U.S. patent application number 16/198230 was filed with the patent office on 2019-03-28 for heat generation segment for an aerosol-generation system of a smoking article.
The applicant listed for this patent is R.J. Reynolds Tobacco Company. Invention is credited to Donna Walker Duggins, Anthony Richard Gerardi, Thaddeus J. Jackson, Brian Keith Nordskog.
Application Number | 20190090537 16/198230 |
Document ID | / |
Family ID | 56373191 |
Filed Date | 2019-03-28 |
United States Patent
Application |
20190090537 |
Kind Code |
A1 |
Nordskog; Brian Keith ; et
al. |
March 28, 2019 |
HEAT GENERATION SEGMENT FOR AN AEROSOL-GENERATION SYSTEM OF A
SMOKING ARTICLE
Abstract
A fuel element adapted for use in a smoking article is provided,
the fuel element including a combustible carbonaceous material in
an amount of at least 25% by dry weight, based on the weight of the
fuel element, and a particulate ignition aid dispersed throughout
the fuel element and selected from ceramic particles, cellulose
particles, fullerenes, impregnated activated carbon particles,
inorganic salts, and combinations thereof, wherein the average
particle size of the ignition aid is less than about 1,000 microns.
Also provided are elongate smoking articles having a lighting end
and an opposed mouth end, and including the above-noted fuel
element configured for ignition of the lighting end.
Inventors: |
Nordskog; Brian Keith;
(Winston-Salem, NC) ; Jackson; Thaddeus J.; (High
Point, NC) ; Duggins; Donna Walker; (Winston-Salem,
NC) ; Gerardi; Anthony Richard; (Winston-Salem,
NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R.J. Reynolds Tobacco Company |
Winston-Salem |
NC |
US |
|
|
Family ID: |
56373191 |
Appl. No.: |
16/198230 |
Filed: |
November 21, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14755205 |
Jun 30, 2015 |
10154689 |
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16198230 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24F 47/006 20130101;
C10L 11/04 20130101; C10L 2230/06 20130101; C10L 2200/0272
20130101; C10L 9/10 20130101; C10L 2270/08 20130101; C10L 2200/029
20130101; C10L 2250/06 20130101; A24B 15/165 20130101; C10L
2200/0218 20130101; C10L 2200/0469 20130101 |
International
Class: |
A24F 47/00 20060101
A24F047/00; C10L 11/04 20060101 C10L011/04; A24B 15/16 20060101
A24B015/16; C10L 9/10 20060101 C10L009/10 |
Claims
1.-26. (canceled)
27. 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; and an aerosol-generation system
comprising: a heat generation portion disposed at the lighting end,
the heat generation portion comprising a fuel element configured
for ignition of the lighting end; and an aerosol-generating portion
comprising a plurality of aerosol-generating elements in the form
of beads or pellets comprising at least one aerosol forming
material, wherein the plurality of aerosol-generating elements are
smoke-treated.
28. The smoking article of claim 27, wherein the plurality of
smoke-treated aerosol-generating elements are treated with wood
smoke.
29. The smoking article of claim 28, wherein the wood is selected
from the group consisting of hickory, maple, oak, apply, cherry,
mesquite, and combinations thereof.
30. The smoking article of claim 27, wherein the plurality of
aerosol-generating elements further comprise one or more of
particulate tobacco, a tobacco extract, and nicotine, wherein the
nicotine is in free base form, salt form, as a complex, or as a
solvate.
31. The smoking article of claim 27, wherein the plurality of
aerosol-generating elements further comprise one or more fillers,
binders, flavorants, and combinations thereof.
32. The smoking article of claim 27, wherein the aerosol forming
material is selected from the group consisting of glycerin,
propylene glycol, water, saline, nicotine, and combinations
thereof.
33. The smoking article of claim 27, further comprising a
particulate ignition aid dispersed throughout the fuel element.
34. The smoking article of claim 33, wherein the particulate
ignition aid is non-catalytic.
35. The smoking article of claim 33, wherein the ignition aid
comprises glass bubbles having an average particle size of about 10
to about 300 microns or cellulose particles having an average
particle size of about 10 to about 300 microns.
36. The smoking article of claim 27, wherein the fuel element
comprises a combustible carbonaceous material.
37. The smoking article of claim 36, wherein the combustible
carbonaceous material is in an amount of at least 25% by dry
weight, based on the weight of the fuel element.
38. The smoking article of claim 27, wherein the plurality of
smoke-treated aerosol-generating elements are treated with wood
smoke by heating wood chips in a container until smoke is produced
and placing the plurality of aerosol-generating elements to be
treated within a closed environment with the smoke produced by the
wood chips.
39. The smoking article of claim 38, wherein the wood chips are
heated to a temperature of about 350.degree. F. to about
400.degree. F.
40. The smoking article of claim 38, wherein the plurality of
aerosol-generating elements are treated with the wood smoke for
between about 5 minutes to about 45 minutes.
Description
BACKGROUND OF THE DISCLOSURE
Field of the Disclosure
[0001] 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
components and configurations of heat-not-burn smoking
articles.
Disclosure of Related Art
[0002] 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
cigarettes 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. Nos. 7,503,330 and 7,753,056, both to
Borschke et al.; which are incorporated herein by reference.
[0003] Certain types of cigarettes that employ carbonaceous fuel
elements have been commercially marketed under the brand names
"Premier," "Eclipse" and "Revo" 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." Furthermore, various types of smoking products
incorporating carbonaceous fuel elements for heat generation and
aerosol formation recently have been set forth in the patent
literature. See, for example, the types of smoking products
proposed in U.S. Pat. No. 7,836,897 to Borschke et al.; U.S. Pat.
No. 8,469,035 to Banerjee et al. and U.S. Pat. No. 8,464,726 to
Sebastian et al.; US Pat. Pub. Nos. 2012/0042885 to Stone et al.;
2013/0019888 to Tsuruizumi et al; 2013/0133675 to Shinozaki et al.
and 2013/0146075 to Poget 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; EP 1808087
to Baba et al. and EP 2550879 to Tsuruizumi et al.; which are
incorporated by reference herein in their entirety. A historical
perspective of technology related to various types of smoking
products incorporating carbonaceous fuel elements for heat
generation and aerosol formation may be found, for example, in the
Background of US Pat. Pub. No. 2007/0215167 to Llewellyn Crooks et
al., which is also incorporated herein by reference.
[0004] It would be highly desirable to provide smoking articles
that demonstrate the ability to provide to a smoker many of the
benefits and advantages of conventional cigarette smoking, without
delivering considerable quantities of incomplete combustion and
pyrolysis products. In conjunction with such desirable
characteristics, it would also be desirable for a direct ignition
smoking article to be readily ignited, and to remain ignited, while
being used by the smoker.
BRIEF SUMMARY OF THE DISCLOSURE
[0005] 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. Such a
smoking article comprises a mouth end portion disposed at the mouth
end, and optionally includes a tobacco portion disposed between the
lighting end and the mouth end portion. An aerosol-generation
system is disposed between the lighting end and the mouth end
portion, wherein the aerosol-generation system including a heat
generation portion disposed at the lighting end, which includes a
combustible fuel element.
[0006] In one aspect of the invention, a combustible fuel element
adapted for use in a smoking article is provided, the fuel element
comprising a combustible carbonaceous material in an amount of at
least 25% by dry weight, based on the weight of the fuel element,
and a particulate ignition aid dispersed throughout the fuel
element and selected from the group consisting of ceramic
particles, cellulose particles, fullerenes, impregnated activated
carbon particles, inorganic salts, and combinations thereof,
wherein the average particle size of the ignition aid is less than
about 1,000 microns and with the proviso that when the ignition aid
is an inorganic salt, the inorganic salt is present in an amount of
no more than about 0.5 dry weight percent based on the total dry
weight of the fuel element. The particulate ignition aid is
advantageously non-catalytic. Exemplary impregnating agents for the
activated carbon include metals, metal oxides, inorganic salts, and
mineral acids. The ignition aid enhances the operation of the fuel
element by reducing the amount of time required to ignite the fuel
element.
[0007] In certain embodiments, the ignition aid comprises ceramic
particles or cellulose particles having an average particle size of
less than about 500 microns, the ceramic particles being glass
bubbles or cenospheres. For example, the ignition aid can include
glass bubbles having an average particle size of about 10 to about
300 microns. Alternatively, the ignition aid can include cellulose
particles having an average particle size of about 10 to about 300
microns. In certain embodiments, the ceramic particles of the
ignition aid are metal-coated ceramic particles. In certain
embodiments, the presence of the ignition aid reduces the time
required to ignite the fuel element by at least 20% as compared to
a control fuel element devoid of the ignition aid.
[0008] The fuel element may include further ingredients, such as a
binding agent, a catalytic metal material, graphite, an inorganic
filler, and combinations thereof. In one embodiment, the fuel
element comprises at least about 30% by dry weight of the
combustible carbonaceous material, based on the dry weight of the
fuel element; between about 0.1% and about 20% by dry weight of the
ignition aid; at least about 5% by dry weight of a binding agent
(e.g., natural gums such as guar gum); at least about 5% by dry
weight of graphite; and at least about 25% by dry weight of an
inorganic filler (e.g., calcium carbonate).
