U.S. patent application number 16/543336 was filed with the patent office on 2019-12-05 for smoking article and associated manufacturing method.
The applicant listed for this patent is R.J. Reynolds Tobacco Company. Invention is credited to Balager Ademe, Vernon Brent Barnes, Billy Tyrone Conner, Evon L. Crooks.
Application Number | 20190364954 16/543336 |
Document ID | / |
Family ID | 52273506 |
Filed Date | 2019-12-05 |
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United States Patent
Application |
20190364954 |
Kind Code |
A1 |
Ademe; Balager ; et
al. |
December 5, 2019 |
SMOKING ARTICLE AND ASSOCIATED MANUFACTURING METHOD
Abstract
A method and apparatus for forming a smoking article are
provided and involve engaging a heat generation segment and a
tobacco rod segment with the wrapping material in a longitudinally
spaced-apart relation, the outer wrapping material having a
heat-conductive strip engaged therewith, and the heat generation
segment and/or the tobacco rod segment at least partially
overlapping one end of the heat-conductive strip. Lateral ends of
the wrapping material are wrapped at most partially about the heat
generation and tobacco rod segments such that the heat generation
and tobacco rod segments cooperate with the heat-conductive strip
to define a longitudinally-extending cavity accessible between the
respective lateral ends of the wrapping material and
heat-conductive strip. Aerosol generation elements are deposited
into the longitudinally-extending cavity (i.e., by gravity feed)
between the lateral ends of the heat-conductive strip, and the
cavity is closed by overlapping and sealing the lateral ends of the
wrapping material.
Inventors: |
Ademe; Balager;
(Winston-Salem, NC) ; Barnes; Vernon Brent;
(Advance, NC) ; Conner; Billy Tyrone; (Clemmons,
NC) ; Crooks; Evon L.; (Mocksville, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
R.J. Reynolds Tobacco Company |
Winston-Salem |
NC |
US |
|
|
Family ID: |
52273506 |
Appl. No.: |
16/543336 |
Filed: |
August 16, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14098137 |
Dec 5, 2013 |
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16543336 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24C 5/10 20130101; A24F
47/006 20130101 |
International
Class: |
A24C 5/10 20060101
A24C005/10 |
Claims
1. A method of forming an elongate smoking article, said method
comprising: engaging a heat generation segment and a tobacco rod
segment with an outer wrapping material in a longitudinally
spaced-apart relation in relation to a length of the outer wrapping
material, the outer wrapping material having a heat-conductive
strip engaged therewith, the heat-conductive strip having
longitudinally spaced-apart ends arranged in relation to the length
of the outer wrapping material, and at least one of the heat
generation segment and the tobacco rod segment at least partially
overlapping one of the longitudinal ends of the heat-conductive
strip; wrapping lateral ends of the outer wrapping material at most
partially about the heat generation segment and the tobacco rod
segment such that the heat generation segment and the tobacco rod
segment cooperate with the heat-conductive strip to define a
longitudinally-extending cavity accessible between the lateral ends
of the outer wrapping material and lateral ends of the
heat-conductive strip; depositing a plurality of aerosol generation
elements into the longitudinally-extending cavity between the
lateral ends of the heat-conductive strip; and closing the
longitudinally-extending cavity by overlapping and sealing the
lateral ends of the outer wrapping material.
2. The method according to claim 1, further comprising engaging the
heat-conductive strip with the length of the outer wrapping
material.
3. The method according to claim 2, wherein engaging the
heat-conductive strip comprises engaging the heat-conductive strip
with the outer wrapping material by applying a lamination adhesive
therebetween.
4. The method according to claim 1, wherein engaging the heat
generation segment and the tobacco rod segment comprises engaging
the heat generation segment and the tobacco rod segment with the
outer wrapping material such that only the heat generation segment
at least partially overlaps one of the longitudinal ends of the
heat-conductive strip.
5. The method according to claim 1, further comprising engaging a
spacer element with the heat generation segment, such that the
spacer element and the tobacco rod segment cooperate with the
heat-conductive strip to define the longitudinally-extending
cavity, the spacer element being one of heat-conductive and air
permeable.
6. The method according to claim 1, wherein wrapping lateral ends
of the outer wrapping material comprises wrapping lateral ends of
the outer wrapping material at most partially about the heat
generation segment and the tobacco rod segment such that the
longitudinally-extending cavity extends vertically downward from an
opening defined between the lateral ends of the heat-conductive
strip.
7. The method according to claim 1, wherein depositing the
plurality of aerosol generation elements comprises depositing the
plurality of aerosol generation elements, selected from the group
consisting of pellets, beads, discrete small units, carbon pieces,
extruded carbon pieces, alumina beads, marumarized tobacco pieces,
extruded or compressed cylindrical or spherical elements, milled
tobacco lamina, fillers, flavors, visible aerosol forming
materials, binders, ovoid elements, irregularly shaped elements,
shredded pieces, flakes, elements including tobacco, elements
including a visible aerosol-forming material, and combinations
thereof, into the longitudinally-extending cavity.
8. The method according to claim 7, wherein depositing the
plurality of aerosol generation elements comprises selecting a
plurality of forms of the aerosol generation elements, and
separately depositing each selected form of the aerosol generation
elements into the cavity.
9. The method according to claim 7, wherein depositing the
plurality of aerosol generation elements comprises selecting a
plurality of forms of the aerosol generation elements, combining
the selected forms of the aerosol generation elements to produce an
aerosol generation element mixture, and depositing the mixture into
the cavity.
10. The method according to claim 1, wherein depositing the
plurality of aerosol generation elements comprises depositing the
plurality of aerosol generation elements into the
longitudinally-extending cavity, such that the cavity is at least
about 65% filled with the aerosol generation elements.
11. The method according to claim 1, wherein closing the
longitudinally-extending cavity comprises wrapping the lateral ends
of the heat-conductive strip about the aerosol generation elements
such that the lateral ends of the heat conductive strip abut each
other.
12. The method according to claim 1, wherein closing the
longitudinally-extending cavity comprises wrapping the lateral ends
of the heat-conductive strip about the aerosol generation elements
such that the lateral ends of the heat-conductive strip
overlap.
13. The method according to claim 1, wherein closing the
longitudinally-extending cavity comprises applying a seam-sealing
adhesive between the overlapping lateral ends of the outer wrapping
material for sealing the lateral ends of the outer wrapping
material together.
14.-26. (canceled)
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 that are
intended for human consumption; and more particularly, to the
assembly of components associated with the production of
segmented-type 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." Examples of tipping materials are described, for
example, in U.S. Pat. No. 7,789,089 to Dube et al., and in U.S.
Pat. App. Publ. Nos. 2007/0215167 to Crooks et al., 2010/0108081 to
Joyce et al., 2010/0108084 to Norman et al., and 2013/0167849 to
Ademe et al.; and PCT Pat. App. Pub. No. 2013/160671 to Dittrich et
al., each of which is incorporated by reference herein. 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. A traditional type of cigarette is employed by a smoker by
lighting one end thereof and burning the tobacco rod. The smoker
then receives mainstream smoke into his/her mouth by drawing on the
opposite end (e.g., the filter end or mouth end) of the cigarette.
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.
Through the years, efforts have been made to improve upon the
components, construction and performance of smoking articles. See,
for example, the background art discussed in U.S. Pat. No.
7,753,056 to Borschke et al.; which is incorporated herein by
reference.
[0003] Certain types of cigarettes that employ carbonaceous fuel
elements have been commercially marketed under the brand names
"Premier" and "Eclipse" by R. J. Reynolds Tobacco Company. See, for
example, those types of cigarettes described in Chemical and
Biological Studies on New Cigarette Prototypes that Heat Instead of
Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) and
Inhalation Toxicology, 12:5, p. 1-58 (2000). Additionally, a
similar type of cigarette recently has been marketed in Japan by
Japan Tobacco Inc. under the brand name "Steam Hot One."
Furthermore, various types of smoking products incorporating
carbonaceous fuel elements for heat generation and aerosol
formation have been described in the patent literature. See, for
example, the types of smoking products and associated components
that are proposed, described and referenced in U.S. Pat. No.
4,793,365 to Sensabaugh et al.; U.S. Pat. No. 7,647,932 to Cantrell
et al., and U.S. Pat. No. 7,836,897 to Borschke et al.; U.S. Pat.
Pub. Nos. 2007/0215168 to Banerjee et al.; 2013/0019888 to
Tsuruizumi et al.; 2013/0133675 to Shinozaki et al., 2013/0269720
to Stone et al.; and 2013/0146075 to Poget et al.; PCT Pat. App.
Pub. Nos. WO 2012/0164077 to Gladden et al.; WO 2013/098380 to
Raether et al.; WO 2013/098405 to Zuber et al.; WO 2013/098410 to
Zuber et al.; WO 2013/104914 to Woodcock; WO 2013/120849 to Roudier
et al., WO 2013/120854 to Mironov; WO 2013/162028 to Azegami et
al.; and WO 2013/160112 to Saleem et al.; and European Pat. App.
Nos. EP 1808087 to Baba et al. and EP 2550879 to Tsuruizumi et al.;
which are incorporated herein by reference.
[0004] Various manners and methods for assembling smoking articles
that possess a plurality of sequentially arranged segmented
components have been proposed. See, for example, the various types
of assembly techniques and methodologies set forth in U.S. Pat. No.
5,469,871 to Barnes et al. and U.S. Pat. No. 7,647,932 to Crooks et
al.; and U.S. Pat. App. Pub. Nos. 2010/0186757 to Crooks et al.;
2012/0042885 to Stone et al., and 2012/0067360 to Conner et al.;
which are incorporated herein by reference.
[0005] 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. Additionally, it would also be highly desirable
to provide an efficient and effective manner and method associated
with the manufacture and assembly of those types of smoking
articles that incorporate a plurality of sequentially arranged
segmented components.
