CN108135289B - Smoking article - Google Patents

Abstract

A smoking article is provided and has opposite lighting and mouth ends. A mouth end portion is disposed at the mouth end, and a heat generating portion is disposed proximate the firing end. An outer wrapping material is wrapped around at least the heat generating portion and extends toward the mouth end portion to define a cylindrical rod. The aerosol-generating portion is disposed within the outer wrapper and between the heat generating portion and the mouth end portion. The aerosol-generating portion is configured to generate an aerosol in response to heat received from the heat-generating portion. The aerosol-generating portion and the heat generation portion are further configured to cooperate to distribute heat received by the aerosol-generating portion from the heat generation portion, thereby avoiding charring of the outer wrapper. Associated methods are also provided.

Description

Smoking article

Background

Technical Field

The present disclosure relates to tobacco products or tobacco derivatives or otherwise tobacco containing products intended for human consumption; and more particularly to segmented smoking articles that produce an aerosol with a significantly reduced amount of incomplete combustion and pyrolysis products relative to tobacco products that produce smoke by burning tobacco.

Description of the Related Art

Common smoking articles such as cigarettes have a generally cylindrical rod-like structure and comprise a charge, roll or column of smokable material such as shredded tobacco (e.g. in the form of cut filler) wrapped in a paper wrapper, thereby forming a so-called "smokable rod", "tobacco rod" or "cigarette rod". Typically, cigarettes have a cylindrical filter element that is aligned in end-to-end relationship with the tobacco rod. Preferably, the filter element comprises a plasticized cellulose acetate tow surrounded by a paper material known as "plug wrap". Preferably, the filter element is attached to one end of the tobacco rod by the use of a circumscribing wrapping material known as "tipping paper". It is also desirable to perforate the tipping material and plug wrap in order to dilute the incoming mainstream smoke with ambient air. Cigarettes and their various components are described in "Tobacco products, Chemistry and Technology" (1999) by Davis et al. A smoker uses a conventional type of cigarette by lighting one end of the cigarette and burning the tobacco rod. The smoker then draws the mainstream smoke into his/her mouth by drawing on the opposite end (e.g., the filter or mouth end) of the cigarette. Over the years, attempts have been made to improve the components, construction and performance of smoking articles. See, for example, the background discussed in U.S. Pat. No. 7,753,056 to Borschke et al.

Certain types of cigarettes that employ carbon fuel elements have been marketed by r.j. raynaud tobaccos (r.j. reynolds tobaco Company) under the trade names "pleummer" and "ellipse". These types of cigarettes are described, for example, in the following documents: chemical and Biological research on novel Cigarette Prototypes with Heat-substituted combustion (Chemical and Biological students on New Cigarette protocol at Heat institute of Burn Tobacco), R.J. Reynolds Tobacco Company Monograph (R.J. Reynolds Tobacco Company) (1988) and Inhalation Toxicology (Inhalation Toxicology), 12:5, pp.1-58 (2000). Additionally, the japanese Tobacco company (Japan tobaco Inc) markets similar types of cigarettes in Japan under the trade name "thermal Steam (stem Hot One)".

Recently, various types of smoking articles comprising carbon fuel elements for generating heat and forming an aerosol have been described in the patent literature; and several patent documents provide historical perspectives of technology relating to smoking products delivering aerosols with chemical compositions that are relatively simple compared to the chemical compositions of mainstream smoke produced by burning tobacco. See, for example, the types of smoking products and associated technology set forth in the following patents: U.S. Pat. No. 7,647,932 to Cantrell et al, U.S. Pat. No. 7,836,897 to Borschke et al, U.S. Pat. No. 8,469,035 to Banerjee et al, U.S. Pat. No. 8,464,726 to Sebastian et al, U.S. Pat. No. 8,616,217 to Tsuruizumi et al, U.S. Pat. No. 8,678,013 to Crooks et al, and U.S. Pat. No. 8,915,255 to Poget et al, U.S. patent application publication No. 2012/0042885 to Stone et al, and U.S. patent application publication No. 2013/0133675 to Shinozaki et al, PCT No. WO 2012/0164077 to Gladden et al, PCT No. WO 2013/098380 to Raether et al, PCT No. WO 2013/098405 to Zuber et al, PCT No. WO 2013/098410 to Zuber et al, PCT No. WO 2013/104914 to Wuder et al, PCT No. WO 2013/120849 to Mivoron et al, PCT No. 2013/120854 to Migoron, and PCT No. WO 2013/162028 to Saleeem et al, EP 1808087 to Baba et al and EP 2550879 to Tsurizumi et al.

It would be highly desirable to provide a smoking article that proves capable of providing a smoker with a substantial portion of the enjoyment of smoking a conventional cigarette without delivering an aerosol containing significant amounts of incomplete combustion and pyrolysis products.

Disclosure of Invention

The above and other needs are met by aspects of the present disclosure which, in one aspect, provides an elongated smoking article having a lighting end and an opposite mouth end, wherein such smoking article includes a mouth end portion disposed at the mouth end and a heat generating portion disposed about the lighting end. An outer wrapping material is wrapped around at least the heat generating portion and extends toward the mouth end portion, thereby defining a cylindrical rod. The aerosol-generating portion is disposed within the outer wrapper and between the heat generating portion and the mouth end portion, wherein the aerosol-generating portion is configured to generate an aerosol in response to heat received from the heat generating portion, and wherein the aerosol-generating portion and the heat generating portion are further configured to cooperate to distribute the heat received by the aerosol-generating portion from the heat generating portion, thereby avoiding scorching of the outer wrapper.

Thus, aspects of the present disclosure provide smoking articles, and in particular rod-shaped or elongate smoking articles such as cigarettes. The smoking article includes a lighting end (i.e., an upstream end) and a mouth end (i.e., a downstream end), each disposed at an opposite end of the smoking article. The smoking article also includes an aerosol-generating system comprising: (i) a heat generation region, portion or section, and (ii) an aerosol-generating region, portion or section located downstream of the heat generation section. The heat generation section contains relatively short (longitudinally extending) heat sources or fuel elements (i.e., heat generating elements); including materials such as, for example, relatively clean burning carbonaceous fuels. The aerosol-generating segment most preferably comprises a substrate region, and in certain embodiments the substrate region comprises pellets or beads formed from tobacco disposed within a substrate cavity. Alternatively, for example, the substrate region comprises material comprising reconstituted type tobacco (e.g., shredded cast sheet type material). The substrate cavity or region in which the substrate material is located is preferably surrounded along the longitudinally extending length of the smoking article by a layer or strip of metal foil (e.g. thermally conductive) laminated to the paper wrapper. The substrate is at least partially composed of tobacco, and serves as a carrier and source of aerosol-forming material.

In certain aspects, the present disclosure provides an elongate smoking article comprising a mouth-end segment portion, region or section disposed at the mouth end and a tobacco rod segment, region or section (or other suitably configured segment) disposed between the lighting end and the mouth-end section. The aerosol-generating system is positioned as a segment disposed between the heat generation segment and the mouth end portion. That is, the aerosol-generating segment is longitudinally disposed adjacent to the heat-generating portion or segment disposed at the firing end; and the two sections are in heat exchange relationship such that heat generated by the means for generating heat from combustion acts on the aerosol-forming means of the aerosol-generating section and causes aerosol to be generated. The longitudinally extending outer surfaces of the heat generation segment and the aerosol-generating segment are surrounded by an outer wrapping material, thereby providing a rod which in turn is attached to the mouth-end segment. A layer of thermally conductive material is arranged below the outer wrapping material, thereby providing an outer interior surface of the aerosol-generating segment. The heat conductive layer overlaps the outer longitudinal surface of the heat generation section, optimally in the region where the heat generation section is adjacent to the aerosol-generating section; and the heat conductive layer may optionally overlie the outer longitudinal surface of the tobacco rod segment in the region of the tobacco rod segment adjacent the aerosol-generating segment. Certain materials within the aerosol-generating segment form an aerosol when acted upon by and in response to heat generated by burning a fuel element of the heat-generating segment.

In certain aspects, the fuel elements or heat sources of the heat generation segment may comprise a material that may be characterized as a carbonized or pyrolyzed material derived from carbonized or pyrolyzed cotton material. In this regard, it is preferred and/or desirable that the fuel material/heat source is ignited and remains burning (i.e. smoldering), but does not dissipate the flame during consumption of the smoking article, while generating sufficient heat for actuating the aerosol-generating segment to generate the aerosol. Thus, aspects of the present disclosure may relate to, for example, a fuel element/heat source configured or arranged to facilitate ignition or ignitability thereof. In some cases, existing fuel elements/heat sources constructed of conventional materials may be optimized to produce desired ignition/ignitability characteristics for the smoking article. In other cases, other substances such as additives (i.e., test carbon or cotton linters) and/or catalysts may be included in existing fuel elements/heat sources constructed of conventional materials to enhance the ignition/ignitability characteristics thereof. Representative aspects of such fuel elements/heat sources are disclosed, for example, in U.S. patent application serial No. 14/755,205 to Nordskog et al.

In certain aspects, the substrate region (aerosol-generating system) comprises a form of tobacco that forms a tobacco smoke exhibiting desirable organoleptic properties. For example, the matrix region may be comprised of a mixture of: (i) pellets or beads composed of tobacco which serve as a carrier for aerosol-forming material, such as glycerol (i.e. aerosol-forming material may be included or otherwise incorporated into or in contact with the pellets/beads and sealed to the pellets/beads by a gelling/sealing agent for maintaining the integrity of the aerosol-forming material and pellets/beads exposed to heat during use); and (ii) a form of tobacco that forms a tobacco smoke exhibiting desirable organoleptic properties. Alternatively, for example, the matrix region may be composed of a mixture of: (i) pieces or portions of reconstituted tobacco material of the cast sheet type, which are used as carriers for aerosol-forming materials, such as glycerin; and (ii) a form of tobacco which forms a tobacco smoke exhibiting desirable organoleptic properties. In particular aspects, the substrate region/aerosol-generating system, directly or in cooperation with the heat-generating segment, may be configured to more evenly or efficiently transfer and distribute heat directed from the heat-generating segment to the substrate region/aerosol-generating system. Preferably, such increased uniformity or efficiency in transferring and distributing heat directed from the heat generation segment to the substrate region/aerosol-generating system also advantageously reduces, minimizes or eliminates charring of the outer wrapper of the smoking article. Additionally, such increased uniformity or efficiency in transferring and distributing heat directed from the heat generation segment to the substrate area/aerosol-generating system may also reduce scorching of the substrate area/aerosol-generating system itself, or at least facilitate reducing or minimizing negative sensory effects on the aerosol inhaled and experienced by the user caused by the scorching of the substrate.

