FI115754B - Method of manufacturing cigarette - involves combining insulated fuel element with substrate and plug of tobacco paper, combining both into cigarette - Google Patents

Abstract

The cigarette has a fuel element (10) surrounded by an insulating and retaining jacket material (12) which are made of fibre glass. In the jacket is an intermediate layer (14) of tobacco paper positioned between two layers of fibre glass. Behind the fuel element (18) is an aerosol generator which is held by a substrate plug (22). This substrate is positioned in a barrier tube (26) with voids (28,30) at either end. This forms a substrate section or component (20).

Description

115754

A method of making filter cigarettes. - Förfarande för framställning av filtercigaretter.

The present invention, separated by F1 application 934074, is directed to 5 methods for making filter cigarettes. Many improved cigarettes have been suggested. For example, several references have proposed cigarettes that produce flavored vapor and / or visible aerosol. Many such cigarettes have utilized a combustible fuel source to generate an aerosol and / or heat the aerosol generating material. See, for example, the prior art referred to in U.S. Patent No. 4,714,082 to Banerjee et al.

The present invention relates to cigarettes, and in particular to cigarettes having a short fuel element and a physically discrete aerosolization interval. they. Cigarettes of this type, as well as materials, processes and / or equipment; : 15 which are useful in them and / or in their preparation are described in the following U.S. Patent Nos. 4,714,082, Banerjee et al., 4,732,168, Resce; ·: ··: 4,756,318, Clearman et al., 4,782,644, Haarer et al., 4,793,365, Sensabaugh et al., 4,802,568, Haarer et al., 4,807,809. Pryor et al., 4,827,950, Banerjee et al., V: 4,858,630, Banerjee et al., 4,870,748, Hensgen et al., 4,881,556, Clearman et al., 20 4,893,637, Hancock et al .; 4,893,639, White; 4,903,714 to Barnes et al .; 4,917,128, »« *

Clearman et al .; 4,928,714, Shannon; 4,938,238 to Barnes et al .; 4,989,619, ··· Clearman et al .; 5,027,836 to Shannon et al .; 5,027,839 to Clearman et al .; I '·· 5,042,509, Banerjee et al .; 5,052,413 to Baker et al .; 5,060,666 to Clearman et al .; 5,065,776 to Lawson et al .; 5,067,499 to Banerjee et al .; 5,076,292 to Baker et al .; *: ··: 25 5,099,861 to Clearman et al .; 5,101,839 to Jakob et al .; 5,105,831 to Banerjee et al .; ; 5,105,837 to Barnes et al. and 5,119,837 to Banerjee et al., 5,183,062 to Clearman et al.

and 5,203,355 to Clearman et al., as well as in the monograph "Chemical and Biological Studies of the New Cigarette Prototypes That Heat Instead of Burn Tobacco", R.J. Reynolds Tobacco Company, 1988 (hereinafter "RJR-30 monograph"). These cigarettes are capable of providing the smoker with the pleasures of smoking (e.g., taste, feel, satisfaction, and the like). Such 115754 2 cigarettes typically provide a low yield of visible sidestream smoke as well as low yields of FTC tar when smoking.

Cigarettes described in the aforementioned patents and / or publications generally utilize a combustible fuel element for heat generation and an Aero sol forming means physically spaced from the fuel element and typically in a heat exchange relationship therewith. Many of these Aero Solar Formation Devices use a substrate or carrier for one or more aerosol forming materials, for example polyhydric alcohols such as glycerin. The aerosol forming materials are evaporated by the heat from the combustible fuel element and, when cooled, form an aerosol. Normally, the fuel cells of such smoking articles are surrounded by an insulating jacket.

..: 15 The present invention is directed to improved methods for such cigarette smoking. * · For the manufacture of devices with a short carbon fuel element and a physically separate aerosolization device.

::: The process according to the invention is characterized by the features set forth in the characterizing part of claim 1.

Preferred ones produced by the process of the present invention; Cigarettes contain a short extruded carbonaceous fuel element, which is surrounded by an insulating jacket. Normally the fuel cell has one •; · ·: 25 or more longitudinal grooves extending along its periphery. Such grooves: · ': Assist in igniting the fuel element and allow heated air to flow along the periphery of the fuel element. The grooves also tend to assist in holding the fuel element inside the sheath.

The fuel cell typically has a length of 3 mm to about 20 mm, preferably about 5 mm to about 16 mm, and most preferably about 6 mm to about 12 mm in length before combustion.

115754 3

The fuel element is retained inside the cigarette of the present invention by an insulating jacket. Preferably, the insulating jacket surrounds the entire longitudinal circumference of the fuel element, although it may extend over each end of the fuel element, effectively depressing the fuel element, separating it from the other components of the cigarette. The advantageous flexible nature of the secretion sheath allows it to extend into any grooves in the periphery of the fuel element. The insulating jacket also helps to retain heat and allows a radial atmosphere of air to hate the fuel element during use.

In a particularly preferred embodiment, the resilient insulating means comprises a fibrous material that surrounds the longitudinal circumference of the fuel element. The fibrous material may comprise fiberglass (Owens Corning "C" glass is particularly preferred), tobacco filler / fiberglass blend, rolled or torn tobacco paper, rolled or torn carbon paper, tobacco cut filler,,, or the like.

; Typically, the carbonaceous pulp is extruded to form a continuous rod of the desired shape:: ', placed directly on a strip of insulating material surrounded by an overlay to form a continuous rod. The jacketed continuous rod 20 is cut to an appropriate length useful in the manufacturing process of the present invention. During manufacture, the aqueous ., a liquid, such as tap water, is targeted in the appropriate: '\. in a quantity of carbonaceous rod and / or insulating material to assist in binding.,.: carbonaceous rod insulating material when dried to a suitable moisture.

The cigarette further comprises an aerosol forming device comprising a substrate and at least one aerosol forming material. The preferred aerosol forming device includes aerosol forming material (e.g., glycerin), 30 tobacco in some form (e.g., tobacco powder, tobacco extract or tobacco dust) and other aerosol forming materials and / or tobacco flavoring agents, such as cocoa and liquorice. The aerosol forming material is generally supported in a substrate material such as a reconstituted tobacco filler or by a substrate such as a tobacco clip filler, rolled paper, rolled tobacco paper, or the like.

Preferably, the substrate is a casting sheet material of reconstituted tobacco cut filler formed as a continuous rod or a substrate tube assembly in a conventional cigarette making machine. Typically, the coating material for the rod is a barrier material, such as a paper foil laminate. Foili acts as a barrier layer and is placed inside the cover.

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Alternatively, the substrate may be a composite paper formed as a rod or needle. When the substrate is a paper-type material, it is highly recommended that such a substrate be placed in a spaced-off relationship. y fuel in the use element. An intermediate ratio is desirable to minimize touch; · ·: 15 between the fuel element and the substrate, thereby preventing the transfer of aerosol •: ·: forming materials to the fuel, and limiting the flaking or burning of the paper substrate. The gap is normally formed during cigarette manufacturing according to one of the manufacturing methods * of the present invention.

