JP2020018313A - Smoking article and associated manufacturing method - Google Patents

Abstract

To provide a smoking article that demonstrates the ability to provide to a smoker many of the benefits and advantages of conventional cigarette smoking, without delivering considerable quantities of incomplete combustion and pyrolysis products.SOLUTION: A method for forming a smoking article involves engaging a heat generation segment 24 and a tobacco rod segment 68 with the wrapping material in a longitudinally spaced-apart relation, an outer wrapping material 80 having a heat-conductive strip 60 engaged therewith, and the heat generation segment and/or the tobacco rod segment at least partially overlapping one end of the heat-conductive strip. Lateral ends of the wrapping material are wrapped at most partially about the heat generation and tobacco rod segments such that the heat generation and tobacco rod segments cooperate with the heat-conductive strip to define a longitudinally-extending cavity 57 accessible between the respective lateral ends of the wrapping material and heat-conductive strip. Aerosol generation elements are deposited into the longitudinally-extending cavity between the lateral ends of the heat-conductive strip, and the cavity is closed by overlapping and sealing the lateral ends of the wrapping material.SELECTED DRAWING: Figure 1

Description

  The present disclosure relates to products made from or derived from tobacco, or otherwise incorporating tobacco and intended for human consumption, and more particularly to the manufacture of segmented smoking articles. Related to the assembly of the components.

  Popular smoking articles, such as cigarettes, have a substantially cylindrical rod-shaped structure and are surrounded by wrapping paper, so-called "smokable rods", "cigarette rods" or "cigarette rods". A filling, scroll, or column of a smokable material, such as shredded tobacco (eg, in cut filler form). Typically, cigarettes have a cylindrical filter element that is aligned in an end-to-end relationship with a 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 using a surrounding wrapper known as "tipping paper". Examples of chipping materials include, for example, Dube et al., U.S. Pat. No. 7,789,089, and Crooks et al., U.S. Patent Application Publication No. 2007/0215167, Joyce et al., 2010/0108081, and Norman et al., U.S. Pat. No. 2010/0108084, and Ademe et al., 2013/0167849, and Dittrich et al., PCT Patent Application Publication 2013/160671, each of which is incorporated herein by reference. It has also become desirable to perforate the tipping material and plug wrap to provide dilution of the drawn mainstream smoke with ambient air. Traditional types of cigarettes are used by smokers by igniting one end and burning a tobacco rod. The smoker then receives mainstream smoke into the mouth by inhaling the opposite end of the cigarette (eg, the filter end or the mouth end). Descriptions of cigarettes and their various components are incorporated herein by reference in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). Over the years, efforts have been made to improve the components, construction, and performance of smoking articles. See, for example, the background art discussed in Borschke et al., US Patent No. 7,753,056, which is incorporated herein by reference.

  Certain types of cigarettes using carbonaceous fuel elements are disclosed in J. Commercially sold by Reynolds Tobacco Company under the brand names "Premier" and "Eclipse". See, for example, Chemical and Biological Studies on New Cigarette Prototypes that Heat Indirect of Burn Tobacco, R.A. J. Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12: 5, p. 1-58 (2000). In addition, a similar type of cigarette has recently been sold in Japan by Japan Tobacco Inc. under the brand name "Steam Hot One". Additionally, various types of smoking products that incorporate carbonaceous fuel elements for heat generation and aerosol formation are described in the patent literature. For example, U.S. Patent Nos. 4,793,365 to Sensabaugh et al., 7,647,932 to Cantrell et al., And 7,836,897 to Borschke et al., Banerjee, which are incorporated herein by reference. U.S. Patent Publication Nos. 2007/0215168, Tsuruizumi et al. 2013/0019888, Shinozaki et al. 2013/0133675, Stone et al. 2013/0269720, and Poget et al. 2013/0146075. PCT Patent Application Publication No. WO2012 / 0164077 to Gladden et al., WO2013 / 098380 to Raether et al., WO2013 / 098405 to Zuber et al., WO2013 / 08405 to Zuber et al. No. 8410, WO2013 / 104914 from Woodcock, WO2013 / 1220849 from Roudier et al., WO2013 / 120854 from Mironov, WO2013 / 162028 from Azegami, et al., And WO2013 / 162028 from Saleem et al. And European Patent Application EP 1 808 087 to Baba et al. And EP 2550879 to Tsuruizumi et al. For a smoking product and related components of the type proposed, described and referenced.

  Various modes and methods have been proposed for assembling smoking articles having a plurality of sequentially arranged segmented components. For example, US Patent Nos. 5,469,871 to Barnes et al. And 7,647,932 to Crooks et al., And US Patent Application Publication No. 2010/01886657 to Crooks et al., Which are incorporated herein by reference. See various types of assembly techniques and methodologies described in Stone et al., 2012/0042885, and Conner et al., 2012/0067360.

  It would be highly desirable to provide a smoking article that exhibits the ability to provide smokers with the benefits and benefits of many conventional cigarette smokings without providing significant amounts of incomplete combustion and pyrolysis products. In addition, it would also be highly desirable to provide efficient and effective modalities and methods associated with the manufacture and assembly of smoking articles of the type that incorporate a plurality of sequentially arranged segmented components.

U.S. Pat. No. 7,789,089 US Patent Application Publication No. 2007/0215167 US Patent Application Publication No. 2010/0108081 U.S. Patent Application Publication No. 2010/0108084 US Patent Application Publication No. 2013/0167849 International Publication No. WO 2013/160671 U.S. Pat. No. 7,753,056 U.S. Pat. No. 4,793,365 U.S. Pat. No. 7,647,932 U.S. Pat. No. 7,836,897 US Patent Publication No. 2007/0215168 US Patent Publication No. 2013/0019888 US Patent Publication No. 2013/0133675 US Patent Publication No. 2013/0269720 US Patent Publication No. 2013/0146075 International Publication No. WO2012 / 0164077 International Publication No. WO 2013/098380 International Publication No. WO 2013/098405 International Publication No. WO 2013/098410 International Publication No. WO 2013/104914 International Publication No. 2013/120849 WO 2013/120854 International Publication No. 2013/162028 WO 2013/160112 U.S. Pat. No. 5,469,871 US Patent Application Publication No. 2010/0186575 US Patent Application Publication No. 2012/0042885 US Patent Application Publication No. 2012/0067360

See Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999) Chemical and Biological Studies on New Cigarette Prototypes that Heat Indirect of Burn Tobacco, R.C. J. Reynolds Tobacco Company Monograph (1988) Inhalation Toxicology, 12: 5, p. 1-58 (2000)

  The above and other needs are satisfied in one aspect by aspects of the present disclosure that provide a method of forming an elongated smoking article. Such a method includes engaging the heat generating segment and the tobacco rod segment with the outer wrapping material in a longitudinally spaced relationship with the length of the outer wrapping material, the outer wrapping material engaging therewith. A thermally conductive strip, the thermally conductive strip having longitudinally spaced ends arranged relative to a length of the outer wrapping material, wherein at least one of a heat generating segment and a tobacco rod segment At least partially overlaps one of the longitudinal ends of the thermally conductive strip. The lateral end of the outer wrapping material is such that the heat-generating segment and the tobacco rod segment cooperate with the heat-conducting strip between the lateral end of the outer wrapping material and the lateral end of the heat-conducting strip. At least partially wrapped around the heat generating segment and the tobacco rod segment to define a longitudinally extending cavity accessible to the tongue. The plurality of aerosol-generating elements are deposited in longitudinally extending cavities between the lateral ends of the thermally conductive strip, the longitudinally extending cavities being aligned with the lateral ends of the outer packaging material. Closed by sealing.

  Another aspect of the present disclosure provides an apparatus for forming an elongated smoking article. Such an apparatus includes an assembly mechanism configured to engage the heat generating segment and the tobacco rod segment with the outer wrapping material in a longitudinally spaced relationship to the length of the outer wrapping material, Has a thermally conductive strip engaging therewith, the thermally conductive strip having longitudinally spaced ends arranged with respect to the length of the outer wrapping material, a heat generating segment and a tobacco rod segment. At least one overlaps at least one of the longitudinal ends of the thermally conductive strip. The wrapping mechanism includes a lateral end of the outer wrapping material, a heat generating segment and a tobacco rod segment cooperating with the thermally conductive strip to cooperate with the lateral end of the outer wrapping material and the lateral end of the thermally conductive strip. The heat generating segment and the tobacco rod segment are configured to wrap at most partially around the heat generating segment and the tobacco rod segment to define an accessible longitudinally extending cavity therebetween. The dispensing mechanism is configured to deposit the plurality of aerosol-generating elements into a longitudinally extending cavity between the lateral ends of the thermally conductive strip, and the sealing mechanism includes: The end-to-end seal is configured to close the longitudinally extending cavity.

  In certain aspects, the present disclosure provides an elongated smoking article having an ignition end and an opposing mouth end. Such smoking articles include a mouth end segment or portion disposed at the mouth end and a tobacco rod segment or portion disposed between the ignition end and the mouth end portion. The aerosol generation system is located as a segment disposed between the ignition end and the tobacco segment. The aerosol-generating segment is disposed longitudinally from a heat-producing portion or segment disposed at the ignition end, and since these two segments are in a heat exchange relationship, aerosol generation is caused by combustion of the components of the heat-generating segment. The heat generated on the aerosol-forming component of the segment causes the generation of aerosol. The longitudinally extending outer surfaces of the heat generating segment, aerosol generating segment, and tobacco rod segment provide a rod that is surrounded by outer wrapping material and then attached to the mouth end segment. A layer of thermally conductive material is disposed below the outer wrapping material to provide an outer inner surface of the aerosol generating segment. The thermally conductive layer most preferably covers the outer longitudinal surface of the heat generating segment in a region adjacent to the aerosol generating segment, and the thermally conductive layer optionally covers the outer longitudinal surface of the tobacco rod segment. , In an area adjacent to the aerosol generating segment. The aerosol-generating segment is a plurality of parts or pieces or elements (e.g., pellets or beads) that incorporate a material that generates an aerosol upon and in response to the heat generated by burning the fuel elements of the heat-generating segment. ) Is further incorporated.

  Another aspect of the present disclosure provides a mode and method for producing an elongated smoking article. That is, the preformed heat generating segments and tobacco rod segments are arranged in place on the inner surface of the web of outer packaging material. A layer of thermally conductive material is also positioned over a predetermined location on the inner surface of the outer packaging material. While wrapping the outer wrapping material around the various segments to form a wrapped rod comprising these three segments, the parts, elements, or pieces of the material incorporating the aerosol-forming substance are placed in a cavity defining the aerosol-generating segment. It is arranged downward. That is, a given amount of pellets or beads may fall into the cavity located between the heat generating segment and the tobacco rod segment. Thereafter, packaging of the outer wrapping material is completed to provide a wrapped rod incorporating three longitudinally aligned cylindrical segments. The aerosol generation area of the wrapped rod consists of a plurality of pellets or beads or other elements surrounded by a layer of thermally conductive material. The wrapped rod incorporating the three longitudinally aligned segments is then attached to a mouthpiece (eg, a cylindrical filter element) to provide the final filtered cigarette.

  The present disclosure includes, but is not limited to, the following embodiments.

  Embodiment 1: A method of forming an elongated smoking article, wherein a heat generating segment and a tobacco rod segment are engaged with an outer packaging material in a longitudinally spaced relationship to a length of the outer packaging material. Wherein the outer packaging material has a thermally conductive strip engaged therewith, the thermally conductive strip having longitudinally spaced ends arranged relative to the length of the outer packaging material. Wherein at least one of the heat generating segment and the tobacco rod segment at least partially overlaps and engages one of the longitudinal ends of the thermally conductive strip; and The heat generating segment and the tobacco rod segment cooperate with the heat conductive strip to form the side end of the outer wrapping material and the heat conductive strip. At least partially wrapping around the heat generating segment and the tobacco rod segment to define an accessible longitudinally extending cavity between the heat generating segment and the tobacco rod segment; and a plurality of aerosol generating elements. Depositing the longitudinally extending cavities in the longitudinally extending cavities between the lateral ends of the thermally conductive strip; and And closing by overlapping and sealing.