BRIEF SUMMARY OF THE DISCLOSURE
[0006] The above and other needs are met by aspects of the present
disclosure which, in one aspect, provides a method of forming an
elongate smoking article. Such a method comprises engaging a heat
generation segment and a tobacco rod segment with an outer wrapping
material in a longitudinally spaced-apart relation in relation to a
length of the outer wrapping material, wherein the outer wrapping
material has a heat-conductive strip engaged therewith, wherein the
heat-conductive strip has longitudinally spaced-apart ends arranged
in relation to the length of the outer wrapping material, and
wherein at least one of the heat generation segment and the tobacco
rod segment at least partially overlaps one of the longitudinal
ends of the heat-conductive strip. Lateral ends of the outer
wrapping material are wrapped at most partially about the heat
generation segment and the tobacco rod segment such that the heat
generation segment and the tobacco rod segment cooperate with the
heat-conductive strip to define a longitudinally-extending cavity
accessible between the lateral ends of the outer wrapping material
and lateral ends of the heat-conductive strip. A plurality of
aerosol generation elements is deposited into the
longitudinally-extending cavity between the lateral ends of the
heat-conductive strip, and the longitudinally-extending cavity is
closed by overlapping and sealing the lateral ends of the outer
wrapping material.
[0007] Another aspect of the present disclosure provides an
apparatus for forming an elongate smoking article. Such an
apparatus comprises an assembly arrangement configured to engage a
heat generation segment and a tobacco rod segment with an outer
wrapping material in a longitudinally spaced-apart relation in
relation to a length of the outer wrapping material, wherein the
outer wrapping material has a heat-conductive strip engaged
therewith, wherein the heat-conductive strip has longitudinally
spaced-apart ends arranged in relation to the length of the outer
wrapping material, and wherein at least one of the heat generation
segment and the tobacco rod segment at least partially overlaps one
of the longitudinal ends of the heat-conductive strip. A wrapping
arrangement is configured to wrap lateral ends of the outer
wrapping material at most partially about the heat generation
segment and the tobacco rod segment such that the heat generation
segment and the tobacco rod segment cooperate with the
heat-conductive strip to define a longitudinally-extending cavity
accessible between the lateral ends of the outer wrapping material
and lateral ends of the heat-conductive strip. A dispensing
arrangement is configured to deposit a plurality of aerosol
generation elements into the longitudinally-extending cavity
between the lateral ends of the heat-conductive strip, and a
sealing arrangement is configured to close the
longitudinally-extending cavity by sealing the lateral ends of the
outer wrapping material together.
[0008] In certain aspects, the present disclosure provides an
elongate smoking article having a lighting end and an opposed mouth
end. Such a smoking article comprises a mouth end segment or
portion disposed at the mouth end, and a tobacco rod segment or
portion disposed between the lighting end and the mouth end
portion. An aerosol generation system is located as a segment
disposed between the lighting end and the tobacco segment. The
aerosol generation segment is longitudinally disposed from a heat
generation portion or segment disposed at the lighting end; and
those two segments are in a heat exchange relationship such that
heat produced by combustion of components of the heat generation
segment upon aerosol forming components of the aerosol generation
segment results in the production of aerosol. The longitudinally
extending outer surfaces of the heat generation, aerosol generation
and tobacco rod segments are circumscribed by an outer wrapping
material so as to provide a rod that is in turn attached to the
mouth end segment. A layer of heat conductive material is disposed
beneath the outer wrapping material so as to provide an outer
internal surface of the aerosol generation segment. The heat
conductive layer most preferably overlies the outer longitudinal
surface of heat generation segment in the region thereof adjacent
to the aerosol generation segment; and the heat conductive layer
optionally can overlie the outer longitudinal surface of the
tobacco rod segment in the region thereof adjacent the aerosol
generation segment. The aerosol generation segment further
incorporates a plurality of parts or pieces or elements (e.g.,
pellets or beads) incorporating materials that generate aerosols
upon the action of and in response to heat produced by a burning
fuel element of the heat generation segment.
[0009] Another aspect of the present disclosure provides a manner
or method for producing an elongate smoking article. That is,
preformed heat generation and tobacco rod segments are arranged
over the inner surface of a web of outer wrapping material in
predetermined locations along that web. Also positioned over a
predetermined location of the inner surface of the outer wrapping
material is a layer of heat conductive material. During wrapping of
the various segments with the outer wrapping material so as to form
a wrapped rod comprising those three segments, parts, elements, or
pieces of materials incorporating aerosol forming substances are
downwardly deposited into a cavity that defines the aerosol
generation segment. That is, a predetermined amount of pellets or
beads can be dropped in a cavity located between the heat
generation and tobacco rod segments. Wrapping of the outer wrapping
material then is completed so as to provide a wrapped rod
incorporating three longitudinally aligned cylindrical segments.
The aerosol generation region of the wrapped rod is comprised of a
plurality of pellets or beads or other elements circumscribed by a
layer of heat conductive material. The wrapped rod incorporating
the three longitudinally aligned segments then is attached to a
mouth end piece (e.g., a cylindrical filter element) so as to
provide a finished filtered cigarette.
[0010] Further features and advantages of the present disclosure
are set forth in more detail in the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0012] FIG. 1 schematically illustrates a longitudinal
cross-sectional view of a representative smoking article, according
to one aspect of the present disclosure;
[0013] FIG. 2 schematically illustrates an enlarged cross-sectional
end view of an aerosol generation segment of a representative
smoking article, taken along line 2-2 in FIG. 1, according to one
aspect of the present disclosure;
[0014] FIG. 3 schematically illustrates a section of a continuous
web or strip of wrapping material used to manufacture a series of
two-up combined upstream rods, according to one aspect of the
present disclosure;
[0015] FIG. 4 schematically illustrates a longitudinal
cross-sectional view of a continuous rod comprised of a series of
two-up combined upstream rods, according to one aspect of the
present disclosure;
[0016] FIG. 5 schematically illustrates a two-up combined upstream
rod, according to one aspect of the present disclosure;
[0017] FIG. 6 schematically illustrates a two-up combined filtered
smoking article, according to one aspect of the present
disclosure;
[0018] FIG. 7 schematically illustrates a longitudinal
cross-sectional view of a representative smoking article, according
to one aspect of the present disclosure;
[0019] FIG. 8 schematically illustrates a section of a continuous
web or strip of wrapping material used to manufacture a series of
two-up combined upstream rods;
[0020] FIG. 9 schematically illustrates a longitudinal
cross-sectional view of a representative smoking article, according
to one aspect of the present disclosure;
[0021] FIG. 10 schematically illustrates a longitudinal
cross-sectional view of a continuous rod comprised of a series of
two-up combined upstream rods, according to one aspect of the
present disclosure;
[0022] FIG. 11 schematically illustrates a two-up combined filtered
smoking article, according to one aspect of the present
disclosure;
[0023] FIG. 12 schematically illustrates a longitudinal
cross-sectional view of a representative smoking article, according
to one aspect of the present disclosure;
[0024] FIG. 13 schematically illustrates an apparatus for forming
an elongate smoking article, according to one aspect of the present
disclosure;
[0025] FIGS. 14 and 15 schematically illustrate alternate
arrangements of a dispensing arrangement for depositing aerosol
generation elements in a smoking article, according to aspects of
the present disclosure; and
[0026] FIG. 16 schematically illustrates a method for forming an
elongate smoking article, according to one aspect of the present
disclosure.
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] Referring to FIG. 1, there is shown a smoking article 10 in
the form of a cigarette that is representative of the present
invention. The smoking article 10 has a generally rod-like shape,
and includes a lighting end 14 at one extreme end. Preferably, the
smoking article 10 has the overall size, shape and general
appearance of a filtered cigarette.
[0029] At the lighting end 14 is positioned a
longitudinally-extending, generally cylindrical, heat generation
segment 24. A typical heat generation segment 24 includes a heat
source or fuel element 27 coaxially circumscribed by insulation 30,
which is in turn coaxially encircled by wrapping material 35. The
heat source 27 preferably is configured to be activated by direct
ignition of the lighting end 14. That is, the heat source or fuel
element is designed to be lit so as to burn and hence produce heat.
Preferably, the fuel element incorporates a combustible
carbonaceous material (e.g., a material that is comprised primarily
of carbon); and most preferably, the fuel element is comprised
primarily of carbonaceous material. Preferably, the insulation is
provided in the form of a non-woven mat of glass filaments.
[0030] Preferably, the wrapping material 35 that circumscribes the
insulation 30 is a paper wrapping material, such as, for example,
the type of paper wrapping material used to as the circumscribing
wrapping material of the insulation region of the heat source
segment of the cigarette marketed under the trade name "Eclipse" by
R. J. Reynolds Tobacco Company. Alternatively, that wrapping
material 35 can be provided in the form of a tobacco-containing
paper or reconstituted tobacco paper material, such as, for
example, the type of tobacco-containing paper used as layer within
the insulation region of the heat source segment of the cigarette
marketed under the trade name "Eclipse" by R. J. Reynolds Tobacco
Company, the gathered tobacco paper segment of the cigarette
marketed under the trade name "Premier" by R. J. Reynolds Tobacco
Company, or as set forth in U.S. Pat. No. 5,065,776 to Lawson et
al. and U.S. Pat. No. 5,271,419 to Arzonico et al., which are
incorporated herein by reference.
[0031] Preferably, each end of the heat generation segment 24 is
open to expose the ends of each of the fuel element 27 and
insulation 30. As such, drawn air can readily pass therethrough.
The fuel element 27 and the surrounding insulation 30 can be
configured so that the lengths of both are co-extensive (i.e., the
ends of the insulation are flush with the respective ends of the
fuel element, and particularly at the downstream end of the heat
generation segment). Optionally, the insulation 30 may extend
slightly beyond (e.g., from about 0.5 mm to about 2 mm beyond)
either or both ends of the fuel element 27.
[0032] The cross-sectional shape and dimensions of the heat
generation segment 24, prior to burning, can vary. Preferably, the
cross-sectional area of the fuel element 27 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; while
the cross-sectional area of the outer or circumscribing region
(comprising the insulation 30 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. For example, for a cylindrical smoking
article 10 having a circumference of about 24 mm to about 26 mm, a
representative fuel element 27 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.
[0033] The smoking article 10 also possesses a mouth end 38 at the
extreme end opposite the lighting end 14, and the mouth end 38 is
considered to be downstream from the lighting end. At the mouth end
38 is located a filter segment 40. A typical filter segment 40 is
comparable in many regards to that type of filter element
traditionally used for the manufacture of cigarettes, and can be a
single segment filter element or a multi-segment filter element.
For purposes of illustration only, the filter segment 40 is a two
piece segment that possesses an upstream piece 42 comprised of a
cylindrical plug of filter material 44 (e.g., plasticized cellulose
acetate tow) circumscribed by an outer plug wrap 45 (e.g., a paper
plug wrap); and a downstream piece 47 comprised of a tubular filter
plug 48 (e.g., a hardened tube of plasticized cellulose acetate
tow). The filter pieces 42, 47 are combined to form the filter
segment 40 using a plug wrap 49 that circumscribes the outer
longitudinal surface of both pieces.