The suitably positioned substrate pins are coated with a barrier layer material to form a substrate tube assembly having spaced apart substrate pins. The substrate tube assembly is cut between the substrate pins · 'to form substrate portions. The substrate portions include a tube fitted with a substrate needle and an empty space, preferably at each end.

The barrier layer material for forming the tube helps to prevent the aerosol former from migrating to other components of the cigarette. The barrier material forming the tube is a relatively rigid material such that when formed into a tube, it maintains its shape and does not collapse during manufacture and use of the cigarette.

115754 5

An appropriate length of the sheathed fuel element is combined with the substrate portion or substrate tube assembly with a coating material which tends to be non-combustible to form the fuel / substrate portion. In preferred embodiments of the cigarette, the cover typically extends from the mouth end of the substrate portion, over the portion of the jacketed fuel element, thereby being spaced from the ignition end of the fuel element. The casing material helps to limit the amount of oxygen that reaches the combustible portion of the fuel element during use, preferably thereby causing the fuel element to extinguish after an appropriate number of blows or shots. In particularly preferred embodiments of the cigarette, the wrapper is paper / foil / paper laminate. Foili provides a route to assist in the removal or transfer of heat generated by the fuel cell during operation. The jacketed fuel element and substrate member are combined with the cover.

Preferably, the tobacco portion is formed by a reconstituted tobacco cut filler rod made in a typical cigarette making machine and:: cut to appropriate lengths. A filter rod is formed and cut; · Being of suitable lengths to be attached to the tobacco portion to form an oral portion 20. The fuel / substrate portion and the oral portion are joined by:.: Aligning the reconstructed ends of each portion and coating to form a cigarette.

; : When using a paper substrate with a tobacco paper rod and a reconstituted clip filler *:! The material rod is preferably formed and cut to appropriate lengths: 'and joined to form a tobacco section.

The tobacco member and the fuel / substrate member are joined by aligning the tobacco cigarette stick end of the tobacco member with the substrate end of the fuel / substrate member and engaging portions extending from the rear of the tobacco roll past the respective portion of the two portions to form a 115754 6 roll / fuel. The tobacco roll / fuel assembly is then attached to the filter using drip material.

In the cigarettes of the present invention, the convection heat is preferably the predominant mode of energy transfer from the combustible fuel element to the aerosol generating means disposed longitudinally behind the fuel element. When the foil / paper laminate is used as an outer sheath to bond the fuel / sub-substrate portion, some heat can be transferred to the substrate by the foil layer. As described above, the heat transfer to the substrate evaporates the aerosol generating material (s) and any flavoring material supported by the substrate and upon cooling, these evaporated materials condense to form a smoke-like aerosol that is sucked through the cigarette during filtration or suction.

>: 15 As used herein, the term "aerosol dispensers" is intended to include vapors, gases, particles, and the like, visible and invisible, and especially those components ·· which a smoker feels to be "smoke-like" formed by heat generated by a fuel cell. effect on the materials included- :. · Contained in an aerosol generating device or other smoking article.

•: As used herein, the term "carbonaceous" means that it consists predominantly of carbon.

In the drawings: ·: ··· 25 j '': Figures 1 and 3 illustrate in sectional view two embodiments of cigarettes made in accordance with the present invention. In these representations, the thickness of the various coatings has been increased for ease of examination and for clarity of structure.

Figure 1A is an end view of the cigarette shown in Figures 1 and 3.

30 115754 7

Figures 2A, 2B, and 2C show a flow chart of a preferred method of making the embodiments of the cigarette of the present invention shown in Figures 1 and 1A.

Figures 4A, 4B and 4C are flow charts of a preferred method of making the cigarette of the present invention as shown in Figure 3.

Figures 1, 1A and 3 illustrate embodiments of a cigarette 15 of the present invention. The cigarette includes a fuel element 10 limited to the inside of the retaining sheath of insulating material 12 (for example, a sheathed fuel element 18). The insulating and retaining sheath material 12 comprises glass fibers.

_ y. As shown in Figure 1A, the fuel element 10, which is preferably a die; ·; The 15 compressed carbonaceous material is substantially cylindrical in shape and has: • a plurality of longitudinally extending circumferential channels 11.

I # i, t f I

The insulating and retaining jacket 12 has an interlayer 14 of tobacco paper, V: sandwiched between two layers of glass fiber. The insulating and retaining jacket 20 12 is surrounded by a paper cover 13. The cover 13 may comprise one or more layers, providing an appropriate porosity and ash stability property.

'>.,.: Located longitudinally behind the jacketed fuel element 18 is •': 25 aerosol generating means. In Figure 1, the substrate stick 22 is preferably made from a grid of cellulosic material web (e.g., paper or tobacco paper) and has a paper cover 24. The substrate 22 holds one or more aerosol forming materials (such as glycerin), tobacco in some form (such as tobacco powder, or dust) and flavor components which are evaporated by heat generated by combustion of the fuel element. The substrate 22 is disposed in the barrier layer tube 26 so that void spaces 28 and 30 are formed at each end of the substrate stick 22 to form a portion or component 20 of substrate stick 115754 8 to assist in preventing the substrate from flaring or burning during use. and, by means of a barrier layer tube, helps to prevent migration of the aerosol forming material (s) from the substrate to the fuel element 5 and other cigarette components.

In Figure 3, the substrate 22 is preferably made of reconstituted tobacco casting sheet cut filler material. Such substrates are described in European Patent Publication No. 545,186, which is incorporated herein by reference.

10

In addition to the substrate rods described above, the other rod of substrate materials may be torn, roasted grain or granule (e.g., roasted rice), or tobacco / roasted grain blend with aerosol forming material and binder applied. see the roasted grain. The aerosol forming material and binder may be •; .: 15 to form a gel supported by a substrate rod. Torn •: · j and roasted grain carrying aerosol forming material can be:: * mixed with tobacco dust and shaped into coated rods using:,: ': cigarette making machine.

Examples of preferred aerosol forming materials include polyhydric alcohols (e.g., glycerin, propylene glycol, triethylene glycol, and tetraethylene glycol), esters of mono-, di- or polycarboxylic acids (e.g., methyl stearate, Hystar TPF, available from Lonza, Inc., and the like, as well; *; 25 mixtures thereof. For example, glycerin, triethylene glycol, and Hystar TPF may be mixed together to form an aerosol forming material. A propylene-glycol / glycerin mixture is also used.

Examples of other aerosol forming materials include volatile flavors and tobacco flavor modifiers. Volatile flavors include menthol, vanillin, cocoa, liquorice, organic acids, high fructose corn syrup and the like. A variety of other flavoring agents for smoking articles are disclosed in Leffingwell et al., 115754 9, "Tobacco Flavoring For Smoking Products" (1972) and European Patent Publication No. 407,792. Tobacco flavor modifiers include levulinic acid, metal salts of levulinic acid (e.g., sodium, potassium, calcium and magnesium) and the like.