  Embodiment 2: The method or a combination thereof according to any of the preceding or subsequent embodiments, further comprising engaging the thermally conductive strip with the length of the outer wrapping material.

  Embodiment 3: Engaging the thermally conductive strip comprises engaging the thermally conductive strip with the outer wrapping material by applying a laminating adhesive therebetween. The method according to any of the embodiments below, or a combination thereof.

  Embodiment 4: Engaging the heat generating segment and the tobacco rod segment comprises connecting the heat generating segment and the tobacco rod segment to one of the longitudinal ends of the heat conductive strip only the heat generating segment. The method or any combination thereof according to any of the preceding or subsequent embodiments, comprising engaging the outer wrapping material so as to at least partially overlap with the outer wrapping material.

  Embodiment 5: Engaging a spacer element with the heat generating segment such that the spacer element and the tobacco rod segment cooperate with the thermally conductive strip to define the longitudinally extending cavity. The method or any combination thereof according to any of the preceding or subsequent embodiments, further comprising: wherein the spacer element is one of thermally conductive and breathable.

  Embodiment 6: Wrapping a side end of the outer wrapping material, wrapping a side end of the outer wrapping material with the longitudinally extending cavity, the side end of the thermally conductive strip Any preceding or succeeding embodiment, including at most partial wrapping around the heat generating segment and the tobacco rod segment to extend vertically downward from an opening defined therebetween. Or the combination thereof.

  Embodiment 7: Depositing the plurality of aerosol-generating elements comprises pellets, beads, discrete small units, carbon pieces, extruded carbon pieces, alumina beads, marumized tobacco pieces, extruded or compressed. Cylindrical or spherical elements, crushed tobacco sheets, fillers, flavoring agents, visible aerosol-forming materials, binders, oval elements, irregular elements, shreds, flakes, elements including tobacco, elements including visible aerosol-forming materials And any of the preceding or subsequent embodiments, comprising depositing the plurality of aerosol generating elements selected from the group consisting of: and a combination thereof, into the longitudinally extending cavity. Methods or combinations thereof.

  Embodiment 8: Depositing the plurality of aerosol-generating elements comprises selecting a plurality of forms of the aerosol-generating elements and depositing each of the selected forms of the aerosol-generating elements separately in the cavity. The method or any combination thereof according to any of the preceding or subsequent embodiments, including.

  Embodiment 9: depositing the plurality of aerosol-generating elements comprises selecting a plurality of forms of the aerosol-generating elements and combining the selected forms of the aerosol-generating elements to form an aerosol-generating element mixture; The method or any combination thereof according to any of the preceding or subsequent embodiments, comprising depositing a mixture in the cavity.

  Embodiment 10: Depositing the plurality of aerosol-generating elements comprises filling the plurality of aerosol-generating elements into the longitudinally extending cavity, wherein the cavity is at least about 65% filled with the aerosol-generating element. The method according to any of the preceding or subsequent embodiments, or a combination thereof, comprising depositing as described above.

  Embodiment 11: Closing the longitudinally extending cavity causes the lateral ends of the thermally conductive strip to be in contact with each other such that the lateral ends of the thermally conductive strip abut each other. The method or any combination thereof according to any of the preceding or subsequent embodiments, comprising wrapping around an aerosol-generating element.

  Embodiment 12: Closing the longitudinally extending cavity causes the aerosol generation such that the lateral end of the thermally conductive strip overlaps the lateral end of the thermally conductive strip. The method or combination thereof according to any of the preceding or subsequent embodiments, comprising wrapping around the element.

  Embodiment 13: Closing the longitudinally extending cavity can be performed between the overlapping side ends of the outer wrapping material to fit and seal the side ends of the outer wrapping material. The method or any combination thereof according to any of the preceding or subsequent embodiments, comprising applying a seam sealing adhesive.

  Embodiment 14: An apparatus for forming an elongated smoking article, wherein the apparatus has a heat generating segment and a tobacco rod segment longitudinally spaced from an outer wrapping material relative to a length of the outer wrapping material. An assembling mechanism configured to engage in relationship, wherein the outer wrapping material has a thermally conductive strip engaged therewith, wherein the thermally conductive strip is adapted to the length of the outer wrapping material. And at least one of the heat generating segment and the tobacco rod segment at least partially with one of the longitudinal ends of the thermally conductive strip. Overlapping the assembling mechanism and the lateral end of the outer wrapping material with the heat generating segment and the tobacco rod segment cooperating with the thermally conductive strip to form the outer Around the heat generating segment and the tobacco rod segment to define an accessible longitudinally extending cavity between the lateral end of the packaging material and the lateral end of the thermally conductive strip. A winding mechanism configured to at most partially wrap a plurality of aerosol-generating elements in the longitudinally extending cavity between the lateral ends of the thermally conductive strip. And a sealing mechanism configured to close the longitudinally extending cavity by sealing together the lateral ends of the outer packaging material. The device.

  Embodiment 15: The apparatus or any thereof according to any of the preceding or subsequent embodiments, further comprising a lamination mechanism configured to engage the thermally conductive strip with the length of the outer packaging material. combination.

  Embodiment 16: Any of the preceding or following, wherein the laminating mechanism is configured to engage the thermally conductive strip with the outer wrapping material by applying a laminating adhesive therebetween. The device according to the embodiment or a combination thereof.

  Embodiment 17: The assembling mechanism adjusts the heat generating segment and the tobacco rod segment such that the heat generating segment only overlaps at least partially with one of the longitudinal ends of the heat conductive strip. The device or any combination thereof according to any of the preceding or subsequent embodiments configured to engage packaging material.

  Embodiment 18: The assembling mechanism includes a spacer element and the heat generating segment such that the spacer element and the tobacco rod segment cooperate with the thermally conductive strip to define the longitudinally extending cavity. The device according to any of the preceding or subsequent embodiments or a combination thereof, wherein the device is configured to engage with the at least one of the first and second embodiments, wherein the spacer element is one of thermally conductive and breathable.

  Embodiment 19: The wrapping mechanism directs a lateral end of the outer wrapping material downward from an opening defined by the longitudinally extending cavity between the lateral ends of the thermally conductive strip. The apparatus or a device thereof according to any of the preceding or subsequent embodiments, configured to wrap at most partially around the heat generating segment and the tobacco rod segment to extend vertically. combination.

  Embodiment 20: The dispensing mechanism is a pellet, a bead, a discrete mini-unit, a piece of carbon, an extruded piece of carbon, an alumina bead, a piece of marmalized tobacco, an extruded or compressed cylindrical or spherical element Crushed tobacco sheets, fillers, flavoring agents, visible aerosol-forming materials, binders, oval elements, amorphous elements, shreds, flakes, elements including tobacco, elements including visible aerosol-forming materials, and combinations thereof. The device or any of the preceding or subsequent embodiments, wherein the plurality of aerosol-generating elements are selected from the group consisting of, and are configured to deposit in the longitudinally extending cavity. combination.

  Embodiment 21: The dispensing mechanism is configured to allow selection of a plurality of forms of the aerosol-generating element and comprises a separate dispensing device for each of the selected forms of the aerosol-generating element. The apparatus according to any of the preceding or subsequent embodiments, or a combination thereof, wherein each dispensing device is configured to dispense the aerosol generating element in the corresponding form into the cavity.

  Embodiment 22: The dispensing mechanism is configured to allow selection of a plurality of forms of the aerosol-generating element and to combine the selected form of the aerosol-generating element to produce an aerosol-generating element mixture; The apparatus according to any of the preceding or subsequent embodiments, or a combination thereof, comprising a dispensing device configured to deposit the mixture into the cavity.

  Embodiment 23: The dispensing mechanism deposits the plurality of aerosol-generating elements into the longitudinally extending cavity such that the cavity is at least about 65% filled with the aerosol-generating element. The apparatus according to any of the preceding or subsequent embodiments, or a combination thereof, configured.

  Embodiment 24: The sealing mechanism wraps the lateral end of the thermally conductive strip around the aerosol generating element such that the lateral ends of the thermally conductive strip abut each other. The apparatus according to any of the preceding or subsequent embodiments, or a combination thereof, wherein

  Embodiment 25: The sealing mechanism is configured to wrap the lateral end of the thermally conductive strip around the aerosol generating element such that the lateral end of the thermally conductive strip overlaps. The device according to any of the preceding or subsequent embodiments, or a combination thereof.

  Embodiment 26: The sealing mechanism applies a seam sealing adhesive between the overlapping side edges of the outer packaging material to seal together the lateral edges of the outer packaging material. The device or any combination thereof according to any of the preceding or subsequent embodiments, wherein the device is configured to:

  These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description when read in conjunction with the accompanying drawings, which are briefly described below. This disclosure may explicitly combine two, three, four, or more features or elements described in this disclosure, or may be otherwise listed in the description of certain embodiments herein. Regardless of any combination of such features or elements. This disclosure is deemed to be intended to mean that any separable feature or element of the disclosure is intended to be combinable in any of its aspects and embodiments, i.e., unless otherwise indicated by the context of the disclosure. It is intended to be read as a whole as it should be.

  Further features and advantages of the present disclosure are described in more detail in the following description.

  Reference will now be made to the accompanying drawings, which describe the present disclosure in general terms, but are not necessarily drawn to scale.

1 schematically illustrates a longitudinal cross-sectional view of an exemplary smoking article according to one aspect of the present disclosure. 2 schematically illustrates an enlarged cross-sectional end view along line 2-2 in FIG. 1 of an aerosol-generating segment of a representative smoking article according to one aspect of the present disclosure. 1 schematically illustrates a section of a continuous web or strip of packaging material used to make a series of two-up composite upstream rods according to one aspect of the present disclosure. 1 schematically illustrates a longitudinal cross-sectional view of a continuous rod consisting of a series of two-up composite upstream rods according to one aspect of the present disclosure. 1 schematically illustrates a two-up composite upstream rod according to one aspect of the present disclosure. 1 schematically illustrates a smoking article with a two-up composite filter according to one aspect of the present disclosure. 1 schematically illustrates a longitudinal cross-sectional view of an exemplary smoking article according to one aspect of the present disclosure. 1 schematically illustrates a section of a continuous web or strip of packaging material used to produce a series of two-up composite upstream rods. 1 schematically illustrates a longitudinal cross-sectional view of an exemplary smoking article according to one aspect of the present disclosure. 1 schematically illustrates a longitudinal cross-sectional view of a continuous rod consisting of a series of two-up composite upstream rods according to one aspect of the present disclosure. 1 schematically illustrates a smoking article with a two-up composite filter according to one aspect of the present disclosure. 1 schematically illustrates a longitudinal cross-sectional view of an exemplary smoking article according to one aspect of the present disclosure. 1 schematically illustrates an apparatus for forming an elongated smoking article according to one aspect of the present disclosure. 3 schematically illustrates an alternating arrangement of dispensing arrangements for depositing aerosol generating elements within a smoking article, in accordance with aspects of the present disclosure. 3 schematically illustrates an alternating arrangement of dispensing arrangements for depositing aerosol generating elements within a smoking article, in accordance with aspects of the present disclosure. 1 schematically illustrates a method for forming an elongated smoking article according to one aspect of the present disclosure.

  The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some but not all aspects of the disclosure are shown. Indeed, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are not intended to limit the disclosure. Provided to meet legal requirements. Like numbers refer to like elements throughout.

  Referring to FIG. 1, there is shown a smoking article 10 in the form of a cigarette representative of the present invention. The smoking article 10 has a generally rod-like shape and includes an ignition end 14 at one extreme. Preferably, smoking article 10 has the overall size, shape, and general appearance of a filtered cigarette.

  A generally cylindrical heat generating segment 24 extending in the longitudinal direction is located at the ignition end 14. A typical heat generating segment 24 includes a heat source or fuel element 27 coaxially surrounded by an insulator 30, which is in turn coaxially surrounded by a packaging material 35. Heat source 27 is preferably configured to operate by direct ignition of ignition end 14. That is, the heat source or fuel element is designed to generate heat by being ignited and burned. Preferably, the fuel element incorporates a combustible carbonaceous material (e.g., a material consisting primarily of carbon), and most preferably, the fuel element mainly comprises a carbonaceous material. Preferably, the insulator is provided in the form of a non-woven mat of glass filaments.