[0009] In another aspect, the invention provides an elongate
smoking article having a lighting end and an opposed mouth end, the
smoking article comprising: a mouth end portion disposed at the
mouth end; a tobacco portion disposed between the lighting end and
the mouth end portion; and an aerosol-generation system disposed
between the lighting end and the tobacco portion, the
aerosol-generation system including a heat generation portion
disposed at the lighting end, the heat generation portion
comprising a fuel element according to any of the embodiments set
forth above and configured to be actuated by ignition of the
lighting end.
[0010] In one particular embodiment, the invention provides an
elongate smoking article having a lighting end and an opposed mouth
end, said smoking article comprising: [0011] a mouth end portion
disposed at the mouth end; [0012] a tobacco portion disposed
between the lighting end and the mouth end portion; and [0013] an
aerosol-generation system disposed between the lighting end and the
tobacco portion, the aerosol-generation system including a heat
generation portion disposed at the lighting end, the heat
generation portion comprising a fuel element configured ignition of
the lighting end, the fuel element comprising: [0014] (a) at least
about 30% by dry weight of the combustible carbonaceous material,
based on the dry weight of the fuel element; [0015] (b) about 0.1%
to about 20% by dry weight of a non-catalytic ignition aid
comprising ceramic particles or cellulose particles having an
average particle size of less than about 500 microns, the ceramic
particles being glass bubbles or cenospheres; [0016] (c) at least
about 5% by dry weight of a binding agent; [0017] (d) at least
about 5% by dry weight of graphite; and [0018] (e) at least about
25% by dry weight of an inorganic filler.
[0019] In yet another aspect of the invention, an elongate smoking
article having a lighting end and an opposed mouth end is provided,
the smoking article comprising: a mouth end portion disposed at the
mouth end (e.g., a filter element); and an aerosol-generation
system disposed between the lighting end and the mouth end portion,
the aerosol-generation system including a heat generation portion
disposed at the lighting end, the heat generation portion
comprising a fuel element configured for ignition of the lighting
end, the fuel element comprising a combustible carbonaceous
material in an amount of at least 25% by dry weight, based on the
weight of the fuel element; and the aerosol-generation system
including an aerosol-generating portion comprising a plurality of
aerosol-generating elements in the form of beads or pellets
comprising at least one aerosol forming material, wherein the
aerosol-generating elements are smoke-treated. Exemplary bead or
pellets are treated with wood smoke, such as smoke generated by a
wood selected from hickory, maple, oak, apply, cherry, mesquite,
and combinations thereof.
[0020] The aerosol-generating elements can further comprise one or
more of particulate tobacco, a tobacco extract, and nicotine,
wherein the nicotine in free base form, salt form, as a complex, or
as a solvate. In addition, the aerosol-generating elements can
further comprise one or more fillers, binders, flavorants, and
combinations thereof. Exemplary aerosol forming materials include
glycerin, propylene glycol, water, saline, nicotine, and
combinations thereof.
[0021] Further features and advantages of the present disclosure
are set forth in more detail in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Having thus described the disclosure in general teems,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0023] FIG. 1 provides a longitudinal cross-sectional view of a
representative smoking article;
[0024] FIGS. 2-4 each show a longitudinal cross-sectional view of a
representative smoking article including a monolithic
substrate;
[0025] FIG. 5 shows a longitudinal cross-sectional view of a
representative smoking article including a tobacco pellet
substrate; and
[0026] FIG. 6 shows a two-up rod that may be used for manufacturing
the smoking article of FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] 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.
[0028] The invention provides a combustible fuel element suitable
for use in certain smoking articles adapted to heat, but not burn,
tobacco. Such smoking articles are sometimes referred to as
"heat-not-burn" tobacco products. The fuel elements of the
invention include a combustible carbonaceous material, such as a
milled carbon powder (e.g., BKO carbon powder). Such combustible
carbonaceous materials generally have high carbon content, such as
carbonaceous materials that can be characterized as comprised
predominantly of carbon, typically having a carbon content 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. The amount of
combustible carbonaceous material incorporated into a fuel element
can vary, but is typically at least about 25 percent, often at
least about 30 percent, and frequently at least about 35 percent,
of the weight of a fuel element, on a dry weight basis. An
exemplary weight range for the combustible carbonaceous material is
about 25 dry weight percent to about 60 dry weight percent, more
typically about 30 dry weight percent to about 50 dry weight
percent.
[0029] In addition to the combustible carbonaceous material, the
fuel element of the invention includes one or more ignition aids.
As used herein, "ignition aid" refers to a component of the fuel
element that reduces the time it takes to ignite the fuel element.
Advantageously, the ignition aid is a non-catalytic material,
meaning the ignition aid does not participate to any meaningful
degree in catalytic reactions, particularly with respect to gas
phase catalyzed reactions such as the catalyzed conversion of
carbon monoxide to carbon dioxide. Exemplary ignition aids include
ceramic materials, cellulose materials, fullerenes, impregnated
activated carbon materials, and combinations thereof. Although not
bound by any particular theory of operation, it is believed that
the ignition aid reduces lightability time of a fuel element of the
invention by either providing a lower ignition temperature as
compared to the primary combustible carbonaceous material or
increasing available surface area of the primary combustible
carbonaceous material.
[0030] The presence of the ignition aid reduces the time required
to ignite the fuel element, when using the lightability test set
forth in the Experimental section of this application. As noted in
the lightability test set forth herein, the goal is a
self-sustaining ignition of the fuel element over a period of time,
meaning the fuel element remains lit at least 20 seconds after
contact with an open flame, as determined by subjecting a smoking
article containing the fuel element to a puff and witnessing
whether the puff causes the fuel element to glow orange or red,
which would indicate strong combustion is taking place. In certain
embodiments, smoking articles containing fuel elements that include
ignition aids as set forth herein exhibit a lightability time of
less than about 4.5 seconds, such as less than about 4.0 seconds or
less than about 3.5 seconds. The reduction in lightability time can
be characterized in terms of a percentage reduction as compared to
a control fuel element devoid of the ignition aid (but otherwise
essentially the same in composition). For example, in certain
embodiments, smoking articles containing fuel elements that include
ignition aids as set forth herein exhibit a lightability time as
compared to a control smoking article that is at least 20% lower
than the lightability time of the control smoking article, such as
at least about 30% lower or at least about 40% lower.
[0031] The amount of ignition aid used in the fuel element can vary
and will depend, in part, on the selection of the ignition aid, the
formulation of the fuel element, and the desired ignition
properties. Typically, the ignition aid will be present in an
amount of at least about 0.01 percent by dry weight of the fuel
element, more typically at least about 0.05 percent by dry weight,
at least about 0.1 percent by dry weight, or at least about 0.5
percent by dry weight. The ignition aid will typically not be used
in amounts exceeding about 40 percent by dry weight, such as less
than about 30 percent by dry weight or less than about 25 percent
by dry weight or less than about 20 percent by dry weight.
Typically, the ignition aid will be present in an amount less than
the combustible carbonaceous material. An advantageous range for
the ignition aid is from about 0.01 dry weight percent to 20 dry
weight percent, such as about 0.01 dry weigh percent to about 10
dry weight percent or about 0.01 dry weight percent to about 5 dry
weight percent.
[0032] It has been surprisingly discovered that very low inclusion
levels of the ignition aids noted herein and successfully reduce
the lightability time of fuel elements of the invention. For
example, in certain cases, ignition aids present in an amount of no
more than about 5 dry weight percent (based on total weight of fuel
element), particularly no more than about 2.5 dry weight percent or
no more than about 1.0 dry weight percent. In some instances, the
ignition aid can be present in any amount of no more than about 0.5
dry weight percent or no more than about 0.25 dry weight percent.
In particular, it is noted that inorganic salts and ceramic
materials can be used successfully at very low inclusion
levels.
[0033] The ignition aid used in the present invention will
typically be in a granular or particulate form (such granular or
particulate materials being generically referred to herein as
"particles"), and the particles of the ignition aid can be solid or
hollow (e.g., particles containing a gas-filled cavity). The
particle size can vary, but the particles are typically sized in a
range that can be referred to as microparticles or nanoparticles.
Exemplary ranges include microparticles having an average particle
size of about 0.1 to about 1,000 microns, such as about 10 to about
300 microns (e.g., about 10 to about 50 microns). In one exemplary
embodiment, the ignition aid is present in the form of
microparticles having an average particle size of less than about
250 microns or less than about 200 microns or less than about 150
microns (e.g., about 20 to about 250 microns). Nanoparticle size
ranges include particles having an average particle size of less
than about 100 nm (e.g., about 50 to about 100 nm). The overall
shape of the particles can vary without departing from the present
invention, and some shapes can be characterized as irregular. In
some embodiments, the particles can be substantially spherical in
shape (e.g., microspheres).
[0034] Average primary particle size can be determined by visually
examining a micrograph of a transmission electron microscopy
("TEM") image or a scanning electron microscopy ("SEM") image,
measuring the diameter of the particles in the image, and
calculating the average primary particle size of the measured
particles based on magnification of the TEM or SEM image. The
primary particle size of a particle refers to the smallest diameter
sphere that will completely enclose the particle, and this
measurement relates to an individual particle as opposed to an
agglomeration of two or more particles. The above-noted size ranges
are average values for particles having a distribution of sizes. It
is also possible to use mixtures of particles having different
average particle sizes within the ranges noted herein (e.g.,
bimodal particle distributions). In certain embodiments,
commercially available materials can be purchases and ground to the
desired size using equipment known in the art, such as bead mills,
ball mills, hammer mills, and the like.