5

Surrounding the casing fuel cell and spaced from its ignition head is a non-flammable or foil backed (e.g., aluminum or other metal) paper cover 32 which also extends over the substrate member 20. The topsheet 32 is preferably of a non-wettable material which prevents the aerosol forming material (s) 10 from the substrate 22 from being absorbed by the fuel element 10, the insulating jacket 12 and / or discoloration of other components of the cigarettes. This cover also minimizes or prevents the circumferential air (radial air) from flowing to the portion of the fuel element positioned longitudinally behind its leading edge, thereby providing oxygen deprivation and prevention; 15 excessive combustion. Although not preferred, the cover 32 may extend; over (or above) the combustible end of the fuel element 10 and be provided with a plurality of piercings (not shown) to permit controlled radial airflow *. to support combustion of the fuel element in the combustion segment.

The empty space 30 of the cigarette 1 functions as a cooling and nucleation chamber in which the hot:: volatile materials leaving the substrate cool and form: an aerosol. If desired, the empty space 30 may be filled with rolled or torn tobacco paper (not shown). Presence of Tobacco Paper Inside the Empty Space: Donates tobacco flavoring to the aerosol.

In the back of and adjacent to the substrate portion 20, there is a tobacco portion or component 34. In Figure 1, the tobacco portion includes a tobacco paper pin 36 provided with a paper cover 37 such as KC P-3284-19 available from Kimberly Clark ("KC"), Neenah, W1, and a tobacco cut filler 38 30 rolls bounded by a paper cover 39. The tobacco portion 34 is coated with a paper cover 40. The tobacco end of the tobacco paper 34 is in contact with the substrate portion and is connected to the outer wrapper paper 42. at the junction between the tobacco paper pin 36 and the substrate portion 20 to form a tobacco / fuel assembly 45.

If desired, a carbon-filled sheet containing a flavoring agent such as menthol may be used to replace or be used in conjunction with a cigarette stick.

In Figure 3, the tobacco portion 34 is a roll of reconstituted tobacco clip filler 38, 10 limited by a paper cover 39.

Located at the extreme oral end of the cigarette is a low-power filter element 44 containing filter material, such as a nonwoven polypropylene fiber assembled web, cellulose acetate, or the like, coated with a plug wrap 47. In Figure 1, the filter is in contact with and connected thereto by dripping paper 46. In Figure 3, the filter is in contact with the tobacco portion 34 and is:.: connected by dripping paper or dipper 46.

In use, the smoker ignites the fuel element 10, which returns to generate heat. During suction, air passes along the periphery of the combustible portion of the fuel element as well as through the mantle 12 of the retaining system. The sucked air is heated * by contact with the combustible part of the fuel element and by heat radiated from the fuel element .... Heated air transfers heat by convection, · ”. 25 to the substrate 22. The transferred heat vaporizes the aerosol forming and flavoring materials supported by the substrate. The evaporated material inside the hot sucked air leaves the substrate. As the vaporized material cools as it passes through the remainder of the substrate, through the void 30 (if any), and through the tobacco portion, an aerosol is formed. The aerosol passes through the tobacco portion, and through the tobacco: 30 paper swab 36 (if present), absorbing the tobacco flavor and passing through the filter material 44 and into the smoker's mouth.

115754 11

Because the rear end of the fuel element does not burn during use, the fuel element will certainly remain in the cigarette and will not tend to be driven away from the cigarette during use. When the fuel element self-extinguishes and no longer generates heat, the cigarette is discarded.

5

Referring to Figures 2A, 2B and 2C, there is illustrated a flow chart of a preferred method of making the embodiments of the cigarette shown in Figures 1 and 1A of the present invention. The method involves the separate preparation of various components of the cigarette, such as a jacketed fuel element, a substrate portion, a tobacco portion and a filter, followed by combining the individually prepared components in a specified order.

As described, the substrate rod 50 is formed by assembling paper-type web materials into a continuous cylindrical rod and coating the continuous rod 15 with a coating material. Preferably, the substrate material is both embossed and assembled to form a substrate rod. The substrate rods may be arranged (i) using the apparatus described in U.S. Patent No. 4,807,809 to Pryor et al .; , v (ii) using the apparatus used in U.S. Patent No. 5,163,452 to Marritt et al .; or (iii) :: using a rod forming unit obtainable under the designation CU-10, CU-20 20 or CU-20S from Decouble sarb, in conjunction with a KDF-2 rod forming apparatus, from Körber & Co., AG, Hamburg, Germany (Körber). The web material is typically formed of a plurality of embossed lines parallel to the machine direction so that the web is assembled into a more uniform pattern.

:: 5 25 ':' Preferred substrates retain the aerosol forming material when not in use and release the aerosol forming material during the smoking period. A preferred type of substrate is a non-woven sheet-like material such as paper, carbon paper or tobacco paper. Typically such; · * 30 substrates are formed as cylindrical rods including embossed and assembled paper web bounded by an outer cover. Other types of web substrate materials include laminates, such as paper / foil laminates.

115754 12

In particular, the continuous web of the substrate material is embossed, assembled into a plurality of longitudinally extending folds while the aerosol forming material is continuously applied to its central portion to form a rod which is then surrounded by an outer covering.

5

The substrate may also be formed from a rod having a concentric structure in which the central core is formed from a paper material which absorbs and retains the aerosol forming material and an outer shell of the barrier layer material which surrounds the core to assist in limiting the migration of the aerosol former.

The outer covering surrounding the assembled substrate material is preferably a paper material and may be coated or treated with the material to limit the migration of the aerosol forming material. An example of such a coating is Hercon 70, available from Hercules, Inc., or a metal foil.

The substrate web is assembled to form substrate rods such that the cross-sectional area of the rod ·, · · · 'is typically in the range of about 5 to about 30%, preferably about 8 to about 25%, and often about 10 to about 20%. The cross-section: '1: 20 blank area (i.e., the area formed in the channels when viewing the rod at the end) can typically be determined using image analysis technology using an IBAS Image Analyzer available from Carl Ziess, Inc.

The aerosol forming material may be applied to the substrate material prior to forming, or may be introduced into the substrate web through a tube centered on the assembly assembly of the 1 KDF rod making machine 53. A measuring pump is used to provide a certain amount of aerosol forming material to the substrate web.

»: The continuous substrate rod is cut into substrate rods of length 50, approximately 60 mm '' and fed to suitable conveyor means for transporting the rods to the following assembly station. Suitable conveyor means for the various subassemblies described herein include batch conveyors, such as HCF 80 plate filler available from Körber, or continuous conveyors such as pneumatic or other conveyor devices known in the art.

The carbonaceous fuel rod 51 is formed using an extruder 55 of a screw or piston type 5. The preferred carbonaceous mixture may be prepared by blending up to 95 parts carbonaceous material, 20 parts binder, and 20 parts tobacco (e.g., tobacco dust and / or tobacco) and extruding the pasta into the desired shape. The water may preferably be provided in the form of an aqueous solution of Na 2 CO 3.

10 See also U.S. Patent No. 5,178,167 to Riggs et al., The disclosure of which is incorporated herein by reference. See also U.S. patents and patent applications cited above for other examples of carbonaceous mixtures.