  Preferably, the packaging material 35 surrounding the insulator 30 comprises J. A paper packaging material such as a paper packaging material of the type used as a surrounding packaging material for the insulator region of the heat source segment of a cigarette sold under the trade name "Eclipse" by Reynolds Tobacco Company. Alternatively, the packaging material 35 may be a R.D. J. A cigarette-containing paper of the type used as a layer in the insulator region of the heat source segment of a cigarette sold under the trade name "Eclipse" by the Reynolds Tobacco Company; J. Wrinkled tobacco paper segment of cigarette sold under the trade name "Premier" by Reynolds Tobacco Company, or Lawson et al., U.S. Patent No. 5,065,776 and Arzonico et al., No. 5, incorporated herein by reference. , 271 419, in the form of tobacco-containing paper or reconstituted tobacco paper material.

  Preferably, each end of the heat generating segment 24 is open to expose each end of the fuel element 27 and the insulator 30. In this way, the drawn air can easily pass through it. The fuel element 27 and the surrounding insulator 30 are coextensive in both lengths (i.e., the ends of the insulator are coplanar with the corresponding ends of the fuel element; At the downstream end of the segment). Optionally, insulator 30 may extend slightly beyond one or both ends of fuel element 27 (e.g., from about 0.5 mm to about 2 mm).

  The cross-sectional shape and dimensions of the heat-generating segment 24 before combustion can vary. Preferably, the cross-sectional area of the fuel element 27 accounts for about 10 percent to about 35 percent, often about 15 percent to about 25 percent of the total cross-sectional area of the segment, while the cross-sectional area of the outer or surrounding area (insulating (Including body 30 and associated outer wrapping material) occupy about 65 percent to about 90 percent, and often about 75 percent to about 85 percent, of the total cross-sectional area of the segment. For example, for a cylindrical smoking article 10 having an outer circumference of about 24 mm to about 26 mm, a typical fuel element 27 has an outer diameter of about 2.5 mm to about 5 mm, often about 3 mm to about 4.5 mm. It has a substantially circular cross-sectional shape.

  The smoking article 10 also has a mouth end 38 at the extreme opposite the ignition end 14, which is considered to be downstream of the ignition end. At the mouth end 38 a filter segment 40 is located. Typical filter segment 40 is in many respects equivalent to the type of filter element typically used in cigarette manufacture, and may be a single segment filter element or a multi-segment filter element. For illustrative purposes only, the filter segment 40 comprises an upstream piece 42 consisting of a cylindrical plug of filter material 44 (eg, plasticized cellulose acetate tow) surrounded by an outer plug wrap 45 (eg, a paper plug wrap); A two-piece segment having a downstream piece 47 comprising a tubular filter plug 48 (eg, a hardened tube of plasticized cellulose acetate tow). The filter pieces 42, 47 are combined to form a filter segment 40 using a plug wrap 49 surrounding the outer longitudinal surfaces of both pieces.

  An aerosol-generating segment 55 consisting of a plurality of pellets or beads or other suitable elements or combinations thereof 58 coaxially surrounded by a generally tubular heat-conducting member 60 is located directly below the heat-generating segment 24. The overall configuration of the aerosol-generating segment 55 within the smoking article 10 may be considered to be substantially cylindrical in nature. Exemplary preferred beads 58 are formed from a formulation that incorporates tobacco, tobacco components, and / or otherwise tobacco-derived materials. Beads 58 most preferably incorporate a flavoring agent and a visible aerosol-forming material (e.g., glycerin or other material that produces visible vapors similar to smoke). That is, the components of the beads 58 are preferably configured to serve as substrate components for the volatile flavorants, vapor-forming materials, and aerosol-forming materials carried thereby. In other aspects, some or all of the beads or pellets may be spherical capsules loaded into the aerosol-generating segment, such that they burst when heated to release glycerin and tobacco flavor and / or nicotine. , May be heat-sensitive. Also, in some aspects, the beads may be comprised of, for example, alumina, absorbent clay, silica, and / or absorbent carbon to retain and release the aerosol former.

  The heat generating segment 24 and the aerosol generating segment 55 are considered to be physically separate from each other, and for the embodiment shown, these segments are such that the downstream end of the heat generating segment is the upstream end of the aerosol generating segment (ie, , Abutting against the back of the fuel element 27 and the surrounding insulator 30). That is, the heat generating segment 24 and the aerosol generating segment 55 are axially aligned in a continuous end-to-end relationship, and most preferably abut each other. For example, even though some of the pellets 58 are physically separated and positioned downstream of the heat generating segment 24, it is highly preferred that they be in physical contact with the downstream internal surface or front of the heat generating segment. Alternatively, the segments 24, 55 may be slightly spaced from each other such that each of the opposite ends of each segment does not necessarily have to make physical contact with the other, and in such a situation, the smoking article 10 An additional segment or spacer element, which is positioned substantially perpendicular to the longitudinal axis and acts as a spacer or screen (not shown, for example, see element 134 in FIG. 7) provides physical separation of these two segments. At the same time, the heat conduction relationship can be maintained. That is, the spacer elements 134 may preferably be thermally conductive and / or may be arranged to conduct heat from the heat generating segment 24 to the aerosol generating segment 55.

  The longitudinally extending outer surface of the aerosol-generating segment 55 is constructed from a layer of thermally conductive material 60 (eg, a layer or strip of metal foil). That is, a representative aerosol-generating segment 55 carries a plurality of pellets and / or other suitable elements 58 that are surrounded along its length by a layer of a strip of metal foil 60. A typical metal foil is, for example, an aluminum foil having a thickness of about 0.01 mm to about 0.05 mm. Preferably, the metal foil 60 extends along the entire length of the outer coaxial surface of the aerosol-generating segment 55 such that the metal foil is in a region of the heat-generating segment 24 adjacent to the aerosol-generating segment 55. It also preferably extends on the outer coaxial surface 63 (including the optional spacer element 134) (ie, at least partially overlaps).

  Immediately below the aerosol-generating segment 55 (and directly above the filter segment 40), the cigarette segment 68 or the smoking article 10 is provided with length and structure while either providing a flavor during use or otherwise providing a smoking article. Other types of segments are located which serve to enhance the sensory properties imparted by. For the embodiment shown, the tobacco segment 68 is considered to be physically separate from the aerosol-generating segment 55 and also from the filter segment 40, and for the embodiment shown these are the aerosol-generating segments Of the tobacco segment abuts the upstream end of the tobacco segment, and the downstream end of the tobacco segment abuts the upstream end of the filter segment. The exemplary tobacco segment 68 carries a roll of filling or tobacco filler 72 wound in an enclosing paper wrapping material 76, and thus has the general form of a tobacco rod. In some aspects, up to about 10.5 mg of menthol can be added to the tobacco in the tobacco rod, or to the tobacco segment 68. However, in other embodiments, it may be preferable to add any flavoring agents or other functional enhancers to the aerosol-generating segment 55.

  For the embodiment shown, there are four segments, namely the heat generating segment 24, the aerosol generating segment 55, the tobacco rod segment 68, and the filter segment 40, each of which is arranged in an abutting end-to-end relationship. Each of the segments is generally cylindrical and each segment is open at each end so that air can easily flow through these segments (i.e., Can enter the upstream end 14 and exit the downstream end 38).

  The heat-generating segment 24, the aerosol-generating segment 55, and the tobacco segment 68 are positioned end-to-end sequentially and have three physically separate but substantially abutting cylindrical segments (and, for example, If an optional spacer element (not shown, see for example element 134 in FIG. 7) is implemented between the back or downstream area of the heat generating segment and the front or upstream area of the aerosol generating segment, Are arranged to have the shape of a substantially cylindrical rod carrying any additional cylindrical segments. These three upstream segments are then superimposed on their corresponding outer coaxial surfaces with the outer wrapper (ie, paper sheet) 80. Thus, an upstream composite rod 84 is provided as a result of the combination of the three upstream segments (see, for example, FIG. 9). Although not shown, at least a portion of the area of the outer wrapping material 80 covering the heat generating segment 24 may be perforated or otherwise relatively permeable to air for transmission of air therethrough. Or provided in a highly porous form, in this manner providing an enhanced atmospheric source for combustion of the fuel element.

  The upstream composite rod 84 physically connects to the filter segment 40. For the embodiment shown, a layer of tipping material 88 (eg, tipping paper) surrounds the outer peripheral surface of filter segment 40 and the adjacent area of outer wrapping material 80 of composite rod 84 (ie, at least a portion of composite rod 84). (See also FIG. 12). Optional air dilution holes 92 may be provided through selected areas of the tipping material 88, the outer wrapping material 80 below the tobacco rod 68 and the wrapping material 76 below. In some aspects, the air dilution holes 92 may be configured to provide, for example, about 24% air dilution.

  In use, the mouth end 38 of the smoking article 10 is inserted into the smoker's mouth. The fuel element 27 located at the ignition end 14 of the smoking article 10 is ignited (eg, using a lighter) to generate heat by burning the fuel element. The fuel element 27 and the aerosol generating segment 55 are configured to be in a heat exchange relationship. That is, the heat generated by the combustion of the fuel element 27 acts to heat beads or other elements 58 located in or near the aerosol-generating segment 55. In addition, the heat resulting from the combustion of the fuel element 27 is transferred to a thermally conductive layer 60 surrounding the length of the aerosol-generating segment 55, thus heating the beads 58 located within the aerosol-generating segment. When a smoker inhales the mouth end 38 of the smoking article 10, air enters the igniting end 14 of the smoking article 10, is heated by the fuel element 27, and the hot air passes through the aerosol generation area 55, causing the air to flow into the aerosol generation area 55. Heat the beads. The drawn air also passes through tobacco rod segment 68, exits filter element 40, and enters the smoker's mouth. During smoking, the flavored aerosol generated from the action of heat on the components of the aerosol generating segment 55 and the components of the tobacco rod 68 is drawn into the smoker's mouth. That is, the smoking article described with reference to FIG. J. It can be used in much the same way as cigarettes sold commercially under the trade name "Eclipse" by Reynolds Tobacco Company and "Steam Hot One" by Japan Tobacco Inc. As a result, when smoking, a highly preferred smoking article 10 provides a flavored, visible mainstream aerosol primarily arising from the volatile components of the aerosol-generating segment 55 and the tobacco rod segment 68, wherein the visible aerosol is a tobacco cut filler. The traditional type of burning cigarettes resembles the mainstream tobacco smoke in many ways.

  The aerosol generated by smoking article 10 includes air-containing components such as vapors, gases, suspended particles, and the like. The aerosol component may include some form of tobacco (and optionally, for example, when the tobacco is incorporated into the fuel element 27 or as a component in the insulator 30 or the surrounding package 35). Burning the other components that burn to generate heat, heating the tobacco, and charring the tobacco (or otherwise, for example, tobacco beads in physical contact with the burning fuel element 27) This can occur by pyrolysis of the tobacco caused by causing some form of smoldering of the tobacco, such as when 58 is heated, and by vaporizing the aerosol-forming material. As such, the aerosol may contain volatile components, combustion products (eg, carbon dioxide and water), incomplete combustion products, and products of pyrolysis. Preferably, the levels of incomplete combustion products and products of pyrolysis are very low compared to the levels characteristic of tobacco products that produce smoke by burning tobacco cut filler. However, the aerosol component is most preferably formed by the action of heat from burning the combustion element (and, optionally, other components that burn and generate heat) on the materials located in a heat exchange relationship. May be generated. That is, the aerosol is generated as a result of the action of the heat generating segment on the components of the aerosol generating segment. Preferably, the components of the aerosol-generating segment have a tendency for these components to undergo a significant degree of pyrolysis (eg, as a result of combustion, smoldering, or pyrolysis) during normal use conditions of the smoking article. Having the overall composition, without having to be positioned within the smoking article.