[0035] In certain embodiments, the ignition aid is in the form of
ceramic particles, preferably in a size range of about 1,000
microns or less. Such ceramic particles are understood to include
inorganic metal-containing (including metalloid-containing) oxide
(e.g., alumina, silica, iron oxide, ceria, zirconia, and the like)
or nonoxide (e.g., carbide, boride, nitride, and the like)
particles that are noncombustible at the combustion temperatures of
the fuel element. In one embodiment, the ceramic particles are
glass bubbles, sometimes referred to as microballoons or glass
microspheres, which are hollow glass particles. Exemplary glass
bubble materials include those materials marketed by 3M as the
3M.TM. Glass Bubble Series such as the K20, S35, XLD3000 and
XLD6000 materials. Other ceramic particulate materials include
those marketed as 3M.TM. Ceramic Microspheres (e.g., W-210, W-410,
or W-610) and the inert ceramic materials marketed by Tipton
Corporation as Ceramic Balls (e.g., BSS18) or High Alumina Balls
(e.g., BSS99). In a further embodiment, the ceramic particles are
cenospheres, which are understood to be hollow spheres formed
largely of silica and alumina and produced as a byproduct of coal
combustion. See, for example, the cenospheres available from
CenoStar Corporation or the cenospheres available from Omya UK Ltd.
under the tradename Fillite.RTM.. Optionally, the ceramic particles
can be metal-coated using metals such as nickel, iron, copper, tin,
silver, and gold. Exemplary metal-coated ceramics are available
from Federal Technology Group of Bozeman, MT or Accumet Materials
Company of Ossining, N.Y. Although not bound by any particular
theory of operation, it is believed that ceramic particles can aid
ignition of the fuel element (i.e., reduce the time it takes to
light the fuel element) by increasing the surface area of the
combustible carbonaceous material in the fuel element.
[0036] In another embodiment, the ignition aid is in the form of
cellulose particles (e.g., made from cotton linters) such as
cellulose particles available from Sigma-Aldrich under the
tradename SIGMACELL. Such cellulose materials are typically
microparticles within the particle size ranges set forth above.
Although not bound by any particular theory of operation, it is
believed that the addition of combustible cellulose material aids
ignition of the fuel element because such materials have an
ignition temperature below that of the combustible carbonaceous
material of the fuel element referenced above.
[0037] In another embodiment, the ignition aid is a fullerene,
which is understood to refer to allotropes of carbon atoms that are
typically in the shape of spheres, ellipsoids, or tubes,
specifically including carbon nanotubes.
[0038] In still further embodiments, the ignition aid is an
impregnated activated carbon particulate material. Exemplary
activated carbon materials are impregnated with metals (e.g., Ag or
Mg), metal oxides (e.g., ZnO, CaO, Al.sub.2O.sub.3, MgO, CuO,
Cu/CrO, Fe.sub.2O.sub.3), inorganic salts (e.g., NaOH, KOH, KI,
KMnO.sub.4, K.sub.2CO.sub.3 and Na.sub.2CO.sub.3), mineral acids
(e.g., H.sub.2SO.sub.4 or H.sub.3PO.sub.4) and the like. One source
for such materials is Calgon Corporation. Such impregnated carbon
materials are typically microparticles within the particle size
ranges set forth above. Although not bound by any particular theory
of operation, it is believed that the addition of impregnated
carbon materials aids ignition of the fuel element because such
materials have an ignition temperature below that of the
combustible carbonaceous material of the fuel element referenced
above.
[0039] The lightability aid could also be in the form of inorganic
salts such as various alkali metal or alkaline earth metal salts,
typically in the form of oxides, halides, or sulfates (including
bisulfates). Examples include sodium chloride, sodium sulfate,
magnesium chloride, magnesium sulfate, calcium chloride, calcium
sulfate, potassium chloride, potassium sulfate, sodium bisulfate,
and the like.
[0040] The fuel element will typically also include a binding agent
to enhance the cohesiveness of the composition. Exemplary binding
agents include natural gums (e.g., guar gum) or alginate materials
(e.g., ammonium alginate or sodium alginate). The binding agent is
typically present in an amount of about 5 percent by dry weight of
the fuel element to about 25 percent by dry weight (e.g., about 7.5
to about 15 percent by dry weight).
[0041] The fuel element composition of the present invention can
also include graphite in addition to the primary carbonaceous
material referenced above. For example, the fuel composition
described above can further comprise at least about 2 dry weight
percent, at least about 5 dry weight percent, or at least about 7.5
dry weight percent powdered graphite, based on the dry weight of
the fuel element. Typically, the amount of graphite added to the
fuel element composition does not exceed about 20 dry weight
percent. The graphite is typically added in a powdered form having
an average particle size of less than about 50 microns.
[0042] The fuel element composition can further comprise an
inorganic filler, such as calcium carbonate or sodium carbonate.
Typical amounts of such inorganic fillers include at least about 1
dry weight percent, at least about 5 dry weight percent, or at
least about 10 dry weight percent, based on the dry weight of the
fuel element. Typically, the amount of inorganic filler added to
the fuel element composition does not exceed about 40 dry weight
percent, and most often is less than about 35 dry weight
percent.
[0043] The fuel element composition may also include a catalytic
metal material, which can reduce the concentration of certain
gaseous components of mainstream smoke generated during use of a
smoking article incorporating the fuel element. As used herein,
"catalytic metal material" refers to elemental metal or a
metal-containing compound that can either directly react with one
or more gas phase components of mainstream smoke generated by a
smoking article or catalyze a reaction involving a gas phase
component of mainstream smoke or both, such that concentration of
the gas phase component is reduced. For example, certain catalytic
metal materials can catalyze the oxidation of CO to CO.sub.2 in the
presence of oxygen in order to reduce the level of CO in mainstream
smoke (i.e., oxidation catalysts). In US 2007/0215168 to Banerjee
et al., which is incorporated by reference herein in its entirety,
smoking articles comprising fuel elements treated with cerium oxide
particles are described. The cerium oxide particles reduce the
amount of carbon monoxide emitted during use of smoking articles
incorporating the treated fuel elements. Additional catalytic metal
compounds are described in U.S. Pat. No. 6,503,475 to McCormick;
U.S. Pat. No. 6,503,475 to McCormick; U.S. Pat. No. 7,011,096 to Li
et al.; and U.S. Pat. No. 8,617,263 to Banerjee et al.; and US Pat.
Publication Nos. 2002/0167118 to Billiet et al.; 2002/0172826 to
Yadav et al.; 2002/0194958 to Lee et al.; 2002/014453 to Lilly Jr.,
et al.; 2003/0000538 to Bereman et al.; and 2005/0274390 to
Banerjee et al., which are also incorporated by reference herein in
their entirety.
[0044] Examples of the metal component of the catalytic metal
material include, but are not limited to, alkali metals, alkaline
earth metals, transition metals in Groups IIIB, IVB, VB, VIB VIIB,
VIIIB, IB, and IIB, Group IIIA elements, Group IVA elements,
lanthanides, and actinides. Specific exemplary metal elements
include Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, Fe, Co, Ni, Ru,
Rh, Pd, Os, Ir, Pt, Cu, Ag, Au, Zn, Y, Ce, Na, K, Cs, Mg, Ca, B,
Al, Si, Ge, and Sn. Catalytic metal materials can be used in a
variety of solid particulate forms including precipitated metal
particles, metal oxide particles (e.g., iron oxides, copper oxide,
zinc oxide, and cerium oxide), and supported catalyst particles
wherein the catalytic metal compound is dispersed within a porous
supporting material. Combinations of catalytic metal materials can
be used, such as a combination of a palladium catalyst with cerium
oxide. The particle size of the catalytic metal materials can vary,
but is typically about 1 nm to about 10 microns. The amount of
catalytic metal material used can vary, but is typically in an
amount of at least about 2.5 dry weight percent, at least about 5
dry weight percent, or at least about 10 dry weight percent, based
on the dry weight of the fuel element. The catalytic metal material
is typically present in an amount of less than about 35 dry weight
percent, more often less than about 30 dry weight percent or less
than about 25 dry weight percent.
[0045] In addition to the above-noted components, the combustible
fuel element of the invention can incorporate tobacco components
(e.g., powdered tobacco or tobacco extract); flavoring agents; or
ammonia sources such as ammonia salts. These types of components
are typically used in amounts of less than about 10 dry weight
percent, and often less than about 5 dry weight percent, based on
the dry weight of the fuel element.
[0046] The various components of the fuel element composition may
be contacted, combined, or mixed together in conical-type blenders,
mixing drums, ribbon blenders, or the like, such as a Hobart mixer.
As such, the overall mixture of various components may, in some
embodiments, be relatively uniform in nature. In particular, it is
advantageous for the ignition aid to be dispersed throughout the
fuel element composition in a substantially uniform manner. Upon
mixing, the fuel element composition is typically in the form of a
moist, dough-like paste. Thereafter, the fuel element can be formed
into the desired shape by techniques such as compression, pressing,
or extrusion. For example, the composition can be extruded using
single screw or twin screw extruder. Exemplary types of extrusion
devices include those types available as ICMA San Giorgio Model No.
