SK142597A3 - Cigarette and heater for use in an electrical smoking system - Google Patents

Abstract

A cigarette (23) comprises a tobacco rod having filled and unfilled portions arranged so that electrical heater elements (31) may overlap both portions. The rod includes a tubular tobacco web. The web is constructed by converting tobacco feedstock into a continuous sheet of tobacco web and converting the continuous sheet of tobacco web into one or ore bobbins of tobacco web suitable for automated manufacture of cigarettes. A heater (25) comprises a supporting hub and electrically resistive heater blades (37) defining a receptacle (27) for an inserted cigarette (23). Each blade comprises first and second heater blade legs each having a first end and a second end, and a connecting section connecting the second end of the first leg and the first end of the second leg. The blades (37) are heated by a resistive heating circuit and heat the inserted cigarette (23). The legs are separated by a gap to permit entrainment of flavour substances upon drawing.

Description

Cigarette and heater for use in an electrical smoking system

Technical field

This smoker collaborate smoking systems.

The invention generally relates to electrical systems, in particular cigarettes, adapted to electric lighters of electrical systems, and to heaters for use in these.

BACKGROUND OF THE INVENTION

Traditional cigarettes give the smoker a taste and aroma, which are the result of burning, during which the mass of some combustible material, especially tobacco, is burned at temperatures that often exceed 800 ° C during cigarette coating. The heat is drawn at the end of the cigarette at the mouth through the adjacent mass of tobacco. During heating, insufficient oxidation of the combustible tobacco material releases a variety of gaseous combustion products and distillates. When these gaseous products are drawn through the cigarette, they cool and condense to form an aerosol that provides the flavors and flavor associated with smoking.

Traditional cigarettes have various perceived deficiencies. One of these drawbacks is the generation of a sidestream smoke during shading between individual coatings, which may be unpleasant to the non-smoker. Once lit, they must be consumed or otherwise extinguished. Re-ignition of a traditional cigarette is possible, but for smoker b with a refined taste it is usually an unattractive choice (for smell, taste, odor) for subjective reasons.

An alternative to a traditional cigarette includes those in which the combustible material does not itself release the tobacco aerosol. Such smoking articles may comprise a combustible, carbon heating element (heat source) that is disposed either at or around one of the ends of the smoking article, and a bed of tobacco-filled elements positioned adjacent the heating element already mentioned. The heater element is ignited by a match or lighter, and when a smoker draws on a cigarette, the heat generated by the heater element is directed into the bed of tobacco-filled elements so as to cause the release of tobacco aerosol through the bed. Although this type of smoking device produces little or no sidestream smoke, it still generates combustion products in the source of the heat and once its source is ignited, it is not easy to quickly extinguish it for future use in a practical sense.

Both in traditional and carbon-heated devices already described, they are burnt in use. This process naturally gives rise to many by-products when the fired material decomposes and reacts with the surrounding atmosphere.

Patent application, which is pending and jointly assigned, and which has serial number 08/380 718, filed September 30, 1995 (PM 1697 Cont) and serial number 07/943 504, filed September 11, 1992 (PM 1350) together with U.S. Patent Nos. 5,093,894, 5,225,498, 5,060,671, and 5,095,921 disclose various heater elements and flavor-generating products that significantly reduce the sidestream smoke while allowing the smoker to arbitrarily (or delay, stop) and again resumed smoking. However, the cigarette products disclosed in these patents are not very durable and may spill, tear or burst with longer or thicker handling. In certain circumstances, these prior cigarettes may be crushed because they are even softer and may tear or burst when removed from the lighter.

The aforementioned United States patent application, which

The cigarette and inserted into the serial number 08 / 380,718 (PM 1697 Cont) and US 5,388,594, disclose an electrical smoking system comprising a new electrically powered lighter and a new cigarette that cooperates with the lighter. A preferred embodiment of the lighter encompasses a plurality of metal, bent (rotating) glowing filaments that are arranged in a configuration that slidably receives the tobacco rod portion of the cigarette.

A preferred embodiment of this cigarette with the serial number 08/380 718 (PM 1697 Cont) and also disclosed in EP-A-0 615 411, comprises a tubular carrier filled with tobacco through which the cigarette paper is wrapped, arranging the flow filter inserts at one end at the mouth , and a filter element at the free (distal) end of the carrier.

The lighter is formed so that when the cigarette of the lighter is activated and the individual heaters are activated at each puff, localized firing occurs at points around the cigarette where each heater (heater element) is leaning against the cigarette (hereinafter referred to as heater imprint). Once all the heaters are activated, these hot spots are spaced from one another and surround the central portion of the portion of the cigarette holder.

Depending on the maximum temperatures and total energies supplied by the heaters, the heating points exhibit more than a mere discoloration of cigarette paper. In most applications, this heating creates at least tiny cracks in the cigarette paper and in the carrier backing material, these cracks tend to mechanically attenuate the cigarette. In order for the cigarette to be withdrawn from the lighter, the heating points must be at least partially displaced outside the heater. When circumstances are worse than when a cigarette is wet, or when someone is playing or twisting it, it can easily tear or leave behind when removed from the lighter. Pieces left in the lighter holder may interfere with the operation of the lighter and / or give off some aftertaste when smoking a future cigarette.