[0034] Located directly downstream from the heat generation segment
24 is an aerosol generation segment 55 comprised of a plurality of
pellets or beads or other appropriate elements or combinations
thereof 58 coaxially circumscribed by a generally tubular-shaped
heat conductive member 60. The overall configuration of the aerosol
generation segment 55 within the smoking article 10 can be
considered to be generally cylindrical in nature. Representative
preferred beads 58 are produced from a formulation that
incorporates tobacco, components of tobacco and/or materials that
are otherwise derived from tobacco. The beads 58 most preferably
incorporate flavors and a visible aerosol forming material (e.g.,
glycerin or other material that generates a visible vapor that
resembles smoke). That is, components of the beads 58 are
preferably configured to act as substrate components for volatile
flavors, vapor forming materials and aerosol forming materials that
are carried thereby. In other aspects, some or all of the beads or
pellets can be spherical capsules loaded into the aerosol
generation segment may be heat sensitive so as to rupture when
heated to release glycerin and tobacco flavor and/or nicotine.
Also, in some aspects, the beads can be comprised of, for example,
alumina, absorbent clay, silica, and/or absorbent carbon to hold
and release an aerosol former.
[0035] The heat generation segment 24 and the aerosol generation
segment 55 are considered to be physically separate from one
another; and for the embodiment shown, those segments are
positioned so that the downstream end of the heat generation
segment abuts the upstream end of the aerosol generation segment
(i.e., the back faces of the fuel element 27 and the circumscribing
insulation 30). That is, heat generation segment 24 and the aerosol
generation segment 55 are axially aligned in a serial end-to-end
relationship, most preferably abutting one another. For example, it
is highly preferred that some pellets 58, though physically
separate and positioned downstream from heat generation segment 24,
physically contact the downstream inner surface or face of the heat
generation segment. Alternatively, those segments 24, 55 can be
slightly spaced apart from one another so as each opposing end of
each segment is not necessarily in physical contact with the other;
and in such a circumstance an additional segment or spacer element
acting as a spacer or screen (not shown, but see, e.g., element 134
in FIG. 7) positioned generally perpendicular to the longitudinal
axis of the smoking article 10 can provide for physical separation
of those two segments while maintaining a heat conductive
relationship. That is, the spacer element 134 may preferably be
heat-conductive and/or arranged to conduct heat from the heat
generation segment 24 to the aerosol generation segment 55.
[0036] The longitudinally extending outer surface of the aerosol
generation segment 55 is constructed from a layer of heat
conductive material 60 (e.g., a layer or strip comprised of metal
foil). That is, a representative aerosol generation segment 55
possesses a plurality of pellets and/or other appropriate elements
58 that are circumscribed along its length by a layer of strip of
metal foil 60. A representative metal foil is, for example,
aluminum foil having a thickness of about 0.01 mm to about 0.05 mm.
Preferably, the metal foil 60 extends along the entire length of
the outer co-axial surface of the aerosol generation segment 55;
and it is also preferred that the metal foil extends over (i.e., at
least partially overlaps) the outer co-axial surface 63 of the heat
generation segment 24 (including the optional spacer element 134)
in the region of the heat generation segment 24 adjacent to the
aerosol generation segment 55.
[0037] Located directly downstream from the aerosol generation
segment 55 (and directly upstream from the filter segment 40) is a
tobacco segment 68, or other type of segment that acts to provide
length and structure to the smoking article 10 while providing
flavor or otherwise enhancing the sensory characteristics imparted
by the smoking article during use. For the embodiment shown, the
tobacco segment 68 is considered to be physically separate from the
aerosol generation segment 55 as well as from the filter segment
40; and for the embodiments shown, those segments are positioned so
that the downstream end of the aerosol generation segment abuts the
upstream end of the tobacco segment, and the downstream end of the
tobacco segment abuts the upstream end of the filter segment. A
representative tobacco segment 68 possesses a charge or roll of
tobacco filler 72 wrapped in a circumscribing paper wrapping
material 76, and hence has the general form of a tobacco rod. In
some aspects, up to about 10.5 mg menthol can be added to the
tobacco in the tobacco rod or otherwise to the tobacco segment 68.
However, in other aspects, it may be preferred to add any flavor or
other sensory enhancement to the aerosol generation segment 55.
[0038] For the embodiment shown, each of the four segments (i.e.,
the heat generation segment 24, the aerosol generation segment 55,
the tobacco rod segment 68 and the filter segment 40, as those
segments are shown as respectively aligned in an abutting
end-to-end relationship) are generally cylindrical in shape, and
each of the segments is open at each end so that air can readily
flow through those segments (i.e., air can enter the upstream end
14 and exit the downstream end 38).
[0039] The heat generation segment 24, aerosol generation segment
55 and tobacco segment 68 are serially positioned end-to-end, and
are aligned so as to have the shape of a generally cylindrical rod
possessing three physically separate, but generally abutting,
cylindrical segments (and any additional cylindrical segment, for
example, if an optional spacer element (not shown, but see, e.g.,
element 134 in FIG. 7) is implemented between the back face or
downstream region of the heat generation segment and the front face
or the upstream region of the aerosol generation segment). Those
three upstream segments are in turn overwrapped over their
respective outer coaxial surfaces with an outer wrapping material
(i.e. a paper sheet) 80. As such, as a result of the combination of
the three upstream segments, there is provided an upstream combined
rod 84 (see, e.g., FIG. 9). Though not shown, at least a portion of
the region of the outer wrapping material 80 that overlies the heat
generation segment 24 can be perforated or otherwise provided in a
form that renders that region relatively air permeable or highly
porous to the transfer of air therethrough; and in such a manner,
there is provided an enhanced source of atmospheric air for
combustion of the fuel element.
[0040] The upstream combined rod 84 is physically connected to the
filter segment 40. For the embodiment shown, a layer of tipping
material 88 (e.g., tipping paper) circumscribes the outer
peripheral surface of the filter segment 40 and an adjacent region
of the outer wrapping material 80 (i.e., overlaps at least a
portion of the combined rod 84) of the combined rod 84 (see, also,
FIG. 12). Optional air dilution perforations 92 can be provided
through selected regions of the tipping material 88, the underlying
outer wrapping material 80 and the underlying wrapping material 76
of the tobacco rod 68. In some aspects, the air dilution
perforations 92 may be configured, for example, so as to provide an
air dilution of about 24%.
[0041] In use, the mouth end 38 of the smoking article 10 is
inserted into the mouth of the smoker. The fuel element 27 located
at lighting end 14 of the smoking article 10 is lit (e.g., using a
cigarette lighter) so that the fuel element burns and hence
produces heat. The fuel element 27 and the aerosol generation
segment 55 are configured so as to be in a heat exchange
relationship. That is, the heat generated by the combustion of the
fuel element 27 acts to heat the beads or other elements 58 located
in the aerosol generation segment 55 nearby or adjacent thereto.
Additionally, heat resulting from the burning fuel element 27 is
transferred to the heat conductive layer 60 that circumscribes the
length of the aerosol generation segment 55; and, as such, the
beads 58 located within the aerosol generation segment are heated.
Upon draw on the mouth end 38 of the smoking article 10 by the
smoker, air enters the lighting end 14 of the smoking article, is
heated by the burning fuel element 27, and the hot air passing
through the aerosol generation region 55 thereby heats the beads of
that aerosol generation region. The drawn air also passes through
the tobacco rod segment 68, and exits the filter element 40 into
the mouth of the smoker. When smoked, flavored aerosol generated
from the action of heat upon the components of the aerosol
generation segment 55 and the components of the tobacco rod 68 are
drawn into the mouth of the smoker. That is, the smoking article
described with reference to FIG. 1 may be used in much the same
manner as those cigarettes that have been commercially marketed
under the trade names "Eclipse" by R. J. Reynolds Tobacco Company
and "Steam Hot One" by Japan Tobacco Inc. As a result, when smoked,
a highly preferred smoking article 10 yields flavored visible
mainstream aerosol resulting principally from volatilized
components of the aerosol generation segment 55 and of the tobacco
rod segment 68, and that visible aerosol resembles in many regards
the mainstream tobacco smoke of a traditional type of cigarette
that burns tobacco cut filler.
[0042] Aerosols that are produced by the smoking article 10 are
those that comprise air containing components such as vapors,
gases, suspended particulates, and the like. Aerosol components can
be generated from burning tobacco of some form (and optionally
other components that are burned to generate heat, such as for
example, when tobacco is incorporated within the fuel element 27 or
as a component within the insulation 30 or circumscribing wrapper
35); by thermally decomposing tobacco caused by heating tobacco and
charring tobacco (or otherwise causing tobacco to undergo some form
of smolder, such as for example, when tobacco beads 58 in physical
contact with the burning fuel element 27 are heated); and by
vaporizing aerosol forming material. As such, the aerosol can
contain volatilized components, combustion products (e.g., carbon
dioxide and water), incomplete combustion products, and products of
pyrolysis. Preferably, the levels of incomplete combustion products
and products of pyrolysis within the aerosol are very low, as
compared to the levels characteristic of tobacco products that
yield smoke by burning tobacco cut filler. However, aerosol
components most preferably are generated by the action of heat from
the burning fuel element (and optionally other components that are
burned to generate heat) upon substances that are located in a heat
exchange relationship therewith. That is, aerosol is generated as a
result of the action of the heat generation segment upon components
of the aerosol generation segment. Preferably, components of the
aerosol generation segment have an overall composition, and are
positioned within the smoking article, such that those components
do not have a tendency to undergo a significant degree of thermal
decomposition (e.g., as a result of combustion, smoldering or
pyrolysis) during conditions of normal use of the smoking
article.
[0043] The overall dimensions of the smoking article 10, prior to
being lit for use, can vary. Typically, a representative smoking
article is a cylindrically shaped rod having a circumference of
about 24 mm to about 27 mm; and an overall length of about 70 mm to
about 120 mm, often about 80 mm to about 100 mm. A representative
heat generation segment 24 typically has a length of up to about 30
mm, often up to about 20 mm, and frequently about 10 mm to about 15
mm. The aerosol generation segment 55 typically has a length of up
to about 30 mm, often up to about 25 mm, and frequently about 10 mm
to about 20 mm. Frequently, the lengths of each of the tobacco rod
68 and filter element 40 segments can vary as desired. For example,
a representative tobacco rod segment 68 has an overall length of
about 20 mm to about 50 mm, often about 30 mm to about 40 mm; and a
representative filter segment 40 has a length of about 10 mm to
about 35 mm, often about 20 mm to about 30 mm.