70-16D or as Welding Engineers Model No. 70-16LD. For an extruded
fuel element containing a relatively high level of carbonaceous
material, the density of the fuel element can be decreased slightly
by increasing the moisture level within the extruded mixture,
decreasing the die pressure within the extruder, or incorporating
relatively low density materials within the extruded mixture.
[0047] Alternatively, the fuel element can be formed using a foamed
carbon monolith structure as the primary carbonaceous material,
such as a carbon monolith formed using a foam process of the type
disclosed in U.S. Pat. App. Pub. No. 2008/0233294 to Lobovsky,
which is incorporated herein by reference. Various additional
components, such as the ignition aid, can be incorporated into the
monolith structure using known techniques such as spray-coating or
dip-coating the monolith structure.
[0048] 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. See, for example, the types of fuel elements,
representative components, designs and configurations thereof, and
manners and methods for producing those fuel elements and the
components thereof, 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. 8,469,035 to Banerjee et al.; and
U.S. Pat. App. Pub. Nos. 2005/0274390 to Banerjee et al.;
2007/0215167 to Crooks et al.; 2007/0215168 to Banerjee et al.;
2012/0042885 to Stone et al.; and 2013/0269720 to Stone et al.; and
U.S. application Ser. No. 14/036,536 to Conner et al. filed Sep.
25, 2013, which are incorporated herein by reference.
[0049] The fuel element prepared according to the method of the
invention can be utilized in a variety of smoking articles, such as
any of the smoking articles set forth in US 2007/0215167 to Crooks
et al. or US 2007/0215168 to Banerjee et al., which are
incorporated by reference herein. Exemplary smoking article
construction may include features such as fibrous filter elements,
foamed ceramic monoliths formed as insulators, and other features
disclosed in U.S. Pat. No. 8,464,726 and U.S. Pat. Pub. No.
2013/0233329; both to Sebastian et al., which are incorporated
herein by reference. Representative types of smoking articles that
can utilize the fuel elements of the invention are set forth in
FIGS. 1 through 6. The fuel element is referred to as a heat source
in the accompanying drawings and forms part of the heat generation
segment of the smoking article.
[0050] FIG. 1 illustrates a representative smoking article 10 in
the form of a 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 may be coaxially encircled by wrapping material 45. The
heat source 40 preferably is configured to be activated by direct
ignition of the lighting end 14. The smoking article 10 also
includes a filter segment 65 located at the other end (mouth end
18), and an aerosol-generating segment 51 (which may incorporate
tobacco) that is located in between those two segments.
[0051] Another embodiment of a fuel element 40 may include a foamed
carbon monolith formed in a foam process. In another embodiment,
the fuel element 40 may be co-extruded with a layer of insulation
42, thereby reducing manufacturing time and expense. Still other
embodiments of fuel elements may include those of the types
described in U.S. Pat. No. 4,819,655 to Roberts et al, or U.S. Pat.
App. Pub. No. 2009/0044818 to Takeuchi et al., each of which is
incorporated herein by reference.
[0052] A representative layer of insulation 42 can comprise 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. The insulation 42 can be provided as a
multi-layer component including an inner layer or mat of non-woven
glass filaments, an intermediate layer of reconstituted tobacco
paper, and an outer layer of non-woven glass filaments. These may
be concentrically oriented or each overwrapping and/or
circumscribing the heat source. Various other insulation
embodiments may be molded, extruded, foamed, or otherwise formed.
Particular embodiments of insulation structures may include those
described in U.S. Pat. App. Pub. No. 2012/0042885 to Stone et al.,
which is incorporated by reference herein in its entirety.
[0053] 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 may 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.
[0054] The heat generation segment 35 preferably is positioned with
one end disposed at the lighting end 14, and is axially aligned in
an end-to-end relationship with a downstream aerosol-generating
segment 51, preferably abutting one another, but 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/fuel element 40 of the heat
generation segment 35.
[0055] The cross-sectional shape and dimensions of the heat
generation segment 35, prior to burning, can vary. Preferably, the
cross-sectional area of the 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 that 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 that segment 35. For example, for a cylindrical smoking
article having a circumference of about 24 mm to about 26 mm, a
representative 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.
[0056] A longitudinally extending, cylindrical aerosol-generating
segment 51 is located downstream from the heat generation segment
35. The aerosol-generating segment 51 includes a substrate material
55 that, in turn, acts as a carrier for an aerosol-forming agent or
material (not shown). For example, the aerosol-generating segment
51 can include a reconstituted tobacco material that includes
processing aids, flavoring agents, and glycerin. The foregoing
components of the aerosol-generating segment 51 can be disposed
within, and circumscribed by, a wrapping material. The wrapping
material 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 51. That is, the aerosol-generating segment 51 and the heat
generation segment 35 can be configured in a heat exchange
relationship with one another. The heat exchange relationship is
such that sufficient heat from the heat source 40 is supplied to
the aerosol-formation region to volatilize aerosol-forming material
for aerosol formation. In some embodiments, the heat exchange
relationship is achieved by positioning those segments in close
proximity to one another. A heat exchange relationship also can be
achieved by extending a heat conductive material from the vicinity
of the heat source 40 into or around the region occupied by the
aerosol-generating segment 51. Particular embodiments of substrates
may include those described below or those described in U.S. Pat.
App. Pub. No. 2012/0042885 to Stone et al., which is incorporated
by reference herein in its entirety.
[0057] A representative wrapping material for the substrate
material 55 may include heat conductive properties to conduct heat
from the heat generation segment 35 to the aerosol-generating
segment 51, in order to provide for the volatilization of the
aerosol forming components contained therein. The substrate
material 55 may be about 10 mm to about 22 mm in length, with
certain embodiments being about 11 mm up to about 21 mm. The
substrate material 55 can be provided from a blend of flavorful and
aromatic tobaccos in cut filler form. Those tobaccos, in turn, can
be treated with aerosol-forming material and/or at least one
flavoring agent. The substrate material can be provided from 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 to about 300
mg of tobacco per 10 mm of linear length. That tobacco, in turn,
can be treated with, or processed to incorporate, aerosol-forming
material and/or at least one flavoring agent, as well as a burn
retardant (e.g., diammonium phosphate or another salt) configured
to help prevent ignition and/or scorching by the heat-generation
segment. A metal inner surface of the wrapping material of the
aerosol-generating segment 51 can act as a carrier for
aerosol-forming material and/or at least one flavoring agent.
[0058] In other embodiments, the substrate 55 may include a tobacco
paper or non-tobacco gathered paper formed as a plug section. The
plug section may be loaded with aerosol-forming materials,
flavorants, tobacco extracts, or the like in a variety of forms
(e.g., microencapsulated, liquid, powdered). A burn retardant
(e.g., diammonium phosphate or another salt) may be applied to at
least a distal/lighting-end portion of the substrate to help
prevent ignition and/or scorching by the heat-generation segment.
In these and/or other embodiments, the substrate 55 may include
pellets or beads formed from marumarized and/or non-marumarized
tobacco. Marumarized tobacco is known, for example, from U.S. Pat.
No. 5,105,831 to Banerjee, et al., which is incorporated herein by
reference. Marumarized tobacco may include, for example, about 20
to about 50 percent (by weight) tobacco blend in powder form, with
glycerol (at about 20 to about 30 percent by weight), calcium
carbonate (generally at about 10 to about 60 percent by weight,
often at about 40 to about 60 percent by weight), along with binder
and flavoring agents. The binder may include, for example, a
carboxymethyl cellulose (CMC), gum (e.g., guar gum), xanthan,
pullulan, and/or an alginate. The beads, pellets, or other
marumarized forms may be constructed in dimensions appropriate to
fitting within a substrate section and providing for optimal air
flow and production of desirable aerosol. A container, such as a
cavity or capsule, may be formed for retaining the substrate in
place within the smoking article. Such a container may be
beneficial to contain, for example, pellets or beads of marumarized
and/or non-marumarized tobacco. The container may be formed using
wrapping materials as further described below.
[0059] As noted above, the aerosol-generating segment 51 may
include aerosol-generating material or elements that can be defined
as beads, pellets, or other discrete small units of a composition
typically including tobacco or some component thereof (e.g.,
marumarized and/or non-marumarized tobacco). Such 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 pellet may range from less than about 1 mm to
about 2 mm. The pellets may at least partially fill a substrate
cavity of a smoking article as described herein. 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 pellets within the substrate cavity may range from
about 200 mg to about 500 mg.
[0060] In general, as used herein, the terms "pellets" and "beads"
are meant to include beads, pellets, or other discrete small units
or pieces of that may include (in addition to those otherwise
disclosed herein), for example, carbon pieces, extruded carbon
pieces cut into pellets, ceramic beads, marumarized tobacco pieces,
and the like, or combinations thereof. For example, granules,
pellets or beads can be generally cylindrical or spherical extruded
or compressed granules, pellets or beads comprised of a moistened
mixture or slurry of milled tobacco lamina, fillers (e.g., granular
calcium carbonate), flavors, visible aerosol forming materials and
binders (e.g., carboxy methylcellulose) that are formed, cut or
spun to the desired size and shape, and then dried to retain the
desired configuration. For example, some or all of the beads or
pellets can comprise spherical capsules that are heat sensitive, so
that when included in the aerosol-generating element and exposed to
heat, the rupture or decomposition thereof causes the release of
glycerin, propylene glycol, water, saline, tobacco flavor and/or
nicotine or other substances or additives. Also, the beads can
comprise ceramic or absorbent clay or silica or absorbent carbon to
hold and release an aerosol former. Further, in some aspects, the
beads/pellets may comprise a heat conductive material such as, for
example, heat conductive graphite, heat conductive ceramic, a
metal, tobacco cast on foil, a metal or other suitable material
impregnated with appropriate aerosol-generating substances such as
glycerin and flavor(s), or a suitable cast sheet material
appropriately formed into the desired beads/pellets.