Accordingly, the present disclosure includes, without limitation, the following embodiments:

example 1: an elongate smoking article having a lighting end and an opposite mouth end, wherein the smoking article comprises a mouth end portion arranged at the mouth end; a heat generating portion disposed around the firing end; an outer wrapper wrapped around at least the heat generating portion and extending toward the mouth end portion, thereby defining a cylindrical rod; and an aerosol-generating portion disposed within the outer wrapper and between the heat generating portion and the mouth end portion, the aerosol-generating portion configured to generate an aerosol in response to heat received from the heat generating portion, the aerosol-generating portion and the heat generating portion further configured to cooperate to distribute heat received by the aerosol-generating portion from the heat generating portion, thereby avoiding scorching of the outer wrapper.

Example 2: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises a rod member having a length and a maximum diameter, and wherein the rod member has a surface area that is greater than a surface area of a right cylinder having a length and a maximum diameter that are equal to the length and the maximum diameter of the rod member, respectively.

Example 3: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises a slotted rod member.

Example 4: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the slotted rod member defines a channel extending longitudinally therethrough.

Example 5: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the grooved rod member is extruded from a mixture comprising finely ground tobacco, calcium carbonate, an adhesive, glycerin, water, and flavoring.

Example 6: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises an aerosol-generating element wrapped by a wrapper disposed between the aerosol-generating element and the outer wrapper.

Example 7: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the wrapping material is selected from the group consisting of a paper-foil stack, a paper-foil-paper stack, a paper-foil-tobacco sheet stack, a non-woven graphite sheet, a graphene-foil stack, a graphene-foil-paper sheet stack; a paper-graphene sheet stack, graphene ink printed on a paper sheet, graphene ink printed on a foil, carbon nanotubes bonded to a paper sheet or foil, fullerenes bonded to a paper sheet or foil, and graphene bonded to a paper sheet or foil.

Example 8: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the graphene ink is printed on the paper or foil according to a continuous pattern or a discontinuous pattern.

Example 9: the paper sheet of any preceding or subsequent embodiment, or combinations thereof, wherein the paper sheet comprises a tobacco-wrapped paper sheet, and wherein the tobacco sheet comprises an extruded tobacco sheet, a cast tobacco sheet, or a reconstituted tobacco sheet.

Example 10: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the foil comprises a continuous foil or a separate foil strip.

Example 11: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising a tobacco portion disposed within the overwrap material and between the heat generating portion and the aerosol-generating portion.

Example 12: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising a tobacco portion disposed within the outer wrapper and between the aerosol-generating portion and the mouth end portion.

Example 13: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising a non-woven graphite sheet or a non-woven composite sheet of graphite and graphene wrapped around a portion of the heat generating portion and around a portion of the aerosol-generating portion, within the outer wrapper and extending toward the mouth end portion.

Example 14: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the non-woven graphite sheets are laminated with an overwrap material.

Example 15: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising a metal foil laminated with an outer wrapping material via a bonding material therebetween, the bonding material comprising a portion of aluminum hydroxide therein, and the metal foil wrapped around the heat-generating portion and around a portion of the aerosol-generating portion within the outer wrapping material and extending toward the mouth end portion.

Example 16: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the overwrap material comprises a portion of aluminum hydroxide, a portion of magnesium hydroxide, or a portion of calcium carbonate therein.

Example 17: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising a fiberglass sheet wrapped around the heat-generating portion and around a portion of the aerosol-generating portion within the outer wrapping material and extending toward the mouth end portion.

Example 18: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising a thermally conductive material engaged with the outer wrapping material, the thermally conductive material disposed within the outer wrapping material and extending to wrap radially at least partially around the heat generating portion and longitudinally from the heat generating portion to the aerosol-generating portion.

Example 19: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the thermally conductive material comprises a conductive ink printed on the overwrap material, a metal layer deposited on selected portions of the overwrap material, graphene bonded to the overwrap material, or a carbon material bonded to selected portions of the overwrap material.

Example 20: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion is comprised of a material selected from the group consisting of a cast sheet of tobacco material in the form of cut filler, a sheet of reconstituted tobacco material in the form of cut filler, cut filler tobacco material treated with glycerol, aerosol-forming beads, ceramic material including glycerol, a cast sheet of non-tobacco material in the form of cut filler, a glass fiber mat including nicotine substances obtained from tobacco, a foil sheet having aerosol-forming material applied thereto, paper including accumulations of nicotine substances obtained from tobacco, non-tobacco material including nicotine substances obtained from tobacco, and combinations thereof.

Example 21: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the cut filler tobacco material treated with glycerol comprises between about 5% and about 25% glycerol.

Example 22: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises a first portion and a second portion, the first portion and the second portion being disposed continuously between the heat-generating portion and the mouth end portion.

Example 23: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises a first portion and a second portion, the first portion of the aerosol-generating portion being constructed of a different material than the second portion of the aerosol-generating portion.

Example 24: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises a first portion and a second portion, the first and second portions mixed together to form a single aerosol-generating element.

Example 25: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises a porous ceramic rod member defining at least one conduit extending longitudinally therethrough.

Example 26: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the porous ceramic rod member comprises an aerosol former, flavoring, or tobacco extract engaged therewith.

Example 27: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-former comprises glycerol and the tobacco extract comprises nicotine obtained from tobacco.

Example 28: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the porous ceramic rod member defines a plurality of longitudinally extending open channels angularly spaced about an outer surface of the rod member.

Example 29: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion is comprised of aerosol-generating beads arranged in series with respect to the heat-generating portion and comprises a non-tobacco plug member arranged between each bead and the mouth end portion.

Example 30: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the aerosol-generating portion comprises a plurality of rod members extending parallel to one another, the rod members being constructed of a tobacco material, a non-tobacco material, or a ceramic material.

Example 31: the article of any preceding or subsequent embodiment, or combinations thereof, wherein the heat generating portion comprises a heating element comprised of a carbonized or pyrolyzed material, comprising an ignitability-enhanced material selected from the group consisting of carbon, cotton linters, glass microspheres, catalysts, and combinations thereof.

Example 32: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising an overwrap material wrapped around at least the outer wrapping material, the outer wrapping material wrapped around at least the heat-generating portion, the overwrap material being embossed so as to be at least partially spaced apart from the outer wrapping material.

Example 33: the article of any preceding or subsequent embodiment, or combinations thereof, further comprising a thermochromic ink material interacting with the outer wrapper, the thermochromic ink configured to provide the visual indicator being responsive to the outer wrapper exceeding a temperature threshold.

These and other features, aspects, and advantages of the present disclosure will become apparent upon reading the following detailed description and the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure or recited in any one or more claims, whether or not such features or elements are expressly combined or otherwise recited in a specific embodiment description or claim herein. Unless expressly stated otherwise in the context of this disclosure, the present disclosure is intended to be read in its entirety such that any separable feature or element of the present disclosure is to be considered as intended, i.e., to be combinable, in any of its aspects and embodiments.

Drawings

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:

fig. 1 schematically illustrates a longitudinal cross-sectional view of a representative smoking article, according to an aspect of the present disclosure;

figure 2 schematically shows a longitudinal cross-sectional view of a representative, disassembled smoking article, according to another aspect of the present disclosure;

figure 3 schematically illustrates a longitudinal cross-sectional view of a representative, disassembled smoking article, in accordance with yet another aspect of the present disclosure; and

figures 4 and 5 schematically illustrate an aerosol-generating substrate element according to an alternative aspect of the invention.

Detailed Description

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, this 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 reference numerals refer to like elements throughout.

Fig. 1 illustrates a representative smoking article 10 in the form of a cigarette according to one aspect of the present disclosure. Preferably, the smoking article 10 has the overall size, shape and general appearance of a filter cigarette. The smoking article 10 has a rod-like shape and includes a lighting end 14 and a mouth end 18. At the firing end 14, a longitudinally extending, generally cylindrical heat generation section 35 is positioned. The heat generation segment 35, which comprises a heat source 40 surrounded by insulation 42, is most preferably coaxially surrounded by an outer wrapping material 75. The heat source 40 is preferably configured to be activated by direct ignition of the firing tip 14. That is, the heat source or fuel element is designed to be ignited to burn or smolder and thereby generate heat. The smoking article 10 also includes a filter segment 55 at the opposite end (i.e., the mouth end 18) and an aerosol-generating segment 61 between the filter segment and the heat source.

The heat generation section 35 most preferably comprises a combustible fuel element 40 having a generally cylindrical shape and containing a combustible carbonaceous material. Such combustible carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials consist essentially of carbon, typically having a carbon content of greater than about 60 percent, typically greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent by dry weight. Such combustible fuel elements may contain ingredients other than combustible carbonaceous materials (e.g., tobacco ingredients such as powdered tobacco or tobacco extracts, flavoring agents, salts such as sodium chloride, potassium chloride, and sodium carbonate, heat stable graphite fibers, iron oxide powders, glass filaments, powdered calcium carbonate, alumina particles, ammonia sources such as ammonium salts, and/or binders such as guar gum, ammonium alginate, and sodium alginate). A representative fuel element, for example, has a length of about 12mm and an overall outer diameter of about 4.2 mm. Representative fuel elements may be extruded or blended using ground or powdered carbon materials and have a dry weight greater than about 0.5g/cm³Is generally greater than about 0.7g/cm³And frequently more than 1g/cm³。

The layered insulation 42 may be comprised of glass filaments or fibers. The thermal insulation 42 may act as a sheath that helps to securely maintain the heat source 40 in place within the smoking article 10 (i.e. disposed between the heat source and the outer wrapper, thereby securing the heat source within the outer wrapper). Preferably, the thermal insulation is provided in the form of a non-woven mat of glass filaments. The insulation 42 may be provided as a multi-layered component, including, for example, an inner layer or mat 67 of non-woven glass filaments, a middle layer 68 of reconstituted tobacco paper, and an outer layer 69 of non-woven glass filaments. The layers may be concentrically oriented or each overwrapped in a continuous stack and/or around the heat source.