When a cigarette breaks into two pieces when being withdrawn from the lighter, the smoker may not only be disappointed with the damaged cigarette product, but may also feel discomfort from removing residues from the clogged lighter before he or she can enjoy the next cigarette.

A preferred embodiment of the cigarette of US Patent No. 08 / 380,718, EP-A-0 615 411 of Patent No. 5,388,594, is a substantially hollow tube between the filter inserts at the end of the cigarette and the insert at the distal end. This embodiment is believed to increase delivery to the smoker by providing sufficient space into which the aerosol can be released from the carrier, with minimal interference and aerosol condensation on any adjacent surface.

Some suggestions have been made that significantly reduce unwanted side-stream smoke while allowing the smoker to stop smoking the product for a desired period of time and then resume smoking. For example, commonly assigned U.S. Patent Nos. 5,093,894, 5,225,498, 5,060,671, and 5,095,921 disclose various heating elements and flavor generating systems. EP-A-0 615 411 and US Patent No. 5,388,594 disclose an electrically smoking system having heaters that are activated when a coating is registered by means of a control and logic circuit. The heaters are preferably formed as a thin, rotary structure for transferring an adequate amount of heat (glow) to a cigarette that is light.

Although these devices and heaters overcome these problems and achieve the intended goal, many embodiments are subject to mechanical weakening and possible failure due to the loading caused by the insertion and removal of the cylindrical tobacco carrier, as well as the adjustment and playing with the inserted cigarette.

Further, when the shape of the heater assembly is changed, for example, when a cigarette is inserted or manipulated, unwanted electrical short circuits may occur.

Electric smoking systems also use electric resistance heaters that have forced relatively complex electrical connections that can be broken by inserting and removing the cigarette.

When using cut filler tobacco with a hollow cigarette structure according to EP-A-0 615 411, it has been found that these cigarettes, when fully filled with cut filler tobacco, tend to function adequately in the electric lighter during the first few strokes. Then their supply tends to shrink. The same phenomenon tends to occur when traditional cigarettes have been smoked in an electric lighter, as disclosed in EP-A-0 615 411.

When left unfilled, the hollow cigarette structures preferably formed according to EP-A-0 615 411 were also vulnerable to spillage under extreme or rough handling.

SUMMARY OF THE INVENTION

The present invention is defined in its various aspects by the appended claims.

A cigarette representing aspects of the present invention has the advantage that it contains cut filler and is still usable with consistency when smoked as part of an electronic smoking system.

The cigarette of the present invention has the advantage that it comprises cut filler and is adapted to cooperate with the electric lighter and provides a satisfactory level of taste and delivery.

The cigarette of the present invention has the advantage that it comprises cut filler and still provides improved delivery consistency from coating to coating.

The cigarettes of the present invention can be easily manufactured and packaged in an attractive package.

The cigarettes of the invention may be physically robust and may minimize condensation and / or filtration of the aerosol inside the cigarette and / or lighter. Furthermore, they may be tear-resistant during removal from the lighter.

The cigarettes of the present invention are suitable for consumption with an igniter of an electrical smoking system, and less vulnerable to spillage or breakage during harsh consumer handling.

The cigarettes of the present invention are suitable for consumption with an igniter of an electrical smoking system, not susceptible to spillage or breakage during manufacture or packaging of the cigarette.

Cigarettes of the present invention operating with an electrical lighter of an electrical smoking system can contribute to a cost-effective method of production and at production rates.

Heaters according to the invention, generating smoke from a tobacco medium (carrier) without sustained combustion, reducing the generation of an undesirable side-stream of smoke, allowing the smoker to interrupt and resume smoking and increasing the generation of aerosol within the smoking bust.

The heater structure of the present invention provides a sufficient amount of coatings and uncomplicated modification to alter the amount and / or duration of strokes provided without sacrificing the subjective properties of the tobacco.

A heating element according to the invention, mechanically suitable for inserting and removing a cigarette.

An electric resistance heater according to the present invention, with simplified connections to an associated power supply.

A heating element according to the invention, mechanically stable during heating (glowing) cycles.

Embodiments of the present invention can minimize the variation in the interface between the heater and the cigarette and prevent changes in heat transfer.

A heater according to the invention which is more economical to manufacture.

One preferred embodiment provides a smoking system for delivering an aromatized tobacco response in response to a smoker. This system includes a cigarette and a second portion of this unfilled or hollow location which is a tobacco rod so.

and an electrically operated lighter, the lighter comprising a plurality of electric heaters (heater fibers), each heater being adapted to either individually or in the assembly, to thermally release a predetermined amount of tobacco aerosol from the cigarette upon its / their activation. The cigarette comprises a tubular tobacco structure in which a first portion of the tubular tobacco structure is filled with a tobacco column, preferably in the form of cut filler tobacco, the tubular tobacco structure being such as to define an empty void in the tobacco column.

More specifically, said cigarette preferably comprises a tobacco rod formed from a tubular tobacco structure and a tobacco plug positioned within the tubular tobacco structure. The tobacco rod is adapted to be slidably received by the electric heater holder (clamp) such that the heater elements are disposed along the tobacco rod at a location between its free end and the opposite end. Preferably, the tobacco plug or column is positioned from the free end of the tobacco rod to spaced from the opposite end that defines an empty (or hollow) space adjacent the opposite end.