[0061] In one particular example, the beads/pellets (particles) may
be comprised, by weight, of between about 15% and about 60% of
finely milled tobacco particles (e.g., a blend of Oriental, burley
and flue-cured tobaccos, essentially all Oriental tobacco,
essentially all burley tobacco, or essentially all flue-cured
tobacco), between about 15% and about 60% of finely milled
particles of calcium carbonate (or finely milled clay or ceramic
particles), between about 10% and about 50% of glycerol (and
optionally a minor amount of flavors), between about 0.25% and
about 15% of a binder (preferably carboxymethylcellulose, guar gum,
potassium, or ammonium alginate), and between about 15% and about
50% of water. In another example, the beads/pellets (particles) may
be comprised of about 30% of finely milled tobacco particles (e.g.,
a blend of Oriental, burley and flue-cured tobaccos, essentially
all Oriental tobacco, essentially all burley tobacco, or
essentially all flue-cured tobacco), about 30% of finely milled
particles of calcium carbonate (or finely milled clay or ceramic
particles), about 15% of glycerol (and optionally a minor amount of
flavors), about 1% of a binder (preferably carboxymethylcellulose,
guar gum, potassium, or ammonium alginate), and about 25% of
water.
[0062] In such examples, the pellets may be compressed to hold the
glycerol and, upon compression, may form a porous matrix that
facilitates migration of the aerosol generating components to
promote efficient aerosol formation. The manner by which the
aerosol forming material is contacted with the substrate material
can vary. The aerosol forming material can be applied to a formed
material, can be incorporated into processed materials during
manufacture of those materials, or can be endogenous to that
material. Aerosol-forming material, such as glycerin, 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 Appl. Pub. No. 2005/0066986
to Nestor et al. and 2012/0067360 to Conner et al.; which are
incorporated herein by reference. The calcium carbonate or other
inorganic filler assists in creating porosity within the particles,
and may also function to absorb heat which may, in some instances
limit or otherwise prevent scorching of the aerosol generating
components, as well as assisting in and promoting aerosol
formation. See also, for example, those types of materials set
forth in U.S. Pat. No. 5,105,831 to Banerjee, et al., and U.S. Pat.
App. Pub. Nos. 2004/0173229 to Crooks et al.; 2011/0271971 to
Conner et al.; and 2012/0042885 to Stone et al.; which are
incorporated herein by reference.
[0063] The tobacco-derived component of the beads or pellets can
include highly purified tobacco-derived nicotine (e.g.,
pharmaceutical grade nicotine having a purity of greater than 98%
or greater than 99%) or a derivative thereof can be used in the
present invention. Representative nicotine-containing extracts can
be provided using the techniques set forth in U.S. Pat. No.
5,159,942 to Brinkley et al., which is incorporated herein by
reference. In certain embodiments, the products of the invention
can include nicotine in any form from any source, whether
tobacco-derived or synthetically-derived. Nicotinic compounds used
in the products of the invention can include nicotine in free base
form, salt form, as a complex, or as a solvate. See, for example,
the discussion of nicotine in free base form in U.S. Pat. Pub. No.
2004/0191322 to Hansson, which is incorporated herein by reference.
At least a portion of the nicotinic compound can be employed in the
form of a resin complex of nicotine where nicotine is bound in an
ion exchange resin such as nicotine polacrilex. See, for example,
U.S. Pat. No. 3,901,248 to Lichtneckert et al.; which is
incorporated herein by reference. At least a portion of the
nicotine can be employed in the form of a salt. Salts of nicotine
can be provided using the types of ingredients and techniques set
forth in U.S. Pat. No. 2,033,909 to Cox et al. and Perfetti,
Beitrage Tabakforschung Int., 12, 43-54 (1983). Additionally, salts
of nicotine have been available from sources such as Pfaltz and
Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals,
Inc. Exemplary pharmaceutically acceptable nicotine salts include
nicotine salts of tartrate (e.g., nicotine tartrate and nicotine
bitartrate), chloride (e.g., nicotine hydrochloride and nicotine
dihydrochloride), sulfate, perchlorate, ascorbate, fumarate,
citrate, malate, lactate, aspartate, salicylate, tosylate,
succinate, pyruvate, and the like; nicotine salt hydrates (e.g.,
nicotine zinc chloride monohydrate), and the like. In certain
embodiments, at least a portion of the nicotinic compound is in the
form of a salt with an organic acid moiety, including, but not
limited to, levulinic acid as discussed in U.S. Pat. Pub. No.
2011/0268809 to Brinkley et al., which are incorporated herein by
reference.
[0064] In one embodiment, the aerosol-generating materials
discussed herein, such as those in the form of beads or pellets,
can be smoke-treated to impart smoky flavor or aroma. For example,
the beads or pellets can be prepared and then subjected to smoke
from a combustible source, such as a wood source (e.g., wood
selected from hickory, maple, oak, apply, cherry, or mesquite). The
beads or pellets can be treated with the smoke for a time
sufficient to impart the desired smoky flavor or aroma, with an
exemplary time range being about 5 to about 45 minutes. The manner
in which the beads or pellets are contacted with smoke can vary,
with one example involving heating wood chips in a container until
smoke is produced (e.g., heating wood chips to a temperature of
about 350-400.degree. F.) and placing the beads or pellets to be
treated within a closed environment with the smoke produced by the
wood chips.
[0065] In still other embodiments, the substrate 55 may be
configured as a monolithic substrate, formed, for example, as
described in U.S. Pat. App. Pub. No. 2012/0042885 to Stone et al.,
which is incorporated herein by reference in its entirety. The
substrate may include or be constructed from an extruded material.
The substrate also may be formed by press-fit or molding/casting.
Thus, the generic term "monolithic substrate" may include a
substrate formed by extrusion or by one of those other methods.
[0066] In some preferred smoking articles, both ends of the
aerosol-generating segment 51 are open to expose the substrate
material 55 thereof. Together, the heat generating segment 35 and
the aerosol-generating segment 51 form an aerosol-generation
system. The aerosol-generating segment 51 is positioned adjacent to
the downstream end of the heat generation segment 35 such that
those segments 51, 35 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 a buffer
region 53. 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 means that includes conductive
and convective heat transfer) from the heat source 40 to the
adjacent substrate material 55, throughout the time that the heat
source is activated (e.g., burned) during use of the smoking
article 10.
[0067] A buffer region 53 may reduce potential scorching or other
thermal degradation of portions of the aerosol-generating segment
51. The buffer region 53 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). The components of the
aerosol-generation system preferably are attached to one another,
and secured in place using an overwrap material 64. For example,
the overwrap material 64 can include a paper wrapping material or a
laminated paper-type material that circumscribes each of the heat
generation segment 35, and at least a portion of outer
longitudinally extending surface of the aerosol-generating segment
51. The inner surface of the overwrap material 64 may be secured to
the outer surfaces of the components it circumscribes by a suitable
adhesive.
[0068] The smoking article 10 preferably includes a suitable
mouthpiece such as, for example, a filter element 65, positioned at
the mouth end 18 thereof. The filter element 65 preferably is
positioned at one end of the cigarette rod adjacent to one end of
the aerosol-generating segment 51, such that the filter element 65
and the aerosol-generating segment 51 are axially aligned in an
end-to-end relationship, abutting one another but without any
barrier therebetween. Preferably, the general cross-sectional
shapes and dimensions of those segments 51, 65 are essentially
identical to one another when viewed transversely to the
longitudinal axis of the smoking article. The filter element 65 may
include filter material that is overwrapped along the
longitudinally extending surface thereof with circumscribing plug
wrap material. In one example, the filter material includes
plasticized cellulose acetate tow, while in some examples the
filter material may further include activated charcoal in an amount
from about 20 to about 80 mg disposed as a discrete charge or
dispersed throughout the acetate tow in a "Dalmatian type" filter.
Both ends of the filter element 65 preferably are open to permit
the passage of aerosol therethrough. The aerosol-generating system
preferably is attached to the filter element 65 using tipping
material 78. The smoking article 10 may include an air dilution
means, such as a series of perforations 81, each of which may
extend through the filter element tipping material 78 and plug wrap
material in the manner shown, and/or which may extend to or into
the substrate 55.
[0069] The filter element 65 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 in their entirety. Filters may include materials and may
be manufactured by methods such as, for example, those disclosed in
U.S. Pat. No. 7,740,019 to Nelson et al., U.S. Pat. No. 7,972,254
to Stokes et al., U.S. Pat. No. 8,375,958 to Hutchens et al.; and
U.S. Pat. Publ. Nos. 2008/0142028 to Fagg, et al.; and 2009/0090372
to Thomas et al., each of which is incorporated herein by
reference.