Preferably, both ends of the heat generation section 35 are open to expose at least the heat source 40 and the thermal insulation 42 at the firing end 14. The heat source 40 and the surrounding insulation 42 may be configured such that the lengths of the two materials are coextensive (i.e., the ends of the insulation 42 are flush with the corresponding ends of the heat source 40, and particularly at the downstream end of the heat generation section). Optionally, although not necessarily preferred, the insulation 42 may extend slightly beyond one or both ends of the heat source 40 (e.g., from about 0.5mm to about 2 mm). In addition, during use of the smoking article 10, heat and/or heated air generated upon ignition at the ignition end 14 may readily pass through the heat generation section 35, through the heat source 40 itself (i.e., through the longitudinal channels extending through the heat source 40), and/or longitudinally through the insulation 42 during draw by a smoker on the mouth end 18.

Preferably, the outer wrapper 75 surrounds the insulation 42 on the longitudinally extending outermost surface of the lighting end 14 of the smoking article 10. The outer wrapping material 75 is typically a paper wrapping material, such as, for example, the type of paper wrapping material used as a surrounding wrapping material for the insulation area of the heat source section of cigarettes marketed by r.j. raynaud Tobacco Company (r.j. reynolds tobacao Company) under the trade names "pleumier" and "ellipse". Thus, "outer wrapper 75" may also be referred to as "outer wrapper paper 75" to indicate such an aspect, but without limitation, the outer wrapper 75 is a paper wrapper.

The heat generation segment 35 is preferably positioned with one end disposed at or very close to the firing tip 14 and axially aligned in end-to-end continuous relationship with the downstream aerosol-generating segment 61, preferably abutting each other, and preferably having no obstructions therebetween (other than an open air gap). The close proximity of the heat generation segment 35 to the firing end 14 provides for direct ignition of the heat source 40 of the heat generation segment 35.

The cross-sectional shape and size of the heat generation section 35 may vary prior to combustion during use. Preferably, the cross-sectional area of the fuel elements/heat sources 40 is about 10 to about 35 percent, often about 15 to about 25 percent, of the total cross-sectional area of the heat generation section 35; while the cross-sectional area of the outer or surrounding region (including the insulation 42 and associated outer wrapping material) is about 65 percent to about 90 percent, often about 75 percent to about 85 percent, of the total cross-sectional area of the heat generation section 35. For example, for a cylindrical smoking article 10 having a circumference of about 24mm to about 26mm, a representative fuel element/heat source 40 has a generally circular cross-sectional shape with an outer diameter of about 2.5mm to about 5mm, often about 3mm to about 4.5 mm.

The components of the heat generation section may vary. One component of the heat generation section is a fuel element. Suitable fuel elements typically include carbonaceous materials having a high carbon content and may also include components such as graphite and/or alumina. Carbon fuel elements include those types of components and constructions that have been incorporated into cigarettes marketed under the trade names "pleumole" (Premier), "ellipse" (Eclipse), and "thermal Steam" (Steam Hot One). Additionally, representative types of heat generation segments, fuel element features and representative components, designs and configurations thereof, as well as ways and methods of producing these heat generation segments and fuel elements therefor, are set forth in the following U.S. patents and U.S. patent applications: U.S. Pat. No. 4,714,082 to Banerjee et al, No. 4,756,318 to Clearman et al, No. 4,881,556 to Clearman et al, No. 4,989,619 to Clearman et al, No. 5,020,548 to Farrier et al, No. 5,027,837 to Clearman et al, No. 5,067,499 to Banerjee et al, No. 5,076,297 to Farrier et al, No. 5,099,861 to Clearman et al, No. 5,105,831 to Banerjee et al, No. 5,129,409 to White et al, No. 5,148,821 to Best et al, No. 5,156,170 to Clearman et al, No. 5,178,167 to Riggs et al, No. 5,211,684 to Shaon et al, No. 5,247,947 to Clearman et al, No. 5,345,955 to Clearman et al, No. 5,461,879 to Barborneos et al, No. 82862 to Barneor et al, No. 828653 to Boreaje et al, and Boreaking et al, No. 368653 to Borear 8653 to Boreaje et al; and U.S. patent application publication No. 2005/0274390 to Banerjee et al, No. 2007/0215168 to Banerjee et al, No. 2012/0042885 to Stone et al; stone et al, No. 2013/0269720; and Conner et al No. 2015/0083150. See also the types of fuel element configurations and components thereof described in U.S. patent No. 4,819,655 to Roberts et al and U.S. patent application publication No. 2009/0044818 to Takeuchi et al.

Certain fuel elements may contain high carbon content carbonaceous materials obtained from cotton-containing fibers (e.g., cotton linters) that have been carbonized or pyrolyzed. For a description of cotton linter materials that have been carbonized or pyrolyzed and the manner and method by which these materials are incorporated into smoking articles, into carbonized smoking materials and fuel elements, see, e.g., U.S. patent No. 4,219,031 to Rainer et al, 4,920,990 to Lawrence et al, 5,007,440 to Robinson et al, 5,060,673 to Lehman, 5,129,409 to White et al, 5,211,684 to Shannon et al, and 8,119,555 to Banerjee et al. The fuel elements of the heat generation stage are most preferably surrounded or otherwise encased by insulation or other suitable material. The thermal shield may be configured and employed to support, maintain and hold the fuel element in place within the smoking article. The insulation may additionally be configured such that the drawn air and aerosol may easily pass therethrough. Suitable insulation components have been included in those types of cigarettes marketed under the trade names "pleummer (Premier)", "ellipse (Eclipse)", and "thermal Steam (Steam Hot One)". Exemplary methods of producing insulation assemblies and heat insulating assemblies for use in the insulation assemblies and packaging of these components in the manner of heat insulating assemblies, and heat insulating assemblies are additionally set forth in U.S. patent nos. Pryor et al 4,807,809, Hancock et al 4,893,637, Barnes et al 4,938,238, Shannon et al 5,027,836, Lawson et al 5,065,776, White et al 5,105,838, Banerjee et al 5,119,837, Clearman et al 5,247,947, Banerjee et al 5,303,720, Clearman et al 5,345,955, Casey san Shih et al 5,396,911, White 5,546,965, mering et al 5,727,571, Wilkinson et al 5,902,431, Cook et al 5,944,025, Thomas et al 8,424,538, Sebastian et al 8,464,726, and Crooks et al 8,678,013.

A longitudinally extending, generally cylindrical aerosol-generating segment 61 is located downstream of the heat generation segment 35. The heat generating segment 61 comprises a substrate element 85 comprising a material which is itself an aerosol-forming agent or aerosol-forming substance, or which otherwise serves as a carrier (not shown) for the aerosol-forming agent or material. For example, the aerosol-generating segment may include reconstituted tobacco material that includes a treatment aid, a flavoring agent, and/or glycerin. The aforementioned components of the aerosol-generating segment may be disposed within and surrounded by a wrapping material 90. The wrapper 90 may be configured to facilitate heat transfer from the lighting end 14 of the smoking article 10 (e.g., from the heat generation section 35) to the components of the aerosol-generating section 61. That is, the aerosol-generating segment and the heat-generating segment may be configured in heat exchange relationship with one another, wherein such heat exchange relationship may be facilitated by the wrapping material 90. The heat exchange relationship is such that sufficient heat from the heat source 40 is supplied to the aerosol-forming section 61 to volatilize the aerosol-forming material (i.e. associated with the matrix elements 85) to form and generate an aerosol. In some cases, the wrapping material 90 may be a separate component relative to the outer wrapping material 75, or may be engaged with the outer wrapping material 75 in various ways. In other cases, the wrapping material 90 may include an insulating material for insulating the matrix element 85 from the outer wrapping material 75. For example, the wrapping material 90 may include a glass fiber mat having a thickness between about 50 μm and about 500 μm.

In one aspect of the present disclosure, the heat exchange relationship is achieved by arranging the heat generating section 35 and the aerosol-generating section 61 in series, close to each other. In some cases, the segments may be arranged end-to-end in continuous contact with each other. The heat exchange relationship may also be achieved by extending a thermally conductive material from adjacent the heat source 40 into and/or around the region occupied by the aerosol-generating segment 61. For example, in one aspect, a representative wrapping material 90 for the substrate element 85 may comprise a thermally conductive element or characteristic for conducting heat from the heat generation segment 35 to the aerosol-generating section 61 (and/or for maintaining heat interacting with the aerosol-generating section 61 along its length), thereby providing for evaporation of aerosol-forming components contained therein (i.e. associated with the substrate element 85). In other aspects, the representative wrapping material 90 and/or the outer wrapping material 75 may include thermally conductive properties for dissipating heat not directed from the heat generation segment 35 to the aerosol-generating segment 61, and/or for distributing heat evenly or more consistently between the heat generation segment 35 and the aerosol-generating segment 61, while still providing for volatilization of aerosol-forming components contained in the aerosol-generating segment 61 or associated with the substrate element 85. Such a wrapping material 90 may be provided by, for example, a laminated paper/foil consisting of an outer layer 94 of a sheet of paper-like material and an inner layer 96 of thermally conductive metal foil. The metal foil 96 may, for example, extend from a region downstream of the heat source 40 and along at least a portion of the length of the aerosol-generating segment 61. The metal foil/inner layer 96 laminate may be associated with the outer layer 94 in the form of a separate, longitudinally extending strip or strips affixed to the outer layer 94 or in the form of a continuous sheet that cooperates with the outer layer 94 to surround a significant area covering the heat generation section 35 and the aerosol-generating section 61.

In various aspects of the present disclosure implementing the wrapping material 90, its thermally conductive arrangement may be implemented in various ways. Generally, the wrapper 90 in the form of a laminated paper/foil may have a typical length (i.e. along the aerosol-generating segment 61) of between about 8mm and about 50mm for a representative smoking article of the type described herein. The laminated paper/foil may be perforated, etched, embossed or primed, for example, to improve ease of manufacture. In some cases, the thickness of the foil used in the laminate may be varied or increased/decreased, for example, between about 0.0001 inches and 0.005 inches, as needed or desired, to alter the properties of the laminated paper/foil sheets and/or to reduce visible scorching of the paper sheet portions (i.e., the outer layers 94) and/or the outer wrapping paper 75 of the laminate wrapped around the wrapping paper 90 and/or the aerosol-generating segment 61.