  The overall dimensions of smoking article 10 before ignition for use can vary. Typically, typical smoking articles are cylindrical rods having an outer circumference of about 24 mm to about 27 mm, and have a total length of about 70 mm to about 120 mm, often about 80 mm to about 100 mm. A typical heat generating segment 24 typically has a length of up to about 30 mm, often up to about 20 mm, frequently about 10 mm to about 15 mm. The aerosol-generating segment 55 typically has a length of up to about 30 mm, often up to about 25 mm, frequently about 10 mm to about 20 mm. Frequently, the length of each of the 68 segments of the tobacco rod and 40 segments of the filter element can vary as desired. For example, a typical tobacco rod segment 68 has an overall length of about 20 mm to about 50 mm, often about 30 mm to about 40 mm, and a typical filter segment 40 has a total length of about 10 mm to about 35 mm, often It has a length of about 20 mm to about 30 mm.

  For purposes of example, a representative smoking article 10 has a length of about 83 mm and an outer diameter of about 25 mm. Such a cigarette 10 comprises a cylindrical heat generating segment 24 having a length of about 12 mm, a cylindrical aerosol generating segment 55 comprising a plurality of beads 58 and having a length of about 13 mm, a tobacco having a length of about 37 mm. It has a rod segment 68 and a filter segment 40 having a length of about 21 mm. The filter segment 40 comprises an upstream piece 42 consisting of a cylindrical plug of plasticized cellulose acetate tow having a length of about 10 mm and a downstream part 47 consisting of a steam-bonded plasticized cellulose acetate tube having a length of about 11 mm. Is a two-piece construction. The cigarette upstream composite rod 84 is constructed using a 62 mm long outer wrapping material 80 having a width of about 27 mm and is wound such that there is a wrap seam of about 2 mm. A layer or patch of metal foil 60 having a thickness of about 0.04 mm, a length of about 17 mm, and a width of about 25 mm is formed by the length of the aerosol generating segment 55 and the adjacent downstream region of the heat generating segment 24 of about 4 mm. Extending over the length of. The aerosol-generating segment 55 has the form of a generally cylindrical hollow cavity 57 into which about 120 to about 150 substantially spherical beads 58 having an average or nominal diameter of about 0.5 mm to about 2 mm. An accumulation of (eg, about 130 substantially spherical beads having a nominal diameter of 1.5 mm) is located. For example, a plurality of beads 58 weighing about 300 mg to about 400 mg (preferably about 335 mg to about 350 mg) may be positioned within a cavity 57 designed to provide the aerosol generating segment. Preferably, sufficient beads are loaded into the cavity 57 of the aerosol-generating segment to fill the beads or other suitable element 58 with at least about 65 percent of the maximum filling of the cavity, in some cases at least It provides about 75 percent fill, in other examples at least about 85 percent fill, and in some situations, at least about 95 percent. Filter segment 40 uses 30-40 gsm of surrounding standard chipping paper surrounding the outer longitudinal surface of the filter segment and overlapping an adjacent 10 mm area of outer wrapping material 80 over tobacco rod segment 68. Then, it is attached to the upstream composite rod 84. The circumscribed ring of each air dilution hole 92 is located about 15 mm from the cigarette tip 38.

  Referring to FIG. 2, an enlarged cross-sectional view of an aerosol-generating segment 55 of a smoking article 10 of the type previously described with reference to line 2-2 of FIG. 1 is shown. That is, a preferred arrangement of a thermally conductive metal foil or foil strip 60 wrapping the outer longitudinally extending surface of the aerosol-generating segment 55 and the outer wrapping material 80 over that segment of the smoking article is shown. A plurality of beads or other suitable elements 58 are located within an inner longitudinally extending tubular cavity 57 defined by an array of metal foils 60. A typical foil has a thickness of about 0.02 mm. For the embodiment shown, the metal foil 60 is formed in a substantially circular shape such that each laterally extending end abuts the other. For example, they may abut each other (as shown in FIG. 2) or almost abut each other (so that a small gap or void is present between these two side ends). , One of the lateral ends may slightly overlap the other, or the lateral ends may be otherwise aligned with one another. In some preferred examples, the lateral ends of the metal foil 60 may be associated in an abutting or almost abutting relationship, but the lateral ends are not necessarily joined, welded, glued, or fixed together. No need to be done

The laterally extending end of the outer wrapping material (i.e., the elongated paper sheet) 80 may be wrapped or overlapped by one side end portion of the outer wrapping material overlapping the opposite side end portion. 95 are arranged. A preferred adhesive material secures these lateral end portions together so that the outer wrapping material is secured in a generally tubular manner around the thermally conductive foil 60 of the heat generating segment 55 such that the overlap zone 98 is secured. Is applied to the area. An exemplary lap seam adhesive material is provided as an adhesive formulation available from Henkel Corporation as Code 2010-57. For purposes of example, a typical outer wrapping material is a wrapping paper made of wood pulp and calcium carbonate treated with sodium citrate and potassium citrate, which has a basis weight of about 50 g / m ² , Delfort Group Specialty Papers Inc. To Item I. D. Available as 20008033. In addition, for purposes of example, metal foil 60 and outer wrapping material 80 typically use a coating of a suitable adhesive material (e.g., an adhesive formulation available from Henkel Corporation as Code 32-220B). And bonded or laminated together.

  Referring to FIG. 3, there is shown a view of a portion of a continuous web of packaging material or paper sheet 80 used to provide the outer packaging of the preferred upstream composite rod previously described with reference to FIG. 1 ( See also FIG. 8). Since a typical continuous web 80, which may be provided as a tape-like strip from a bobbin or other suitable source, has a width of about 27 mm, the web is cylindrical with an outer diameter of about 25 mm and an overlapping seam of about 2 mm Designed to provide a rod. A series of patches or strips of a thermally conductive strip, such as a metal foil 60, are positioned along the web 80 in a staggered, but fixed, predetermined interval. Each foil patch or strip 60 extends along the length of the web approximately a distance corresponding to the distance that the foil extends along the length of the aerosol-generating segment, and along at least a portion of the length of the heat-generating segment. , And in some instances, extends (optionally) along at least a portion of the length of the tobacco rod segment. That is, the foil patch or strip 60 extends longitudinally along the wrapping material 80 by the length of the aerosol generating segment 55 and at least partially overlaps the heat generating segment 24. In some examples, the foil patch or strip 60 may also extend longitudinally and at least partially overlap the tobacco rod segment 68. If desired, although not shown, areas of the web 80 corresponding to areas of the location of the various heat generating segments are perforated or otherwise made porous or permeable to allow passage of air therethrough. Can be enhanced. The first distance f of separation between two adjacent foil patches or strips 60 is determined by the sum of the lengths of the two heat generating segments, each heat generating segment being covered by each respective foil patch or strip. Or it corresponds to the product minus twice the overlapping length. Thus, for example, in the case of a two-up heat-generating segment having a length of 24 mm (ie, two heat-generating segments each 12 mm long) with each downstream end having a 4 mm metal foil overlap, two adjacent segments The distance f of the separation of the foil patch is 16 mm. The second distance t of separation between two adjacent foil patches corresponds to the sum of the lengths of the two tobacco rod segments. Thus, for example, for a two-up tobacco rod segment having a length of 74 mm (ie, two tobacco rods each having a length of 37 mm), the separation distance t of two adjacent foil patches is 74 mm and the spacing t Is reduced accordingly if a portion of the foil patch or strip covers or overlaps an adjacent area of the tobacco rod segment. Thus, the spacing of adjacent patches or strips along the length of the continuous web is a staggered alternating pattern of f, t, f, t, f, t (and so forth). As a result, the metal foil strips or patches 60 are located on the continuous web 80 in a staggered but constant repeating pattern, and most preferably, the metal foil patches or strips are each patch corresponding to the corresponding aerosol of the smoking article. Positioned and aligned in a predetermined manner to align with the location of the originating segment. In addition, the representative foil patches each have a width of about 25 mm and, as shown by the distance s, do not laterally cover the area of the web 80 intended to provide overlapping seams. Be positioned. Light monitoring devices and / or other monitoring devices may be included within or with the assembly machine, and during assembly of the smoking article, other smoking article components (eg, heating elements / heat generating segments and tobacco rods / It can be incorporated into the operation to maintain precise alignment / alignment of the foil patch / strip with the tobacco rod segment).

  Referring to FIG. 4, a portion of a continuous rod 105 consisting of a series of two-up upstream composite rods 108 is shown. A continuous series of two-up heat generation segment 110, aerosol generation segment 55, two-up tobacco rod segment 115, and aerosol generation segment 55 are shown. Each two-up heat generating segment 110 is then cut in half, perpendicular or horizontal to its longitudinal axis, along line 5-5 as shown. Thus, a continuous pattern of intermediate two-up heat source segments 110 and intermediate two-up tobacco rod segments 115 is arranged on a continuous web of outer wrapping material 80 for each aerosol-generating segment 55 defined by a metal foil patch or strip. There is also a continuous web of outer wrapping material that carries segments of such metal foil 60 in spaced apart, pre-selected areas along the length of outer wrapping material 80, each defining a location of an aerosol-generating segment 55. Provided.

  The positioning of such foil strips or segments 60 on a continuous web or sheet of paper is offset in a predetermined patterning relationship. That is, for the embodiment shown, the distance separating one end of the foil segment 60 from the opposite end 60 of the adjacent foil segment is equal to the length of the two-up tobacco rod 115 while the foil segment The distance separating the other end of 60 from the other adjacent foil segment 60 is equal to the length of the two-up heat source segment 110 minus the overlap at each end of that segment 110. Thus, for example, for continuous webs used in the manufacture of a series of continuous two-up rods, two-up tobacco rods, foil strips, two-up heat generating segments, foil strips, two-up tobacco rods, foil strips, two-up A continuous arrangement of heat generating segments, foil strips, and so on, on the web is provided.

  The continuous web or elongate paper sheet 80 is formed to overlap the various segments and create a type of hollow longitudinally extending cavity 57 in the area 120 defined by the location of the foil strip 60. That is, the outer wrapping material 80 is at most partially wrapped around the heat generating segment 24 and the tobacco rod segment 68 (i.e., so as to form an elongated "U" channel) therein, and is adjacent thereto. One or more spaced cavities may be defined by the cooperation of the heat generating segment 24 and the tobacco rod segment 68 with the thermally conductive strip 60 disposed therebetween. Such partial wrapping may be achieved, for example, by an assembly mechanism, which biases the outer wrapping material 80 against the corresponding perimeter of the heat generating segment 24 and the tobacco rod segment 68 engaged therewith, and partially coincides with the perimeter. Can be provided. Prior to providing complete overlap of the continuous rod thus formed, a predetermined amount of beads or other suitable elements 58 may be provided between adjacent heat generating segments 24 and tobacco rod segments 68 and between them. Disposed in each cavity 57 defined by cooperation with the disposed thermally conductive strip 60. Thus, sealing the continuous rod 105 forms each fully manufactured aerosol-generating segment 55.

  Accordingly, such aspects of the present disclosure provide a method and apparatus for forming the disclosed smoking article, wherein a plurality of aerosol-generating elements are provided for delivery to and incorporation into the smoking article. Incorporating a plurality of individual aerosol-generating elements into a smoking article, without necessarily needing to be carried by a carrier member in a coherent form or to maintain the plurality of aerosol-generating elements in a coherent form Enable. However, those skilled in the art will appreciate that incorporation of multiple aerosol-generating elements in a bundled form with or without a carrier member may be implemented as a further aspect of the present disclosure. Further, such aspects of the devices and methods of the present disclosure may include, for example, pre-forming the cylindrical member from the outer wrapping material, and then incorporating various components, including individual aerosol-generating elements, into a suitable length within the smoking article. The directional positioning avoids the complications associated with longitudinally inserting the end of the cylindrical member. The plurality of aerosol-generating elements can be inserted directly into the cavity 57 located at a suitable location along the length of the outer wrapping material, and upon insertion, carefully positioned heat-generating segments (and optional spacer elements) ) And suitably supported by the tobacco rod segments, a faster manufacturing process may be achieved (ie, the smoking article may, for example, include any of the components in its outer wrapping material when formed, with its longitudinal Can be manufactured "in-line" or in a single orientation (i.e., horizontal orientation) without changing its orientation, for introduction through one of the directional ends), as well as thermally conductive strips / foil, etc. Greater efficiency, accuracy, and precision in bringing various other components of the smoking article into engagement with the outer packaging material may also be achieved. In this way, significant cost savings can also be realized.