[0070] The overall dimensions of the smoking article 10, prior to
burning, can vary. Typically, smoking articles 10 are cylindrically
shaped rods having circumferences of about 20 mm to about 27 mm,
have overall lengths of about 70 mm to about 130 mm--often about 83
mm to about 100 mm. The aerosol-generation system has an overall
length that can vary from about 20 mm to about 65 mm. The heat
generation segment 35 of the aerosol-generation system may have a
length of about 5 mm to about 30 mm; and the aerosol-generating
segment 51 of the aerosol-generation system may have an overall
length of about 10 mm to about 60 mm.
[0071] The combined amount of aerosol-forming agent and substrate
material 55 employed in the aerosol-generating segment 51 can vary.
The material preferably may be employed so as to fill the
appropriate section of the aerosol-generating segment 51 (e.g., the
region within the wrapping material thereof) at a packing density
of about 100 to about 400 mg/cm.sup.3.
[0072] During use, the smoker lights the lighting end 14 of the
smoking article 10 using a match or cigarette lighter, in a manner
similar to the way that conventional smoking articles are lit, such
that the heat source/fuel element 40 at the lighting end 14 is
ignited. The mouth end 18 of the smoking article 10 is placed in
the lips of the smoker. Thermal decomposition products (e.g.,
components of tobacco smoke) generated by the aerosol generation
system are drawn through the smoking article 10, through the filter
element 65, and into the mouth of the smoker. That is, when smoked,
the smoking article yields visible mainstream aerosol that
resembles the mainstream tobacco smoke of traditional cigarettes
that burn tobacco cut filler.
[0073] Direct ignition actuates the fuel element 40 of the heat
generation segment 35 such that it preferably will be ignited or
otherwise activated (e.g., begin to burn). The heat source 40
within the aerosol-generation system will burn, and provide heat to
volatilize aerosol-forming material within the aerosol-generating
segment 51 as a result of the heat exchange relationship between
those two segments. Certain preferred heat sources 40 will not
experience volumetric decrease during activation, while others may
degrade in a manner that reduces their volume. Preferably, the
components of the aerosol-generating segment 51 do not experience
thermal decomposition (e.g., charring or burning) to any
significant degree. Volatilized components are entrained in the air
that is drawn through the aerosol-generating region 51. The aerosol
so formed will be drawn through the filter element 65, and into the
mouth of the smoker.
[0074] During certain periods of use, aerosol formed within the
aerosol-generating segment 51 will be drawn through the filter
element 65 and into the mouth of the smoker. Thus, the mainstream
aerosol produced by the smoking article 10 includes tobacco smoke
produced by the volatilized aerosol-forming material.
[0075] Flavor may be provided or enhanced by capsule or
microcapsule materials on or within the substrate material 55 of
the aerosol-generating segment 51, the wrapping materials, the
filter element 65, or any other component capable of holding and
releasing flavorants, preferably with minimal thermal degradation
that would undesirably alter the flavor. Other flavor components
associated with a filter may also be used; see, for example, U.S.
Pat. No. 5,724,997 to Fagg, et al.
[0076] As noted above, the fuel element preferably will be
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.
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, 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.; and U.S.
Pat. No. 8,464,726 to Sebastian et al.; which are incorporated
herein by reference. Insulation assemblies have been incorporated
within the types of cigarettes commercially marketed under the
trade names "Premier" and "Eclipse" by R. J. Reynolds Tobacco
Company, and as "Steam Hot One" cigarette marketed by Japan Tobacco
Inc.
[0077] Flame/burn retardant materials and additives useful in
insulation may include silica, carbon, ceramic, metallic fibers
and/or particles. When treating cellulosic or other fibers such
as--for example--cotton, boric acid or various organophosphate
compounds may provide desirable flame-retardant properties. In
addition, various organic or metallic nanoparticles may confer a
desired property of flame-retardancy, as may diammonium phosphate
and/or other salts. Other useful materials may include
organo-phosphorus compounds, borax, hydrated alumina, graphite,
potassium tripolyphosphate, dipentaerythritol, pentaerythritol, and
polyols. Others such as nitrogenous phosphonic acid salts,
mono-ammonium phosphate, ammonium polyphosphate, ammonium bromide,
ammonium chloride, ammonium borate, ethanolammonium borate,
ammonium sulphamate, halogenated organic compounds, thio-urea, and
antimony oxides may be used but are not preferred agents. In each
embodiment of flame-retardant, burn-retardant, and/or
scorch-retardant materials used in insulation, substrate material
and other components (whether alone or in any combination with each
other and/or other materials), the desirable properties most
preferably are provided without undesirable off-gassing or
melting-type behavior.
[0078] An insulation fabric preferably will have sufficient oxygen
diffusion capability to sustain a smoking article such as a
cigarette in a lit condition during a desired usage time.
Accordingly the insulation fabric preferably will be porous by
virtue of its construction. In knit, woven, or combined woven and
knit constructions, the required porosity may be controlled by
configuring the assembly machinery to leave sufficient (desirably
sized) gaps between fibers to allow for oxygen diffusion into the
heat source. For non-woven fabrics, which may not be porous enough
to promote evenly sustained combustion, additional porosity may be
achieved by perforations into the insulation by methods known in
the art including, for example, hot or cold pin perforation, flame
perforation, embossing, laser cutting, drilling, blade cutting,
chemical perforation, punching, and other methods. Each of the
buffer and the insulation may include non-glass material that is
woven, knit, or a combination thereof, a foamed metal material, a
foamed ceramic material, a foamed ceramic metal composite, and any
combination thereof, and the material in the insulation may be the
same as or different than that in the buffer.
[0079] The aerosol-forming material can vary, and mixtures of
various aerosol-forming materials can be used, as can 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), wrapping
materials, mouth-end pieces, filter elements, plug wrap, and
tipping material. Representative types of these components are set
forth in U.S. Pat. App. Pub. No. 2007/0215167 to Llewellyn Crooks,
et al., which is incorporated herein by reference in its
entirety.
[0080] The substrate material can incorporate tobacco of some form,
normally is composed predominantly of tobacco, and can be provided
by virtually all tobacco material. The form of the substrate
material can vary. In some embodiments, the substrate material is
employed in an essentially traditional filler form (e.g., as cut
filler). The substrate material can be otherwise formed into
desired configurations (see, e.g., U.S. Pat. Pub. No. 2011/0271971
to Conner et al., which is incorporated herein by reference). The
substrate material can be used in the form of 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, which is incorporated herein by
reference in its entirety. The substrate material can be used 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, which is
incorporated herein by reference in its entirety. The substrate
material can have the form of a loosely rolled sheet, such that a
spiral type of air passageway extends longitudinally through the
aerosol-generating segment. Representative types of tobacco
containing substrate materials can be manufactured from mixtures of
tobacco types; or from one predominant type of tobacco (e.g., a
cast sheet-type or paper-type reconstituted tobacco composed
primarily of burley tobacco, or a cast sheet-type or paper-type
reconstituted tobacco composed primarily of Oriental tobacco).
[0081] The substrate material also 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. Publication 2004/0173229 to Crooks et al., which is
incorporated herein by reference in its entirety.
[0082] 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.
[0083] 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
tobacco cut filler 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.
[0084] In other embodiments, the substrate portion of an
aerosol-generation segment may include or may be constructed from
an extruded or other monolithic material. An extruded substrate may
be formed in the same manner as described herein with reference to
other extruded components. The extruded or other monolithic
substrate may include, or may be essentially comprised of, tobacco,
glycerin, water, and binder material. In certain embodiments, a
monolithic substrate may include about 10 to about 90 weight
percent tobacco, about 5 to about 50 weight percent glycerin, about
1 to about 30 weight-percent water (before being dried and cut),
and about 0 to about 10 weight percent binder. It may also include
a filler such as, for example, calcium carbonate and/or
graphite.
[0085] Following extrusion, drying, and cutting to a desired
length, the substrate may be assembled into a segmented smoking
article such as an Eclipse-type cigarette using a manual assembly
method or a cigarette-making machine (e.g., KDF or Protus by Hauni
Maschinenbau AG). Smaller diameter monolithic substrate elements
may be combined by being wrapped, adhered, or otherwise assembled
together for use in a smoking article as described for other
substrate embodiments herein. Preferred substrate wraps include
foil paper, heavy-gauge paper, plug wrap, and/or cigarette
paper.
[0086] Cigarettes described with reference to FIG. 1 may be used in
much the same manner as those cigarettes commercially marketed
under the trade name "Eclipse" by R. J. Reynolds Tobacco Company.
See also the "Steam Hot One" cigarette marketed by Japan Tobacco
Inc.
[0087] In one embodiment, a smoking article may be constructed with
a monolithic substrate 463, described here with reference to FIG.
2, which is a longitudinal section view of a cigarette 410 having a
lighting end 414 and a mouth end 418. The monolithic substrate 463
(which may be used in other embodiments such as, for example, those
discussed with reference to FIG. 1) may be formed by any
appropriate extrusion method and is shown with a center-hole 495
extending longitudinally therethrough. The monolithic substrate,
cut to length may comprise about 1/16 to about 5/8 of the total
length of the cigarette, often about 1/10 to about 1/2 thereof
(e.g., a 10 mm, 12 mm, or 50 mm long substrate element in an 85 mm
or 130 mm long cigarette). The substrate segment 455 of the
cigarette body includes a hollow spacing tube 467 disposed between
the substrate 463 and the filter 470. The filter 470 is shown as
constructed with overlying layers of plug wrap 472 and tipping
paper 478. The substrate 463 and tube 467 are surrounded by a
wrapping material 458, which may be configured--for example--as a
heat-conducting material (e.g., foil paper), heavy-gauge paper,
plug wrap, or cigarette paper. A cylindrically-encompassing
wrapping material 464 (such as, for example, cigarette paper or
heavy-gauge paper) may be provided to connect the heat-generation
segment 435, central substrate segment 455, and filter segment 465.