[0044] For purposes of example, a representative smoking article 10
has a length of about 83 mm and a circumference of about 25 mm.
Such a cigarette 10 has a cylindrical heat generation segment 24
having a length of about 12 mm, a cylindrical aerosol generation
segment 55 comprised of a plurality of beads 58 and having a length
of about 13 mm, a tobacco rod segment 68 having a length of about
37 mm, and a filter segment 40 having a length of about 21 mm. The
filter segment 40 is of a two piece construction having an upstream
piece 42 comprised of a cylindrical plug of plasticized cellulose
acetate tow having a length of about 10 mm, and a downstream piece
47 comprised of a steam bonded, plasticized cellulose acetate tube
have having a length of about 11 mm. The upstream combined rod 84
of the cigarette is constructed using a 62 mm length of outer
wrapping material 80 having a width of about 27 mm, and wrapped
such that there is a lap seam of about 2 mm. A layer or patch of
metal foil 60 having a thickness of about 0.04 mm, a length of
about 17 mm and a width of about 25 mm extends over the length of
aerosol generation segment 55 and about 4 mm of the length of the
adjacent downstream region of the heat generation segment 24. The
aerosol generating segment 55 has the form of a generally
cylindrical hollow cavity 57 into which there is positioned a
collection of about 120 to about 150 generally spherical beads 58
having a mean or nominal diameter of about 0.5 mm to about 2 mm
(e.g., about 130 generally spherical beads of having an nominal
diameter of 1.5 mm). For example, a plurality of beads 58 weighing
about 300 mg to about 400 mg (preferably about 335 mg to about 350
mg) can be positioned within the cavity 57 that is designed to
provide that aerosol generation segment. Preferably, sufficient
beads are loaded into the aerosol generation segment cavity 57 to
provide at least about 65 percent fill; in some instances, at least
about 75 percent fill; in other instances, at least about 85
percent fill; and in some situations, at least about 95 percent of
maximum fill, of that cavity with beads or other suitable elements
58. The filter segment 40 is attached to the upstream combined rod
84 using circumscribing standard tipping paper of 30 to 40 gsm that
encircles the outer longitudinal surface of the filter segment and
overlaps an adjacent 10 mm region of the outer wrapping material 80
that overlies the tobacco rod segment 68. A circumscribing ring of
individual air dilution perforations 92 is positioned about 15 mm
from the extreme mouth end 38 of the cigarette.
[0045] Referring to FIG. 2, there is shown an enlarged
cross-sectional view of the aerosol generation segment 55 of a
smoking article 10 of the type described previously with reference
to line 2-2 in FIG. 1. That is, there is shown a preferred
arrangement of the heat conductive metal foil or foil strip 60 that
comprises the outer longitudinally extending surface of the aerosol
generation segment 55 and outer wrapping material 80 that overlies
that segment of the smoking article. A plurality of beads or other
suitable elements 58 are located within the inner
longitudinally-extending tubular cavity 57 defined by the
arrangement of the metal foil 60. A representative foil has a
thickness of about 0.02 mm. For the embodiment shown, the metal
foil 60 is formed into a generally circular shape such that each
laterally extending end abuts the other. For example, those lateral
ends can abut one another (as shown in FIG. 2), nearly abut one
another (so that a slight gap or space exits between those two
lateral ends), one of the lateral ends can slightly overlap the
other, or the lateral ends can otherwise be arranged to be aligned
with each other. In some preferred instances, the lateral ends of
the metal foil 60 may be arranged to meet in an abutting or nearly
abutting relation, but the lateral ends need not necessarily be
joined, welded, adhered, or otherwise secured to each other.
[0046] The laterally extending ends of the outer wrapping material
(i.e., the elongate paper sheet) 80 are arranged so that one
lateral end portion of the outer wrapping material overlaps the
opposite lateral end portion, thereby forming a lap or overlap zone
95. A suitable adhesive material is applied in the region of
overlap zone 98 so as to secure those lateral end portions together
and hence secure the outer wrapping material in a generally tubular
fashion around the heat conductive foil 60 of the heat generation
segment 55. A representative lap seam adhesive material is provided
as an adhesive formulation available as Code 2010-57 from Henkel
Corporation. For purposes of example, a representative outer
wrapping material is a paper wrapper comprised of wood pulp and
calcium carbonate that is treated with sodium citrate and potassium
citrate, has a basis weight of about 50 g/m.sup.2 and is available
as Item I.D. 20008033 from Delfort Group Specialty Papers Inc.
Additionally, for purposes of example, the metal foil 60 and outer
wrapping material 80 are adhered or laminated together, typically
using a coating of a suitable adhesive material (e.g., an adhesive
formulation available as Code 32-220B from Henkel Corporation).
[0047] Referring to FIG. 3, there is shown a view of a portion of a
continuous web of wrapping material or paper sheet 80 that is
employed to provide the outer wrapper of a preferred upstream
combined rod that is described previously with reference to FIG. 1
(see, also, FIG. 8). A representative continuous web 80, which can
be provided as a tape-like strip off of a bobbin or other suitable
source, has a width of about 27 mm; and as such, the web is
designed so as to provide a cylindrical rod having a circumference
of about 25 mm and an overlap seam of about 2 mm. Positioned at
staggered but regular predetermined intervals along the web 80 are
a series of patches or strips of a heat-conductive strip such as a
metal foil 60. Each foil patch or strip 60 extends along the length
of the web for a distance that roughly corresponds to the distance
that the foil extends along the length of the aerosol generation
segment, along at least a portion of the length of the heat
generation segment, and in some instances, along at least a portion
of the length of the tobacco rod segment (as the case may be). That
is, the foil patch or strip 60 extends longitudinally along the
wrapping material 80 for the length of the aerosol generation
segment 55, and at least partially overlaps the heat generation
segment 24. In some instances, the foil patch or strip 60 may also
extend longitudinally to at least partially overlap the tobacco rod
segment 68. If desired, though not shown, the regions of the web 80
that correspond to the regions of locations of the various heat
generation segments can be perforated or otherwise rendered porous
or permeable to enhanced air passage therethrough. A first distance
of separation f between two adjacent foil patches or strips 60
corresponds to the product of the sum of the lengths of two heat
generation segments minus twice the length that each heat
generation segment is covered or overlapped by each respective foil
patch or strip. Thus, for example, for a two-up heat generation
segment having a length of 24 mm (i.e., two heat generation
segments, each of 12 mm length), with the downstream end of each
having a metal foil overlap of 4 mm, the distance f of separation
of the two adjacent foil patches is 16 mm. A second distance of
separation t between two adjacent foil patches corresponds to the
sum of the lengths of two tobacco rod segments. Thus, for example,
for a two-up tobacco rod segment having a length of 74 mm (i.e.,
two tobacco rods, each of 37 mm length), the distance t of
separation of the two adjacent foil patches is 74 mm; and the
spacing is accordingly reduced if a portion of the foil patch or
strip covers or overlaps an adjacent region of the tobacco rod
segment. Thus, the spacing of the adjacent patches or strips
longitudinally along the continuous web is a staggered alternating
pattern of f, t, f, t, f, t, and so on. As a result, metal foil
strips or patches 60 are located on the continuous web 80 in a
staggered, but regularly repeating pattern; and most preferably,
the patches or strips of metal foil are positioned and aligned in a
predetermined manner so that each patch aligns with the location of
the corresponding aerosol generation segment of the smoking
article. Additionally, representative foil patches each have widths
of about 25 mm and are laterally positioned so as to not overlie
the region of the web 80 intended to provide the overlap seam, as
shown by distance s. Optical monitoring devices and/or other
monitoring devices can be included in or with an assembly machine
and incorporated into its operation to maintain accurate
alignment/registration of the foil patches/strips with other
smoking article components (e.g., the heating element/heat
generation segment and the tobacco rod/tobacco rod segment) during
assembly of smoking articles.
[0048] Referring to FIG. 4, there is shown a portion of a
continuous rod 105 that is comprised of a series of two-up upstream
combined rods 108. There is shown a continuous series of a two-up
heat generation segment 110, an aerosol generation segment 55, a
two-up tobacco rod segment 115 and an aerosol generating segment
55. In turn, each two-up heat generation segment 110 is cut in half
perpendicular or laterally to its longitudinal axis, along line 5-5
as shown. As such, a continuing pattern of the intermediate two-up
heat source segments 110 and intermediate two-up tobacco rod
segments 115 is arranged on the continuous web of outer wrapping
material 80 in relation to each aerosol generation segment 55, as
defined by the metal foil patch or strip; and there also is
provided a continuous web of outer wrapping material that possesses
segments of such a metal foil 60 in spaced apart, pre-selected
regions, longitudinally along the outer wrapping material 80, that
each define the location of the aerosol generation segment 55.
[0049] The positioning of each foil strip or segment 60 on the
continuous web or paper sheet is staggered in a pre-determined,
patterned relationship. That is, for the embodiment shown, the
distance separating one end of a foil segment 60 from the opposing
end 60 of an adjacent foil segment is equal to the length of the
two-up tobacco rod 115; while the distance separating the other end
of that foil segment 60 from the other adjacent foil segment 60 is
equal to the length of the two-up heat source segment 110 minus the
overlap at each end of that segment 110. As such, for example, for
a continuous web used for the manufacture of a series of continuous
two-up rods, there is provided a continuous arrangement on that web
of two-up tobacco rod, foil strip, two-up heat generation segment,
foil strip, two-up tobacco rod, foil strip, two-up heat generation
segment, foil strip, and so on.
[0050] The continuous web or elongate paper sheet 80 is formed so
as to overwrap the various segments and to create a type of hollow
longitudinally-extending cavity 57 in the region 120 defined by the
location of the foil strip 60. That is, the outer wrapping material
80 may be at most partially wrapped about the heat generation and
tobacco rod segments 24, 68 (i.e., to form an elongate "U" shaped
channel), and therein forming one or more spaced-apart cavities
defined through cooperation of adjacent heat generation and tobacco
rod segments 24, 68 and the heat-conductive strip 60 disposed
therebetween. Such partial wrapping may be provided, for example,
by the assembly arrangement causing the outer wrapping material 80
to be urged against and partially into conformity with the
respective perimeters of the heat generation and tobacco rod
segments 24, 68 engaged therewith. Prior to providing complete
overwrap of the continuous rod that is thereby formed,
predetermined amounts of beads or other appropriate elements 58 are
deposited into each cavity 57 defined by the cooperation of
adjacent heat generation and tobacco rod segments 24, 68 and the
heat-conductive strip 60 disposed therebetween. As such, upon
sealing of the continuous rod 105, each completely manufactured
aerosol generation segment 55 is formed.