Extruded carbonaceous rods can be formed as follows. Carbon particle-15 coils are arranged in particulate form by ball milling techniques. Tobacco leaf blades may also be ball-milled to a fine particle size (e.g., 5-15 µm, preferably 7-12 µm-average) and mixed with the carbon particles, v. Other fuel components or additives (for example, calcium carbonate: '': particulates or graphite) may be blended with carbon particles or a mixture of carbon and tobacco particles. The particles are then physically mixed with the dry, * t 'powdery binder. The resulting dry mix is then physically agitated while being subjected to an atomized water jet. The resulting moist mixture typically has a moisture content of about 30 to about 40% by weight on a wet basis, preferably 32 to 38 and most preferably 34 to 36. Said moisture content depends on the type of extruder used and to some extent the structure of the carbonaceous blend. If desired, water-soluble materials or additives .. '' (e.g., tobacco extracts, salts, and the like) may be included in the mixture by dissolving such materials or additives in water. Preferably, the wet mixture is extruded using a combination extruder (for example, a double screw combination extruder). Optionally, the moist mixture is extruded into pre-mixed pills using a Baker-Perkins MP-50-35 115754 14 DE XLT extruder; and then the pellets are extruded to the desired shape using a piston extruder such as HET-120A from Hydramet American Inc. The mixture may also be extruded to the desired shape using a dual screw combination extruder provided with a screw comprising 5 screw segments and blade segments.

The circumferential grooves are included in the final fuel elements during extrusion. It is preferred that the grooves are deeper than their width, preferably the depth should be up to about twice the width. Typical widths for grooves in the fuel elements of this invention are from about 0.25 mm to about 1.5 mm, preferably from about 0.5 mm to about 1.0 mm. These grooves generally have a depth in the range of about 1 mm to about 1.5 mm. The grooves may have either a rounded (concave or convex) base or a square or rectangular base. The preferred shape is the concave base.

15

The extruded mixture exits the mold as a continuous extrusion of the desired cross-sectional shape and is placed on top of the airfoil.

The extruded continuous carbonaceous fuel rod 51 is wrapped in an insulating material 20 and an outer paper wrap using modified KDF 56 as described in U.S. Patent No. 4,893,637 to form a coated fuel / insulating assembly 52.

Preferably, the insulating material allows the sucked air to pass therethrough and assists in holding the fuel element in place. In some embodiments, the insulating and / or retaining material is compressed around the fuel element, 7 thereby ensuring a good, stable positioning and tightness of the fuel element; atonement to it. Typically, in the preferred embodiments, the pectin '' binder in the fiberglass insulating material is reactivated by applying water to the insulating material upon drying.

115754 15

The composition of the insulating and / or retaining material surrounding the fuel element may vary. This material is preferably one which has no tendency to burn or material that is combustible but does not decompose. Examples of suitable materials include glass fibers and other materials of the type described in U.S. Patent No. 5,105,838 to White et al .; European Patent Publication No. 366,690; and a monograph entitled "Chemical and Biological Studies of the New Cigarette Prototypes That Heat Instead of Burn Tobacco," by R. J. Reynolds Tobacco Co. (1988) pages 48-52.

Examples of other suitable insulating and / or retaining materials are glass fiber and tobacco blends, such as those described in U.S. Patent No. 4,756,318 to Clearman et al. and U.S. Patent No. 5,065,776.

As shown in Figures 1 and 1A, the insulating and / or retaining material that surrounds the fuel element is limited by a paper cover. This paper cover may comprise one or two layers, which may vary in air permeability and ash stability properties. Papers having these properties are described in U.S. Patent Nos. 4,938,238 and 5,105,837 to Barnes et al.

An example of a suitable outer paper cover is available as P-3122-153, from Kimberly-Clark Corp. and No. 15456 Ecusta, P.H. Cladfelder Division.

When leaving the extrusion process, the carbonaceous fuel rod 51 has a moisture content of about 30 to 38% by weight. After the fuel is coated, the continuous coated fuel rod is cut to form six-fold - *, 25-shell fuel rods 52, approximately 72 mm in length. If desired at this point in the manufacturing process, the jacketed fuel rod may be dried to reduce the moisture content of the carbonaceous rod. Preferably, the moisture content should be maintained at an appropriate level such that the carbonaceous rods can be cut during subsequent manufacturing steps without fracturing or cracking.

· '30 Normally a moisture content between 38 and 12% is acceptable. The dryer used (not shown) may be a passive drying device such as a timed battery accumulator system (e.g. Resy available from Körber or S-90, 115754 16 available from GD. Societe Per Azioni, Bologna, Italy, optionally in a humidity controlled environment) or a positive imaging system such as a hot air blower system. Sheathed fuel rods are fed to a drip unit 60, such as the Max R-1 available from Körber 5.

60 mm substrate rods 50 are fed to a pin tube connecting device such as Mulfi R-1 consisting of GC unit 62 and KDF-2D unit 63 available from Körber. The substrate rods are cut into 10 mm needles, which are sorted, aligned and placed at 10 mm intervals on the GC unit. The 10 mm needle pairs are transferred to the KDF-2D at approximately 12 mm intervals and aligned. The intermediate needles 22 are coated with a cover 26 (Fig. 1), which forms a tube with substrate needles spaced 10 mm and 12 mm apart. The tube is cut approximately 10 mm apart from the center to form 15 double substrate tubes 64 having a length of approximately 42 mm having voids of approximately 5 mm at each end, two substrate sticks approximately 10 mm in length and a gap of approximately 12 mm · Λ: Between the substrate stick.

The coating material is preferably a foil / paper laminate. The foil layer forms an additional barrier layer to help prevent aerosol forming material migration. The coating material is designed so that after forming the tube, it does not bend or collapse during the manufacturing process or during the use of the cigarette.

»25

Preferably, the KDF-2D 63 of the rod / tube combination device is directly connected to the drip device 60 so that the substrate tubes 64 are transferred to a suitable drum in the drip device. The dip device 60 also receives the jacketed fuel rods 52 from the fuel extrusion process described above. In the tip device 60, the 72 mm '30 jacketed fuel rods, or sixfold jacketed fuel rods, are cut to lengths of about 12 mm to form the jacketed fuel elements 18. The jacketed fuel elements are then sorted, aligned in pairs 115754 17 apart, and the element 18 adjacent to the empty space 28 and at each end of the substrate tube 64. The aligned components are coated with a cover or drip material 32 (Figure 1) to form a double fuel / subs-5 wire portion 65, approximately 66 mm in length having a fuel element 18 at each end, two voids 28, two substrate sticks 22 and a central void 69. the drip material 32 is approximately 54 mm in length x approximately 26 mm in width and is applied to the double fuel substrate portion 65 such that approximately 6 mm of each envelope fuel element 10 extends over the edge of the drip material and thus is not coated with the drip material. Preferably, the tip material is paper / foil / paper laminate.

As the fuel / substrate portion 65 exits the drip device 60, the portion passes through the drying portion 66 to dry the carbonaceous fuel elements. The drying may be carried out in a passive manner using an accumulator such as Resy or S-90, optionally in a humidity controlled environment or in a positive heating process. The heating process should not be so large that the Aero,? Forming agent and other flavors evaporate off the substrate.