The heat-generation segment 435 and other components may be
constructed as described herein and elsewhere in this and other
embodiments configured to be practiced within the scope of the
present disclosure.
[0088] In another embodiment, a smoking article may be constructed
with an elongate monolithic substrate 563, described here with
reference to FIG. 3, which is a longitudinal section view of a
cigarette 510 having a lighting end 514 and a mouth end 518. The
elongate monolithic substrate 563 (which may be used in other
embodiments) may be formed by any appropriate extrusion method and
is shown with a center-hole 595 extending longitudinally
therethrough. The filter 570 is shown as constructed with overlying
layers of plug wrap 572 and tipping paper 578. The substrate 563 is
surrounded by a wrapping material 558, which may be configured--for
example--as a heat-conducting material (e.g., foil paper),
heavy-gauge paper, plug wrap, or cigarette paper. A
cylindrically-encompassing wrapping material 564 (such as, for
example, cigarette paper or heavy-gauge paper) may be provided to
connect the heat-generation segment 535, central substrate segment
555 (consisting essentially of the substrate in this embodiment),
and filter segment 565. The heat-generation segment 535 and other
components may be constructed as described herein and elsewhere in
this and other embodiments configured to be practiced within the
scope of the present disclosure.
[0089] In one embodiment, a smoking article may be constructed with
a monolithic substrate 663, described here with reference to FIG.
4, which is a longitudinal section view of a cigarette 610 having a
lighting end 614 and a mouth end 618. The monolithic substrate 663
(which may be used in other embodiments) may be formed by any
appropriate extrusion method and is shown with a center-hole 695
extending longitudinally therethrough. The cigarette body includes
a tobacco rod 669 disposed between the substrate 663 and the filter
670. The filter 670 is shown as constructed with overlying layers
of plug wrap 672 and tipping paper 678. The substrate segment 655,
formed by the substrate 663 and tobacco rod 669, is surrounded by a
wrapping material 658, which may be configured--for example--as a
heat-conducting material (e.g., foil paper), heavy-gauge paper,
plug wrap, or cigarette paper. A cylindrically-encompassing
wrapping material 664 (such as, for example, cigarette paper or
heavy-gauge paper) may be provided to connect the heat-generation
segment 635, central substrate segment 655, and filter segment 665.
The heat-generation segment 635 and other components may be
constructed as described herein and elsewhere in this and other
embodiments configured to be practiced within the scope of the
present disclosure.
[0090] In another embodiment, a smoking article may be constructed
with a substrate 763 in the form of beads or pellets as noted
above, described here with reference to FIG. 5, which is a
longitudinal section view of a cigarette 710 having a lighting end
714 and a mouth end 718. The substrate 763 (which may be used in
other embodiments) may be formed by any appropriate method, such as
a marumarization method noted above. The cigarette body includes a
tobacco rod 769 disposed between the substrate 763 and the filter
770. The filter 770 is shown as constructed with overlying layers
of plug wrap 772 and tipping paper 778. The heat-generation segment
735 and other components may be constructed as described herein and
elsewhere in this and other embodiments configured to be practiced
within the scope of the present disclosure.
[0091] The substrate 763 may be contained within a substrate cavity
756 (see, e.g., U.S. Pat. Pub. No. 2012/0067360 to Conner et al.,
which is incorporated herein by reference). The substrate cavity
756 may be formed by the heat-generation segment 735 at one end,
the tobacco rod 769 at the opposite end, and a wrapping material
764 around the circumference of at least the substrate (and--in
some embodiments--extending along an entire length from the filter
to the lighting end). A cylindrical container structure (not shown)
may circumferentially encompass the substrate cavity 756 within the
wrapping material 764 and between the heat-generation segment 735
at one end and the tobacco rod 769 at the opposite end. The
heat-generation segment 735 and the tobacco rod 769 may be joined
to one another by the wrapping material 764. To that end, the
wrapping material 764 may circumscribe at least a downstream
portion of the heat-generation segment 735 and at least an upstream
portion of the tobacco rod 769. The heat-generation segment 735 and
the tobacco rod 769 may be spaced longitudinally from one another.
In other words, the heat-generation segment 735 and the tobacco rod
769 may not be in abutting contact with one another. The substrate
cavity 756 may be defined by a space extending longitudinally
within the wrapping material 764 between the downstream end of the
heat-generation segment 735 and the upstream end of the tobacco rod
769 as shown in FIG. 5. The substrate 763 may be positioned within
the substrate cavity 756. For example, the substrate cavity 756 may
be at least partially filled with tobacco pellets. The substrate
cavity 756 may contain the substrate 763 to prevent migration of
the tobacco pellets.
[0092] The wrapping material 764 may be configured, for example, as
a heat-conducting material (e.g., foil paper), insulating material,
heavy-gauge paper, plug wrap, cigarette paper, tobacco paper, or
any combination thereof. Additionally, or alternatively, the
wrapping material 764 may include foil, ceramic, ceramic paper,
carbon felt, glass mat, or any combination thereof. Other wrapping
materials known or developed in the art may be used alone or in
combination with one or more of these wrapping materials. In one
embodiment, the wrapping material 764 may include a paper material
having strips or patches of foil laminated thereto. The wrapping
material 764 may include a paper sheet 783. The paper sheet 783 may
be sized and shaped to circumscribe the heat-generation segment
735, the substrate cavity 756, and the tobacco rod 769 as described
above. To that end, the paper sheet 783 may be substantially
rectangular in shape with a length extending along the longitudinal
direction of the smoking article and a width extending in a
direction transverse to the longitudinal direction. The width of
the paper sheet 783 may be slightly larger than the circumference
of the smoking article 710 so that the paper sheet may be formed
into a tube or a column defining an outer surface of the smoking
article. For example, the width of the paper sheet 783 may be from
about 18 to about 29 mm. The length of the paper sheet 783 may be
sufficient to extend longitudinally along an entire length of the
substrate cavity 764 and to overlap the heat-generation segment 735
and the tobacco rod 769. For example, the length of the paper sheet
783 may be about 50 to about 66 mm. The paper sheet 783 may have a
length sufficient to overlap substantially an entire length of the
tobacco rod 769 as shown in FIG. 5. In one example, the paper sheet
(or other wrapping material) may have a thickness of about 1 mil to
about 6 mil (about 0.025 mm to about 0.15 mm).
[0093] A foil strip or patch 784 may be laminated to the paper
sheet 783 to form a laminated coated region. The foil strip 784 may
have a width extending along substantially the entire width of the
paper sheet 783 to circumscribe substantially the entire
circumference of the heat-generation segment 735, the substrate
cavity 764, and the tobacco rod 769 as further described below. The
foil strip 784 also may have a length extending along a portion of
the length of the paper sheet 783. Preferably, the foil strip 784
may extend along a sufficient portion of the length of the paper
sheet 783 such that the foil strip extends along the entire length
of the substrate cavity 756 and overlaps at least a portion of the
heat-generation segment 735 and the tobacco rod 769. For example,
the length of the foil strip 784 may be from about 16 to about 20
mm. In one example, the foil strip may have a thickness of about
0.0005 mm to about 0.05 mm.
[0094] An intermediate segment of a smoking article may include a
heat-generation segment, a substrate segment (e.g., a monolithic
substrate or a substrate cavity including pellets or beads of
substrate material), and a tobacco rod. It may be desirable to
provide such an intermediate segment from so-called "two-up" rods
that may be handled using conventional-type or suitably modified
cigarette rod handling devices, such as tipping devices available
as Lab MAX, MAX, MAX S or MAX 80 from Hauni-Werke Korber & Co.
KG. See, for example, the types of devices set forth in U.S. Pat.
No. 3,308,600 to Erdmann et al.; U.S. Pat. No. 4,281,670 to
Heitmann et al.; U.S. Pat. No. 4,280,187 to Reuland et al.; U.S.
Pat. No. 4,850,301 to Greene, Jr. et al.; U.S. Pat. No. 6,229,115
to Vos et al.; U.S. Pat. No. 7,434,585 to Holmes; and U.S. Pat. No.
7,296,578 to Read, Jr.; and U.S. Pat. Appl. Pub. No. 2006/0169295
to Draghetti, each of which is incorporated by reference
herein.
[0095] For example, FIG. 6 illustrates a two-up rod that may be
produced in the process of manufacturing a smoking article 710 of
FIG. 5, or other smoking article described herein. The two-up rod
may include two intermediate segments as described above, the
intermediate segments being joined to one another at a common
tobacco rod. The two-up rod may include two heat-generation
segments 835a, 835b positioned at opposite longitudinal ends
thereof. A tobacco rod 869 may be substantially centered along the
longitudinal axis of the rod. The tobacco rod 869 may include two
portions 869a, 869b each associated with one intermediate segment.