The relative dimensions of the cigarette and lighter heater holder are determined such that by inserting the cigarette into the lighter each heater (heater filament) will be positioned along the tobacco rod at a predetermined location along the tobacco rod and preferably so that the longitudinal extent of contact between the heater further, the heater imprint) covers at least a portion of the aforementioned void and at least the CaB 'of the tobacco plug. Thus, Ba receives a consistent and satisfactory delivery when the cigarette is electrically smoking and the consistency of the tobacco aerosol in or around the heater elements is limited.

In an alternative embodiment, the relative dimensions of the cigarette and the lighter heater holder are determined such that each heater will be δ by inserting the cigarette into the lighter

positioned along the tobacco rod so that at least a portion, if not all, of the heater fingerprint overlaps only the filled portion of the tobacco rod (through the tobacco plug). In such configurations, an empty space may still be used to facilitate aerosol formation and to help cool the smoke.

Preferably, the cigarette paper is wrapped around the tubular tobacco structure to provide the smoker with the appearance and feel of a traditional cigarette during smoking.

Preferably, the tobacco web includes a nonwoven tobacco web and a layer of tobacco material disposed along at least one side of the tobacco web.

The cigarette also preferably includes a filter tip in the aforementioned opposite end of the tobacco rod, which includes a flow filter insert (also known as a blower insert in the art), a filter mouthpiece and a tip paper connecting the insert to the tobacco rod.

When the cigarette of the present invention is inserted into the lighter of the electrical smoking system, the cigarette is in a back-up against a stop located within the lighter holder (or some equivalent back-up) so that the electric lighter heater elements are coherent along the cigarette in the same location. When a coating is initiated, the at least one lighter heater is activated to heat the cigarette at the aforementioned location along the tobacco rod. As the coating proceeds, the tobacco rod is heated and an aerosol is expelled from the tobacco web and filler. Each heater fingerprint overlaps the void space in the rod released almost immediately into the tobacco, the tobacco aerosol being the space defined inside that unfilled portion of the tobacco rod and withdrawn from the cigarette. The tobacco structure contributes mostly to this fraction of the total aerosol delivered by the cigarette, and its immediacy is that it positively affects the nature and extent of the cigarette smoker's pull. To increase the weight of the tobacco in the filled portion of the tobacco rod, there is a slight delay in the release of the aerosol from the point where the heater fingerprint overlaps the filled portion of the rod. The aerosol that is expelled from the filled portion of the tobacco rod contributes to the additional, dominant flavor and character of the smoke.

Another aspect of the invention is the ability to determine the delivery of a cigarette in an electrical smoking system in which a proportional amount of overlap between the filled and unfilled portion of the tobacco rod by the heater imprint makes desired adjustment in delivery from one brand of cigarette to another or within the same product line.

Yet another aspect of the present invention is a method of increasing the level and consistency of aerobol delivery from a cigarette cooperating with an electric heater device in which the cigarette has a free end and an opposite end. The method comprises the steps of overlapping the heater fingerprint over both the tobacco-filled portion of the cigarette adjacent the free end and the unfilled portion of the cigarette adjacent the opposite end, while simultaneously resisting heating along the heater fingerprint and coating the cigarette with its opposite ends.

Yet another aspect of the present invention is to provide a filler-containing cigarette that cooperates with an electric lighter, wherein the cigarette comprises a tobacco rod with a free flow filter and a portion of a filler-free bar adjacent the free flow filter to promote consistent production. aerosol.

Another aspect of the present invention is a reinforced tubular tobacco structure having a flax or wood cellulose fiber added to its backing structure to provide additional strength. In an alternative, the cellulosic fiber of the staple processing raw material may be in the composition of the underlying substrate, such as a reinforcing agent.

The stiffness of the cigarette is increased by incorporating cut filler within the edges of its tubular tobacco structure so that

8a has developed a cigarette that can withstand better treatment, including the handling of cigarettes by production machines and consumers.

Preferably, the heater of the present invention comprises a support throat and a plurality of electrical resistance glowing blades that form a receptacle for receiving a retracted cigarette. Each blade comprises a first heater blade arm having first and second ends and being provided in a first end from the support throat, a second heater blade arm having first and second ends, and a connecting section that connects the second end of the first arm and the first end second arm. The second end of the second arm is provided towards the support throat and is electrically insulated therefrom. The resistive heater circuit is configured to heat an electrically resistive heater blade that heats the inserted cigarette. The first and second arms are separated by a gap to allow air to be drawn in to aid in the development of flavor substances from the heated cigarette upon smoker's coating.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be further described by way of example and with reference to the accompanying drawings, in which:

Fig. 1 and 2 are perspective views of an electrical smoking system in accordance with a preferred embodiment of the present invention.

Fig. 3 is an exploded perspective view of the cigarette engaged within the handle of the smoking system heating system shown in FIG. First

Fig. 4A is a side cross-sectional view of a cigarette constructed in accordance with a preferred embodiment of the present invention.