[0051] Accordingly, such aspects of the present disclosure provide
a method and apparatus for forming the disclosed smoking article
which allow for the incorporation of a plurality of discrete
aerosol generation elements into the smoking article, without
necessarily requiring the plurality of aerosol generation elements
to be in a cohesive form, or otherwise to be carried by a carrier
member for maintaining the plurality of aerosol generation elements
in a cohesive form, for delivery to and incorporation in the
smoking article. However, one skilled in the art will appreciate
that incorporating the plurality of aerosol generation elements, in
a cohesive form with or without a carrier member, may be
implemented as a further aspect of the present disclosure. Further,
such aspects of the disclosed apparatus and method avoid the
complexity associated with, for example, pre-forming a cylindrical
member from the outer wrapping material, and then inserting the
various components, including the discrete aerosol generation
elements, longitudinally through an end of the cylindrical member
for appropriate longitudinal positioning within the smoking
article. Because the plurality of aerosol generation elements can
be inserted directly into the cavity 57 disposed at an appropriate
location along the length of the outer wrapping material, and be
appropriately supported by the deliberately placed heat generation
(and optional spacer element) and tobacco rod segments upon
insertion, a higher speed manufacturing process may be realized
(i.e., the smoking article can be manufactured "in-line," or in a
single orientation (i.e., in a horizontal orientation), without
changing the orientation thereof, for example, to introduce any of
the components into the as-formed outer-wrapping material through
one of the longitudinal ends thereof), along with greater
efficiency, accuracy, and precision in placing the various other
components of the smoking article, such as the heat-conductive
strip/foil into engagement with the outer wrapping material. As
such, significant cost savings may also be realized.
[0052] The manner by which a representative smoking article is
manufactured can vary. The web or bobbin of wrapping material can
be manufactured and supplied using known techniques. The various
patches or strips of metal foil or appropriate heat-conducting
strip also can be manufactured and supplied using known techniques.
The foil patches or strips can be applied to predetermined
locations on the continuous web of wrapping material using
equipment such as that supplied by Montrade Srl and Strouse
Corporation. The various segments of the upstream combined rod can
be arranged at predetermined locations on the continuous web using
equipment such as that available as Merlin from Hauni Maschinenbau
AG and Combi from Montrade. Then the various cavities that are
created along that continuous partially formed rod can be filled
with pellets, beads, flakes, filler, or other appropriate elements,
or combinations thereof. Filling of the various cavities with the
materials that provide aerosol forming components can be
accomplished using pneumatic dosing equipment, or other suitable
means for providing a dropping or downward or gravity-facilitated
filling of those cavities with the desired materials or appropriate
elements. The partially sealed continuous rod so formed then is
transferred to a rod forming unit (e.g., a type of device commonly
used in the tobacco industry for production of a continuous filter
rod) to seal the foil strip 60 and/or the continuous web 80 to form
a continuous rod comprised of a repeating pattern of combined
rods.
[0053] Referring to FIG. 5 (see, also, FIG. 10), there is shown a
representative two-up upstream combined rod 108 that is provided by
cutting the continuous rod shown in FIG. 4 at regular intervals
through the center of each two-up heat generation segment (e.g.,
each two-up heat generation segment of the continuous rod is
severed about its longitudinal center). Such a combined rod 108 is
provided as a series of two-up upstream combined rods, each having
a central two-up tobacco rod 115 and a heat generation segment 24
at each end (i.e., the inner segment of the two-up tobacco rod is
configured as two intermediate segments jointed to one another as a
common tobacco rod). Such a two-up upstream combined rod can
facilitate handling during manufacturing of a smoking article. For
example, a two-up rod can be processed using standard types of
cigarette component processing and manufacturing equipment. In
turn, each two-up upstream combined rod is cut in half
perpendicular to its longitudinal axis (i.e., through the two-up
tobacco rod at the location designed by line 5-5 in FIG. 5 and line
10-10 in FIG. 10) to provide two separate upstream combined
rods.
[0054] Referring to FIG. 6 (see, also, FIG. 11), there is shown a
representative two-up filtered cigarette 120 that is provided by
positioning an upstream combined rod 84 at each end of a two-up
filter segment 130. Each upstream combined rod is attached to each
end of the two-up filter segment using tipping material to provide
a two-up filtered cigarette (i.e., two intermediate cigarettes
joined to one another by a common filter segment that has the
configuration of two intermediate filter segments joined to one
another). Subsequently, each two-up filtered cigarette is cut in
half perpendicular to its longitudinal axis (i.e., through the
two-up filter element in the location designated by line 6-6 in
FIG. 6 and line 11-11 in FIG. 11) to provide two finished filtered
cigarettes (see, e.g., FIG. 12).
[0055] Referring to FIG. 7, there is shown a smoking article 10
generally similar to that shown previously with reference to FIG.
1. The smoking article 10 possesses a heat conductive layer (i.e.,
foil strip 60) that that provides an outer coaxial surface of the
aerosol generation segment 55. The heat conductive layer 60 also
overlies an optional spacer segment 134 that is positioned between
the heat generation segment 24 and the plurality of beads or other
appropriate elements 58 of the aerosol generation segment 55.
Typically, the spacer segment 134 is generally cylindrical in shape
and of one piece construction, and is air permeable to allow the
passage of drawn air through. Most preferably, the spacer segment
134 is heat conductive in nature, so that heat generated by the
burning fuel element 27 can be readily conducted to the aerosol
generation region 55. The length of the spacer segment can vary,
and that segment typically extends about 5 mm to about 10 mm along
the length of the upstream combined rod 84. Typically, the spacer
segment 134 is comprised of a heat resistant material, such as a
porous ceramic, a porous graphite material, a metal mesh or screen,
a high temperature-resistant plastic or the like. In some
instances, the spacer element 134 may include, for example,
longitudinally-extending air passageways formed during
design/manufacture, drilled therethrough, or otherwise molded,
extruded, or shaped into the spacer element during manufacture
thereof. If desired, the spacer segment 134 can incorporate
catalytic materials, such as materials incorporating cerium or
copper ions or oxides and/or salts of cerium and copper ions. See,
for example, U.S. Pat. No. 8,469,035 to Banerjee et al. and U. S.
Pat. Appl. Pub. Nos. 2007/0215168 to Banerjee et al., and
2011/0180082 to Banerjee et al.; which are incorporated herein by
reference.
[0056] The heat conductive layer or foil strip 60 also
circumscribes (and at least partially longitudinally overlaps) the
outer longitudinally extending surface of the heat generation
segment 24 in the region 138 thereof that is adjacent to the
aerosol generation segment. The heat conductive layer 60 also
circumscribes (and at least partially longitudinally overlaps) the
outer longitudinally extending surface of the tobacco rod 68 in the
region 140 thereof that is adjacent to the aerosol generation
segment 55. For example, the heat conductive layer 60 can extend
over or overlap about 2 mm to about 6 mm of the downstream
longitudinal surface of the heat generation segment 24; and the
heat conductive layer can extend over or overlap up to about 10 mm
of the upstream longitudinal surface of the tobacco rod segment
68.
[0057] The filter element 40 is a one piece segment that is
positioned at one end of the upstream combined rod 84 adjacent to
one end of the tobacco rod segment 68, such that those segments are
axially aligned in an end-to-end relationship, abutting one another
and without any barrier therebetween. Preferably, the general
cross-sectional shapes and dimensions of those aligned segments 24,
55, 134, 68 are essentially identical to one another when viewed on
an end elevation perpendicularly to the longitudinal axis of the
smoking article 10; and those segments are circumscribed by a layer
of outer wrapping material 80. The region of the outer wrapping
material 80 that overlies the heat generation segment 55 is
provided with a series of perforations 150 (e.g., that region of
the outer wrapping material is perforated with, for example, a
series of electrostatic perforations, mechanically punched
perforations or laser perforations) so as to provide a porous outer
wrap around the heat generation region and hence allow for passage
of air through the longitudinally extending region of the heat
generation segment. The filter element possesses filter material 44
that is overwrapped along the longitudinally extending surface
thereof with circumscribing plug wrap material 45. The cigarette
can be air diluted by incorporation of a circumscribing ring of a
plurality of perforations 92 through the tipping material 88 and
the plug wrap 45 of the filter element. In one example, the filter
material 44 includes plasticized cellulose acetate tow. Both ends
of the filter element 40 are open to permit the passage of drawn
air therethrough. Such a cigarette can be assembled by suitable
modification of the materials and techniques described previously
with reference to FIG. 3 through 6.
[0058] The components of the heat generation segment can vary. One
component of the heat generation segment is the fuel element.
Suitable heat generation segments and associated fuel elements
thereof, and representative components, designs and configurations
thereof, as well as manners and methods for producing those heat
generation segments and the components thereof, are set forth in
U.S. Pat. No. 4,714,082 to Banerjee et al.; U.S. Pat. No. 4,756,318
to Clearman et al.; U.S. Pat. No. 4,881,556 to Clearman et al.;
U.S. Pat. No. 4,989,619 to Clearman et al.; U.S. Pat. No. 5,020,548
to Farrier et al.; U.S. Pat. No. 5,027,837 to Clearman et al.; U.S.
Pat. No. 5,067,499 to Banerjee et al.; U.S. Pat. No. 5,076,297 to
Farrier et al.; U.S. Pat. No. 5,099,861 to Clearman et al.; U.S.
Pat. No. 5,105,831 to Banerjee et al.; U.S. Pat. No. 5,129,409 to
White et al.; U.S. Pat. No. 5,148,821 to Best et al.; U.S. Pat. No.
5,156,170 to Clearman et al.; U.S. Pat. No. 5,178,167 to Riggs et
al.; U.S. Pat. No. 5,211,684 to Shannon et al.; U.S. Pat. No.