The laminated paper/foil may be formed in different ways. For example, a thermally conductive ink (in some cases a thermally conductive metallic ink) may be used to print on the paper portion such that the printed ink forms a foil layer (sheet or strip) on the paper portion (and/or may be at least partially absorbed into/integral with the paper portion). Such thermally conductive ink may include, for example, carbon, graphite, graphene, silver, or any suitable thermally or thermally conductive material, or combinations thereof, to conduct heat along the paper portion, wherein the conducted heat in turn heats the substrate element to generate an aerosol therefrom. Preferably, such thermally conductive ink may be printed on the foil or conventional cigarette paper according to a continuous or discontinuous pattern, wherein the basis weight of the cigarette paper is in the range of about 20gsm to about 100 gsm.

In other cases, a thermally or thermally conductive material such as, for example, a metal foil (i.e., silver), a thermally conductive carbon material (i.e., graphene), or any other suitable thermally conductive material, or combinations thereof, may be deposited on or otherwise attached to the conventional cigarette paper in various configurations (i.e., discrete strips, whole pieces, complete coatings, etc.), for example, using "island placement" or selective deposition/bonding techniques, to facilitate ease of manufacture and to enhance functionality. In any event, the implementation of the laminated paper/foil as the wrapping paper 90 may sometimes dissipate or redirect the heat generated by the heat generating section 35 to reduce scorching of the outer wrapping paper 75 and/or of other components of the smoking article. Thus, elimination of scorch may enhance the taste or sensory perception imparted to the user by the generated aerosol. That is, the charred material may impart an undesirable taste or sensory perception to the generated aerosol, and reducing, minimizing, or eliminating such charring may, for example, improve the taste that the aerosol imparts to the user and remove undesirable visual effects resulting from such charring. Thus, aspects of the present disclosure relate to more completely and efficiently directing and distributing heat generated by the heat generation segment 35 and directed to the aerosol-generating segment 61 without charring the substrate element 85, the outer wrapper 90, or other components that contribute to or otherwise affect the aerosol drawn and experienced by the user. Further, as the aerosol-generating segment 61 may sometimes include glycerin or other leachable substances, aspects of the wrapping material 90 disclosed herein may also relate to avoiding or minimizing the leaching of glycerin or other leachable substances from the aerosol-generating segment 61 into the outer wrapping paper 75. That is, aspects of the present disclosure may include a wrapper 90 configured to avoid or minimize discoloration of the outer wrapper 75 that may result from the leaching of glycerol or other leachable substances from the aerosol-generating segment 61.

In certain aspects, the wrapping paper 90 may comprise cigarette/foil/tobacco paper in the form of a three-ply laminate, wherein such a three-ply laminate construction may also facilitate an enhancement in the taste or sensory perception of the generated aerosol as perceived by the user, for example, by reducing, minimizing, or eliminating scorching or charring of particular components of the smoking article and by directing more heat toward the aerosol-generating segment 61. The tobacco paper/sheet composition may vary and may include and consist of, for example, burley, flue-cured, oriental, or any other suitable type of tobacco, or combinations thereof, in varying proportions. The tobacco may be included in the tobacco paper/sheet in an amount up to about 85% tobacco, and the tobacco paper/sheet may have a basis weight ranging from about 20gsm to about 100 gsm. In some cases, the three-ply laminate form of the wrapping paper 90 may be constructed of tobacco paper/foil/tobacco paper as needed or desired. In other cases, a two-layer stack of tobacco paper/foil may be implemented, wherein the tobacco paper may be laminated to an aluminum or other thermally conductive foil having a thickness in the range of about 0.0005 inches to about 0.002 inches, wherein such a two-layer stack sheet may have a basis weight of between about 60gsm and about 100 gsm.

According to still other aspects, the wrapping paper 90 may be configured as any of a paper-foil stack, a paper-foil-paper sheet stack, a paper-foil-tobacco sheet stack, a non-woven graphite sheet, a non-woven graphite and graphene composite sheet, a graphene-foil stack, a graphene-foil-paper sheet stack, a paper-graphene sheet stack, a graphene ink printed on a paper sheet, a graphene ink printed on a foil, carbon nanotubes engaged with a paper sheet or foil, fullerenes engaged with a paper sheet or foil, and graphenes engaged with a paper sheet or foil. In such a case, for example where the graphene comprises one of the outer layers of the stack, it may be desirable for the graphene layers of the stack to provide the original layers of the stack closest to the substrate element 85. In other cases, for example, in the case of a graphene-foil stack, it may be desirable for the foil layers of the stack to provide the original layers of the stack closest to the substrate element 85, while the graphene layers function as a heat shield between the substrate element 85 and the outer wrapper 75, or the order may be reversed, where the graphene layers of the stack are the original layers of the stack closest to the substrate element 85 and the foil layers function as a heat shield between the substrate element 85 and the outer wrapper 75. In the case where the wrapping paper 90 includes a heat conductive layer and a paper sheet or foil, a heat insulating layer or a heat layer may be disposed therebetween.

In performing aspects of, for example, an lithographene ink, the ink may be applied using a variety of printing processes, such as, for example, gravure, flexographic, offset, screen, ink jet, or other suitable printing methods, to provide varying thicknesses, patterns, surface coverage, and ingredient formulations.

In other aspects, a graphene foil or graphene conductive sheet may be placed between the cigarette paper (i.e., the outer wrapping material 75) and the aluminum foil (i.e., the foil layer associated with the wrapping paper 90) to create a paper/graphene/foil laminate structure that surrounds the outer wrapping material 75 and the wrapping paper 90. In this case, the graphene portion may be completely encapsulated (i.e., between the inner and outer layers) to avoid or minimize material transfer or migration therefrom during product manufacture and use, which may also avoid or minimize leaching of any glycerol from the matrix element 85 to the outer wrapping material 75. However, those skilled in the art will appreciate that the wrapping material 90 configured for use herein may be constructed and composed in many different ways other than the various configurations disclosed herein, and that these exemplary configurations are not intended to be limiting in this regard.

The outer wrapping material 75 is generally configured to wrap around the heat generation segment 35 and extend longitudinally (downstream) to wrap around the aerosol-generating segment 61 and along at least a portion of its length. When so engaged to wrap around significant components of the smoking article, the outer wrapper 75 also extends outside the interface between the heat generation segment 35 and the aerosol-generating segment 61, and thus may also desirably have no or minimal propensity to char(and tendency to prevent leaching). Thus, in certain aspects of the present disclosure, the overwrap paper 75 may be, for example, calcium carbonate (CaCO) as a filler in the paper matrix of the overwrap paper 75₃) Aluminum hydroxide, magnesium hydroxide, and/or combinations thereof, at least as an anti-scorch agent.

Those skilled in the art will also appreciate that the wrapper 90 and/or outer wrapper 75, when wrapped around appropriate components of the smoking article, may have their opposite ends (even if the angularly overlapping ends form a seam extending longitudinally along the smoking article) sealed together, for example by adhesive material. Thus, in certain aspects of the present disclosure, the bonding material may also include materials such as calcium carbonate (CaCO)₃) Aluminum hydroxide, magnesium hydroxide, and/or combinations thereof, thereby reducing, minimizing, or eliminating scorching or carbonization of the bonding material and/or the outer wrapper 75 along the longitudinally extending seam of the outer wrapper 75 wrapped around the components of the smoking article.

The substrate element 85 forming part of the aerosol-generating segment 61 may comprise tobacco. More specifically, if tobacco is included, the substrate element 85 may be composed of a mixture of flavorful tobacco, for example, in the form of cut filler. The tobacco may in turn be treated with an aerosol-forming material and/or at least one flavoring agent. Matrix element 85 can also be constructed of treated tobacco in the form of cut filler (e.g., reconstituted tobacco manufactured using cast sheet or paper-type processes). Certain cast sheet constructions may include about 270mg to about 300mg of tobacco per 10mm of straight length of the cast sheet. In other cases, the matrix element 85 may be composed of a mixture of shaped tobacco pellets. In certain aspects of the present disclosure, the substrate element 85 comprised of one form of tobacco may in turn be treated or processed with an aerosol-forming material and/or at least one flavoring agent and a combustion retardant (e.g., diammonium phosphate, other similar types of salts, and/or suitable combustion retardant materials) to include an aerosol-forming material and/or at least one flavoring agent and a combustion retardant (e.g., diammonium phosphate, other similar types of salts, and/or suitable combustion retardant materials). The inclusion of the combustion-retarding material in the matrix members may be configured to prevent ignition of the matrix-forming material by the heat generation section and/or to avoid charring of the matrix members. Additionally, the metallic inner layer or surface 96 of the wrapper/outer layer 94 of the aerosol-generating segment 61 may serve as a carrier for the aerosol-forming material, the tobacco component, and/or the at least one flavoring agent.

As used herein, the term "tobacco pellets" is meant to include beads, pellets or other discrete small units of tobacco that have been formed, shaped, compressed, extruded or otherwise formed into a desired shape. For example, tobacco pellets may be formed using a so-called pelletizing process. The tobacco pellets may have a smooth, regular external shape (e.g., spheres, cylinders, ovoids, etc.) and/or they may have an irregular external shape. In one example, the diameter of each tobacco pellet may be in a range of less than about 1mm to about 2 mm. The tobacco pellets may at least partially fill a substrate cavity of a smoking article as described herein. That is, the matrix elements 85 may take the form of pellets or other bulk items that occupy space within the aerosol-generating section 61 adjacent to and downstream of the heat generation section 35. In one example, the volume of the substrate cavity may range from about 500mm³To about 700mm³(e.g., a substrate cavity of a smoking article, wherein the cavity diameter is from about 7.5 to about 7.8mm and the cavity length is from about 11 to about 15mm, wherein the cavity has a generally cylindrical geometry). In one example, the mass of tobacco pellets within the matrix cavity may be in a range from about 200mg to about 500 mg. For example, tobacco pellets may be used so as to be at about 100 to about 400mg/cm³To fill the appropriate section of the aerosol-generating section 61 (e.g., the cylindrical region within its wrapper and bounded by the ends of the heat generation section 35 and the filter section 55).