Preferably, the carbonaceous fuel is dried to a moisture content of about 12-14% by weight. If desired, the drying parts can be eliminated and repositioned, as they depend on the moisture content and time interval of the extruded rod; ·; ' between the different stages of the manufacturing process.

Preferably, simultaneously with the manufacture of the fuel / substrate portion 65, the tobacco portion 34 of the cigarette 5 (Fig. 1), as shown in Fig. 2B, is prepared.

A continuous tobacco rod is formed in a cigarette making machine 71, such as, for example, Protos VE / SE, available from Körber, using cut filler material such as tobacco, reconstituted tobacco or the like. The continuous tobacco rod is cut to lengths of 120 mm to form tobacco rolls or rods 30 70.

115754 18

A tobacco clip filler rod is attached to a tobacco paper stick, shown as 34 in Figure 1. A tobacco paper stick is continuously provided from a tobacco paper stick, as described in previous U.S. Patent No. 4,807,809. The tobacco cigarette sticks are coated with a suitable cigarette paper using a web feeder and modifier KDF 77 as described therein, and cut into cigarette paper rods 75 about 80 mm in length.

A 120mm tobacco rod 70 and an 80mm tobacco paper rod 75 are fed into the feed cones of a needle / tube connector device such as a Multi R-2 including a GC 79 and 10 KD-2D 80. The tobacco rod and the tobacco paper rods are cut into 40 mm and 20 mm segments, respectively. The segments are sorted and aligned in the GC unit to alternate contact position when moving to the KDF-2D unit, where the rod segments are paper coated and cut into cut filler / tobacco paper assemblies or quadruple tobacco portions 81 with 20 mm mm with tobacco paper segment 83 at each end.

·

As shown in Figure 2C, the quadruple tobacco portion 81 is fed to a drip unit assembly 85, such as a Max R-2 drip device available from Körber. In the dip device, the quadruple portion 81 is cut at its center

M II

through segment 86 to form a double tobacco portion 87 having a 40 mm center roll tobacco segment and 10 mm tobacco paper segments at each end. The double tobacco portions 87 are sorted and aligned.

The double fuel / substrate portion 65 is fed to a drip device 85 which cuts the double fuel / substrate portion 65 at its center through the substrate tube, sorts, aligns, and positions the two halves of tobacco; * on opposite sides of portion 87 with fuel / substrate void space 30 (Figure 1) '/ adjacent to cigarette paper segments 83. This configuration of components: * '30 is then coated with a suitable cover 42 (Fig. 1) to form double tobacco / fuel units 88 of approximately 126 mm in length having a fuel element disposed at opposite ends. The edge of the cover 42 extends beyond the point of contact of the fuel substrate unit 32 and the tobacco portion 87. The double tobacco / fuel unit is transported to a dripping unit 92, such as a Max R-3, available from Körber.

A filter material, such as a nonwoven polypropylene web, is formed into a continuous rod using a web feeder and a KDF 90 filter manufacturing device described in U.S. Patent No. 4,807,809. The continuous filter rod is cut into four filter segments 97, approximately 80 mm in length. The quadrant filter segments 97 are transferred to the drip device 92. In the dip device 92, the quadruple filter segments 97 are cut into double filters 98, approximately 40 mm in length, sorted and aligned. The double tobacco / fuel unit 88 is cut at its center through the tobacco roll segment 82, sorted, aligned, and the individual units positioned on opposite sides of the double filter 98. Tip paper 46 is applied to the components assembled by the Max R-15 3 (Körber), attaching a double filter 98 between the tobacco / fuel units to form a double cigarette 102. The double cigarette 102 is then cut from the center of the filter segment 98 to form a single cigarette 104. the cigarettes 104 are rotated 180 ° to align them so that all 20 cigarettes have the same orientation. Cigarettes 104 may then be transferred to the HCF -: tray filling unit 106 or to an accumulator such as Resy, which may; be connected to the packaging equipment.

Referring to Figures 4A, 4B and 4C, there is shown a flowchart of a preferred method of making the cigarette embodiment of the present invention shown in Figures 3 and 1A. Again, the method involves separately preparing the various components of the cigarette, and combining the individually manufactured components in a specific order. The method illustrated in Figures 4A, 4B and 4C is a simple one; method.

• 30

The jacketed fuel cell 52 is fabricated, as previously described in connection with the method described in Figure 2, and is cut to 72 mm or six times 115754 20 and fed to a Max 1 drip unit 200 available from Körber.

The substrate rod 50 is formed by providing a reconstituted tobacco casting sheet-5 material as described in Example 2 herein. The cut filler material is formed into a continuous rod and coated with a cigarette making machine 202, such as Protos, available from Körber, and cut to rod lengths of 62mm or twice lengths and transferred to a Max 1 unit 200 feed cone.

10

In the dip unit 200, the 72 mm jacketed fuel rods are cut to lengths of about 12 mm to form the jacketed fuel elements 18. As previously described, the jacketed fuel elements 18 are joined to the substrate 50 using the method 32 of Figure 2. The cover 32 is approximately 74 by 15 mm in length and is applied with its edges approximately 6 mm apart from the free end of each jacketed fuel element 18 to form a double fuel substrate portion 65.

Preferably, simultaneously with the manufacture of the fuel / substrate portion 65: The tobacco portion 34 of the cigarette 5 (Figure 3) is prepared as shown in Figure 4B.

Il I

A continuous tobacco rod is formed on a cigarette making machine 71 such as Protos VE / SE available from Körber using cut filler material such as tobacco, reconstituted tobacco or the like. The continuous tobacco rod is cut to lengths of 80 mm (fourfold) to form tobacco rolls, 25 rolls or rods 70.

> t Filler material such as low-power cellulose acetate wadding * »: * is formed into a continuous rod using a KDF filter making machine 300

«· F * I

| 'And cut into four filter segments 97, approximately 80 mm in length; · '30.

115754 21

The quadruple tobacco rods 70 and quadruple filter segments 97 are transferred to a combining device 61, such as a Multi, consisting of a GC unit 62 and a KDF-2D unit 63 available from Körber. The tobacco rod 70 and the filter segments 97 are cut to lengths of 40 mm and alternately placed in the GC unit, 5 sorted and aligned, and transferred to the KDF-2 D unit. There they are coated and cut into double tobacco / filter sections 206, about 80 mm in length. The double tobacco / filter sections have a 40 mm central filter segment and 20 mm tobacco segments at each end.

As shown in Figure 4C, double tobacco / filter unit 206 and double fuel / substrate portion 65 are transferred to another drip unit unit 208 (see Figure 4C), such as Max 2, available from Körber. The double fuel / substrate portions 65 are approximately cut from their centers and sorted and aligned with the individual fuel / substrate portion 15 where they are spaced and positioned at opposite ends of the tobacco / filter portion 206 with the substrate adjacent the tobacco portion. The targeted components are coated with drip material 49, RJR type 1000011, to form a double cigarette 202. The double cigarette is then approximately cut from the center of the filter to form a single cigarette 104. The alternate cigarette 20 is rotated 180 ° so that all cigarettes have same trend. The cigarettes may be transferred to an HCF tray filler or accumulator such as Resy, which may be connected to a cigarette packing apparatus.