  The manner in which typical smoking articles are manufactured can vary. The web or bobbin of packaging material can be manufactured and supplied using known techniques. Various patches or strips of metal foil or suitable thermally conductive strips may also be manufactured and supplied using known techniques. The foil patch or strip can be applied to a predetermined location on the continuous web of packaging material using equipment such as that supplied by Montrade Srl and Strouse Corporation. The various segments of the upstream composite rod may be arranged in place on the continuous web using equipment such as those available from Hauni Maschinenbau AG as Merlin and from Montrade as Combi. The various cavities created along the continuous partially formed rod may then be filled with pellets, beads, flakes, fillers, or other suitable elements, or a combination thereof. Filling the various cavities with the material that provides the aerosol-forming component can be performed by pneumatic equipment, or other means to provide dripping or lowering of these cavities with the desired material or suitable elements or to provide gravity-promoting filling. It can be achieved using any suitable means. The partially sealed continuous rod thus formed is then conveyed to a rod forming unit (e.g., a device of the type commonly used in the tobacco industry for the production of continuous filter rods) and the foil strip Seal 60 and / or continuous web 80 to form a continuous rod consisting of a repeating pattern of composite rods.

  Referring to FIG. 5 (also see FIG. 10), the continuous rod shown in FIG. 4 is cut at regular intervals past the center of each two-up heat generating segment (eg, each two-up heat generating segment of the continuous rod). Is cut at its longitudinal center). An exemplary two-up upstream composite rod 108 is shown. Such composite rods 108 are provided as a series of two-up upstream composite rods, each having a central two-up tobacco rod 115 and a heat generating segment 24 at each end (ie, the inner segment of the two-up tobacco rod is (Configured as two intermediate segments joined together as a common tobacco rod). Such a two-up upstream composite rod may facilitate handling during manufacture of a smoking article. For example, a two-up rod can be processed using standard types of cigarette component processing and manufacturing equipment. Each two-up upstream composite rod is then cut in half perpendicular to its longitudinal axis (i.e., at the location defined by line 5-5 in FIG. 5 and line 10-10 in FIG. 10). (Through rods) to provide two separate upstream composite rods.

  Referring to FIG. 6 (also see FIG. 11), a representative two-up filter cigarette 120 provided by positioning an upstream composite rod 84 at each end of the two-up filter segment 130 is shown. Each upstream composite rod is attached to each end of the two-up filter segment using tipping material to provide a two-up filter cigarette (i.e., having a configuration of two intermediate filter segments joined together). Two intermediate cigarettes) joined together by a common filter segment. Subsequently, each cigarette with the two-up filter is cut in half perpendicular to its longitudinal axis (ie, at the location defined by line 6-6 in FIG. 6 and line 11-11 in FIG. 11). Provide two final filtered cigarettes (through the up-filter element) (see, eg, FIG. 12).

  Referring to FIG. 7, there is shown a smoking article 10 generally similar to that previously shown with reference to FIG. Smoking article 10 carries a thermally conductive layer (ie, foil strip 60) that provides an outer coaxial surface of aerosol-generating segment 55. The heat conducting layer 60 also covers an optional spacer segment 134 located between the heat generating segment 24 and a plurality of beads or other suitable elements 58 of the aerosol generating segment 55. Typically, the spacer segments 134 are generally cylindrical in shape, have a one-piece configuration, and are breathable to allow the drawn air to pass through. Most preferably, the spacer segments 134 are thermally conductive such that heat generated by the combustion of the fuel element 27 is easily conducted to the aerosol generation region 55. The length of the spacer segment can vary, and the segment extends from about 5 mm to about 10 mm along the length of the upstream composite rod 84. Typically, the spacer segments 134 comprise a refractory material, such as a porous ceramic, a porous graphite material, a metal mesh or screen, a high temperature resistant plastic, or the like. In some examples, the spacer elements 134 may include, for example, longitudinally extending air passages that are formed during, drilled through, or otherwise designed during design / manufacturing. During its manufacture, the spacer element is molded, extruded or molded. If desired, spacer segments 134 may incorporate a catalytic material, such as a material that incorporates cerium or copper ions or oxides, and / or salts of cerium and copper ions. See, for example, Banerjee et al., U.S. Patent No. 8,469,035, and Banerjee et al., U.S. Patent Application Publication No. 2007/0215168 and Banerjee et al. I want to.

  The thermally conductive layer or foil strip 60 surrounds (and at least partially longitudinally overlaps) the outer longitudinally extending surface of the heat generating segment 24 in its area 138 adjacent to the aerosol generating segment. Thermally conductive layer 60 also surrounds (and at least partially longitudinally overlaps) the outer longitudinally extending surface of tobacco rod 68 in its region 140 adjacent aerosol-generating segment 55. For example, the heat conducting layer 60 may extend or overlap about 2 mm to about 6 mm above the downstream longitudinal surface of the heat generating segment 24, and the heat conducting layer may extend upstream of the tobacco rod segment 68. It may extend up to about 10 mm above the surface or may overlap.

  The filter element 40 is positioned at one end of the upstream composite rod 84 adjacent one end of the tobacco rod segment 68 such that these segments are axially aligned in an end-to-end relationship, abutting each other and between them. A one-piece segment that eliminates any barriers. Preferably, the overall cross-sectional shape and dimensions of these aligned segments 24, 55, 134, 68 are essentially identical to one another when viewed in an end view perpendicular to the longitudinal axis of the smoking article 10. , These segments are surrounded by a layer of outer packaging material 80. A series of holes 150 are provided in the area of the outer wrapping material 80 that covers the heat generating segment 55 (eg, that area of the outer wrapping material is perforated with, for example, a series of electrostatic perforations, mechanical punches, or laser perforations). ), Thereby providing a porous outer wrap around the heat-generating area to allow passage of air through the longitudinally extending area of the heat-generating segment. The filter element carries a filter material 44 that surrounds the plug wrap material 45 along its longitudinally extending surface. The cigarette can be air diluted by incorporating a circumscribed ring of holes 92 through the tipping material 88 and the plug wrap 45 of the filter element. In one example, filter material 44 includes plasticized cellulose acetate tow. Both ends of the filter element 40 are open to allow the passage of drawn air therethrough. Such cigarettes can be assembled by suitable modifications of the materials and techniques described above with reference to FIGS.

  The components of the heat generating segment can vary. One component of the heat generating segment is the fuel element. Suitable heat generating segments and their associated fuel elements, as well as representative components, designs and configurations thereof, as well as modes and methods for producing these heat generating segments and their components, are hereby incorporated by reference. U.S. Patent Nos. 4,714,082 to Banerjee et al., 4,756,318 to Clearman et al., 4,881,556 to Clearman et al., And 4,989 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., And 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., Shannon et al. No. 5,211,684, Clearman et al., No. 5,247,947, Clearman et al., No. 5,345,955, Barnes et al., No. 5,469,871, and Riggs No. 5,469,871. No. 5,551,451, Meiring et al., No. 5,560,376, Meiring et al., No. 5,706,834, Meiring et al., No. 5,727,571, Borschke et al. No. 836,897, Banerjee et al., No. 8,119,555, and Banerjee et al., No. 8,469,035, Baner. U.S. Patent Application Publication No. 2005/0274390 to ee et al., 2007/0215167 to Crooks et al., and 2007/0215168 to Banerjee et al., and U.S. Patent Application No. 13 / 448,835 to Stonee et al. No. 14 / 036,536 to Conner et al. Other exemplary types of heat generating segments and associated fuel elements are described in US Pat. No. 4,819,655 to Roberts et al. Or US Patent Application Publication No. 2009 / No. 0044818.

  Typically, preferred fuel elements include high carbon content flammable carbonaceous materials and may also include components such as graphite or alumina. A typical carbonaceous fuel element is J. Structure and composition of fuel elements of the type incorporated in cigarettes commercially sold under the trade names "Premier" and "Eclipse" by Reynolds Tobacco Company and "Steam Hot One" by Japan Tobacco Inc. Can hold component types.

  The heat generating segment most preferably carries a fuel element that is surrounded or otherwise coated by an insulator (eg, a nonwoven mat or a layer of glass filaments or glass fibers), or other suitable material. The insulator may also be provided in a multilayer configuration including, for example, an inner layer of the insulator, an intermediate layer of reconstituted tobacco paper, and an outer layer of the insulator. The insulator may be configured and used to support, maintain, and hold the fuel element in place within the smoking article. Preferably, the cylindrical fuel element is oriented concentrically and overlaps the insulator along its longitudinally extending surface. Insulator material, components of the insulator assembly, configuration of a representative insulator assembly in the heat generating segment, packaging material for the insulator assembly, and for producing these components and assemblies Examples of formats and methods are described in US Pat. Nos. 4,807,809 to Pryor et al., 4,893,637 to Hancock et al., And 4,938, Barnes et al., Which are incorporated herein by reference. No. 238, No. 5,027,836 to Shannon et al., No. 5,065,776 to Lawson et al., No. 5,105,838 to White et al., No. 5,119,837 to Banerjee et al. No. 5,247,947 to Clearman et al., No. 5,303,720 to Banerjee et al., No. 5,345,955 to Clearman et al., Cas. 5,396,911 to White, 5,546,965 to White, 5,727,571 to Meiring, et al., 5,902,431 to Wilkinson, et al., Cook. No. 5,944,025, Thomas et al., No. 8,424,538, and Sebastian et al., No. 8,464,726; Stonee et al., U.S. Patent Application Publication No. 2012/0042885; Conner et al. In US patent application Ser. No. 14 / 036,536. The insulator assembly is a R.R. J. Within the heat generating segment of a type of cigarette commercially sold by Reynolds Tobacco Company under the trade names "Premier" and "Eclipse" and sold by Japan Tobacco Inc. as "Steam Hot One" cigarettes Built in.

  The components of the aerosol generation segment can vary. The aerosol-generating segment incorporates components that can be vaporized, aerosolized, or entrained in air that is drawn through the smoking article during use. Most preferably, these components provide organoleptic and organoleptic effects, such as aroma, flavor, mouthfeel, perception of visible aerosol, and the like. Examples of aerosol-generating segment components that are drawn into the smoker's mouth while inhaling include water (eg, as water vapor), visible aerosol-forming materials (eg, glycerin), various volatile flavoring agents (eg, Vanillin and menthol), the volatile constituents of tobacco (eg, nicotine) and the like.

  Preferred aerosol-forming materials produce a visible aerosol when they are provided with sufficient heat or by the effect of aerosol-forming conditions using components of a smoking article. Highly preferred aerosol-forming materials produce visible aerosols that can be considered "smoke-like". Preferred aerosol-forming materials are chemically simple compared to the chemistry 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 can be combined with other liquid materials, such as water. For example, the aerosol-forming material formulation may incorporate a mixture of glycerin and water, or a mixture of propylene glycol and water. See, for example, the various aerosol-forming materials referenced in Crooks et al., U.S. Patent Application Publication No. 2010/0186575, which is incorporated herein by reference.