The configuration and arrangement of the matrix elements 85 may vary in accordance with various aspects of the present disclosure. In one aspect, the matrix element 85 may be formed as a unitary or integrated structure via, for example, an extrusion, molding, or casting process. In certain preferred aspects, the unitary substrate element 85 can comprise tobacco or a tobacco product. For example, in one aspect, the unitary matrix element 85 formed in an extrusion process can include glycerin, finely ground tobacco, calcium carbonate, a binder, flavoring, and water. More specifically, the dry weight of the extrusion material may include about 37.86% finely ground tobacco, about 39.82% calcium carbonate, about 1.00% binder such as carboxymethyl cellulose (CMC) or cellulose gum, and about 21.32% glycerol and flavoring (of which 20% is glycerol).

The monolithic substrate element 85 formed by the extrusion, molding, or casting process may have different final forms and shapes, wherein the forms/shapes may facilitate improved heat transfer from the heat generation section 35 and/or more efficient and effective heat distribution to the substrate element 85 rather than to other proximal components of the smoking article, thereby reducing, minimizing, or eliminating smoking article charring or charring. For example, the extruded matrix element 85 may have the form and configuration of a unitary slotted rod member 300 (see, e.g., fig. 4). That is, the stalk member may include a plurality of lobes 310 angularly spaced around the circumference of the stalk member, with adjacent lobes defining longitudinally extending open channels 320 therebetween. In some cases, the slotted rod member may further define one or more conduits 330 extending longitudinally through a central portion of its cross-section or through one or more protrusions. The positioning, size, and/or configuration of the open channels and/or conduits may be varied as needed or desired to achieve particular performance characteristics. For example, one effect of the open channel and/or increased exposed surface area as compared to a solid cylindrical rod member, in turn, has benefits such as increased cigarette throughput (i.e., increased useful life) and reduced pressure drop along the smoking article (i.e., less resistance to draw).

The effective diameter (i.e., the maximum outside diameter) of the slotted rod member can vary, for example, from about 5.8mm to about 7.3 mm. To incorporate the slotted rod members into the aerosol-generating segment 61, the larger diameter extrusion may be wrapped, for example, with a paper/foil laminate or a paper/foil/paper laminate, while the smaller diameter extrusion may be wrapped, for example, with a single layer fiberglass mat, and then further wrapped with either a paper/foil laminate or a paper/foil/paper laminate, prior to wrapping the aerosol-generating segment with the outer wrapping material 75 (although any configuration of the wrapping material 90 disclosed herein may be implemented as needed or desired). The increased surface area of the slotted rod member results in less surface area of the rod member in contact with the wrap disposed between the rod member and the outer wrapper 75, which in turn results in less heat being transferred to the outer wrapper 75 during use of the smoking article. The inner conduit may also provide additional surface area of the rod members that is heated by the heat generation section, and may be used to draw some heat away from the outermost surface of the grooved rod members (i.e., the outermost portion of the lobes). Thereby, visible scorching of the wrapping material 75 may be reduced. Furthermore, the increased surface area of the slotted rod member, which may be further enhanced by the additional conduit(s), may provide additional capacity for aerosol-forming material incorporated into the substrate element 85 and exposed to heat from the heat generation section 35 (i.e. proportional to the surface area of the substrate element 85), as well as reduce the puff required by the user to be imparted on the smoking article, as compared to a solid cylindrical rod member. Accordingly, such smoking articles may have an improved useful life as compared to smoking articles comprising solid cylindrical substrate elements 85.

In the alternative to a paper/foil laminate or a paper/foil/paper laminate forming the outer wrapper of the matrix element 85 directly, or with a single layer of glass fibre mat arranged between them, a tobacco paper double or triple laminate may be used as the outer wrapper. In this case, the original layer of the outer wrapper stack may preferably comprise tobacco paper if the outer wrapper is subjected to sufficient heat from the heat generation stage to carbonise or char the outer wrapper. In this way, the charring or carbonization of the tobacco paper layer can provide tobacco flavor to the formed aerosol and thus have little or no adverse effect on the taste or sensory perception of the formed aerosol. More specifically, a tobacco paper such as a cast sheet or extruded tobacco paper may be laminated to a paper/foil double stack to form a paper/foil/tobacco paper triple stack, wherein the tobacco paper provides the original layer of the stack closest to the substrate element 85. Such a three-laminate arrangement may, for example, be applied to both tobacco-containing and smokeless-grass substrate elements, and may, for example, promote improved adhesion along the weld formed by wrapping the three-laminate around the substrate element (i.e., the weld would be formed between the tobacco paper and the cigarette paper forming the outer layer of the three-laminate), and may add a positive aspect to the taste and/or sensory perception characteristics of the aerosol experienced by the user. One skilled in the art will appreciate, upon understanding the inventive aspects of the present disclosure, that a paper/foil/tobacco paper tri-laminate of the type disclosed herein may also be applied to any of the various tobacco-containing or smokeless grass substrate elements and aerosol-generating segments set forth in the present disclosure.

In another aspect of the present disclosure, the matrix elements 85 may take the form of a plurality of solid cylindrical rod members 400 extending parallel to one another from the interface of the heat generation section 35 and the aerosol-generating section 61 (see, e.g., fig. 5). Such solid cylindrical rod members may suitably be formed using an extrusion process or by moulding or casting, and may for example be composed of glycerol, finely ground tobacco, calcium carbonate, adhesive, flavouring and water. In some cases, a solid cylindrical rod member may have a diameter of about 2.9mm, wherein a plurality of such rods may be bundled or stacked for insertion into the aerosol-generating segment 61 as a matrix element 85. The overall solid cylindrical rod member may then be overwrapped in a similar manner, under similar circumstances, as the slotted rod member configurations disclosed herein.

In still other aspects, the material composition used for the extruded rod, i.e., for example, glycerin, finely ground tobacco, calcium carbonate, binder, flavoring, and water, may alternatively be used to form a flat sheet having a thickness of between about 0.3mm to about 1.7 mm. In certain aspects, the sheet may also be formed by an extrusion process (or molding or casting where appropriate), wherein the sheet is then dried to form the matrix material. The dried pieces can then be broken, for example, by cutting the pieces into strips or shredding the pieces. The cut/shredded portions of the formed sheet may then be stacked or gathered and deposited in the aerosol-generating segment 61 as substrate elements 85 in a manner similar to cut filler tobacco (i.e., deposited rather than cut filler tobacco, but in a similar manner).

In certain aspects, the matrix element 85 can be constructed, for example, from a cast sheet comprising a tobacco material. Such cast sheets may be formed in a process wherein a selected tobacco-containing mixture is cast, dried and cut into strips or shredded. In some cases, the shredded portions or cut strips of cast sheet can be mixed with other cut filler (i.e., traditional cut filler tobacco, with or without additional aerosol former) to provide the user desired taste and sensory perception and to aid in the manufacturing process. In one example, the selected tobacco-containing mixture may be characterized as a pectin-releasing mixture comprising, for example, (dry weight) about 66.60% finely ground tobacco, about 3.75% diammonium phosphate, about 4.65% ammonium hydroxide, and about 25% glycerol and flavoring. To process the pectin-releasing mixture, the finely ground tobacco, diammonium phosphate, ammonium hydroxide, and water may be heated, for example, to about 160 ° f for about 1.5 hours to improve or enhance the organoleptic qualities of the resulting mixture. The glycerol and flavoring can then be added to the remainder of the mixture upon cooling following the heating step. The resulting mixture can then be used to form a cast sheet.

In another example, the selected tobacco-containing mixture may be characterized as a non-ammoniated mixture that includes, for example, (dry weight) about 65.62% finely ground tobacco, about 4.5% sodium alginate, about 1.13% sodium hydroxide or other pH modifier, about 25% glycerol, and about 3.75% wood pulp. To process the non-ammoniated mixture, the finely ground tobacco, sodium alginate and water may be heated, for example, to about 160 ° f for about 1.5 hours to improve or enhance the organoleptic quality of the resulting mixture. The hydrated wood pulp, binder, glycerin, and flavoring can then be added to the remainder of the mixture upon cooling following the heating step. The resulting mixture can then be used to form a cast sheet.

In another example, the selected tobacco-containing blend can be characterized by a tobacco-containing reconstituted material comprising, for example, (dry weight) about 51.8% tobacco pulp, about 4.2% wood pulp, about 22.0% concentrated tobacco extract, and about 22.0% glycerin, and flavorings. The sheet may be formed from tobacco-containing reconstituted material in a manner similar to conventional reconstituted sheets. For example, the water-soluble elements are first removed from the tobacco pulp sheet, and the remaining tobacco pulp is concentrated to about 25% solids content. The wood pulp may then be added to the tobacco pulp to form a base sheet, which may vary in basis weight from about 120 grams per square meter (gsm) to about 240 gsm. Glycerol may then be mixed (i.e., in a 1:1 ratio) with concentrated nicotine (TDN) extract from tobacco and added to the substrate. The formed substrate may then be dried and cut into strips or chopped. Similar to the cast sheet, the cut strips or shredded reconstituted sheets can be mixed with other cut filler (i.e., conventional cut filler tobacco, with or without additional aerosol former).

In another example, the selected tobacco-containing blend can be characterized as a conventional cut filler tobacco material having an increased glycerol content. In this case, the cut filler tobacco may be loaded with or interact with between about 5% and about 30% glycerol. The cut filler tobacco material with increased glycerol content may then be used as a primary substrate (i.e., the substrate material forming the substrate element) or may be mixed with a cast sheet material such that the resulting mixture forms the substrate material of the substrate element. Based on the amount of glycerin needed or desired, glycerin can be applied to cut filler tobacco, for example, as a charge for cutting (i.e., to a separate rod of tobacco), as a super flavor, or both. Such cut filler tobacco with increased glycerol content can be blended, for example, with various cast sheets, reconstituted sheets, and/or tobacco beads as desired or needed to form a matrix material for matrix element 85. In such a case of a base element 85 having an elevated glycerol level, it may be desirable to include an outer wrapper of the base element 85 that will minimize or eliminate any leaching of the contained glycerol onto the outer wrapper material 75.