Fig. 4B is a detailed perspective view of the cigarette shown in FIG. 4A, with certain components of the cigarette partially unwrapped.

Fig. 5A and 5B are flow diagrams of the steps in the preferred process for manufacturing the cigarette rolls of the cigarette structure shown in FIGS. 4A and 4B, in which FIGS. 5A illustrates the steps of converting the tobacco feedstock into a tobacco web, and FIG. 4B illustrates the steps of converting the tobacco web into the coils of the tobacco web.

Fig. 6A is a side cross-sectional view of a cigarette constructed in accordance with a substantially hollow embodiment of the present invention.

Fig. 6B is a graphical representation of aerosol production verse. the time during which each stroke is generated by a cigarette formed in accordance with the substantially hollow embodiment of the present invention in FIG. 6A.

Fig. 6C is a diagram of a smoke measurement device that was used to obtain the data shown in FIG. 6B, 7B and 8.

Fig. 7A is a side cross-sectional view of a cigarette constructed in accordance with a substantially full embodiment of the present invention.

Fig. 7B is a graphical representation of aerosol production verse. the time during which each stroke is generated by the cigarette formed in accordance with the fully filled embodiment of FIG. 7A.

Fig. 8 is a graphical comparison of the aerosol volume in each subsequent coating as delivered by each of the cigarettes described with reference to FIG. 4A, 6A and 7A.

Fig. 9 is a graphical representation of the relationship between total particulate matter (TPM) delivery and heater overlap size over a full portion of a partially filled cigarette, constructed in accordance with a preferred embodiment (FIG. 4A) of the present invention.

Fig. 10 is a side cross-sectional view of a cigarette formed in accordance with a second preferred embodiment of the present invention;

Fig. 11 is a side cross-sectional view of a cigarette formed in accordance with a third preferred embodiment of the present invention;

Fig. 12 is a side cross-section through the heater handle showing another aspect of the present invention;

Fig. 13 is a side view of a heater assembly illustrating another aspect of the present invention;

14 is a side cross-section through the heater handle showing another aspect of the present invention using an electrical insulator coating.

Fig. 15 is a side cross-section through the heater handle illustrating an aspect of the present invention using an electrical insulator coating that forms the neck.

Fig. 16 is a side cross-section through the heater handle showing an aspect of the present invention using rotatably shaped heater blade arms.

Fig. 17A is a front cross-sectional view through a heater blade having a flat bottom portion facing the inserted cigarette.

17B is a front cross-sectional view through a heater blade having a lower edge turned towards the inserted cigarette.

Fig. 17C is a front cross-sectional view through a heater blade having a curved lower portion facing the inserted cigarette.

Fig. 18 is a plan view of a symmetrical arrangement of a plurality of blades in a flat state before being rolled.

Fig. 19 is a plan view of the asymmetrical arrangement of the heater blades in a flat condition before being rolled.

20 is a radial cross-section through an electrical smoking system embodying the present invention, showing an alternative heater embodiment.

21 shows a longitudinal cross-section through the cartridge b with a flavor that receives the cavities of the electrical smoking system of FIG. 20 taken along line A-A in FIG.

Fig. 22 is a radial cross-section showing another alternative heater embodiment;

Fig. 23 is a longitudinal cross-section through the cartridge 8 with a flavor that receives cavities of the electrical smoking system of Figs. 22 taken along line B-B in FIG. 22.

An exemplary embodiment of the invention by means of screws to facilitate replacement

In FIG. 1 and 2, a preferred embodiment of the present invention provides a smoking system 21 comprising a partially filled refill cigarette 23 and a reusable lighter 25. The cigarette 23 is adapted to be retractable and removed from the socket 27 at the front end portion 29 of the lighter 25. the cigarette 23 is retracted, the smoking system 21 is used in much the same way as a traditional cigarette, but without igniting or shielding the cigarette

23. The cigarette 23 is discarded after the smoker has drawn it one or more times. Preferably, each cigarette is formed such that the smoker can draw eight or more cycles of it per smoking. However, it is a matter of expedient design (s) to make the cigarette smaller or more usable strokes.

The lighter 25 encompasses the housing 21 having front and rear portions 33 and 35. One or more of the batteries 35a are removably disposed at the rear of the housing 35 and supply power to a plurality of electrically resistive glowing elements 37 disposed within the front of the housing 33. The control circuit 41 at the front of the housing 23 forms an electrical connection between the batteries 35a and the heater elements 37. The rear portion 35 is preferably adapted to be easily opened and closed, for example or by parts of the latch assembly, on the batteries. If desired, an electrical outlet or contacts may be provided to recharge the batteries with household current or the like.

The front part of the housing 33 is preferably removably connected to the rear part of the housing 25 (for example by a dovetail connection or by means of a plug). The housing 31 is preferably made of a hard heat resistant material. Metallic materials are preferred, but polymeric materials are more preferred. The housing 31 has overall dimensions of about 10.7 cm by 3.8 by 1.5 cm, so that it fits comfortably in the hand of a smoker.