I »

The present invention will be further described with reference to the following examples,

* »I I

which help in understanding the present invention, but are not construed as limitations thereof. All percentages herein unless otherwise stated are by weight.

I I

'1 EXAMPLE 1

: ·: 30 PREPARING THE COMPONENTS

Sheathed fuel rod 115754 22

The jacketed fuel rod, approximately 7.5 mm in diameter, including a carbonaceous fuel rod and an insulating material, is manufactured by directly extruding the carbonaceous fuel rod into a multilayer fiberglass / tobacco paper strip. The jacketed fuel rod is cut to a length of about 72 mm.

5

Carbon fuel rod

A carbonaceous fuel rod with an apparent density (bulk density) of about 1.02 g / cm3 is prepared from about 73.4 parts of hardwood charcoal having an average 10 particle size of 12 microns in diameter, 10 parts ammonium alginate (Amoloid HV, Kelco Co.) , 0.2 parts of Na 2 CO 3, 8.4 parts of graphite, about 8 microns in particle size, 3 parts of Ca 2 CO 3 powder and 5 parts of American Blend rolled tobacco. Hardwood charcoal is prepared by carbonating non-talc grade Grande Prairie Canadian kraft paper in a nitrogen jacket, incrementally increasing the temperature sufficiently to minimize oxidation of the paper to a final carbonation temperature of at least 750 ° C. The resulting. The carbon material is cooled under nitrogen to below 35 ° C and then milled to a fine powder having an average particle size of about 12 microns in diameter.

I * 20; The finely ground hard charcoal is dry blended with ammonium alginate binder, levulinic acid and tobacco, and then a 3% by weight aqueous Na 2 CO 3 solution is added to form an extrudable mixture having a final: sodium carbonate level of about 0.9 parts.

25 »« »; * ·" Carbonaceous fuel rods are extruded using a screw extruder: '": of a mixture of approximately 4.2 mm diameter with six evenly spaced circumferential grooves (approximately 0.5 mm wide and approximately 1 mm) deep) with rounded bottoms running from end to end.

The extruded rods have an initial moisture level in the range of about 36% to about 38% by weight.

115754 23

sheath

The mantle material consists of two layers of Owens-Coming C glass mat, each about 1 mm thick before being pressed by a felt forming machine 5 (for example, as described in U.S. Patent No. 4,807,809), and after forming, each about 0.6 mm thick. Sandwiched between the two layers of C glass, there is one or two sheets of reconstituted tobacco paper, Kimberly-Clark's P-3510-96-2. Cigarette paper, designated P-3122-153 from Kimberly-Clark, covers the outer layer. The reconstituted sheet of tobacco-10 paper is a paper-like sheet containing mixed tobacco extract. The width of the reconstituted tobacco sheets prior to shaping is approximately 17 mm and the outside width of the cigarette paper is approximately 25.5 mm. The sealant used for the outer coating may be a cold sealant CS 1242 available from RJR Packaging, R.J. Reynolds, Winston-Salem, N.C.

15

Substrate tube '' \ Continuous substrate rod about 7.5 mm in diameter, formed by a wide,. a heavily embossed, 36 gsm, about 7 inch wide paper web, t: 20 containing 25% calcium sulfate, available from Kimberly-Clark (K-C) under the designation P3284-19, for example in a modified KDF-2 rod forming apparatus. The substrate rod is coated with a paper / foil laminate having a width of about 24.5 mm, the foil being continuously cast 0.0005 aluminum foil, and the paper being '': Simpson Paper Co. (Simpson) RJR 002A Paper. The laminating adhesive is 25 silicate adhesive No. 06-50-05-0051 available from RJR Packaging.

: -. Centerline adhesive, cold adhesive CS 1242M, available from RJR

;: Packaging, spray application to the laminate, to hold the substrate in place, '_. inside the cover. The joint is sealed with hot melt adhesive 444-227 from RJR Packaging.

The coated rod is cut into 60 mm segments. Approximately 900 mg of an aerosol forming material containing glycerin, propylene glycol, and flavoring agents such as tobacco extract is applied to the web during continuous substrate bar formation. The substrate segment is cut into substrate sticks, about 10 mm in length, and coated with Simpson RJR 002A / 0005 film laminate described above with a width of about 25.5 mm. The needles are placed alternately at 5 and 10 mm and 12 mm apart along the tube. The needles are attached to the tube by the respective application of hot melt adhesive No. 448-37A, RJR Packaging. The joint is sealed with hot melt adhesive 444-227 from RJR Packaging.

The continuous tube is cut into substrate void space tube portions, about 42 mm in length, having a center gap of about 12 mm, two substrate sticks 10 mm wide, and a blank space at each end, about 5 mm wide.

Tobacco Part 15 The reconstituted tobacco clip filler, prepared as described in U.S. Patent No. 5,159,942 to Brinkley et al., Is formed into a rod about 7.5 mm in diameter. and coated with paper, for example KC 646, 25.5 mm wide, used. fully Protos cigarette making machine using standard tip adhesive.

,,,,: The coated roll of tobacco is cut into 120 mm segments.

20. The tobacco rod, about 7.5 mm in diameter, is formed on average; ·; embossed, 127mm wide tobacco paper web, labeled P-144-GNA-CB, available from Kimberly-Clark, for example, using a rod-shaped "": dispenser as described in U.S. Patent No. 4,807,809. The rod is coated with '25 KC paper P1487. -184-2, about 25 mm wide, and cut into segments 80 mm long.

The roll of tobacco and the segments of tobacco paper are cut 40 mm and 20 mm respectively. ·. segments and are rotated in order and overlaid with KC

30,646 paper covers 25.5 mm wide using centerline hot melt adhesive 448-37A, RJR Packaging, and seam adhesive 448-195K hot melt adhesive, RJR Packaging. The composite tobacco roll / tobacco paper assembly is cut into a double tobacco section of 60 mm length having a 40 mm tobacco roll center segment and 10 mm tobacco paper segment at each end of the tobacco roll segment.

5 Filter

A polypropylene filter rod, about 7.5 mm in diameter, is formed from a PP-100 mat, about 260 mm wide, available from Kimberly-Clark, and coated with a 25.5 mm wide P1487-184-2 paper web, available from Kimberly-Clark, e.g. using a device described in U.S. Patent No. 4,807,809, and a 448-195K heat seal adhesive. The coated rod is cut into segments 80 mm long.

Cigarette configuration

15 Fuel / substrate component,. The jacketed fuel rod is cut into 12 mm fuel elements.

The two fuel elements are placed on opposite sides of the substrate / void tube section and aligned. These components are coated with a cover having a width of about 20: 26.5 mm and a length of about 54 mm, comprising paper / foil / paper laminate including Ecusta 15456 paper / continuous cast-0.0005 foil /: ·; Ecusta 29492 paper laminated to foil using Airflex Adhesive 465. The laminate is bonded to the jacketed fuel and substrate / void tube assembly with MT-8014 cold adhesive, RJR Packaging applied to the entire inner surface of the laminate. The upper surrounds the substrate tube and •. f extends about 6 mm inside the free end of each fuel element to form: a double fuel / substrate portion of the earth.