In yet another example, the selected tobacco-containing blend can be characterized as a non-tobacco material. For example, a cast sheet used to form a substrate element, an extruded substrate element, or a substrate element in the form of a bead (pellet) may include calcium carbonate, rice flour, a binder, diammonium phosphate, glycerol, a flavoring, nicotine obtained from Tobacco (TDN), and water. More specifically, such cast smokeless grass sheets can include, for example, about 41.25% calcium carbonate, about 13.75% rice flour, about 6% ammonium alginate, about 5.5% wood pulp, about 3.5% diammonium phosphate, and about 30% glycerol. In addition, nicotine (TDN) obtained from tobacco, certain acids (i.e., levulinic acid and/or citric acid), and flavors may be included in the glycerol. The extruded matrix member or matrix member in the form of a ball (pellet) may include, for example, about 51.94% calcium carbonate, about 17.15% rice flour, about 1% TDN, about 1% carboxymethylcellulose (CMC), about 0.66% levulinic acid, about 0.44% lactic acid, about 20% glycerol, and about 9.41% flavoring. In some cases, the cast sheet may be processed into cut strips, shredded or processed into a shredded filler form. In some cases, if the matrix element 85 comprises a ball bearing, the ball bearing may be positioned against, adjacent to, or closest to the heat generation segment. In these cases, selected components may be implemented from the balls opposite the heat generation segment, thereby securing the balls in place. For example, such selected components may include a folded paper filter material or other smokeless tobacco paper plug (paper plug).

In another example of a substrate element 85 formed from a smokeless tobacco material, nicotine (TDN) obtained from tobacco, glycerin (i.e., aerosol former), and flavoring may be added to an extruded ceramic substrate having a relatively high porosity (i.e., a high porosity extruded ceramic rod member). In this case, the ceramic rod member may be extruded so as to define one or more longitudinally extending channels (i.e., open channels or slots disposed around the outer surface and/or conduits extending through the central portion of the rod member). In a similar manner to the grooved rod members previously disclosed, the increased surface area of the ceramic rod members (i.e. due to the open channels around the surface of the ceramic rod members) results in less surface area of the rod members in contact with the wrapper arranged between the rod members and the outer wrapper 75, which in turn results in less heat being transferred to the outer wrapper 75 during use of the smoking article. The inner conduit may further provide additional surface area of the rod members heated by the heat generation section and may be used to draw some heat away from the outermost surface of the slotted ceramic rod members (i.e., the outermost portion of the bosses). Thereby, visible scorching of the wrapping material 75 may be reduced. Furthermore, the increased surface area of the slotted ceramic rod member, which may be further enhanced by the additional conduit(s), may provide additional capacity for aerosol-forming material to be incorporated into the substrate element 85 and exposed to heat from the heat generation section 35 (i.e. proportional to the surface area of the substrate element 85), as well as reduce user demand to impart puff to the smoking article, as compared to a solid cylindrical rod member. Accordingly, such smoking articles may have an improved useful life as compared to smoking articles comprising solid cylindrical substrate elements 85. Furthermore, the open channel/duct may provide less resistance to suction.

In certain aspects of the present disclosure, the matrix element 85 may be segmented (i.e., the matrix element 85 may comprise a plurality of consecutively arranged components or a plurality of parallel arranged components) or may comprise a combination of two or more matrix materials. For example, the matrix elements may include a combination of cast sheets and/or reconstituted sheets, each shredded or cut into strips, mixed with cut filler tobacco treated with glycerol. Cut filler tobacco can have various levels of glycerin, ranging, for example, from about 5% to about 25%. In another example, shredded or cut into strips of cast sheet may be mixed with tobacco-containing beads. In addition to the extruded substrate element wrapped with a glass fiber mat, the extruded substrate element 85 may alternatively be wrapped with tobacco paper or a laminate comprising layers of tobacco paper, wherein the substrate element 85 may be constituted by e.g. bundled smaller diameter rod members arranged in parallel, or strips of cast sheet, extruded sheets or reconstituted tobacco sheets processed in a similar manner to cut filler tobacco, or rolled together to form a substantially cylindrical substrate element.

In addition to the components disclosed herein, the matrix element 85 may be constructed from many different combinations of these components. In particular aspects, such components may additionally be selected from the group consisting of, for example, a fiberglass mat having a TDN/glycerol (B3) solution applied thereto, a porous ceramic element having an aerosol former such as glycerol applied thereto, a cast sheet comprising a pectin release material, a non-ammoniated cast sheet, a non-tobacco cast sheet, a gathered or shredded foil sheet having an aerosol former applied thereto or a rod formed therefrom, a non-tobacco product such as gathered paper treated with an extract such as TDN, a roll ball, or gathered carbon or non-carbon paper.

The components of the aerosol-generating segment may vary. The aerosol-generating segment contains components entrained in air that may be vaporized, aerosolized, or drawn through the smoking article during use. More preferably, these ingredients, alone or in combination, provide sensory and sensorial effects such as aroma, flavor, mouthfeel, visual aerosol, and the like. Examples of constituents of the aerosol-generating segment that are drawn into the mouth of a smoker during puffing include water (e.g., as water vapor), visible aerosol-forming materials (e.g., glycerin), various volatile flavors (e.g., vanillin or menthol), volatile constituents of tobacco (e.g., nicotine), and so forth.

The preferred aerosol-forming material produces a visible aerosol upon application of sufficient heat thereto, or by the action of aerosol-forming conditions caused by the composition of the smoking article. Highly preferred aerosol-forming materials produce a visible aerosol that can be considered "smoky". Preferred aerosol-forming materials are chemically simple relative to the chemical characteristics of the smoke produced by burning tobacco. The preferred visible aerosol-forming material is a polyol, and exemplary preferred aerosol-forming materials include glycerin, propylene glycol, and mixtures thereof. If desired, the aerosol-forming material may be combined with other liquid materials, such as water. For example, the aerosol-forming material formulation may comprise a mixture of glycerol and water or a mixture of propylene glycol and water. See, for example, various aerosol-forming materials referenced in Sensabaugh, Jr et al, U.S. Pat. No. 4,793,365, Jakob et al, U.S. Pat. No. 5,101,839, and Crooks et al, U.S. Pat. No. 8,678,013, and Biggs et al, PCT WO 98/57556.

The materials that may be used to provide the substrate of aerosol-forming material within the aerosol-generating region may vary. Suitable insulating elements and associated aerosol-forming materials have been included in those types of cigarettes marketed under the trade names "pleummer (Premier)", "ellipse (Eclipse)", and "thermal Steam (Steam Hot One)". The substrate element may comprise some form of tobacco, typically consisting essentially of tobacco, and may be provided almost entirely of tobacco material. For example, in certain embodiments, at least a portion of the total matrix material is employed in substantially conventional filler form (e.g., as cut filler). Formation of aerosol formulations in Sensabaugh et al, U.S. Pat. No. 4,793,365 to White, U.S. Pat. No. 4,893,639 to White, U.S. Pat. No. 5,099,861 to Clearman et al, U.S. Pat. No. 5,101,839 to Jakob et al, U.S. Pat. No. 5,105,836 to Gentry et al, U.S. Pat. No. 5,109,122 to Clearman et al, U.S. Pat. No. 5,159,942 to Brinkley et al, U.S. Pat. No. 5,203,355 to Clearman et al, U.S. Pat. No. 5,271,419 to Arzonico et al, U.S. Pat. No. 5,327,917 to Lekwauwa et al, U.S. Pat. No. 5,396,911 to Casey san et al, U.S. Pat. 5,533,530 to Yong et al, U.S. Pat. No. 5,588,446 to Clearman et al, U.S. Pat. No. 5,598,868 to Jakob et al, U.S. Pat. No. 5,715,844 to Yengson et al, U.S. Pat. 395838 to Beesson et al, and U.S. Pat. 3,596 et al (to Conager et al), as well as to Conager et al, U.S. patent applications for inclusion of the disclosure of Including cast sheet and paper reconstituted tobacco material). Additionally, the matrix material may be of the type of form or construction set forth in U.S. patent No. 8,839,799 to Conner et al; either as a gathered web or sheet, using a type of technology generally set forth in U.S. patent No. 4,807,809 to Pryor et al, or in the form of a web or sheet shredded into a plurality of longitudinally extending strips, using a type of technology generally set forth in U.S. patent No. 5,025,814 to Raker.

The manner in which the aerosol-forming material is contacted with the substrate material (e.g. tobacco material) may vary. In the process of making these materials, the aerosol-forming material may be applied to the formed tobacco material, or may be incorporated into the processed tobacco material. The aerosol-forming material may be dissolved or dispersed in an aqueous liquid, or other suitable solvent or liquid carrier, and sprayed onto the substrate material. See, for example, U.S. patent application publication No. 2005/0066986 to Nestor et al. The amount of aerosol-forming material employed relative to the dry weight of the matrix material may vary. It can be difficult to process materials that include too high a level of aerosol-forming material into cigarette rods using conventional types of automated cigarette manufacturing equipment.

Cast sheet type materials may contain relatively high levels of aerosol-forming materials. Reconstituted tobacco manufactured using paper-type processes may contain moderate levels of aerosol-forming materials. Tobacco rod and cut filler tobacco may contain smaller amounts of aerosol-forming material. Various paper and non-paper substrates including bunched, laminated metal/metal, strip, beads such as alumina beads, open cell foam, foamed monoliths, air permeable substrates and other materials may be used within the scope of the present disclosure. See, for example, U.S. patent nos. 5,183,062, 5,203,355, and 5,588,446 to Clearman.

The laminated paper or other wrapping material may be constructed according to the disclosure of Marton, U.S. Pat. No. 6,849,085, or according to other suitable methods and/or materials.

In certain preferred smoking articles, the aerosol-generating segment 61 is open at both ends to expose its substrate element 85. Together, the heat generation section 35 and the aerosol-generating section 61 form an aerosol-generating system 99. The aerosol-generating segment is positioned adjacent a downstream end of the heat generating segment such that the segments are axially aligned in end-to-end relationship. The segments may be positioned against one another or in a slightly spaced relationship, which may include an optional buffer region 110 (which may in some cases include thermally conductive and air permeable porous spacer elements). The external cross-sectional shapes and dimensions of the segments may be substantially the same as one another when viewed transverse to the longitudinal axis of the smoking article 10. The physical arrangement of these components is preferably such that heat is transferred (e.g. by mechanisms including conductive and convective heat transfer) from the heat source 40 to the adjacent substrate element 85 during use of the smoking article 10 and throughout the time that the heat source is activated (e.g. combusted).