The size of the batteries 35a is sufficient to provide sufficient performance of the heater elements 32 / to function as intended and preferably includes a replaceable rechargeable type. Alternative energy sources are useful, such as capacitors. Preferred embodiments of the respective power supply include nickel-cadmium battery cells connected in series with a total, unloaded, voltage of approximately 4.8 to 5.6 volts. However, the characteristics required from the power supply are selected with respect to the characteristics of the other components in the smoking system 21, in particular the characteristics of the heater elements 3Z-US Patent No. 5,962,249. No. 5,144,962 (PM 1345), thus incorporated herein, describes several types of power supplies useful in connection with the smoking buster of the present invention, such as rechargeable battery packs and power arrangements that include a capacitor that is recharged by a battery.

According to the embodiment shown in FIG. 3, the front portion of the lighter housing 33 supports a substantially cylindrical heater holder 32 that slidably receives a cigarette 23. The heater holder 39 has heater elements 32 disposed therein and adapted to support the inserted cigarette 22 in a fixed relationship (position) to the heating elements 32 such that the heating elements 37 are positioned along the cigarette, in approximately the same location along each cigarette. The location where each heater element 37 presses (or is in thermal contact with) against a fully inserted cigarette 22 is referred to herein as a heater fingerprint.

In order to ensure a coherent location of the heater elements 32 relative to each cigarette 22, from cigarette to cigarette, the heater fixture 32 is provided with a stop 182 relative to FIG. 13, which may be used to align the cigarette 23 with respect to the lighter 25. Other suitable means could be used instead.

The front of the lighter housing 33 also includes an electrical control circuit 41 that delivers a predetermined amount of power from the power supply 35a to the heater elements 50. In a preferred embodiment, the heater fixture 39 comprises eight circumferentially spaced heater elements 37 that are concentrically aligned with the sleeve 27 and have a spiral form. The details of these (heater) heater elements 37 are shown and described in commonly assigned US Application Serial No. 07 / 943,504 (PM 1550), discussed in conjunction with this application, and in commonly assigned US Patent No. 5,388,934 (PM 1697). , both of these documents are incorporated here. The additional heater clamps 37, which are operative as part of the lighter 25, include those disclosed in commonly assigned, commonly pending U.S. patent application having the serial number: --------- (not shown), filed

6 January 1995 (Agenda No: PM 17293 CIP II), in commonly-assigned, commonly-pending U.S. application Serial No: 08/291 690, filed Aug. 16, 1995

1994 (agenda no .: PM 1719); all of these documents are incorporated herein, and up to 23 below. The heater fibers 37 are a power supply 35a. by heating the perimeter 41 to heat the cigarette 25, preferably eight times at spaced locations around the perimeter 25. The heating provides the ability for the smoker to draw from the cigarette 25, as is usually the case with smoking a traditional cigarette. It may be allowed to glow so that the smoker once prefers the cigarette eight times (filament).

Another embodiment of the heater.

more than one heater or multiple times of the preferred cigarette is disclosed in a co-ordinated, co-assigned sensor tube 45. suitable for indicator 51 shown 53 will record the presence of U.S. patent application Ser. No. 08/224 848 filed 8 April 1994 (PM-1729B), which is hereby incorporated herein.

According to the embodiment shown in FIG. 2, the circuit 41 is preferably activated by a pull-activated sensor (s) 45 that is sensitive to either pressure changes or size changes in the airflow that occur as a smoker begins to draw from the cigarette 23. The pull-activated sensor 45 is preferably located within the front portion of the lighter housing 25 and communicating with the space inside the heater fixture 33 adjacent the cigarette 33 by a passage formed through a spacer in the base portion of the heater fixture 39 and, if desired, ( not shown). A pull-activated sensor for use in the smoking system 21 is described in commonly assigned U.S. Pat. No. 5,060,671 (PM 1337), the contents of which are incorporated herein. The coating sensor 45 preferably comprises a silicone sensor. Model 163PCO1D35, manufactured by MicroSwitch of Honeywell, Inc., Freeport, Illionis. Flow sensing devices, such as those employing hot wire anemometry principles, have also been successfully applied as being useful for activating the respective one of the heater elements 37 by detecting a change in the air flow. Once activated by the sensor 45, the control drain 45 directs electrical current to one of the respective heater elements 37.

The indicator S1 is disposed along the outer portion of the lighter 25 / preferably on the front casing 33 to indicate the remaining number of strokes when smoking the cigarette 23. The indicator S1 preferably comprises a liquid seven-segment crystal display. In the preferred embodiment, the number 8 is when the cigarette detector is a cigarette in the heater fixture 39.

Preferably, the cigarette detector 33 comprises a light sensor at the base of the heater fixture 33 which detects when a light beam is reflected from the inserted cigarette 23. Based on suggests a puff,

cigarette 22 O. When the cigarettes 52

the cigarette detector 53 provides a signal to the circuit 41 which, in response, provides a signal to the indicator 51. Representation of the number 8 on the indicator S1 that eight tons are available in each cigarette 22. i.e., none of the heater elements 37 has been activated to heat the cigarette 23. After it is completely smoking, the indicator shows the number the cigarette 23 is removed from the lighter 25, the detector 53 no longer detects the presence of the cigarette 23 and the indicator 51 is off. The cigarette detector 53 is modulated so that it does not immediately emit a light beam that would otherwise create an unnecessary load on the power supply 35a. A preferred cigarette detector 53 suitable for use with this smoking system is a light sensor. Type OPB5005, manufactured by OPTEX Technology, Inc., 1215 West Croeby Road, Carrollton, Texas.