  The aerosol-forming material is carried or supported by a substrate so as to maintain these aerosol materials in the desired area of the smoking article. Exemplary base materials, and exemplary formulations that incorporate aerosol-forming materials, are described in US Pat. No. 4,793,365 to Sensabaugh et al., And US Pat. No. 4,893 to White, incorporated herein by reference. No. 5,099,861 to Clearman et al., US Pat. No. 5,101,839 to Jakob et al., US Pat. No. 5,105,836 to Gentry et al., US Pat. U.S. Patent No. 5,203,355 to Clearman et al., U.S. Patent No. 5,271,419 to Arzonico et al., U.S. Patent No. 5,327,917 to Lekwawa et al. U.S. Patent No. 5,396,911; Young et al. U.S. Patent No. 5,533,530; Clear. U.S. Patent No. 5,588,446, Jakob et al., U.S. Patent No. 5,598,868, and Young et al., U.S. Patent No. 5,715,844, and Nestor et al., U.S. Patent Application Publication No. 2005/2005. 0066986. Chemical and Biological Studies on New Cigarette Prototypes that Heat Indirect of Burn Tobacco, R.C. J. See also Reynolds Tobacco Company Monograph (1988). Exemplary substrate materials include those described in J. It is incorporated into cigarettes of the type sold commercially under the trade names "Premier" and "Eclipse" by Reynolds Tobacco Company.

  As used herein, the terms “pellet” and “bead” are used to refer to carbon pieces, extruded carbon pieces cut into pellets, alumina beads, marumized tobacco pieces, etc., or a combination thereof. Is meant to include beads, pellets, or other discrete small units or pieces thereof. For example, pellets or beads are formed, cut, or spun into the desired size and shape, and then dried to retain the desired configuration, ground tobacco slats, fillers (eg, particulate calcium carbonate), flavors. It can be a generally cylindrical or spherical extruded or compressed pellet or bead of a wet mixture or slurry of an agent, a visible aerosol-forming material, and a binder (eg, carboxymethylcellulose). However, such "pellets" or "beads" may include any suitable element or combination of elements, thereby satisfying the preferred embodiments disclosed herein. For example, some or all of the beads or pellets may be thermosensitive, such that when deposited in the cavity and exposed to heat, their rupture releases glycerin and tobacco flavor and / or nicotine. It may include a spherical capsule. Also, the beads may be composed of alumina, or absorbent clay, or silica, or absorbent carbon, and may retain and release the aerosol-forming agent. Further, in some embodiments, the beads / pellets may be made of a suitable aerosol-generating material such as, for example, thermally conductive graphite, thermally conductive ceramic, metal, tobacco cast on foil, glycerin, and flavoring agent (s). , Or a thermally conductive material such as a suitable cast sheet suitably formed into the desired beads / pellets. In one particular example, the beads / pellets (particles) are from about 15% to about 60% finely divided tobacco (eg, a blend of oriental, burley, and yellow tobacco, or essentially all yellow tobacco). About 15% to about 60% calcium carbonate finely divided particles (or finely divided clay or alumina particles), about 10% to about 50% glycerol (and optionally small amounts of flavoring agents), about 0.25% To about 15% of a binder (preferably, carboxymethylcellulose, guar gum, potassium, or ammonium alginate), and about 15% to about 50% water. In another example, beads / pellets (particles), about 30% finely divided tobacco (eg, a blend of oriental, burley, and yellow tobacco, or essentially all yellow tobacco), about 30% carbonated tobacco Finely divided particles of calcium (or finely divided clay or alumina particles), about 15% glycerol (and optionally small amounts of flavoring agents), about 1% binder (preferably carboxymethylcellulose, guar gum, potassium, or alginic acid) Ammonium), and about 25% water. In such an example, the particles may be compressed to retain and release the glycerol, and upon compression, form a porous matrix that facilitates movement of the aerosol-generating component and facilitates efficient aerosol formation. Calcium carbonate or other inorganic fillers assist in creating porosity within the particles and may also function to absorb heat, which in some cases, limits the scorching of the aerosol generating component Or may prevent it, and may assist and facilitate aerosol formation. For example, U.S. Patent Nos. 5,105,831 to Banerjee et al. And U.S. Patent Application Publication No. 2004/01732329 to Crooks et al., 2011/02711971 to Conner et al., And Stone, incorporated herein by reference. See also materials of the type described in U.S. Patent No. 2012/0042885.

  In some aspects, if the aerosol-generating element includes, for example, beads or pellets cast from or extruded from the various types of materials described above (ie, graphite beads including tobacco extract and glycerin), it is "wet". During or before drying, for example, rolling between adjacent roller elements may flatten the corresponding bead / pellet shape. In some cases, the various types of materials described above may be extruded in the form of filamentary strands, and these strands are assembled into cylindrical rods or other rods for application in an aerosol-generating segment. A suitably shaped material may be formed (ie, at a size relative to the beads / pellets otherwise used to form the aerosol-generating segment). After drying, the flattened beads / pellets are then chopped or processed to, for example, strands, flakes, or other fillers that include flat or flat segments that prevent or prevent curl. An arrangement may be formed. Any random configuration resulting from the shredding process may be sufficient. In such an example, the flattened and chopped beads / pellets may then be deposited as aerosol-generating elements in longitudinally extending cavities 57, the irregular or random configuration of which may be, for example, A plurality of intermediate cavities throughout the generation segment may be facilitated, which in turn may facilitate heat transfer from the heat generation segment to individual aerosol generating elements within the cavity. That is, heating of the air in the intermediate space within the aerosol-generating segment may expose more of the aerosol-generating element to heat from the heat-generating segment, and thus may result in enhanced or improved heating of the aerosol-generating segment.

  In some aspects, the beads / pellets may result from tobacco material cast on the foil / paper laminate. More specifically, the tobacco material may include, for example, a slurry comprising reconstituted tobacco, glycerin, and a binding material. Such tobacco materials are disclosed, for example, in Jakob et al., U.S. Patent No. 5,101,839, Crooks et al., U.S. Patent Application No. 2010/0186575, which are incorporated herein by reference. In addition, the slurry may incorporate a particulate inorganic material (ie, calcium carbonate). The slurry may be foiled, for example, as disclosed in Crooks et al., U.S. Patent Application No. 2010/0186757, and Cantrell et al., U.S. Patent No. 7,647,932, which are incorporated herein by reference in their entirety. The cast sheet product cast and assembled on the paper element of the paper laminate is then dried, for example, by the application of heat (ie by hot air, microwave drying, etc.). The paper element may, for example, have a certain porosity or texture to facilitate intimate contact and interaction with the slurry, for example, by direct contact between the slurry and the foil. However, the exemplary embodiments presented herein do not preclude casting the tobacco material (ie, slurry) directly onto a metal foil or other suitable thin film thermal conductor. Such a laminate, when cast, can be formed into various configurations for use as a tobacco substrate in smoking articles, for example, rolled into a rod-shaped configuration. For example, if such a rod-shaped substrate is R.D. J. See US Patent No. 5,469,871 to Barnes et al., Incorporated in a cigarette of the type sold commercially under the trade name "Eclipse" by Reynolds Tobacco Company. However, in response to this application, the dried cast sheet (ie, the foil / paper / tobacco material may be chopped, diced, or otherwise separated into a plurality of cast sheet sub-elements; Each such element preferably includes a portion of the tobacco material (i.e., substrate) that interacts closely with a portion of the paper element, which paper element is likewise a foil element of the foil-paper laminate. The plurality of cast sheet sub-elements then extend longitudinally of the smoking article disclosed herein as all or a portion of the aerosol generating element forming the substrate. May be deposited in the cavity.

  One skilled in the art will recognize that in some situations, a cast sheet sub-element inserted into the cavity as all or part of the aerosol generating element cooperates to form a part of these cast sheet sub-elements. It will be appreciated that improved heat transfer to the abutment element in the material or cavity may be facilitated. More specifically, in some instances, the heat transfer from the heat generating segment to the tobacco material forming the aerosol generating element / substrate material is to heat the outer perimeter of the cavity and the aerosol generating element in contact therewith. Beyond the point of contact between them can be limited by thermally conductive strips that form an additional mechanism for conducting heat from the heat generating segments of the heat sink. In embodiments that include a cast sheet sub-element inserted into the cavity as all or part of the aerosol-generating element, the heat conducting portion of the foil element associated with the cast sheet sub-element may e.g. May form a plurality of additional heat conducting paths. That is, in addition to direct contact between the heat generating segment and the aerosol generating segment and between the thermally conductive (peripheral) strip and the outer aerosol generating element in the cavity, it is used as all or part of the aerosol generating element. The cast sheet sub-element provides an additional thermally conductive element interspersed throughout the aerosol-generating element within the cavity, thereby enhancing heat transfer from the heat-generating segment to the aerosol-generating element within the cavity of the aerosol-generating segment. Or could improve. In other words, one particular potentially advantageous aspect of this application is that the thermally conductive element is interspersed throughout the aerosol-generating segment of the disclosed smoking article, from the heat-generating segment to the aerosol-generating element within the aerosol-generating segment. With improved heat transfer. In achieving such an embodiment, for example, the method disclosed in US Pat. No. 5,469,871 to Barnes et al. J. Substrates mounted on similar products, such as cast tobacco sheet substrate material forming a substrate incorporated into a type of cigarette commercially sold under the trade name "Eclipse" by Reynolds Tobacco Company It may be further advantageous to chop or process the stock material.

Pellets or other elements may have a smooth and regular profile (eg, spherical, cylindrical, oval, etc.) and / or may have an irregular profile (eg, small pieces, flakes, etc.). In one example, the diameter of each pellet can range from less than about 0.05 mm to about 2 mm. The pellet or other element may at least partially fill the aerosol-generating cavity region of the smoking article described herein. In one example, the volume of the cavity may range from about 500 mm ³ ~ about 700 mm ³ (for example, a cavity diameter of about 7.5 to about 7.8 mm, the cavity length is about 11 to about 15 mm, A cavity of a smoking article, wherein the cavity has a generally cylindrical shape extending longitudinally along the smoking article). In one example, the mass of the pellet in the cavity can range from about 200 mg to about 500 mg.

  The manner in which the aerosol-forming material is contacted with the substrate material can vary. Aerosol-forming materials can be applied to the formed materials, incorporated into the processing materials during the manufacture of these materials, or can occur inside the materials. An aerosol-forming material such as glycerin can be dissolved or dispersed in an aqueous solution or other suitable solvent or liquid carrier and sprayed onto the substrate material. See, e.g., U.S. Patent Application Publication No. 2005/0066986 to Nestor et al. And 2012/0067360 to Conner et al., Incorporated herein by reference.

  Tobacco rod segments can vary. Typically, tobacco rod segments consist of small pieces or pieces of tobacco cut filler wrapped in longitudinally extending wrapping paper. Most preferably, the rod is substantially cylindrical in shape and the upstream and downstream ends are open to allow drawn air to pass therethrough. Exemplary tobacco rods, their components, and their methods of manufacture and methods are described in Crooks et al., US Patent Application Publication No. 2007/0215167, which is incorporated herein by reference. Where the cigarette (i.e., the smoking article) is a menthol cigarette, the menthol flavor formulation uses a traditional type of technique for applying menthol to tobacco rods or other tobacco compositions. It can be applied to tobacco rods, as will be appreciated by those skilled in the art.

  If desired, the tobacco rod segments can be replaced or combined with similarly sized segments, but can be made of materials other than or in addition to tobacco cut filler. For example, the tobacco cut filler may be replaced by an open cell extrudate (eg, an extrudate of starch, tobacco, etc.) that allows the drawn air to pass therethrough. Alternatively, the tobacco cut filler is replaced by a steam-bonded plasticized cellulose acetate tube that provides elasticity, structure, and length to the smoking article while allowing the passage of drawn air through it. You may.

  The mouth end segment can vary. Typically, the mouth end segment has the form of a filter element that is generally similar in many respects to the types of filter elements characteristic of traditional types of smoking articles, such as cigarettes. For example, various types of mouthpiece end pieces, filter element assemblies, filter element components, as described and referenced in Crooks et al., US Patent Application Publication No. 2010/0186757, which is incorporated herein by reference. And plug wrap materials. Also, for example, U.S. Patent Nos. 7,479,098 to Thomas et al., 7,740,019 to Nelson et al., 7,793,665 to Dube et al., Which are incorporated herein by reference. Nos. 7,972,254 to Stokes et al., 8,186,359 to Ademe et al., And 8,375,958 to Hutchens et al., And U.S. Patent Publication No. 2008/0142028 to Fagg et al. See also filter elements and filter element components of the type described.