The buffer region 110 may reduce potential charring or other thermal damage to portions of the aerosol-generating segment 61. The buffer region may comprise primarily an empty air space, or it may be partially or substantially completely filled with a non-combustible material such as, for example, a metal, organic, inorganic, ceramic, or polymeric material, or any combination thereof. The cushioning region thickness (length) may be from about 1mm to about 10mm or more, but the thickness (length) will often be from about 2mm to about 5 mm. If desired, the buffer region or spacer 110 may comprise a catalytically acting material, such as a material comprising cerium or copper ions or oxides and/or salts of cerium and copper ions. See, for example, U.S. patent No. 8,469,035 to Banerjee et al and U.S. patent No. 8,617,263 to Banerjee et al, as well as U.S. patent publication No. 2007/0215168 to Banerjee et al.

The components of the aerosol-generating system 99 are preferably attached to each other and secured in place using the outer wrapper 118. For example, the wrapper may comprise a paper wrapper or a laminated paper-like material that surrounds at least a portion of the downstream portion of the heat generation section 35 and the outer longitudinally extending surface of the aerosol-generating section 61. The inner surface of the outer cover 118 may be secured to the outer surface of the components that it surrounds with a suitable adhesive. Those skilled in the art will appreciate that the aspects disclosed herein relating to reducing, minimizing, or eliminating scorching or carbonization of the outer wrapper 75 or the wrapper 90 may thus also be applicable to the outer wrapper 118 to the extent that the outer wrapper 118 overlaps the outer wrapper 75 or extends outside the interface between the heat generation segment 35 and the aerosol-generating segment 61.

The smoking article 10 preferably includes a suitable mouthpiece portion such as, for example, a filter element 135, positioned at the mouth end 18 thereof. The filter element 135 is preferably positioned at one end of the aerosol-generating system 99 such that the filter element 135 and the aerosol-generating section 99 are axially aligned in end-to-end relationship, abutting against each other without any obstruction therebetween. Preferably, the overall cross-sectional shape and dimensions of the segments 99, 135 are substantially identical to one another when viewed transverse to the longitudinal axis of the smoking article. The filter element 135 may comprise a filter material 140 which is wrapped along its longitudinally extending surface with a surrounding plug wrap material 142. In one example, the filter material 140 comprises plasticized cellulose acetate tow or other suitable cigarette-type filter material. Both ends of the filter element 135 are preferably open to allow the aerosol to pass therethrough. In some instances, the filter element 135 may be configured to include any combination of a filter rod paper plug, a cavity, and conventional cigarette filter material (i.e., cellulose acetate tow) as needed or desired.

The filter element may include crushable flavor capsules of the type described in U.S. patent No. 7,479,098 to Thomas et al and U.S. patent No. 7,793,665 to Dube et al, and U.S. patent No. 8,186,359 to Ademe et al.

The aerosol-generating system 99 is preferably attached to the filter element 135 using tipping material 150. Examples of tipping materials are described, for example, in U.S. patent No. 7,789,089 to Dube et al, and U.S. patent application publication No. 2007/0215167 to Crooks et al, U.S. patent application publication No. 2010/0108081 to Joyce et al, U.S. patent application publication No. 2010/0108084 to Norman et al, and U.S. patent application publication No. 2013/0167849 to Ademe et al, and PCT patent application publication No. 2013/160671 to dittrch et al.

The smoking article 10 may include an air dilution means, such as a series of perforations 160, each of which may extend through the filter element tipping material 150 and the plug wrap material 142. Alternatively, the various perforations may extend as rings around the smoking article in the region upstream as shown.

A representative smoking article 10 has a length of between about 80mm and about 100 mm. For example, for a smoking article 10 having a length of about 85mm, a representative heat generation segment 35 may have a length of between about 10mm and about 15mm, a representative aerosol-generating segment 61 may have a length of between about 40mm and about 55mm, and a representative filter element 135 may have a length of between about 20mm and about 30 mm.

The cigarettes described with reference to fig. 1 can be used in much the same way as cigarettes already marketed under the trade names "pleummer" and "ellipse" by r.j. reynolds tobaco Company and sold under the trade name "thermal Steam (stem Hot One)" by japanese Tobacco Company. I.e., using a match or cigarette lighter to ignite a fuel element or heat source. The burning fuel element/heat source resulting from such ignition generates heat that is transferred to the substrate element within the aerosol-generating region of the cigarette. The substrate element(s) comprising aerosol-generating material and tobacco flavour and ingredients are heated and volatilised and form an aerosol. The aerosol is entrained in the drawn air and drawn through the filter element into the mouth of the smoker.

Fig. 2 illustrates another representative smoking article 10 in the form of a cigarette, according to another aspect of the present disclosure. Preferably, the smoking article 10 has the overall size, shape and general appearance of the smoking article previously described with reference to figure 1 and incorporates these types of components. However, compared to the embodiment of fig. 1, the length of the filter element 135 is extended, while the length of the aerosol-generating segment 61 is reduced. For example, for the embodiment shown, the filter element 135 is a two-piece segment; having a terminal mouth end section 182, and a tubular section 184 positioned between the aerosol-generating section and the terminal mouth end section. Thus, the representative smoking article of fig. 2 is a four-segment smoking article, while the representative smoking article of fig. 1 is a three-segment smoking article.

Generally, the tubular section 184 is constructed of steam bonded and plasticized cellulose acetate tubes that provide resistance, structure and length to the smoking article while allowing drawn air to pass therethrough. Alternatively, the tubular section is made of a heat-resistant plastic material (e.g. a tube made of polycarbonate) or of a ceramic material.

A representative smoking article 10 of the type shown in figure 2 has a length of between about 80mm and about 100 mm. For example, for a smoking article 10 having a length of about 85mm, a representative heat generation segment 35 may have a length of between about 10mm and about 15mm, a representative aerosol-generating segment 61 may have a length of between about 10mm and about 25mm, a representative tubular segment 184 may have a length of between about 30mm and about 50mm, and a representative filter element 135 may have a length of between about 20mm and about 30 mm.

Fig. 3 shows another representative smoking article 10 in the form of a cigarette. Preferably, the smoking article 10 has the overall size, shape and general appearance of the smoking article previously described with reference to figure 2 and contains those types of components. However, the tobacco segment 198 of cut filler tobacco 200 wrapped in the paper wrapper 205 may be positioned between the aerosol-generating system 99 and the filter element 135. The overall length of the two-piece filter segment is reduced compared to the embodiment of fig. 2 to accommodate segments of cut filler tobacco. Thus, the representative smoking article of fig. 3 is a five-segment smoking article, while the representative smoking article of fig. 2 is a four-segment smoking article.

The upstream section of the two-piece filter section 135 may include a stiffening tube of cellulose acetate tow, a section of cellulose acetate tow with discrete activated carbon particles dispersed throughout, a section of cellulose acetate with breakable flavor-containing capsules positioned therein. Typically, the downstream segment of the two-piece filter segment 135 is a segment constructed from plasticized cellulose acetate tow or gathered polypropylene web. If desired, the two-piece filter segment may be replaced with a single segment filter element or a three-piece cavity filter.

A representative smoking article 10 of the type shown in figure 3 has a length of between about 80mm and about 100 mm. For example, for a smoking article 10 having a length of about 85mm, a representative heat generation segment 35 may have a length of between about 10mm and about 15mm, a representative aerosol-generating segment 61 may have a length of between about 10mm and about 25mm, a representative tobacco filler segment 198 may have a length of between about 30mm and about 50mm, and a representative filter element 135 may have an overall length of between about 20mm and about 30 mm. For a representative filter element for the illustrated embodiment, the upstream filter element segment 220 may have a length between about 5mm and about 20mm, while the downstream filter element segment 225 may have a length between about 5mm and about 20 mm. For example, a representative smoking article having an overall length of about 83mm may have a heat generation segment 35 having a length of about 12mm, an aerosol-generating segment 61 having a length of about 13mm, a tobacco filler segment 198 having a length of about 37mm, a cellulose acetate tube filter segment 220 having a length of about 7mm, and a low efficiency plasticized cellulose acetate tow segment 225 having a length of about 14 mm.

Typical smoking articles also contain various components associated with their construction. For example, these types of components include wrapping materials, thermally conductive materials, metal foil and foil laminates, mouth end pieces, filter elements, plugwrap, tipping materials, and adhesives. Additionally, a typical smoking article may contain any of a variety of tobacco types, forms of tobacco, and mixtures thereof. See, for example, those representative types of components set forth in or referenced in U.S. patent No. 5,724,997 to Fagg et al and U.S. patent application publication No. 2015/0157052 to Ademe et al.

Various combinations and variations of flavoring agents, including various materials that alter the organoleptic and/or sensorially perceived characteristics or properties of the aerosol mainstream of a smoking article, can be included in suitable smoking articles. The substrate material and various tobacco components of the smoking article may also be treated with tobacco additives of the type conventionally used in the manufacture of cigarettes, such as flavoring and/or super-flavoring components. See, for example, Crooks et al, U.S. patent No. 8,678,013 for parts of the type set forth.

Means and methods for assembling representative types of smoking articles are set forth in U.S. patent No. 5,469,871 to Barnes et al and U.S. patent No. 8,678,013 to Crooks et al, and in U.S. patent application publication No. 2012/0042885 to Stone et al, U.S. patent application publication No. 2012/0067360 to Conner et al, U.S. patent application publication No. 2014/0261470 to Amiss et al, and U.S. patent application publication No. 2015/0157052 to Ademe et al.

In view of the possible interrelationships between the various aspects of the disclosure in providing the significant benefits and advantages associated therewith, the disclosure thus includes embodiments that represent various combinations of the disclosed aspects, both specifically and clearly, without limitation. Thus, the present disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure, whether or not such features or elements are expressly combined or otherwise stated in the description of a particular embodiment herein. Unless expressly stated otherwise in the context of this disclosure, the present disclosure is intended to be read in its entirety such that any separable feature or element of the present disclosure is to be considered as intended, i.e., combinable, in any of its divisional aspects and embodiments.

The aerosol produced by the cigarettes of the present disclosure is an aerosol comprising air-containing components such as vapors, gases, suspended particles, and the like. Tobacco can be thermally decomposed from some form of burning tobacco (and optionally other ingredients that burn to generate heat), by heating and carbonizing the tobacco (or otherwise subjecting the tobacco to some form of smoldering combustion); and generating an aerosol composition by evaporating the aerosol former. As such, the aerosol may contain volatile components, combustion products (e.g., carbon dioxide and water), incomplete combustion products, high temperature pyrolysis products, and aerosols that are otherwise described as smoke.