75006, USA.

As an alternative to showing the rest of the number of moves, the detector may instead be arranged to indicate whether the system is activated or not (on or off).

As one of several possible alternatives when using the aforementioned cigarette detector 53, a mechanical switch (not shown) may be provided to detect the presence or absence of the cigarette 23 and a knob may be used that is resetting to reset the circuit 41 when the new cigarette is inserted. to the lighter 25, for example, to indicate indicator 51 to represent β, etc. Power sources, circuits, coating activated sensors, and indicators useful in the smoking system 21 of the present invention are described in U.S. Pat. No. 5,060,671 (PM 1337), which was jointly assigned, and co-assigned in U.S. Patent Application Serial No. 07 / 943,504 (PM 1550). Both are incorporated herein by reference.

According to the embodiment shown in FIG. 4A and 4B, the cigarette 22, as formed according to a preferred embodiment of the present invention, comprises a tobacco rod 60 and approximately 6 mm through the tobacco rod 62 is preferably a filter tip 62 which are joined together by a paper tip 64.

The partially filled, refill cigarette 23 preferably has a substantially constant diameter along its length and, as more traditional cigarettes, is preferably about 7.5 mm and 8.5 mm in diameter so that the smoking system 21 gives the smoker a confidential mouthfeel. In a preferred embodiment, the cigarette 23 has an overall length of 62 mm and thus makes it easy to use traditional packaging machines when packing cigarettes 23. The combined length of the mouthpiece filter 104 and the free passage filter 102 is preferably 30 mm. The top paper is preferably drawn through tobacco 60. The total length of the rod is 32 mm. Instead of these dimensions of the preferred embodiment, other length and diameter sizes may be selected.

The tobacco rod 60 of the cigarette 23 preferably comprises a tobacco web 66 which has been folded into a tubular form.

The wrap Zi tightly encapsulates the tobacco web 66 and is held together along the longitudinal seam, as is customary in making traditional cigarettes. The wrap 71 holds the tobacco structure 66 in a wrapped state around the free pass filter 74 and the tobacco plug 80.

Preferably, the paper of the teen cigarette wrapper 7i is wrapped around the tobacco web 66 so as to give it an outer appearance and feel than a more traditional cigarette. It has been found that tastier smoke is obtained when the wrapper paper 71 is a standard type of cigarette paper, preferably flax paper having a value of about 20-50 COBEST (defined as the amount of air measured in cubic centimeters passing through one square centimeter of material, e.g. , in one minute at a pressure drop of 1.0 kPa) and preferably about 30 to 45 COREST, with a basis weight of about 23 to 35 grams per square meter (g / m ² ) and more preferably about 23 to 30 g / m ² , and filling a filler (preferably calcium carbonate) of about 23 to 35% by weight and more preferably 28 to 33% by weight.

The paper of the wrapper 71 preferably contains little or no citrate, or other flame modifier, that a citrate level preferably ranging from 0 to about 2.6% by weight of the paper of the wrapper 71, and more preferably less than 1%.

Preferably, the tobacco web itself comprises a backing structure 68 and a layer of tobacco flavor material 70 positioned along the inner surface of the backing structure 68. At the tip end 72 of the tobacco rod 60, the tobacco structure 66 is wrapped around the tubular tubing. , the free-flow filter element 74. The free flow filter 74 provides the structural definition and support of the tip end 72 of the tobacco rod 60 and allows the aerosol to be drawn from inside the tobacco rod 60 with a minimum pressure drop. This free flow filter 74 also acts as a flow restriction at the tip end Z2. tobacco rods 60, and is believed to aid in aerosol formation as the smoker draws on the cigarette

25. The free flow filter is preferably at least 7 mm long to facilitate cigarette handling machines and is preferably annular, although other low power filter shapes and types b are also suitable, including cylindrical filter cartridges.

At the free end 78 of the tobacco rod 60, the tobacco structure is fefi. and a wrapper 71 wrapped around a cylindrical tobacco plug. Preferably, the tobacco plug 80 is assembled separately from the tobacco web 66 and includes a relatively short column of cut filler tobacco that is wrapped inside and held by the wrapper 84.

Preferably, the tobacco plug 80 is formed on a traditional tobacco rod manufacturing machine in which the cut filler (preferably a blend) is air formed into a continuous tobacco rod on a conveyor belt and wrapped with a continuous ribbon wrapper 84 that is then glued along its longitudinal seal and closed. However, in accordance with a preferred embodiment of the present invention, the wrapper of the liner 84 is preferably composed of a cellulosic structure with little or no filler, with adhesive or flame additives (each below 0.5% by weight) and preferably with little or no adhesive . Preferably, the wrapper of the liner 84 has a basis weight, below 15 grams per square meter, and more preferably about 13 grams per square meter. The wrapper of such an insert 84 preferably has a high permeability in the range of from about 20,000 to 35,000 CORESTA and more preferably in the range of from about 25,000 to 35,000 CORESTA and is preferably composed of fibrous pulp of softwood pulp of Manila hemp or other pulp with long fibers. Such papers can be purchased from Papierfabrik Schoeller & Hoechst GMBH, Postfach 1155, D-76584, Gernsback, Germany. Yet another paper suitable for use in wrapping tobacco web 84 is TW 2000 paper from DeMauduit of Euimprle, France, with the addition of carboxy-methyl cellulose at a level of 2.5% by weight.