The tobacco rod 869 and the two heat-generation segments 835a, 835b
may be joined to one another with wrapping material 864 as
described above with reference to FIG. 5. A substrate cavity 856a
may be defined within the wrapping material 864 between the
heat-generation segment 835a and the tobacco rod 869. A substrate
863a may be contained within the substrate cavity 856a. Likewise, a
substrate cavity 856b may be defined within the wrapping material
864 between the heat-generation segment 835b and the tobacco rod
869. A substrate 863b may be contained within the substrate cavity
856b. The wrapping material 864 may include a paper sheet 883 with
foil strips 884a, 884b laminated thereto. The foil strips may be
generally aligned with the substrate cavities as described above
with reference to FIG. 5. The rod may be severed at about its
longitudinal center to form two intermediate segments, each
generally configured as described above. A tobacco rod, a hollow
tube, and/or a filter element may be attached to the downstream end
of each intermediate segment by any means to form a smoking article
as described above. The method may include providing the wrapping
material circumscribing at least a portion of the heat generation
segment, the substrate cavity, the tobacco rod, the second
substrate cavity, and at least a portion of the second heat
generation segment, a second foil strip of the wrapping material
circumscribing the second substrate cavity, wherein the foil strip
and the second foil strip are registered at a discrete interval
apart from each other, said interval calibrated to accurately and
repeatably dispose the foil strip and the second foil strip at a
desired location relative to the substrate cavity, the second
substrate cavity, the heat generation segment, and the second heat
generation segment.
[0096] Such a two-up rod and/or an intermediate segment may
facilitate handling of the substrate material during manufacturing
of a smoking article. For example, a two-up rod and/or an
intermediate segment may be processed using standard processing
equipment as described above while retaining the tobacco pellets
substrate 863 between the heat generation segment 835 and the
tobacco rod 869 and within the substrate cavity 856. In other
words, the tobacco pellets substrate may be contained within the
two-up rod and/or intermediate segment so that further processing
may be completed while avoiding migration and/or loss of the
tobacco pellets substrate. Smoking articles of the type disclosed
herein may be assembled as otherwise disclosed, for example, in
U.S. Pat. No. 5,469,871 to Barnes et al. or U.S. Pat. App. Pub. No.
2012/0042885 to Stone et al. or 2010/0186757 to Crooks et al., each
being incorporated herein by reference.
[0097] 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 explicitly 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 a specific embodiment
description 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.
EXPERIMENTAL
[0098] The present invention is more fully illustrated by the
following examples, which are set forth to illustrate the present
invention and are not to be construed as limiting thereof. In each
example, lightability of each fuel element is determined by placing
the fuel element in a smoking article of the general format set
forth in FIG. 1 and placing the smoking article in a holder.
Thereafter, a fuel element is exposed to a flame for a set time
(e.g., 0.5 seconds, 1.0 seconds, etc.) and a puff is then taken on
the smoking article of approximately 55 ml volume. The fuel element
is then removed from the flame and 15 seconds is allowed to pass.
Thereafter, a second puff of same volume is taken. If the fuel
element glows orange/red during second puff, it is considered lit.
The same general experiment is repeated, each experiment using a
incrementally higher set time of flame exposure until the fuel
element is considered lit at the time of the second puff. The
lowest set time at which the fuel element remains lit at the time
of the second puff is recorded as the lightability time. So, for
example, if a particular fuel element is exposed to a flame for 0.5
seconds according to the above test and does not glow orange or red
during the second puff, but does glow orange or red when retested
at a flame exposure time of 1.0 seconds, then the lightability time
is considered to be 1.0 seconds.
Example 1: Use of Ceramic Materials or Glass Bubbles as Ignition
Aid
[0099] Several fuel element compositions comprising milled carbon,
guar gum as a binder, calcium carbonate, and graphite are formed
and heat-not-burn cigarettes are constructed therewith. The time
required to ignite each fuel element composition is measured and
compared to the commercially available ECLIPSE product (which has
five exterior grooves in the fuel element) as well as another
control fuel element having 8 external grooves in the fuel element.
The tested compositions include varying amounts of ceramic
microspheres (W-610 microspheres available from 3M) including
microsphere inclusion levels of 0.05 weight percent, 0.075 weight
percent, and 0.1 weight percent (wherein the milled carbon amount
is reduced to accommodate the ceramic microspheres). Some of the
experimental compositions are fashioned into a fuel element with
either 5 or 8 external grooves, and in one case, with both 8
grooves and a center hole therethrough.
[0100] The ECLIPSE product with five grooves (no ceramic
microspheres) has a lightability time of 6.0-6.5 seconds. The
8-groove control (no ceramic microspheres) has a lightability of
5.0-5.5 seconds. The 8-groove control with a center hole (no
ceramic microspheres) has a lightability of 3.5 seconds.
[0101] The lightability time for the experimental fuel element with
0.05 weight percent of ceramic microspheres and 5 grooves is
3.5-4.0 seconds. The lightability time for the experimental fuel
element with 8 grooves and 0.05 weight percent, 0.075 weight
percent, or 0.1 weight percent of ceramic microspheres is 3.0-3.5
seconds, 3.5 seconds, 2.8-3.0 seconds, respectively. A fuel element
with 8 grooves, a center hole, and 0.1 weight percent ceramic
microspheres has a lightability time of 1.5 seconds.
[0102] A similar test was conducted with glass bubbles (also
available from 3M) at an inclusion level of 0.05 weight percent. A
fuel element containing the glass bubbles and having 8 grooves and
a center hole has a lightability time of 1.8-2.0 seconds.
[0103] A similar test was conducted using fuel element compositions
containing alumina powder available from CeramTec (product number
T64-325) at an inclusion level of 0.1 weight percent and with 8
external grooves on the fuel element. The lightability time is
within range of 3.0-3.5 seconds.
[0104] A similar test was conducted using fuel element compositions
containing sand available from ACROS Organics (Fisher Scientific)
at an inclusion level of 0.1 weight percent and with 8 external
grooves on the fuel element. The lightability time is within range
of 3.2-3.4 seconds.
[0105] A similar test was conducted using fuel element compositions
containing C-glass (fiberglass) particles (formed by cutting
insulation mat of ECLIPSE product into pieces) at an inclusion
level of 0.1 weight percent and with 8 external grooves on the fuel
element. The lightability time is within range of 3.2-4.0
seconds.
[0106] As can be seen, the presence of any of the various ceramic
materials significantly reduced the lightability time as compared
to the control fuel elements.
Example 2: Use of Impregnated Carbon Particles or Cellulose
Particles as Ignition Aid
[0107] In a manner similar to Example 1, several fuel element
compositions comprising milled carbon, guar gum as a binder,
calcium carbonate, and graphite are formed and heat-not-burn
cigarettes are constructed therewith. The time required to ignite
each fuel element composition is measured and compared to the
commercially available ECLIPSE product. The tested compositions
include: (A) milled carbon, guar gum, calcium carbonate, graphite;
(B) milled carbon, guar gum, calcium carbonate, graphite, and 5% by
weight impregnated carbon (ST1-X impregnated carbon available from
Calgon Corporation) wherein the milled carbon content was reduced
5% as compared to (A); (C) composition of (B) except with 10% by
weight of impregnated carbon, wherein the milled carbon content was
reduced 10% as compared to (A); (D) composition of (C) except with
15% by weight of impregnated carbon, wherein the milled carbon
content was reduced 15% as compared to (A); (E) milled carbon, guar
gum, calcium carbonate, graphite, and 5% by weight cellulose
particles (Sigmacell cellulose available from Sigma-Aldrich)
wherein all other ingredients were substantially proportionally
decreased as compared to (A); (F) milled carbon, guar gum, calcium
carbonate, graphite, 10% by weight ST1-X activated carbon and 5% by
weight Sigmacell cellulose, wherein all other ingredients were
reduced but with the milled carbon being reduced the most as
compared to (A); and (G) composition of (B) except with 3% by
weight of impregnated carbon, wherein the graphite content was
reduced 3% as compared to (A).
[0108] The results of the lightability test are set forth in Table
1. As shown, the presence of the impregnated carbon and/or the
cellulose particles decrease the time required to ignite the fuel
element.
TABLE-US-00001 TABLE 1 Sample Lightability Time (seconds) ECLIPSE
6.0-6.5 A 5.2 B 4.1 C 3.7 D 3.8 E 4.4 F 3.5 G 4.1
Example 3: Use of Inorganic Salts as Ignition Aid
[0109] Several fuel element compositions comprising milled carbon,
guar gum as a binder, calcium carbonate, and graphite are formed
and heat-not-burn cigarettes are constructed therewith. The time
required to ignite each fuel element composition is measured and
compared to the commercially available ECLIPSE product (which has
five exterior grooves in the fuel element) as well as another
control fuel element having 8 external grooves in the fuel
element.
[0110] A test similar to Example 1 is conducted using fuel element
compositions containing either sodium chloride particles or
potassium chloride particles at an inclusion level of 0.1 weight
percent and with 8 external grooves on the fuel element. The
lightability time for the fuel element containing sodium chloride
is 2.8-3.0 seconds and the lightability time for the fuel element
containing potassium chloride is 2.9 seconds. Accordingly, the
lightability time for the experimental compositions containing
inorganic salts is much lower than the control fuel elements noted
in Example 1.
[0111] 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. 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.
* * * * *