5,247,947 to Clearman et al.; U.S. Pat. No. 5,345,955 to Clearman
et al.; U.S. Pat. No. 5,469,871 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. 8,119,555 to Banerjee et al.; and U.S. Pat. No. 8,469,035
to Banerjee et al.; U.S. Pat. App. Pub. Nos. 2005/0274390 to
Banerjee et al.; 2007/0215167 to Crooks et al.; and 2007/0215168 to
Banerjee et al.; and U.S. patent application Ser. No. 13/448,835 to
Stone et al. and Ser. No. 14/036,536 to Conner et al.; which are
incorporated herein by reference. Other representative types of
heat generation segments and associated fuel elements are 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.; which are incorporated herein
by reference.
[0059] Typically, a preferred fuel element comprises a combustible
high carbon content carbonaceous material, and also can include
ingredients such as graphite or alumina. Representative
carbonaceous fuel elements can possess the types of configurations
and components of those types of fuel elements that have been
incorporated within those cigarettes commercially marketed under
the trade names "Premier" and "Eclipse" by R. J. Reynolds Tobacco
Company and "Steam Hot One" by Japan Tobacco Inc.
[0060] The heat generation segment most preferably possesses a fuel
element that is circumscribed or otherwise jacketed by insulation
(e.g., a non-woven mat or layer of glass filaments or fibers), or
other suitable material. The insulation also can be provided in a
multi-layer configuration that includes, for example, an inner
layer of insulation, an intermediate layer of reconstituted tobacco
paper and an outer layer of insulation. The insulation can be
configured and employed so as to support, maintain and retain the
fuel element in place within the smoking article. Preferably, a
cylindrical fuel element is concentrically oriented and overwrapped
along its longitudinally extending surface with the insulation.
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.; U.S. Pat. App. Pub. No.
2012/0042885 to Stone et al.; and U.S. patent application Ser. No.
14/036,536 to Conner et al.; which are incorporated herein by
reference. Insulation assemblies have been incorporated within the
heat generation segments of those types of cigarettes that have
been 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.
[0061] The components of the aerosol generation segment can vary.
The aerosol generation segment incorporates components that can be
vaporized, aerosolized or entrained in air drawn through the
smoking article during use. Most preferably, those components
provide sensory and organoleptic effects, such as aroma, flavor,
mouthfeel, visible aerosol sensations, and the like. Examples of
components of the aerosol generation segment that are drawn into
the mouth of the smoker during draw include water (e.g., as water
vapor), visible aerosol forming materials (e.g., glycerin), various
volatile flavors (e.g., vanillin and menthol), volatile components
of tobacco (e.g., nicotine), and the like.
[0062] A preferred aerosol-forming material produces a visible
aerosol upon the application of sufficient heat thereto, or
otherwise through the action of aerosol forming conditions using
components of the smoking article. A highly preferred
aerosol-forming material produces a visible aerosol that can be
considered to be "smoke-like." A preferred aerosol-forming material
is chemically simple, relative to the chemical nature of the smoke
produced by burning tobacco. A preferred visible aerosol-forming
material is a polyol, and exemplary preferred aerosol forming
materials include glycerin, propylene glycol, and mixtures thereof.
If desired, aerosol forming materials can be combined with other
liquid materials, such as water. For example, aerosol forming
material formulations can incorporate mixtures of glycerin and
water, or mixtures of propylene glycol and water. See, for example,
the various aerosol forming materials referenced in U.S. Pat. App.
Pub. No. 2010/0186757 to Crooks et al., which is incorporated
herein by reference.
[0063] The aerosol forming materials are carried or supported by
substrate materials so as to maintain those aerosol materials
within the desired region of the smoking article. Exemplary
substrate materials, and exemplary formulations incorporating
aerosol-forming materials, are set forth in U.S. Pat. No. 4,793,365
to Sensabaugh et al.; U.S. Pat. No. 4,893,639 to White; U.S. Pat.
No. 5,099,861 to Clearman et al.; U.S. Pat. No. 5,101,839 to Jakob
et al.; U.S. Pat. No. 5,105,836 to Gentry et al.; U.S. Pat. No.
5,159,942 to Brinkley et al.; U.S. Pat. No. 5,203,355 to Clearman
et al.; U.S. Pat. No. 5,271,419 to Arzonico et al.; U.S. Pat. No.
5,327,917 to Lekwauwa et al.; U.S. Pat. No. 5,396,911 to Casey, III
et al.; U.S. Pat. No. 5,533,530 to Young et al.; U.S. Pat. No.
5,588,446 to Clearman; U.S. Pat. No. 5,598,868 to Jakob et al.; and
U.S. Pat. No. 5,715,844 to Young et al.; and U.S. Patent
Application Pub. No. 2005/0066986 to Nestor et al.; which are
incorporated herein by reference. See, also, Chemical and
Biological Studies on New Cigarette Prototypes that Heat Instead of
Burn Tobacco, R. J. Reynolds Tobacco Company Monograph (1988).
Exemplary substrate materials have been incorporated within the
types of cigarettes commercially marketed under the trade names
"Premier" and "Eclipse" by R. J. Reynolds Tobacco Company.
[0064] 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 carbon pieces, extruded carbon pieces cut into
pellets, alumina beads, marumarized tobacco pieces, and the like,
or combinations thereof. For example, pellets or beads can be
generally cylindrical or spherical extruded or compressed pellets
or beads of 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. However, such "pellets" or "beads" may comprise any
suitable elements, or combination of elements, meeting the
preferred aspects as disclosed herein. For example, some or all of
the beads or pellets can comprise spherical capsules that are heat
sensitive, so that when deposited into the cavity and exposed to
heat, the rupture thereof causes the release of glycerin and
tobacco flavor and/or nicotine. Also, the beads can comprise
alumina 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. In one
particular example, the beads/pellets (particles) may be comprised
of between about 15% and about 60% of finely milled tobacco (e.g.,
a blend of Oriental, burley and flue-cured tobaccos, or essentially
all flue-cured tobacco), between about 15% and about 60% of finely
milled particles of calcium carbonate (or finely milled clay or
alumina 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 (e.g., a blend
of Oriental, burley and flue-cured tobaccos, or essentially all
flue-cured tobacco), about 30% of finely milled particles of
calcium carbonate (or finely milled clay or alumina 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. In such
examples, the particles may be compressed to hold and release the
glycerol and, upon compression, may form a porous matrix that
facilitates migration of the aerosol generating components to
promote efficient aerosol formation. 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 generation
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.
[0065] In some aspects, where the aerosol generation elements
comprise, for example, beads or pellets cast or extruded from
materials of the various types set forth above (i.e., a graphite
bead including tobacco extract and glycerin), while "damp" or
otherwise before drying, may be rolled, for example, between
adjacent roller elements, to flatten the shape of the respective
beads/pellets. In some instances, the materials of the various
types set forth above may be extruded in the form of filamentary
strands, wherein the strands may be gathered to form a cylindrical
rod or other suitably shaped material (i.e., relative in size to
the beads/pellets used to otherwise form the aerosol generation
segment) for application in the aerosol generation segment. Upon
drying, the flattened beads/pellets may then be shredded or
otherwise processed to form, for example, strands, flakes, or other
filler configuration that is flat or includes a planar segment that
inhibits or prevents roll. Any random configurations resulting form
the shredding process may be sufficient. In such instances, the
flattened and shredded beads/pellets may then be deposited in the
longitudinally-extending cavity 57 as the aerosol generation
elements, and the irregular or random configurations thereof may
promote, for instance, a plurality of interstitial air spaces
throughout the aerosol generation segment, wherein the interstitial
air spaces may, in turn, promote heat transfer from the heat
generation segment to the individual aerosol generation elements
within the cavity. That is, heating of the air in the interstitial
spaces within the aerosol generation segment may expose more of the
aerosol generation elements to the heat from the heat generation
segment, and thus result in enhanced or otherwise improved heating
of the aerosol generation segment.
[0066] In some aspects, the beads/pellets may originate from a
tobacco material cast on a foil/paper laminate. More particularly,
the tobacco material may comprise, for example, a slurry including
reconstituted tobacco, glycerin, and a binder material. Such a
tobacco material is disclosed, for example, in U.S. Pat. No.
5,101,839 to Jakob et al. and U.S. Patent Application No.
2010/0186757 to Crooks et al., which are incorporated herein by
reference. In addition, the slurry can incorporate granular
inorganic material (i.e., calcium carbonate). The slurry is cast
unto a paper element of a foil-paper laminate, such as disclosed,
for example, in U.S. Patent Application No. 2010/0186757 to Crooks
et al. and U.S. Pat. No. 7,647,932 to Cantrell et aL, which is also
incorporated herein by reference, and the assembled cast sheet
product is then dried, for instance by the application of heat
(i.e., by heated air, microwave drying, etc.). The paper element
may have, for instance, a particular porosity or texture to promote
an intimate contact and interaction with the slurry, for instance,
over direct contact between the slurry and the foil. However, the
exemplary aspect presented herein does not preclude casting the
tobacco material (i.e., slurry) directly on a metal foil or other
suitable thin film heat conductor. Once such a laminate is cast, it
may be formed into various configurations such as, for example,
rolled into a rod-shaped form for use as a tobacco substrate in a
smoking article. See, e.g., U.S. Pat. No. 5,469,871 to Barnes et
al., wherein such a rod-shaped substrate has been incorporated
within the types of cigarettes commercially marketed under the
trade name "Eclipse" by R. J. Reynolds Tobacco Company. However, in
aspects of the present application, the dried cast sheet (i.e., the
foil/paper/tobacco material may be shredded, diced, or otherwise
separated into a plurality of cast sheet portion elements, wherein
each such element preferably includes a portion of the tobacco
material (i.e., the substrate) intimately interacted with a portion
of the paper element which, in turn, is in intimate contact with a
portion of the foil element of the foil-paper laminate. A plurality
of the cast sheet portion elements may then be deposited in the
longitudinally-extending cavity of the smoking article disclosed
herein as all or part of the aerosol-generating elements forming
the substrate.