The tobacco rod manufacturing machine is operated to provide a tobacco rod density of about 0.17 to 0.30 grams per cubic centimeter (g / cc), but preferably in the range of at least 0.20 to 0.30 g / cc and most preferably between about 0.24 to 0.28 g / cc. Increased densities are preferred in order to avoid the free ends at the free end 78 of the fifth tobacco rod. However, it will be appreciated that lower densities of the tobacco rod will allow a column of tobacco

80. to contribute to greater proportions of aerosol and flavor to smoking. Accordingly, a balance must be struck between the delivery of the aerosol (which favors low density in the tobacco column 32) and avoiding the free ends (and this favors an increased tobacco rod density range).

The tobacco column 84 preferably comprises a cut filler of a mixture of typical tobacco in the industry comprising blends of distinctive, strong and oriental tobacco together with optionally reconstituted tobacco and other components of the blend that contain traditional cigarette flavors. However, in a preferred embodiment, the cut filler of the tobacco column 84 encompasses a blend of strong, strong, and oriental tobacco 84 at a ratio of about 45:30:25 on the US market without incorporating reconstituted tobacco or other flavors. Optionally, the composition may comprise an expanded tobacco component to adjust the density of the bar, and flavors may be added.

The continuous tobacco rod formed as described above is cut in accordance with a predetermined length of the liner into the tobacco liner Sfi. This length is at least 7 mm to facilitate machine handling. Although the length may vary from about 7 mm to 25 mm or more, depending on the preferred design of the cigarette, this will be apparent in the description that follows, referring to FIG. 4A and 4B.

As a general matter, the length of the tobacco web 86 is preferably adjusted in proportion to the total length of the tobacco. the tobacco rod 60 such that a void space 20 is defined along the tobacco rod 60 between the filter and the free flow 74 and the tobacco plug 70. The void space 60 corresponds to the unfilled portion of the tobacco rod fefi and is in fluid communication with the tip < through a free flow filter of fifi tobacco rod 74 ·

According to the embodiment shown in FIG. 4A, the length S6 of the tobacco plug 80 and its relative placement along the tobacco rod 60 is also selected in relation to the characteristic features of the heater elements 32. When the cigarette is properly positioned against the heater clamp stop 182, a portion 92 of each heater element 37 will contact the tobacco rod. 60 along one region of the tobacco rod

60. This contact region is referred to as the heater fingerprint 94. The heater fingerprint 94 (as shown by the double arrow in Fig. 4A) is not part of the cigarette structure itself, but is instead a representation of the tobacco rod region 60 where it is expected Accordingly, since the heater elements have a fixed distance 96 from the heater fixture stopper 33, the heater fingerprint 94 is consistently positioned along the tobacco rod fifl. at the same predetermined distance 96 from the free end 78 of the tobacco rod 60 of each cigarette 23 that is fully inserted into the lighter

23rd

Preferably, the length of the tobacco plug 80, the length of the heater imprint 24, and the distance between the heater imprint 24 and the stop 182 are selected such that the heater imprint 94 is positioned behind the tobacco insert 80 and overlaps a portion of the void 90 by 2fi distance. the void space 90 (the unfilled portion of the tobacco rod 60) is also referred to as the void cavity cover by the heater. The distance that the remainder of the heater fingerprint overlaps the tobacco plug 80 is called the filler overlap with the heater 22. ·

The tip 62 preferably includes a free flow filter 102 disposed adjacent the tobacco rod 60 and a mouthpiece filter insert 104 at the distal end of the tip 62 from the tobacco rod 60. Preferably, the free flow filter 102 is tubular and carries air with very little pressure drop. However, other, low-performance, standard filters could also be used. The internal diameter of the free flow filters 96 is preferably at or between 2 and 6 mm and is preferably larger than the free flow filter 74 of the tobacco rod 6fi.

The mouthpiece filter insert 104 closes the free end of the tip 62 for appearance and when desired to perform some filtration, although it is preferred that the mouthpiece filter insert 104 contains a low efficiency filter with about 15-25% efficiency.

The free flow filter 102 and the mouthpiece filter insert 104 are preferably joined together as a combination insert 110 with a cartridge wrap 112. The cartridge wrap LL2. it is preferably a porous, lightweight liner wrapper that is traditionally applicable to a person working in a particular cigarette manufacturing technique. The combination liner 110 is attached to the tobacco rod 60 by paper 64 in a manner that is standard and traditionally used throughout the cigarette industry. The tip paper 64 may be of cork, white or other color according to aesthetic preferences.

Preferably, the cigarette 23, formed in accordance with a preferred embodiment, has an overall length of approximately 62 mm, of which 30 mm comprises a combined insert 110 of the tip 62. Accordingly, the tobacco rod 60 is 32 mm long. Preferably, the free flow filter 74 of the tobacco rod 60 is at least 7 mm long and the hollow space Si between the free flow filter 24 and the tobacco plug fifl is preferably at least 7 mm long. In a preferred embodiment, the heater fingerprint 94 is approximately 12 mm long and positioned to provide a 3 mm overlap of the void space with a heater, leaving a 9 mm heater fingerprint overlapping the tobacco plug 10.