Tobacco fuel unit 30

The double fuel / substrate portion is cut at its center and positioned on opposite sides of the double tobacco portion and is positioned such that the empty end of each fuel / substrate portion is adjacent and in contact with each end of the double tobacco portion. The assembled components are coated with Ecusta E30336 paper, about 70 mm long and about 26 mm wide. The cover is attached to the fuel / substrate 5 portion and the tobacco portion with MT-8009 adhesive, RJR Packaging, to form a double tobacco / fuel unit approximately 126 mm in length.

Cigarette 10 The double tobacco / fuel unit is cut off at its center and positioned on opposite sides of the double filter unit and aligned so that the tobacco roll side of the single tobacco / fuel unit is adjacent to and in contact with the double filter. The assembled components are covered with a drip cover, RJR tip code number 1000011, approximately 50 mm in length and approximately 26 mm in width, extending approximately 5 mm across each junction between the double filter and each tobacco / fuel unit. The overlay is adhered to the assembled surface components with MT-8009, RJR Packaging, 100% Coating, to form a double cigarette. Double cigarette. 20 is approximately cut from the middle (i.e., the center of the double filter) to form a single cigarette.

EXAMPLE 2

• ·: MANUFACTURE OF COMPONENTS

25 Sheathed fuel rod "·; Fuel element with a apparent density of about 4.2 mm in diameter; (bulk density) of about 1.02 g / cm3, prepared from about 72.6 parts of hardwood charcoal: ·. - having an average particle size 12 µm in diameter, 10 parts of 30 ammonium alginate (Amoloid HV, Kelco Co.), 8.4 parts of graphite powder, 1 part of Na 2 CO 3, 3 parts of CaCO 3, and 5 parts of American Blend tobacco.

115754 27

Hardwood charcoal is produced by carbonating non-talc grade Grande Prairie Canadian kraft paper in an inert atmosphere, increasing the temperature stepwise enough to minimize the oxidation of the paper to a final carbonation temperature of at least 750 ° C. The resulting carbon-5 material is cooled in an inert atmosphere to below 35 ° C and then ground to a fine powder having an average particle size (as determined using a Microtrac Analyzer, Leeds% Northrup) of about 12 µm in diameter.

The finely ground hardwood charcoal is dry blended with graphite, CaCO3, ammonium alkali 10 binder, levulinic acid and tobacco, and then 3% by weight aqueous Na2CO3 is added to form an extrudable mixture having a final level of sodium carbonate of about 1.

The jacketed fuel rod is manufactured by extruding directly the carbonaceous fuel rod into a multilayer fiberglass / tobacco paper strip. The jacketed fuel rod is cut to a length of about 72 mm.

The Sheath Material 20 The sheath material consists of two layers of Owens-Corning C glass mat, each about 1 mm thick before being pressed on a sheathing machine (exemplified as described in U.S. Patent No. 4,893,637), and each molded. about 0.6 mm thick. Between two layers of C glass, one or two sheets of reconstructed tobacco paper, Kimberly-Clark's P-3510-176-60, are sandwiched. Cigarette paper with note 15456, Ecusta'-; ' *., East, covers the outer layer. The reconstructed sheet of tobacco paper is a paper: a fine sheet containing a blended tobacco extract. The reconstituted,!.: Tobacco sheets have a width of about 17 mm before shaping, whereas cigarette paper •. ·. the width of the outermost sheet is approximately 25.5 mm. The sealant used for the outer sheath 30 may be a cold seal CS 1242 available from RJR Packaging, R.J. Reynolds, Winston-Salem, N.C.

28 1 1 5754

Substraattisauva

The casting sheet material is formed by casting an aqueous slurry of components from a headbox onto a 5 stainless steel belt heated to a nominal thickness of about 30 inches. Casting slurry has a solids content of about 12%. The slurry is formed by dispersing in water about 32 parts tobacco pulp in the form of picked stalks and leaf blades, about 8.75 parts flue-gas dried tobacco leaf blade, about 8.755410 parts burley tobacco leaf blade, and about 14.5 parts picked burley blades. As such, a slurry is formed having about 1 to 10 parts of tobacco and about 8 parts of water. The resulting slurry is refined using a wafer wafer and transferred to a mixer. To a slurry containing about 32 parts of tobacco is added about 55 parts glycerin; about 6 parts of the tobacco extract type described in U.S. Pat. No. 5,159,942 to Brinkley et al., column 11, lines 5-37, diluted with water in about 8 parts of extract and about 92 parts of water; and about 15 to 2 parts of a commercial flavor, such as Lovage. However, the selection and relative amounts of these components, such as flavorings. . and tobacco extracts, may vary as desired to produce the desired [. organoleptic properties.

.: 20 The resulting slurry is mixed to produce a consistent feature.

•. Then, about 5 parts of ammonium alginate, available under the designation Amoloid HV from the Kelco division of Merk & Co., Inc., are added to the slurry. The resulting slurry is thoroughly mixed under ambient conditions using a Breddo [: Likwifier high-shear propeller mixer. The slurry is cast on a stainless steel: 25 steel strap heated to about 220 ° F (104 ° C). The dried cast slurry is sliced and cut to about 25 fillets per inch (about 1 clip per mm). The cut filler is conditioned to produce a substrate having approx. ..; A moisture content of 15% by weight and a thickness of about 6 inches per thousand.

The cast sheet substrate material is formed into rods using a rod forming device such as Protos from Körber. The substrate rod includes a paper / aluminum foil laminate cover having a width of about 25.5 mm, a foil of 115754 29 cast aluminum, 0.0005 in. (0.013 mm) thick, and the paper is available as Ref. No. 29492, from Ecusta. The laminate is formed with a silicate knot known as RJR LAM-1-5001 available from RJR Packaging. Laminated paper is formed into a tube (with foil inside)

5 overlapping joints using CS1242 adhesive, available from RJR

Packaging. The coated rod is cut into 62 mm long segments. The 62 mm rod weighs about 800 mg.

The tobacco section 10

The reconstituted tobacco cut filler, prepared as described in U.S. Patent No. 5,159,942, is formed into a rod, about 7.5 mm in diameter, and coated with paper, e.g., Ecusta No. 15456, 25.5 mm wide using a Protos cigarette maker using a standard seam gripper. substance-15 it. The coated roll of tobacco is cut into segments of 80 mm.

Filter

A cellulose acetate filter rod, about 7.5 mm in diameter, is formed of 20 10 / 35,000 denier cellulose acetate vats containing 0.6% triacetin, and ·. coated with a 646 pin cover web, about 25.5 mm wide, available from Kimberly-Clark or Ecusta, in a standard filter rod manufacturing apparatus. The coated rod is cut into segments 80 mm long.

»

j 25 CIGARETTE ASSEMBLY

• .. Fuel substrate section, Sheathed fuel rod is cut into fuel elements 12 mm long. a. Two fuel elements are disposed on opposite sides 30 of the substrate portion and aligned. These components are coated with a cover of approximately 26.5 mm in width and approximately 74 mm in length, comprising a paper / foil / paper laminate comprising an Ecusta 99952 paper / continuous cast 0.0005 inch (0.013115754 30 mm) aluminum foil / Ecusta 99951 paper which is laminated to foil using RJR LAM-5001 (1.0 Ibs / ream) available from RJR Packaging. The laminate is adhered to the casing fuel and substrate assembly with a cold adhesive MT-8009B, RJR Packaging, applied to the entire inner surface of the laminate. The cover covers the substrate tube and extends about 6 mm inside the free end of each fuel element to form a double fuel / substrate member.