The aerosol composition may also be generated by the action of heat generated by the combustion of some form of tobacco (and optionally other components that combust to generate heat) that acts on a substance positioned in heat exchange relationship with the combusted tobacco material and the other components of the combustion. The aerosol composition may also be generated by the aerosol-generating system due to the action of the heat-generating segment on the aerosol-generating segment. In certain embodiments, the components of the aerosol-generating segment have an overall composition and are positioned within the smoking article such that these components will tend not to undergo a large degree of pyrolysis (e.g., due to combustion, smoldering, or high temperature pyrolysis) during normal use conditions.

Many modifications and other aspects of the disclosure set forth herein will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, those skilled in the art will appreciate that embodiments not specifically illustrated herein may be practiced within the scope of the present disclosure, including that features described for different embodiments herein may be combined with each other and/or with presently known or future developed techniques while remaining within the scope of the claims set forth herein. In certain aspects, for example, alternative arrangements for reducing, minimizing or eliminating scorching, carbonization or discoloration of the outer wrapper may be implemented, such as using an embossed outer wrapper (i.e., constructed of paper) as yet another layer external to the outer wrapper (i.e., cigarette paper). In this case, the increased surface area provided by the embossing and/or the embossed outer wrap material, at least partially spaced from the outer wrap material, may result in the outer wrap material acting as an external air cooling device (i.e., cooling fins). In still other cases, various measures may be implemented to provide visual cues of excessive heating or over-temperature. For example, the embossed outer wrapper and/or the outer wrapper may be printed with thermochromic inks that visually appear or change appearance above a temperature threshold or within a specific temperature range and/or disappear below a temperature threshold or within a specific temperature range. In this way, for example, the user may be guided to avoid using the smoking article in case of over-temperature until the marking provided by the thermochromic ink changes appearance to indicate the appropriate temperature of the smoking article, wherein such measures may avoid over-temperature use which may result in scorching or charring or any other component of the outer wrapper being subjected to the heat generated by the heat generation section. In still other cases, the outer wrapping material 75 or wrapping paper/material 90 may include or be associated with non-woven graphite or graphene sheets as a thermally conductive element or otherwise direct excess heat away from the outer wrapping paper 75. That is, the non-woven graphite or graphene sheets may be wrapped around a portion of the heat generating portion and around a portion of the aerosol-generating portion within the outer wrapping material and extend toward the mouth end portion.

Therefore, it is to be understood that the disclosure is not to be limited to the specific aspects disclosed and that equivalents, modifications, and other aspects are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Aspects of the present disclosure are illustrated in greater detail by examples herein, which are set forth to illustrate certain aspects of the present disclosure and are not to be construed as limiting the scope of the present disclosure. All parts and percentages are by weight unless otherwise indicated.

Claims (32)

1. An elongated smoking article having a lighting end and an opposite mouth end, the smoking article comprising:

a mouth end portion disposed at the mouth end;

a heat generating portion disposed proximate the firing end;

an outer wrapping material wrapped around at least the heat generating portion and extending toward the mouth end portion, thereby defining a cylindrical rod; and

an aerosol-generating portion disposed within the outer wrapping material and between the heat generation portion and the mouth end portion, the aerosol-generating portion comprising an aerosol-generating element wrapped by a wrapping material disposed between the aerosol-generating element and the outer wrapping material and extending from the heat generation portion to the aerosol-generating portion, the aerosol-generating portion being configured to generate an aerosol in response to heat received from the heat generation portion, the wrapping material being a multi-layer structure comprising at least a foil layer, the wrapping material being arranged to distribute heat from the heat generation portion away from the outer wrapping material such that heat from the heat generation portion is directed to the aerosol-generating portion, thereby avoiding scorching of the outer wrapping material.

2. The smoking article of claim 1, wherein the aerosol-generating portion comprises a rod member having a length and a maximum diameter, and wherein the rod member has a surface area greater than a surface area of a right cylinder having a length and a maximum diameter equal to the length and maximum diameter of the rod member, respectively.

3. The smoking article of claim 1, wherein the aerosol-generating portion comprises a slotted rod member.

4. A smoking article according to claim 3, wherein the slotted rod member defines a passage extending longitudinally therethrough.

5. The smoking article of claim 3, wherein the grooved rod member is extruded from a mixture comprising finely ground tobacco, calcium carbonate, an adhesive, glycerol, water, and a flavoring.

6. The smoking article of claim 1, wherein the wrapping material is selected from the group consisting of paper-foil-tobacco sheet laminates, non-woven graphite sheets layered with foil, graphene-foil laminates, graphene-foil-tobacco sheet laminates; the paper-graphene sheet stack layered with the foil, the graphene ink printed on the paper sheet layered with the foil, the graphene ink printed on the foil, the carbon nanotubes bonded to the paper sheet layered with the foil, the carbon nanotubes layered with the foil, the fullerene bonded to the paper sheet layered with the foil, the fullerene layered with the foil, the graphene bonded to the paper sheet layered with the foil, and the graphene layered with the foil are selected from the group consisting of.

7. The smoking article of claim 6, wherein the graphene ink is printed on the paper sheet or foil according to a continuous pattern or a discontinuous pattern.

8. The smoking article of claim 6, wherein the paper sheet comprises a tobacco-wrapped paper sheet, and wherein the tobacco sheet comprises an extruded tobacco sheet, a cast tobacco sheet, or a reconstituted tobacco sheet.

9. The smoking article of claim 6, wherein the foil comprises a continuous foil sheet or a separate foil strip.

10. The smoking article of claim 1, further comprising a tobacco portion disposed within the outer wrapper and between the heat generation portion and the aerosol-generating portion.

11. The smoking article of claim 1, further comprising a tobacco portion disposed within the outer wrapper and between the aerosol-generating portion and the mouth end portion.

12. The smoking article of claim 1, further comprising a non-woven graphite sheet or a non-woven composite sheet of graphite and graphene wrapped within the outer wrapper around a portion of the heat generation portion and around a portion of the aerosol-generating portion and extending toward the mouth end portion.

13. The smoking article of claim 12, wherein the non-woven graphite sheet is laminated with the overwrap material.

14. The smoking article of claim 1, further comprising a metal foil laminated with the outer wrapping material via an adhesive material therebetween, the adhesive material including a portion of aluminum hydroxide therein, and the metal foil being wrapped within the outer wrapping material, around the heat generation portion and around a portion of the aerosol-generating portion, and extending toward the mouth end portion.

15. The smoking article of claim 1, wherein the outer wrapper comprises a portion of aluminum hydroxide, a portion of magnesium hydroxide, or a portion of calcium carbonate therein.

16. The smoking article of claim 1, further comprising a fiberglass sheet wrapped within the outer wrapper around the heat generation portion and around a portion of the aerosol-generating portion and extending toward the mouth end portion.

17. The smoking article of claim 1, further comprising a thermally conductive material engaged with the outer wrapping material, the thermally conductive material being disposed within the outer wrapping material and extending to wrap radially at least partially around the heat-generating portion and longitudinally from the heat-generating portion to the aerosol-generating portion.

18. The smoking article of claim 17, wherein the thermally conductive material comprises a conductive ink printed on the outer wrapper, a metal layer deposited on a selected portion of the outer wrapper, graphene bonded to the outer wrapper, or a carbon material bonded to the selected portion of the outer wrapper.

19. The smoking article of claim 1, wherein the aerosol-generating portion is comprised of a material selected from the group consisting of a cast sheet of tobacco material in the form of cut filler, a sheet of reconstituted tobacco material in the form of cut filler, cut filler tobacco material treated with glycerol, aerosol-forming beads, ceramic material including glycerol, a cast sheet of non-tobacco material in the form of cut filler, a glass fiber mat including nicotine material obtained from tobacco, a foil having aerosol-forming material applied thereto, gathered paper including nicotine material obtained from tobacco, non-tobacco material including nicotine material obtained from tobacco, and combinations thereof.

20. The smoking article of claim 19, wherein the cut filler tobacco material treated with glycerol comprises between 5% and 25% glycerol.

21. The smoking article of claim 19, wherein the aerosol-generating portion comprises a first portion and a second portion, the first portion and the second portion being continuously disposed between the heat generating portion and the mouth end portion.

22. The smoking article of claim 19, wherein the aerosol-generating portion comprises a first portion and a second portion, the first portion of the aerosol-generating portion being composed of a different material than the second portion of the aerosol-generating portion.

23. The smoking article of claim 19, wherein the aerosol-generating portion comprises a first portion and a second portion that mix together to form a single aerosol-generating element.

24. The smoking article of claim 1, wherein the aerosol-generating portion comprises a porous ceramic rod member defining at least one conduit extending longitudinally therethrough.

25. The smoking article of claim 24, wherein the porous ceramic rod member comprises an aerosol former, a flavoring, or a tobacco extract engaged therewith.

26. The smoking article of claim 25, wherein the aerosol former comprises glycerol and the tobacco extract comprises nicotine obtained from tobacco.

27. The smoking article of claim 24, wherein the porous ceramic rod member defines a plurality of longitudinally extending open channels angularly spaced around an outer surface of the porous ceramic rod member.

28. The smoking article of claim 1, wherein the aerosol-generating portion is comprised of aerosol-generating beads arranged in series relative to the heat generation portion, and comprising a non-tobacco plunger member arranged between the beads and the mouth end portion.

29. The smoking article of claim 1, wherein the aerosol-generating portion comprises a plurality of rod members extending parallel to one another, the rod members being constructed of a tobacco material, a non-tobacco material, or a ceramic material.

30. The smoking article of claim 1, wherein the heat generating portion comprises a heating element comprised of a carbonized or pyrolyzed material, including an ignitability-enhancing material selected from the group consisting of carbon, cotton linters, glass microspheres, catalysts, and combinations thereof.

31. The smoking article of claim 1, further comprising an outer wrapper wrapped around at least the outer wrapper, the outer wrapper wrapped around at least the heat generating portion, the outer wrapper being embossed so as to be at least partially spaced from the outer wrapper.

32. The smoking article of claim 1, further comprising a thermochromic ink material interacting with the outer wrapper material, the thermochromic ink configured to provide a visual indicator being responsive to the outer wrapper material exceeding a temperature threshold.

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