mm, a representative aerosol-generating segment 61 can have a
length of between about 40 mm and about 55 mm, and a representative
filter element 135 can have a length of between about 20 mm and
about 30 mm.
[0070] Cigarettes described with reference to FIG. 1 may be used in
much the same manner as those cigarettes that have been
commercially marketed under the trade names "Premier" and "Eclipse"
by R. J. Reynolds Tobacco Company, and "Steam Hot One" by Japan
Tobacco Inc. That is, the fuel element or heat source is lit using
a match or cigarette lighter. The burning fuel element/heat source
resulting from such ignition produces heat which is transferred to
the substrate element within the aerosol-generating region of the
cigarette. The substrate element(s), including the aerosol forming
materials, and tobacco flavors and components, are heated and
volatilize, and form aerosol. That aerosol is entrained in drawn
air, and drawn through the filter element into the mouth of the
smoker.
[0071] FIG. 2 illustrates another representative smoking article 10
in the form of a cigarette, according to another aspect of the
present disclosure. Preferably, the smoking article 10 has the
overall size, shape and general appearance, and incorporates those
types of components, of that smoking article described previously
with reference to FIG. 1. However, as compared to the embodiment of
FIG. 1, the length of the filter segment 135 is extended, and the
length of aerosol-generating segment 61 is decreased. For example,
for the embodiment shown, the filter element 135 is a two piece
segment; possessing an extreme mouth end segment 182, and a tubular
segment 184 positioned between the aerosol-generating segment and
the extreme mouth end segment. As such, the representative smoking
article of FIG. 2 is a four-segment smoking article, while the
representative smoking article of FIG. 1 is a three-segment smoking
article.
[0072] Typically, the tubular segment 184 is comprised of a steam
bonded and plasticized cellulose acetate tube that provides
resilience, structure, and length to the smoking article while
allowing for passage of drawn air therethrough. Alternatively, the
tubular segment is comprised of a heat resistant plastic material
(e.g., a tube comprised of polycarbonate) or a ceramic
material.
[0073] A representative smoking article 10 of the type shown in
FIG. 2 has a length of between about 80 mm and about 100 mm. For
example, for a smoking article 10 having a length of about 85 mm, a
representative heat generation segment 35 can have a length of
between about 10 mm and about 15 mm, a representative
aerosol-generating segment 61 can have a length of between about 10
mm and about 25 mm, a representative tubular segment 184 can have a
length of between about 30 mm and about 50 mm, and a representative
filter element 135 can have a length of between about 20 mm and
about 30 mm.
[0074] FIG. 3 illustrates another representative smoking article 10
in the form of a cigarette. Preferably, the smoking article 10 has
the overall size, shape and general appearance, and incorporates
those types of components, of that smoking article described
previously with reference to FIG. 2. However, a tobacco segment 198
of cut filler tobacco 200 wrapped in a paper wrapper 205 is
positioned between the aerosol generation system 99 and the filter
element 135. As compared to the embodiment of FIG. 2, the overall
length of the two piece filter segment is decreased to accommodate
the segment comprised of cut filler tobacco. As such, the
representative smoking article of FIG. 3 is a five-segment smoking
article, while the representative smoking article of FIG. 2 is a
four-segment smoking article.
[0075] The upstream segment of the two piece filter segment 135 can
be comprised of a hardened tube comprised of cellulose acetate tow,
a segment of cellulose acetate tow having discrete particles of
activated carbon particles dispersed throughout, a segment of
cellulose acetate having a breakable flavor-containing capsule
positioned therein, or the like. Typically, the downstream segment
of the two piece filter segment 135 is a segment comprised of
plasticized cellulose acetate tow or gathered polypropylene web. If
desired, the two piece filter segment can be replaced with a single
segment filter element or a three piece cavity filter.
[0076] A representative smoking article 10 of the type shown in
FIG. 3 has a length of between about 80 mm and about 100 mm. For
example, for a smoking article 10 having a length of about 85 mm, a
representative heat generation segment 35 can have a length of
between about 10 mm and about 15 mm, a representative
aerosol-generating segment 61 can have a length of between about 10
mm and about 25 mm, a representative tobacco filler segment 198 can
have a length of between about 30 mm and about 50 mm, and a
representative filter element 135 can have an overall length of
between about 20 mm and about 30 mm. For a representative filter
element for the embodiment shown, the upstream filter element
segment 220 can have a length of between about 5 mm and about 20 mm
and the downstream filter element segment 225 can have a length of
between about 5 mm and about 20 mm. For example, a representative
smoking article having an overall length of about 83 mm can have a
heat generation segment 35 having a length of about 12 mm, an
aerosol-generating segment 61 having a length of about 13 mm, a
tobacco filler segment 198 having a length of about 37 mm, a
cellulose acetate tube filter segment 220 having a length of about
7 mm and a low efficiency plasticized cellulose acetate tow segment
225 having a length of about 14 mm.
[0077] Typical smoking articles also incorporate various components
associated with their construction. For example, those types of
components include wrapping materials, heat conductive materials,
metallic foils and foil laminates, mouth-end pieces, filter
elements, plug wraps, tipping materials and adhesives.
Additionally, typical smoking articles can incorporate any of a
wide variety of tobacco types, forms of tobacco, and blends
thereof. See, for example, those representative types of components
that are set forth and referenced in U.S. Pat. No. 5,724,997 to
Fagg, et al.; U.S. Pat. No. 8,678,013 Crooks, et al. and U.S. Pat.