TOBACCO / filter section

The 80mm tobacco rod and 80mm filter segment are cut into 40mm sections and alternately aligned and coated with a cover about 25.5mm wide, for example Type 646, from Kimberly-Clark, using a standard mildew adhesive. The resulting rod is cut into 80mm segments having a 40mm central filter segment together with 20mm tobacco rolls at 15 opposite ends to form a double tobacco / filter member.

Savuke i * »t. ,.: The double fuel / substrate portion is cut at its center and positioned on opposite sides of the 20 double tobacco / filter portion, and aligned so that the substrate end of the single fuel / substrate unit is adjacent to and in contact with the tobacco roll / filter portion.

The assembled components are covered with a drip cover, RJR tipping code No. 4 1000011, approximately 90 mm in length and approximately 26 mm in width, extending: approximately 5 mm across each junction between the tobacco / filter and each fuel / substrate unit. The cover is adhered to the entire surface area: assembled components with MT-8009 (RJR Packaging) adhesive. 100% coverage, to form a double cigarette. Double; the cigarette is approximately cut from its center (i.e., the center of the double filter) to form a single cigarette.

1 1 5754 31

The present invention has been described in detail including its preferred embodiments. However, it will be understood that those skilled in the art, upon reading the present specification, may make modifications and / or improvements to the present invention and still remain within the scope and spirit of the present invention as set forth in the following claims.

Claims (15)

A method for continuously producing filter cigarettes (104) with an insulated fuel element (18) forming the ignition end of the cigarette, a substrate (20), a tobacco member (34) and a filter element (44, 47) forming the rear of the cigarette, wherein at least two of said components are joined to a coating material, characterized in that the method comprises the steps of: (a) providing an isolated fuel element (18) continuously; (b) providing a substrate portion (20) continuously; (C) the isolated fuel element (18) and the substrate portion (64) are continuously joined to the coating material (32) to form the fuel substrate portion (65); (d) said tobacco portion (34) is provided continuously; (e) the fuel substrate portion (65) and the tobacco portion (34) are continuously aligned so that the substrate portion (20) is adapted to the tobacco portion (34) and abuts against it and the fuel substrate portion and the tobacco portion are joined to the coating (42) so that forming the tobacco fuel unit (88); (f) a filter element member (44, 47) is provided continuously; (g) the tobacco fuel unit (88) and filter element portion (44, 47) are continuously aligned, and the filter element (44, 47) is continuously joined to the tobacco fuel unit,: 20 (45, 88) to form the filter cigarette (104). Method according to claim 1, characterized in that the tobacco part (34) is a tobacco cutting filler roll (38). / 25 3. A method according to claim 1, characterized in that the tobacco portion (34) is formed by the following steps: (a) a roll (38) of tobacco cutting fillers is provided continuously; •: (b) a stick (36) of tobacco-containing paper is provided continuously; (c) the tobacco roll (38, 70) and the stick (36) of the tobacco-containing paper are continuously joined (79, 80) to the cover (40). 115754 37 Method according to Claim 1, characterized in that the substrate part (20) is formed by the following steps: (a) a bar (50) of continuous substrate material is formed; (b) cutting the substrate material (62) to desired lengths to form the substrate pins 5 (22, 24); (c) the substrate stick (22, 24) is fitted and separated (62) at desired distance (69); (d) forming a uniform tube (26) around the substrate pins (22, 24) disposed and spaced apart from each other; (e) the unitary tube (26) is cut at selected points to form a substrate tube assembly (64) with at least one substrate tube (22, 24) provided with a blank space (28, 30) on opposite sides of the substrate pin (22, 24). Method according to claim 4, characterized in that it further comprises a step of introducing aerosol generating material into the substrate material (22) at the same time as forming a uniform substrate rod (50). 6. A method according to claim 4, characterized in that it comprises. a step of introducing aerosol generating material into the substrate tube (22, 24) within the ·· substrate tube assembly (64). i 20 Process according to claim 1, characterized in that the insulated fuel element (18) is arranged: (a) by extrusion (55) of a uniform carbonaceous rod (51) of the desired shape, in a cover of a uniformly insulating coating material (12, 14) to provide a continuous insulated fuel rod (52); and (b) by cutting (56) the unitary insulated fuel rod (52) to desired lengths to provide a continuously insulated fuel element (18). Method according to claim 7, characterized in that it further comprises a step of drying the insulated carbonaceous fuel elements (18) to the desired moisture content. 115754 38 9. A process according to claim 8, characterized in that the carbonaceous fuel elements (18) are dried to a moisture content of between 12-14% by weight. 10. A process according to claim 8, characterized in that said drying step is performed in two separate steps during the cigarette manufacturing process. 11. A method according to claim 7, characterized in that the insulated fuel rod (52) is cut into six-fold lengths and further comprises the steps of: (a) a six-fold isolated fuel rod (52) is cut into insulated fuel elements (18); (B) the isolated fuel elements (18) are separated (60); (c) inserting a double substrate portion (64) (60) between the fuel elements (18); (d) the double substrate portion (64) and the isolated fuel elements (18) are fitted and juxtaposed; and (e) the dual substrate portion (64) and the isolated fuel elements (18) are coated (60) with a coating (32) to form a dual fuel substrate portion (65). 12. A method according to claim 3, characterized in that the roller (38) with: the tobacco cutting filler is arranged in its double length and the tobacco paper pin (36) is arranged in its double lengths, and where: (a) the roller (38) with the tobacco cutting filler and the tobacco paper spinners (36) fits into an alternating adjacent sequence; : (b) the alternating adjacent tobacco rolls (38) and tobacco paper spinners (36) are coated with a coating; and, (c) the coated components (81) are cut into double tobacco parts (87) with a .1 double roll of tobacco cutting filler (38) in the center portion provided with a tobacco pin (36) at opposite ends. t ; ; A method according to claim 11 or 12, characterized in that it further comprises the steps of: (a) dividing the dual fuel substrate portion (65) in the middle; (b) separating the fuel substrate parts; (C) introducing a tobacco portion (34; 87) between the fuel substrate portions (65); (d) the respective fuel substrate portion (65) is both fitted and brought into contact with a double tobacco portion; and (e) transferring the composite components to form a dual tobacco fuel unit (88). Method according to Claim 13, characterized in that the filter elements (44, 47) are arranged in double lengths and the method therefor comprises the steps of: (a) dividing the dual fuel tobacco unit (88) in the middle; (B) a dual filter (98) is inserted between two tobacco fuel units (88); (c) coating the composite components with a coating (46) to form a double filter cigarette (102); and (d) the dual filter cigarette (102) is cut at the center of the filter (98) to form a filter cigarette (104). 15 »» * t «* t» t »* * t i»