[0067] One skilled in the art will appreciate that, in some
circumstances, the cast sheet portion elements inserted into the
cavity as all or part of the aerosol generation elements may
cooperate to promote improved heat transfer to the tobacco material
forming a portion of those cast sheet portion elements or otherwise
to abutting elements within the cavity. More particularly, in some
instances, heat transfer from the heat generation segment to the
tobacco material forming the aerosol generation elements/substrate
material may be limited past the interface therebetween, with the
heat-conducting strip forming an additional mechanism for
conducting heat from the heat generation segment for heating the
outer perimeter of the cavity and the aerosol generation elements
in contact therewith. In aspects including the cast sheet portion
elements inserted into the cavity as all or part of the aerosol
generation elements, the heat-conductive portions of the foil
element associated with the cast sheet portion elements may form,
for example, a plurality of additional heat conductive pathways
extending medially through the aerosol generation segment to the
tobacco segment. That is, in addition to the immediate contact
between the heat generation segment and the aerosol generation
segment, and between the heat-conducting (perimetric) strip and the
outer aerosol generation elements within the cavity, the cast sheet
portion elements used as all or part of the aerosol generation
elements may provide additional heat-conductive elements
interspersed throughout the aerosol generation elements within the
cavity to thereby enhance or otherwise improve heat transfer from
the heat generation segment to the aerosol generation elements
within the cavity of the aerosol generation segment. That is, one
particular and possibly advantageous aspect of the present
application involves the interspersing of heat-conductive elements
throughout the aerosol generation segment of the disclosed smoking
article so as to improve heat transfer from the heat-generation
segment to the aerosol generation elements within the aerosol
generation segment. In achieving such an aspect, it may be further
advantageous to shred or process a substrate material implemented
in similar products, such as, for example, the cast tobacco sheet
substrate material forming the substrate incorporated within the
types of cigarettes commercially marketed under the trade name
"Eclipse" by R. J. Reynolds Tobacco Company, as disclosed, e.g., by
U.S. Pat. No. 5,469,871 to Barnes et al.
[0068] The pellets or other elements may have smooth, regular outer
shapes (e.g., spheres, cylinders, ovoids, or the like) and/or they
may have irregular outer shapes (e.g., shredded pieces, flakes, or
the like). In one example, the diameter of each pellet may range
from less than about 0.05 mm to about 2 mm. The pellets or other
elements may at least partially fill an aerosol generation cavity
region of a smoking article as described herein. In one example,
the volume of the cavity may range from about 500 mm.sup.3 to about
700 mm.sup.3 (e.g., a 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 extending longitudinally along the smoking
article). In one example, the mass of the pellets within the cavity
may range from about 200 mg to about 500 mg.
[0069] 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.
[0070] The tobacco rod segment can vary. Typically, the tobacco rod
segment is comprised of shreds or pieces of tobacco cut filler
wrapped in a longitudinally extending paper wrapper. Most
preferably, the rod is generally cylindrical in shape, and the
upstream and downstream ends are open so that drawn air can pass
therethrough. Exemplary tobacco rods, components thereof and
manners and methods for their manufacture are set forth in U.S.
Patent Appl. Pub No. 2007/0215167 to Crooks et al., which is
incorporated herein by reference. In the event that the cigarette
(i.e., smoking article) is a menthol cigarette, the menthol flavor
formulation can be applied to the tobacco rod using traditional
types of techniques for applying menthol to a tobacco rod or other
tobacco compositions, as will be appreciated by one skilled in the
art.
[0071] If desired the tobacco rod segment can be replaced by, or
combined with, a segment of similar dimension, but comprised of
materials other than, or additional to, tobacco cut filler. For
example, the tobacco cut filler can be replaced by an open cell
extrudate (e.g., an extrudate of starch, tobacco, or the like) that
allows for passage of drawn air therethrough. Alternatively, the
tobacco cut filler can be replaced by a steam bonded and
plasticized cellulose acetate tube that provides resilience,
structure, and length to the smoking article while allowing for
passage of drawn air therethrough.
[0072] The mouth end segment can vary. Typically, the mouth end
segment has the form of a filter element that is generally similar
in many regards to those types of filter elements characteristic of
traditional types of smoking articles, such as cigarettes. See, for
example, the various types of mouth end pieces, filter element
assemblies, filter element components and plug wrap materials
described and referenced in U.S. Pat. App. Pub. No. 2010/0186757 to
Crooks et al., which is incorporated herein by reference. See also,
for example, the types of filter elements and filter element
components set forth in U.S. Pat. No. 7,479,098 to Thomas et al.;
U.S. Pat. No. 7,740,019 to Nelson et al.; U.S. Pat. No. 7,793,665
to Dube et al.; U.S. Pat. No. 7,972,254 to Stokes et al.; U.S. Pat.
No. 8,186,359 to Ademe et al.; and U.S. Pat. No. 8,375,958 to
Hutchens et al.; and U.S. Pat. Publ. Nos. 2008/0142028 to Fagg et
al.; which are incorporated herein by reference.
[0073] The outer wrapping material can 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 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
aspect, the wrapping material may include a paper material having
strips or patches of foil laminated thereto. Examples of
representative papers are set forth in U.S. Patent Appl. Pub No.
2007/0215167 to Crooks et al., which is incorporated herein by
reference.
[0074] A foil strip or patch may be laminated to the paper sheet to
form a laminated coated region. In one example, the foil strip may
have a thickness of about 0.0005 mm to about 0.05 mm. The foil
strip may be laminated on an interior surface of the paper sheet.
The foil strip may be laminated on the paper sheet using any now
known or future developed technique including, for example, heat
laminating. The foil strip may be laminated on the paper sheet
using any now known or future developed adhesive. In one example,
the adhesive may be configured as a cold glue adhesive of the type
used to secure tipping materials to other components of a
cigarette. The foil strip may be laminated or patched to the paper
sheet with or without a lubricant. Preferably, the foil strip may
be laminated to the interior surface of the paper sheet (e.g., the
surface of the paper sheet that faces toward the cavity) to at
least partially contact the heat-generation segment, the substrate
material (i.e., the beads, pellets, and/or other appropriate
elements), and/or the tobacco rod segment. The laminated paper or
other wrapping material may be constructed in accordance with the
disclosure of U.S. Pat. No. 6,849,085 to Marton, which is
incorporated herein by reference in its entirety, or in accordance
with other appropriate methods and/or materials.
[0075] The foil strip preferably enhances heat transfer between the
heat generation segment and the aerosol forming materials of the
aerosol generation segment. Such enhanced heat transfer aids in
volatilizing the aerosol forming material in the substrate (i.e.,
the beads, pellets, and/or other appropriate elements) for aerosol
formation. To that end, the foil strip is formed from a heat
conducting material. The foil strip may be formed from any heat
conducting material including, for example, tin, aluminum, copper,
gold, brass, other thermoconductive materials, and/or any
combination thereof. In this manner, the cavity may be defined by a
foil-lined paper tube or column formed by the wrapping material.
The wrapping material may include a registered facing of the foil
strip at a discrete location on and along the wrapping
material.
[0076] The heat conducting material can be provided by means other
than the use of metal foil. For example, the layer of metal foil
can be replaced by a metal mesh or screen. Alternatively, the metal
foil can be replaced by a heat conductive fabric, such as a layer
or sheet of graphite fibers or heat conductive ceramic fibers.
Alternatively, the heat conductive material can be provided by
application of a heat conductive ink, such as a coating of ink or
paint that incorporates metal particles, graphite fibers, particles
of heat conductive ceramic materials, or the like.
[0077] Other types of components useful for constructing smoking
articles are set forth in U.S. Pat. App. Pub. No. 2007/0215167 to
Crooks et al., which is incorporated herein by reference in its
entirety.
[0078] One further aspect of the present disclosure comprises an
apparatus 200 for forming an elongate smoking article of the type
disclosed herein (see, e.g., FIG. 13). As disclosed, one aspect
involves engaging the heat conducting material/metal foil with the
elongate outer wrapping material and, as such, a suitable
manufacturing apparatus may include, for example, a lamination
arrangement 250 configured to engage the heat conducting
material/foil strip 60 with a length of the outer wrapping
material/elongate paper sheet 80 (see, e.g., FIG. 8). As disclosed,
each foil strip 60 includes longitudinally spaced-apart ends
arranged in relation to the length of the elongate paper sheet 80,
and successive foil strips may be longitudinally spaced apart along
the outer wrapping material at specified intervals, as previously
discussed. In some instances, the lamination arrangement 250 may be
configured to engage the foil strip with the elongate paper sheet
by applying a lamination adhesive or other appropriate adhesive
material therebetween. The lamination arrangement may include, for
example, equipment such as that supplied by Montrade Srl and
Strouse Corporation, for applying the heat-conductive strips (i.e.,
foil) to predetermined locations on the continuous web of wrapping
material.
[0079] An assembly arrangement 300 may be configured to engage the
heat generation segment 24 (i.e., the fuel element 27 and/or the
insulation 30) and the tobacco rod segment 68 (i.e., the tobacco
filler 72 and/or the circumscribing wrapping paper 76) with the
elongate paper sheet (i.e., the outer wrapping material 80) in a
longitudinally spaced-apart relation in relation to the length of
the elongate paper sheet. In so arranging the heat generation
segment 24 and the tobacco rod segment 55, the heat generation
segment 24 and/or the tobacco rod segment 55 at least partially
overlap one of the longitudinal ends of the foil strip. That is,
the assembly arrangement may be configured to place the heat
generation segment 24 and/or the tobacco rod segment 55 with
respect to the length of the elongate paper sheet such that the
heat generation segment 24 and/or the tobacco rod segment 55
overlap and lie on one of the ends of the foil strip extending
along the length of the elongate paper sheet (see, e.g., FIG. 9).
In some aspects, the assembly arrangement 300 is configured to
engage the heat generation segment and the tobacco rod segment with
the elongate paper sheet such that only the heat generation segment
at least partially overlaps one of the longitudinal ends of the
foil strip. In other aspects, as shown, for example, in FIG. 7, the
assembly arrangement 300 may be configured to engage a spacer
element 134 with the heat generation segment, such that the spacer
element and the tobacco rod segment cooperate with the foil strip
to define the longitudinally-extending cavity 57. In such
instances, the selected spacer element may desirably be
heat-conductive and/or air permeable. The assembly arrangement may
include, for example, equipment such as that available as Merlin
from Hauni Maschinenbau AG and Combi from Montrade, for arranging
the various segments of the upstream combined rod at predetermined
locations on the continuous web.