App. Pub. No. 2015/0157052 to Ademe et al.; which are incorporated
herein by reference.
[0078] Various combinations and varieties of flavoring agents
(including various materials that alter the sensory and/or
organoleptic character or nature of mainstream aerosol of a smoking
article) can be incorporated within suitable smoking articles. The
substrate material and various tobacco components of the smoking
article can be treated with tobacco additives of the type that are
traditionally used for the manufacture of cigarettes, such as
casing and/or top dressing components. See, for example, the types
of components set forth in U.S. Pat. No. 8,678,013 Crooks, et al.;
which is incorporated herein by reference.
[0079] Manners and methods for assembling representative types of
smoking articles are set forth in U.S. Pat. No. 5,469,871 to Barnes
et al. and U.S. Pat. No. 8,678,013 Crooks, et al.; and U.S. Pat.
App. Pub. Nos. 2012/0042885 to Stone et al.; 2012/0067360 to Conner
et al.; 2014/0261470 to Amiss et al.; and 2015/0157052 to Ademe et
al.; which are incorporated herein by reference.
[0080] In light of possible interrelationships between aspects of
the present disclosure in providing the noted benefits and
advantages associated therewith, the present disclosure thus
particularly and expressly includes, without limitation,
embodiments representing various combinations of the disclosed
aspects. Thus, the present disclosure includes any combination of
two, three, four, or more features or elements set forth in this
disclosure, regardless of whether such features or elements are
expressly combined or otherwise recited in the description of a
specific embodiment herein. This disclosure is intended to be read
holistically such that any separable features or elements of the
disclosure, in any of its aspects and embodiments, should be viewed
as intended, namely to be combinable, unless the context of the
disclosure clearly dictates otherwise.
[0081] Aerosols that are produced by cigarettes of the present
disclosure are those that comprise air-containing components such
as vapors, gases, suspended particulates, and the like. Aerosol
components can be generated from burning tobacco of some form (and
optionally other components that are burned to generate heat); by
thermally decomposing tobacco caused by heating tobacco and
charring tobacco (or otherwise causing tobacco to undergo some form
of smolder); and by vaporizing an aerosol-forming agent. As such,
the aerosol can contain volatilized components, combustion products
(e.g., carbon dioxide and water), incomplete combustion products,
products of pyrolysis, and aerosols otherwise described as
smoke.
[0082] Aerosol components also may be generated by the action of
heat from burning tobacco of some form (and optionally other
components that are burned to generate heat), upon substances that
are located in a heat exchange relationship with tobacco material
that is burned and other components that are burned. Aerosol
components may also be generated by the aerosol generation system
as a result of the action of the heat generation segment upon an
aerosol-generating segment. In some embodiments, components of the
aerosol-generating segment have an overall composition, and are
positioned within the smoking article, such that those components
will have a tendency not to undergo a significant degree of thermal
decomposition (e.g., as a result of combustion, smoldering or
pyrolysis) during conditions of normal use.
[0083] Many modifications and other aspects of the disclosures set
forth herein will come to mind to one skilled in the art to which
these disclosures pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. For example, those of skill in the art will appreciate
that embodiments not expressly illustrated herein may be practiced
within the scope of the present disclosure, including that features
described herein for different embodiments may be combined with
each other and/or with currently-known or future-developed
technologies while remaining within the scope of the claims
presented here. In some such aspects, for instance, alternate
provisions for reducing, minimizing or eliminating scorching,
charring, or discoloration of the outer wrapping material may be
implemented, such as using an embossed overwrap material (i.e.,
comprised of paper) as a further layer over the outer wrapping
material (i.e., cigarette paper). In such instances, the increased
surface area provided by the embossing and/or the embossed overwrap
material being at least partially spaced apart from the outer
wrapping material may cause the overwrap material to act as an
external air-cooled device (i.e., cooling fins). In still other
instances, various measures could be implemented to provide visual
cues of overheating or over-temperature. For example, the embossed
overwrap material and/or the outer wrapping material may be printed
with a thermochromic ink that visually appears or changes
appearance over a temperature threshold or within a specific
temperature range, and/or disappears under a temperature threshold
or within a specific temperature range. In this manner, for
instance, the user may be directed to refrain from using the
smoking article in an over-temperature condition until the indicia
provide by the thermochromic ink changes in appearance to indicate
a suitable temperature of the smoking article, wherein such a
measure may prevent over-temperature usage which may lead to the
scorching or charring of the outer wrapping material or any other
component experiencing the heat generated by the heat generation
segment. In still other instances, the outer wrapping material 75
or wrapping paper/material 90 can comprise or have associated
therewith a non-woven graphite or graphene sheet as a heat
conductive element or otherwise to direct excess heat away from the
outer wrapping paper 75. That is, the non-woven graphite or
graphene sheet may be wrapped about a portion of the heat
generation portion and about a portion of the aerosol-generating
portion, within the outer wrapping material, and extend toward the
mouth end portion.
[0084] Therefore, it is to be understood that the disclosures are
not to be limited to the specific aspects disclosed and that
equivalents, modifications, and other aspects are intended to be
included within the scope of the appended claims Although specific
terms are employed herein, they are used in a generic and
descriptive sense only and not for purposes of limitation. Aspects
of the present disclosure are more fully illustrated by the
examples herein, which are set forth to illustrate certain aspects
of the present disclosure and are not to be construed as limiting
the scope thereof. Unless otherwise noted, all parts and
percentages are by weight.
* * * * *