  The outer wrapping material may be configured, for example, as a thermally conductive material (eg, foil paper), an insulating material, cardboard, plug wrap, cigarette paper, tobacco paper, or any combination thereof. Additionally or alternatively, the packaging material may include foil, ceramic, ceramic paper, carbon felt, glass mat, or any combination thereof. Other packaging materials known or developed in the art may be used alone or in combination with one or more of these packaging materials. In one aspect, the packaging material may include a paper material having a foil strip or patch laminated thereto. Representative paper examples are described in Crooks et al., US Patent Application Publication No. 2007/0215167, which is incorporated herein by reference.

  The foil strip or patch can be laminated to a paper sheet and can be laminated to form a coated area. In one example, the foil strip may have a thickness from about 0.0005 mm to about 0.05 mm. The foil strip may be laminated on the inner surface of the paper sheet. The foil strip may be laminated onto the paper sheet using any currently known or later developed technique including, for example, thermal lamination. The foil strip can be laminated onto the paper sheet using any currently known or later developed adhesive. In one example, the adhesive may be configured as a low temperature glue adhesive of the type used to secure the chipping material to other components of the cigarette. The foil strip can be laminated or patched to a paper sheet with or without lubricant. Preferably, the foil strip is formed of a paper sheet to at least partially contact the heat generating segment, the substrate material (ie, beads, pellets, and / or other suitable elements), and / or the tobacco rod segment. It can be laminated to the inner surface (eg, the surface of the paper sheet facing the cavity). The laminated paper or other packaging material may be constructed according to the disclosure of Marton US Pat. No. 6,849,085, which is hereby incorporated by reference in its entirety, or in accordance with other suitable methods and / or materials. Can be done.

  The foil strip preferably enhances heat transfer between the heat generating segment and the aerosol forming material of the aerosol generating segment. Such enhanced heat transfer assists in volatilizing the aerosol-forming material in the substrate (ie, beads, pellets, and / or other suitable elements) for aerosol formation. Therefore, the foil strip is formed from a thermally conductive material. The foil strip may be formed from any thermally conductive material including, for example, tin, aluminum, copper, gold, brass, other thermally conductive materials, and / or any combination thereof. In this manner, the cavities may be defined by foil-lined paper tubes or columns formed by packaging material. The packaging material may include an aligned overlay of the foil strip at a discrete location on or along the packaging material.

  The thermally conductive material can be provided by means other than the use of metal foil. For example, a layer of metal foil may be replaced by a metal mesh or screen. Alternatively, the metal foil may be replaced by a thermally conductive cloth, such as a layer or sheet of graphite fibers or thermally conductive ceramic fibers. Alternatively, the thermally conductive material may be provided by providing a thermally conductive ink, such as an ink or coating of paint incorporating metal particles, graphite fibers, particles of a thermally conductive ceramic material, and the like.

  Other types of components useful for constructing smoking articles are described in Crooks et al., US Patent Application Publication No. 2007/0215167, which is incorporated herein by reference in its entirety.

  One further aspect of the present disclosure includes an apparatus 200 for an elongated smoking article of the type disclosed herein (see, eg, FIG. 13). As disclosed, one aspect involves engaging the thermally conductive material / metal foil with the elongate outer wrapping material, so that suitable manufacturing equipment may include, for example, the thermally conductive material / foil strip 60 with the outer wrapping material / It may include a laminating mechanism 250 configured to engage the length of the elongated paper sheet 80 (see, for example, FIG. 8). As disclosed, each foil strip 60 includes longitudinally spaced ends aligned with the length of the elongate paper sheet 80, and the continuous foil strips, as discussed above, are designated as discussed above. Can be longitudinally spaced along the outer packaging material. In some examples, the laminating mechanism 250 may be configured to engage the foil strip with the elongated paper sheet by applying a laminating adhesive or other suitable adhesive material therebetween. The lamination mechanism may include equipment, such as, for example, those supplied by Montrade Srl and Strouse Corporation to apply the thermally conductive strip (ie, foil) to a predetermined location on the continuous web of packaging material.

  The assembly mechanism 300 converts the heat generating segment 24 (ie, the fuel element 27 and / or the insulator 30) and the tobacco rod segment 68 (ie, the tobacco filler 72 and / or the surrounding wrapper 76) to the length of the elongated paper sheet. May be configured to engage the elongated paper sheet (i.e., outer wrapping material 80) in a longitudinally spaced relationship with respect to. In arranging heat generating segment 24 and tobacco rod segment 55 in this manner, heat generating segment 24 and / or tobacco rod segment 55 at least partially overlap one of the longitudinal ends of the foil strip. In other words, the assembling mechanism is such that the heat generating segments 24 and / or tobacco rod segments 55 overlap and lie on one of the ends of the foil strip extending along the length of the elongated paper sheet. The 24 and / or tobacco rod segments 55 may be configured to be positioned relative to the length of the elongated paper sheet (see, eg, FIG. 9). In some aspects, the assembly mechanism 300 may engage the heat generating segment and the tobacco rod segment with the elongate paper sheet such that only the heat generating segment overlaps at least partially one of the longitudinal ends of the foil strip. It is composed of In other aspects, for example, as shown in FIG. 7, the assembly mechanism 300 may include a spacer element 134 such that the spacer element and tobacco rod segment cooperate with the foil strip to define a longitudinally extending cavity 57. May be configured to engage the heat generating segment. In such an example, the selected spacer element may desirably be thermally conductive and / or breathable. The assembly mechanism can include equipment, such as, for example, those available as Merlin from Hauni Maschinenbau AG and Combi from Montrade to arrange the various segments of the upstream composite rod in place on the continuous web.

  The wrapping mechanism 350 comprises a longitudinally extending cavity in which the heat generating segment and the tobacco rod segment cooperate with the foil strip and are accessible between a lateral end of the elongated paper sheet and a lateral end of the foil strip. To define 57, the lateral end of the elongated paper sheet 80 may be configured to wrap at most partially following the heat generating segment and the tobacco rod segment. That is, the wrapping mechanism 350 causes the longitudinally extending cavity 57 to extend vertically downward (i.e., so as to form a "U" pocket) from the opening defined between the lateral ends of the foil strip. As such, the lateral end of the elongate paper sheet may be configured to at most partially wrap around the heat generating segment and the tobacco rod segment. The openings may be accessible between the lateral edges of the elongated paper sheet (see, for example, FIG. 9).

  Once the "U" pocket or cavity 57 has been formed, the dispensing mechanism 400 is arranged to deposit a plurality of aerosol generating elements into the longitudinally extending cavity 57 between the lateral ends of the foil strip. And configured. That is, dispensing mechanism 400 may be configured to deposit a plurality of aerosol generating elements into longitudinally extending cavity 57, typically under gravity. However, in some aspects, dispensing mechanism 400 may be configured to force a plurality of aerosol-generating elements into the cavity, for example, using pneumatics. Such aerosol-generating elements include pellets, beads, individual small units, carbon pieces, extruded carbon pieces, alumina beads, marumized tobacco pieces, extruded or compressed cylindrical or spherical elements, ground tobacco sheets. Fillers, flavors, visible aerosol-forming materials, binders, oval elements, irregular elements, shreds, flakes, elements including tobacco, elements including visible aerosol-forming materials, and combinations thereof. Can be done.

  In some aspects, dispensing mechanism 400 may be configured to allow for the selection of multiple forms of aerosol-generating elements (eg, FIGS. 14 and 15 where the selection of three types of aerosol-generating elements is shown by way of example). ), So that a separate dispensing device 450A, 450B, 450C may be provided for each of the selected forms of aerosol-generating elements, each dispensing device having a corresponding form of aerosol-generating element in the cavity. (In some cases directly into cavity 57). That is, in some aspects, it may be desirable to deposit a combination of different types or forms of aerosol-generating elements, such as pellets and beads, within a single cavity 57. In such an example, the dispensing mechanism 400 may include a dispensing device for aerosol-generating elements of various types or forms, i.e., a dispensing device for pellets and a separate dispensing device for beads, according to the examples provided. May be included. In such an embodiment, each dispensing device may be configured to dispense a corresponding type or form of aerosol generating element directly into the longitudinally extending cavity 57 (see, eg, FIG. 14). However, in other aspects, the dispensing mechanism may be configured to combine selected forms or types of aerosol-generating elements to produce an aerosol-generating element mixture, and the associated dispensing device may include an aerosol-generating element. An element mixture may be configured to be deposited in the cavity 57 (see, for example, FIG. 15). As previously disclosed, the dispensing mechanism 400 is configured to deposit a plurality of aerosol-generating elements into a longitudinally extending cavity such that the cavity is at least 65 percent filled with the aerosol-generating element. Can be done. In some examples, the cavities are at least about 75 percent filled with an aerosol-generating element, in other examples at least about 85 percent of the maximum charge with an aerosol-generating element, and in some situations, at least about 95 percent It may be desirable to be filled. Filling the cavities with the material that provides the aerosol-forming components provides, for example, a dispensing mechanism that includes pneumatic equipment, or dripping or lowering or gravity-promoting filling of these cavities with the desired material or suitable elements. It can be achieved using other suitable means for doing so.

  In a further aspect, one of ordinary skill in the art will appreciate that one or more dispensing devices disclosed herein for aerosol-generating elements may include various dispensing devices, for example, to form a substrate in a cavity. It will be appreciated that the system may also include a control system for controlling the amount or relative amount of the material containing the aerosol generating element dispensed from the device. The control system may be common to all dispensing devices (ie, a single controller that communicates with and controls all of the dispensing devices) or a separate control for each dispensing device. And each controller may communicate with one or more of the other controllers for coordinating the controlled dispensing of various aerosol generating elements from the corresponding dispensing device. Sometimes not. By controlling the relative amounts of the various aerosol-generating elements dispensed into the cavity, for example, thermal conductivity, intermediate voids, or other features of the aerosol-generating element within the cavity of the aerosol-generating segment (and / or It may be possible to control, customize, or determine the interactions between them. For example, as discussed above, in addition to or instead of implementing cast sheet sub-elements, as aerosol-generating elements, specific materials comprising, for example, metal, graphite, or other suitable thermally conductive materials Of the heat conductive elements (ie, beads, pellets) may be dispensed in a sufficient proportion into the cavities in the aerosol generating segment to provide a desired heat transfer conduction path. In another example, controlled dispensing (whether random or not) of differently configured aerosol-generating elements strictly acquires certain features of intermediate voids in cavities on pellets and / or beads. Can promote.

  When the cavity 57 is sufficiently and properly filled with a certain amount of aerosol-generating element, the sealing mechanism 500 extends longitudinally by sealing the side edges of the elongated paper sheet 80 together. The cavity 57 may be configured to close. In such an embodiment, the sealing mechanism 500 may be configured to wrap the lateral ends of the foil strip around the aerosol generating element such that the lateral ends of the foil strip abut each other (eg, FIG. 2). See). In other aspects, the sealing mechanism 500 may be configured to wrap the side edges of the foil strip around the aerosol generating element such that the side edges of the foil strip overlap. If necessary or desired, the sealing mechanism 500 may also apply a seam sealing adhesive or any suitable adhesive material to seal the side edges of the elongated paper sheet together. It may be configured to be applied between overlapping side edges of the elongated paper sheet. The sealing mechanism 500 may be used to seal a continuous web of thermally conductive strip and / or outer wrapping material to seal the cavity and form a continuous rod consisting of a repeating pattern of composite rods, for example, a rod forming unit. (Eg, devices of the type commonly used in the tobacco industry for the production of continuous filter rods).