[0080] A wrapping arrangement 350 may be configured to subsequently
wrap lateral ends of the elongate paper sheet 80 at most partially
about the heat generation segment and the tobacco rod segment such
that the heat generation segment and the tobacco rod segment
cooperate with the foil strip to define a longitudinally-extending
cavity 57 accessible between the lateral ends of the elongate paper
sheet and lateral ends of the foil strip. That is, the wrapping
arrangement 350 may be configured to wrap lateral ends of the
elongate paper sheet at most partially about the heat generation
segment and the tobacco rod segment such that the
longitudinally-extending cavity 57 extends vertically downward
(i.e., to form a "U" shaped pocket) from an opening defined between
the lateral ends of the foil strip. The opening may also be
accessible between the lateral ends of the elongate paper sheet
(see, e.g., FIG. 9).
[0081] Once the "U" shaped pocket or cavity 57 is formed, a
dispensing arrangement 400 may be arranged and configured to
deposit a plurality of aerosol generation elements into the
longitudinally-extending cavity 57 between the lateral ends of the
foil strip. That is, the dispensing arrangement 400 may be
configured to deposit the plurality of aerosol generation elements
into the longitudinally-extending cavity 57, typically under the
force of gravity. However, in some aspects, the dispensing
arrangement 400 may be configured to force feed the plurality of
aerosol generation elements into the cavity, for example, using air
pressure. Such aerosol generation elements may be selected from the
group consisting of pellets, beads, discrete small units, carbon
pieces, extruded carbon pieces, alumina beads, marumarized tobacco
pieces, extruded or compressed cylindrical or spherical elements,
milled tobacco lamina, fillers, flavors, visible aerosol forming
materials, binders, ovoid elements, irregularly shaped elements,
shredded pieces, flakes, elements including tobacco, elements
including a visible aerosol-forming material, and combinations
thereof.
[0082] In some aspects, the dispensing arrangement 400 may be
configured to permit selection of a plurality of forms of the
aerosol generation elements (see, e.g., FIGS. 14 and 15, wherein a
selection of 3 types of aerosol generation elements is shown as an
example), and, as such, may comprise a separate dispensing device
450A, 450B, 450C for each selected form of the aerosol generation
elements, wherein each dispensing device may be configured to
dispense the respective form of the aerosol generation elements
into the cavity 57, in some instances, directly into the cavity 57.
That is, in some aspects, it may be desirable for a combination of
different types or forms of aerosol generation elements, such as
pellets and beads, to be deposited into a single cavity 57. In such
instances, the dispensing arrangement 400 may include a dispensing
device for each type or form of aerosol generation element, namely
a dispensing device for the pellets and a separate dispensing
device for the beads, in accordance with the provided example. In
such aspects, each dispensing device may be configured to dispense
the respective type or form of aerosol generation element directly
into the longitudinally-extending cavity 57 (see, e.g., FIG. 14).
However, in other aspects, the dispensing arrangement may be
configured to combine the selected forms or types of the aerosol
generation elements to produce an aerosol generation element
mixture, and an associated dispensing device may be configured to
deposit the aerosol generation element mixture into the cavity 57
(see, e.g., FIG. 15). As previously disclosed, the dispensing
arrangement 400 may be configured to deposit the plurality of
aerosol generation elements into the longitudinally-extending
cavity, such that the cavity is at least about 65 percent filled
with the aerosol generation elements. In some instances, it may be
desirable for the cavity to be at least about 75 percent filled
with the aerosol generation elements; in other instances, at least
about 85 percent filled; and in some situations, at least about 95
percent of maximum fill with the aerosol generation elements.
Filling of the cavities with the materials that provide aerosol
forming components can be accomplished using, for example, a
dispensing arrangement including pneumatic dosing equipment, or
other suitable means for providing a dropping or downward or
gravity-facilitated filling of those cavities with the desired
materials or appropriate elements.
[0083] In further aspects, one skilled in the art will appreciate
that the one or more dispensing devices disclosed herein for the
aerosol generation elements may also include, for example, a
control system for controlling the amount or relative amounts of
the materials comprising the aerosol generation elements dispensed
from the various dispensing devices to form the substrate within
the cavity. The control system may be common to all dispensing
devices (i.e., a single controller in communication with and
controlling all of the dispensing devices) or may comprise a
separate controller for each dispensing device, wherein each
controller may or may not be in communication with on or more of
the other controllers for coordinating the controlled dispensation
of the various aerosol generation elements from the respective
dispensing devices. By controlling the relative amounts of the
various aerosol generation elements dispensed into the cavity, it
may be possible, for example, to control, customize, or otherwise
determine the heat conductivity, interstitial air space, or other
characteristics of the aerosol generation elements (and/or the
interaction therebetween) within the cavity of the aerosol
generation segment. For example, in addition or in the alternative
to implementing the cast sheet portion elements, as previously
discussed, as the aerosol generation elements, particular
heat-conducting elements (i.e., beads, pellets) comprised, for
instance, of metal, graphite, or other suitable heat-conducting
material, may be dispensed in sufficient proportion into the cavity
within the aerosol generation segment to provide the desired heat
transfer conduction pathways. In other instances, the controlled
dispensation of different configurations of aerosol generation
elements (whether random or not) may facilitate attaining certain
characteristics of the interstitial air space within the cavity
over strictly pellets and/or beads.
[0084] Once the cavity 57 is sufficiently and appropriately filled
with a certain amount of the aerosol generation elements, a sealing
arrangement 500 may be configured to close the
longitudinally-extending cavity 57 by sealing the lateral ends of
the elongate paper sheet 80 together. In such aspects, the sealing
arrangement 500 may be configured to wrap the lateral ends of the
foil strip about the aerosol generation elements such that the
lateral ends of the foil strip abut each other (see, e.g., FIG. 2).
In other aspects, the sealing arrangement 500 may be configured to
wrap the lateral ends of the foil strip about the aerosol
generation elements such that the lateral ends of the foil strip
overlap. As appropriate or desired, the sealing arrangement 500 may
also be configured to apply a seam-sealing adhesive or any
appropriate adhesive material between the overlapping lateral ends
of the elongate paper sheet for sealing the lateral ends of the
elongate paper sheet together. The sealing arrangement 500 may
include, for example, a rod forming unit (e.g., a type of device
commonly used in the tobacco industry for production of a
continuous filter rod) to seal the heat conductive strip and/or the
continuous web of outer wrapping material to seal the cavities and
to form a continuous rod comprised of a repeating pattern of
combined rods.
[0085] In accordance with the disclosure herein, one aspect thus
comprises a method of forming an elongate smoking article (see,
e.g., FIG. 16). As disclosed, such a method comprises engaging a
heat generation segment and a tobacco rod segment with an outer
wrapping material in a longitudinally spaced-apart relation in
relation to a length of the outer wrapping material (block 600). In
particular instances, the outer wrapping material has a
heat-conductive strip engaged therewith, and the heat-conductive
strip has longitudinally spaced-apart ends arranged in relation to
the length of the outer wrapping material. In some aspects, the
heat generation segment and/or the tobacco rod segment (either or
both) at least partially overlap one of the longitudinal ends of
the heat-conductive strip. In particular aspects, only the heat
generation segment at least partially overlaps one of the
longitudinal ends of the heat-conductive strip. In still other
aspects, the method may further comprise engaging a spacer element
with the heat generation segment, such that the spacer element and
the tobacco rod segment cooperate with the heat-conductive strip to
define the longitudinally-extending cavity. In such instances, it
may be preferred for the spacer element to be heat-conductive
and/or air permeable.
[0086] In some aspects, the method may further comprise engaging
the heat-conductive strip with the length of the outer wrapping
material, for example, in a lamination procedure, wherein such a
lamination procedure may involve, for instance, engaging the
heat-conductive strip with the outer wrapping material by applying
a lamination adhesive therebetween.
[0087] Lateral ends of the outer wrapping material are then
wrapped, at most partially, about the heat generation segment and
the tobacco rod segment such that the heat generation segment and
the tobacco rod segment cooperate with the heat-conductive strip to
define a longitudinally-extending cavity accessible between the
lateral ends of the outer wrapping material and lateral ends of the
heat-conductive strip (block 625). In some instances, the lateral
ends of the outer wrapping material are wrapped at most partially
about the heat generation segment (and optional spacer element) and
the tobacco rod segment such that the longitudinally-extending
cavity extends vertically downward from an opening defined between
the lateral ends of the heat-conductive strip.
[0088] Once the outer wrapping material is configured to define the
longitudinally-extending cavity, a plurality of aerosol generation
elements into the longitudinally-extending cavity between the
lateral ends of the heat-conductive strip (block 650), wherein the
plurality of aerosol generation elements may be selected from the
group consisting of, for example, pellets, beads, discrete small
units, carbon pieces, extruded carbon pieces, alumina beads,
marumarized tobacco pieces, extruded or compressed cylindrical or
spherical elements, milled tobacco lamina, fillers, flavors,
visible aerosol forming materials, binders, ovoid elements,
irregularly shaped elements, shredded pieces, flakes, elements
including tobacco, elements including a visible aerosol-forming
material, and combinations thereof.
[0089] In some aspects, a plurality of forms of the aerosol
generation elements may be selected, and each selected form of the
aerosol generation elements then subsequently deposited into the
cavity, in some instances, directly into the cavity. In other
instances, the selected forms of the aerosol generation elements
may be combined, prior to deposition into the cavity, to produce an
aerosol generation element mixture, and the mixture then
subsequently deposited into the cavity. In some aspects, the
mixture is deposited directly into the cavity. As previously
disclosed, the plurality of aerosol generation elements may be
dispensed into the longitudinally-extending cavity, such that the
cavity is at least about 65 percent filled with the aerosol
generation elements. In some instances, it may be desirable for the
cavity to be at least about 75 percent filled with the aerosol
generation elements; in other instances, at least about 85 percent
filled; and in some situations, at least about 95 percent of
maximum fill with the aerosol generation elements.
[0090] Once the longitudinally-extending cavity is appropriately
filled, the longitudinally-extending cavity may be closed by
overlapping and sealing the lateral ends of the outer wrapping
material (block 675). In some aspects, closing the
longitudinally-extending cavity may comprise wrapping the lateral
ends of the heat-conductive strip about the aerosol generation
elements such that the lateral ends of the heat conductive strip
abut each other. In other aspects, closing the
longitudinally-extending cavity may comprise wrapping the lateral
ends of the heat-conductive strip about the aerosol generation
elements such that the lateral ends of the heat-conductive strip
overlap. In particular instances, closing the
longitudinally-extending cavity may comprise applying a
seam-sealing adhesive between the overlapping lateral ends of the
outer wrapping material for sealing the lateral ends of the outer
wrapping material together.
[0091] 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.
* * * * *