  In accordance with the disclosure herein, one aspect thus includes a method of forming an elongated smoking article (see, eg, FIG. 16). As disclosed, the method includes engaging the heat generating segment and the tobacco rod segment with the outer wrapping material in a longitudinally spaced relationship to the length of the outer wrapping material (block 600). In certain examples, the outer wrapping material has a thermally conductive strip engaging it, the thermally conductive strip having ends longitudinally spaced relative to the length of the outer wrapping material. In some aspects, the heat generating segment and / or tobacco rod segment (one or both) at least partially overlap one of the longitudinal ends of the thermally conductive strip. In certain aspects, only the heat generating segment at least partially overlaps one of the longitudinal ends of the thermally conductive strip. In yet another aspect, the method engages the spacer element with the heat generating segment such that the spacer element and the tobacco rod segment cooperate with the thermally conductive strip to define a longitudinally extending cavity. May further be included. In such instances, it may be preferred that the spacer element be thermally conductive and / or breathable.

  In some aspects, the method may further include engaging the thermally conductive strip with a length of the outer wrap, for example, in a laminating procedure, wherein the laminating procedure includes attaching the thermally conductive strip to the outer wrap. May involve engaging by applying a laminating adhesive therebetween.

  The lateral ends of the outer wrapping material, in turn, the heat generating segment and the tobacco rod segment cooperate with the thermally conductive strip to form At least partially wrapped around the heat generating segment and the tobacco rod segment to define an accessible longitudinally extending cavity between the heat generating segment and the tobacco rod segment (block 625). In some cases, the lateral ends of the outer wrapping material are such that the longitudinally extending cavities extend vertically downward from an opening defined between the lateral ends of the thermally conductive strip. , At most partially around the heat generating segment (and optional spacer element) and the tobacco rod segment.

  When the outer wrapping material is configured to define a longitudinally extending cavity, a plurality of aerosol-generating elements enter the longitudinally extending cavity between the lateral ends of the thermally conductive strip (block). 650), the plurality of aerosol-generating elements can be, for example, pellets, beads, discrete small units, carbon pieces, extruded carbon pieces, alumina beads, marumized tobacco pieces, extruded or compressed cylindrical or Spherical elements, crushed tobacco sheets, fillers, flavoring agents, visible aerosol-forming materials, binders, oval elements, amorphous elements, shreds, flakes, elements including tobacco, elements including visible aerosol-forming materials, and the like. It can be selected from the group consisting of combinations.

  In some aspects, more than one form of aerosol-generating element may be selected, and each of the selected forms of aerosol-generating element then follows in the cavity (in some cases directly in the cavity). Deposited. In another example, the selected form of the aerosol-generating element is combined prior to deposition into the cavity to produce an aerosol-generating element mixture, and the mixture is then subsequently deposited into the cavity. In some aspects, the mixture is deposited directly into the cavity. As disclosed above, the plurality of aerosol-generating elements may be dispensed into a longitudinally extending cavity such that the cavity is at least about 65 percent filled with the aerosol-generating element. In some examples, the cavities are at least about 75 percent filled with an aerosol-generating element, in other examples at least about 85 percent of the maximum charge with an aerosol-generating element, and in some situations, at least about 95 percent It may be desirable to be filled.

  Once the longitudinally extending cavity is properly filled, the longitudinally extending cavity may be closed by overlapping and sealing between the lateral ends of the outer packaging material (block 675). In some aspects, closing the longitudinally extending cavity causes the lateral ends of the thermally conductive strip to abut the aerosol generating element such that the lateral ends of the thermally conductive strip abut each other. This may include wrapping around. In another aspect, closing the longitudinally extending cavity wraps the lateral ends of the thermally conductive strip around the aerosol generating element such that the lateral ends of the thermally conductive strip overlap. May be included. In certain instances, closing the longitudinally extending cavity may include a seam seal between overlapping side edges of the outer wrapping material to seal together the side edges of the outer wrapping material. It may include applying an adhesive.

  Many modifications and other aspects of the present disclosure described herein, which have the benefit of the teachings presented in the above description and associated drawings, will occur to those skilled in the art to which these disclosures pertain. It comes to mind. For example, those skilled in the art will recognize that features described herein for different embodiments may be combined with each other and / or with currently known or later developed technologies while simultaneously claiming the claims presented herein. It will be understood that embodiments illustrated, but not explicitly, herein, including staying within the scope, may be practiced within the scope of the disclosure. Therefore, it is understood that this disclosure is not limited to the particular embodiments disclosed, and equivalents, modifications, and other aspects thereof are intended to be included within the scope of the appended claims. Should. Although specific terms are used herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (26)

A method of forming an elongated smoking article, comprising:
Engaging the heat-generating segment and the tobacco rod segment with the outer wrapping material in a longitudinally spaced relationship with the length of the outer wrapping material, wherein the outer wrapping material engages the heat-generating segment. A conductive strip, the heat conductive strip having longitudinally spaced ends aligned with the length of the outer wrapping material, wherein the heat generating segment and the tobacco rod segment At least one overlaps and engages one of the longitudinal ends of the thermally conductive strip; and
The lateral end of the outer wrapping material, the heat generating segment and the tobacco rod segment cooperate with the thermally conductive strip to form the lateral end of the outer wrapping material and the thermally conductive strip. At least partially wrapping around the heat generating segment and the tobacco rod segment to define an accessible longitudinally extending cavity between the lateral end and the tobacco rod segment;
Depositing a plurality of aerosol generating elements in the longitudinally extending cavity between the lateral ends of the thermally conductive strip;
Closing the longitudinally extending cavity by overlapping and sealing the lateral ends of the outer packaging material.   2. The method of claim 1, further comprising engaging the thermally conductive strip with the length of the outer wrapping material.   3. The method of claim 2, wherein engaging the thermally conductive strip comprises engaging the thermally conductive strip with the outer wrapping material by applying a laminating adhesive therebetween. The method.   Engaging the heat-generating segment and the tobacco rod segment causes the heat-generating segment and the tobacco rod segment to at least partially overlap the heat-generating segment with one of the longitudinal ends of the thermally conductive strip. The method of claim 1, comprising engaging the outer wrapping material so as to overlap.   Further comprising engaging a spacer element with the heat generating segment such that the spacer element and the tobacco rod segment cooperate with the heat conductive strip to define the longitudinally extending cavity. The method of claim 1, wherein the spacer element is one of heat conductive and breathable.   Wrapping a lateral end of the outer packaging material may define a lateral end of the outer packaging material with a longitudinally extending cavity defined between the lateral ends of the thermally conductive strip. 2. The method of claim 1, comprising wrapping at most partially around the heat generating segment and the tobacco rod segment so as to extend vertically downward from the opening.   Depositing the plurality of aerosol-generating elements may include pellets, beads, discrete mini-units, carbon pieces, extruded carbon pieces, alumina beads, marumized tobacco pieces, extruded or compressed cylindrical or Spherical elements, crushed tobacco sheets, fillers, flavoring agents, visible aerosol-forming materials, binders, oval elements, amorphous elements, shreds, flakes, elements including tobacco, elements including visible aerosol-forming materials, and the like. The method of claim 1, comprising depositing the plurality of aerosol generating elements selected from the group consisting of a combination within the longitudinally extending cavity.   The method of claim 1, wherein depositing the plurality of aerosol-generating elements comprises selecting a plurality of forms of the aerosol-generating element and depositing each of the selected forms of the aerosol-generating elements separately in the cavity. The method of claim 7.   Depositing the plurality of aerosol-generating elements comprises selecting a plurality of forms of the aerosol-generating elements, combining the selected forms of the aerosol-generating elements to form an aerosol-generating element mixture, and placing the mixture in the cavity. 9. The method of claim 7, comprising depositing in.   Depositing the plurality of aerosol-generating elements deposits the plurality of aerosol-generating elements into the longitudinally extending cavity such that the cavity is at least about 65% filled with the aerosol-generating element. The method of claim 1, comprising:   Closing the longitudinally extending cavity may cause the lateral ends of the thermally conductive strip to abut against each other such that the lateral ends of the thermally conductive strip abut each other. The method of claim 1, comprising wrapping around.   Closing the longitudinally extending cavity causes the lateral end of the thermally conductive strip to wrap around the aerosol generating element such that the lateral end of the thermally conductive strip overlaps. The method of claim 1, comprising wrapping.   Closing the longitudinally extending cavity may provide a seam seal between the overlapping side ends of the outer wrapping material so as to seal together the side ends of the outer wrapping material. The method of claim 1, comprising applying an adhesive. An apparatus for forming an elongated smoking article, comprising:
The heat generating segment and the tobacco rod segment are configured to engage the outer wrapping material in a longitudinally spaced relationship with the length of the outer wrapping material, wherein the outer wrapping material engages the heat generating segment. A conductive strip, the heat conductive strip having longitudinally spaced ends aligned with the length of the outer wrapping material, wherein the heat generating segment and the tobacco rod segment An assembly mechanism, at least one of which at least partially overlaps one of the longitudinal ends of the thermally conductive strip;
The lateral end of the outer wrapping material, the heat generating segment and the tobacco rod segment cooperate with the thermally conductive strip to form the lateral end of the outer wrapping material and the thermally conductive strip. A wrap configured to wrap at most partially around the heat generating segment and the tobacco rod segment to define an accessible longitudinally extending cavity between the lateral ends. Mechanism and
A dispensing mechanism configured to deposit a plurality of aerosol generating elements in the longitudinally extending cavity between the lateral ends of the thermally conductive strip;
A sealing mechanism configured to close the longitudinally extending cavity by sealing together the lateral ends of the outer wrapping material.   The apparatus of claim 14, further comprising a lamination mechanism configured to engage the thermally conductive strip with the length of the outer wrapping material.   16. The apparatus of claim 15, wherein the laminating mechanism is configured to engage the thermally conductive strip with the outer wrapping material by applying a laminating adhesive therebetween.   The assembling mechanism engages the heat generating segment and the tobacco rod segment with the outer wrapping material such that only the heat generating segment at least partially overlaps one of the longitudinal ends of the thermally conductive strip. 15. The device of claim 14, wherein the device is configured to combine.   The assembly mechanism engages a spacer element with the heat generating segment such that the spacer element and the tobacco rod segment cooperate with the thermally conductive strip to define the longitudinally extending cavity. 15. The apparatus of claim 14, wherein the spacer element is configured to be one of heat conductive and breathable.   The winding mechanism vertically extends a lateral end of the outer wrapping material downwardly from an opening defined between the lateral ends of the thermally conductive strip with the longitudinally extending cavity. 15. The device of claim 14, wherein the device is configured to wrap at most partially around the heat generating segment and the tobacco rod segment.   The dispensing mechanism comprises pellets, beads, individual small units, carbon pieces, extruded carbon pieces, alumina beads, marumized tobacco pieces, extruded or compressed cylindrical or spherical elements, crushed tobacco sheets Fillers, flavors, visible aerosol-forming materials, binders, oval elements, irregular elements, shreds, flakes, elements including tobacco, elements including visible aerosol-forming materials, and combinations thereof. The apparatus of claim 14, wherein the apparatus is configured to deposit the plurality of aerosol-generating elements in the longitudinally extending cavity.   The dispensing mechanism is configured to allow selection of a plurality of forms of the aerosol-generating element, and comprises a separate dispensing device for each of the selected forms of the aerosol-generating element; 21. The apparatus of claim 20, wherein a device is configured to dispense the corresponding form of the aerosol-generating element into the cavity.   The dispensing mechanism is configured to allow selection of a plurality of forms of the aerosol-generating element, and to combine the selected form of the aerosol-generating element to form an aerosol-generating element mixture; 21. The apparatus of claim 20, comprising a dispensing device configured to deposit in the cavity.   The dispensing mechanism is configured to deposit the plurality of aerosol-generating elements into the longitudinally extending cavity such that the cavity is at least about 65% filled with the aerosol-generating element. The device according to claim 14.   The sealing mechanism is configured to wrap the lateral end of the thermally conductive strip around the aerosol generating element such that the lateral ends of the thermally conductive strip abut each other. 15. The apparatus of claim 14, wherein:   The sealing mechanism is configured to wrap the lateral end of the thermally conductive strip around the aerosol-generating element such that the lateral ends of the thermally conductive strip overlap. Item 15. The device according to Item 14.   The sealing mechanism is configured to apply a seam sealing adhesive between the overlapping side ends of the outer packaging material to seal together the side edges of the outer packaging material. 15. The device of claim 14, wherein the device is:

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