It is to be understood that the length of the cavity 91 and the length of the tobacco plug 80 can be adjusted to facilitate manufacture and, most importantly, to modify the smoking characteristics of the cigarette 23, including adjustments in its taste, pull and delivery. The length of the hollow space 91 and the amount of filler overlap by the heater (and the hollow space overlap by the heater) can also be manipulated to adjust the immediate response to promote consistency in delivery (from puff to puff as well as between cigarettes) and control condensation of aerosol in or around heaters.

In a preferred embodiment, the void space 31 (portion of the tobacco rod 60 without filler) is positioned approximately 7 mm to provide adequate clearance between the heater fingerprint 94 and the free flow filter 24. In this way, the heater fingerprint 94 is not heated during smoking. free flow 24 · Other lengths are also suitable, for example, when manufacturing tolerance permits, the hollow space 91 could be made approximately 4 mm short or shorter, or alternatively longer than 7 mm to form an elongated portion without filler along the tobacco rod 60. The length range of the filler-free portion (cavity 21) is preferably about 4 to 18 mm, more preferably 5 to 12 mm.

The backing layer 68 physically separates the heater elements 37 from the tobacco flavor material, transmits the heat generated by the heater elements 37 to the flavor material 70 and maintains the physical consistency of the tobacco rod during insertion of the cigarette into the lighter 25 and removal of the cigarette after smoking.

In the description that follows, certain percentages and / or relative weights of the various components that include the tobacco structure are set 66. Unless explicitly stated otherwise or readily apparent to one of ordinary skill in the art, on the contrary, percentages are given. the ratios are on a dry weight basis, ie said percent and / or relative weight levels do not contain moisture.

The process for manufacturing the tobacco web 66 is preferably without the addition of carbon fiber as described in the following paragraphs. At the conclusion of the preferred manufacturing process, the backing structure 68 preferably has a total basis weight of about 35 to 45 g / m ² , more preferably about 40 g / m ² . At a weight of 40 g / m ^2, the backing structure 68 preferably comprises about 28 g / m ^{2 of} tobacco fiber and about 12 g / m ^{2 of} cellulose fiber such as wood pulp or flax. The cellulosic fiber serves as a cellulosic reinforcing agent in the composite of the backing structure 68. It is preferred to minimize the amount of cellulosic fiber in the backing for subjective reasons (to avoid the possibility of making a note on the paper taste of the cigarette). Generally speaking, the ratio of tobacco fiber to cellulose fiber in the dry weight backing layer 68 should be in the range of about 2: 1 to 4: 1. The preferred cellulosic material is unbleached kraft softwood pulp, although most wood and flax fibers are functional.

An alternative strengthening agent of the backing layer 68 is a cellulose fiber of the produced tobacco stem.

Although this is not preferred, it is possible to apply fifi along the side along one side. an alginate coating of approximately 1 g / m ² . If alginate is applied, then it is preferred to use it on the side of the backing layer 60, the opposite side receiving the tobacco flavor material 70.

Tobacco material. is preferably spiked onto the backing layer 68 at a dry weight level of at least two and preferably about three to four times greater than the backing layer 68. In a preferred embodiment, the tobacco material has a basis weight of about 130 g / m 2 so that the total weight of the tobacco structure 66 is approximately 170 g / m 2. Based on dry weight, the tobacco material 70 comprises a proportion of ground tobacco and extracted solids in a ratio of about 3.5: 1 to 5: 1 by weight, although this ratio may vary from about 3: 1 to 9: 1. In a preferred embodiment, the ratio is about 4: 1.

Preferably, about 12 * dry weight of tobacco material 70 is added to the tobacco material 70 as a moisture stabilizer and its aerosol precursor at a level of about 10 to 14, but this level may change at any time from about 5 to 20% or more of the dry weight of tobacco material 70. When the glycerin is reduced to only about 5 to 7% of the dry weight of the compound, the tobacco web 66 may be somewhat stiffer and more resistant to spillage when rolled into a tubular form.

Also added to the tobacco material 70 is pectin at a weight percent in the range of about 0.5 to 29%, preferably 1.4%. Pectin is added as a coating. In its absence, the tobacco material 70 may tend to penetrate the excess backing 68 during the coating operation, thereby giving the texture a granular surface to the treated tobacco web 66. Very much pectin interferes with penetration and weakens the bond between the tobacco material 70 and the fifi backing. At about 199, pectin promotes adequate penetration and bonding between the layers so that the backing layer 68 can withstand the stresses of automated cigarette manufacturing.

Most preferably, the tobacco material 70 on the backing layer 68 comprises approximately 16-20% dry weight of the extracted tobacco solids, 66-71% dry weight of the ground tobacco particles, 8-1449% of glicerin, and approximately

1.4% pectin. Ground tobacco marketed in the United States, which is processed into the respective tobacco material 70, preferably comprises a blend of strong, strong and oriental tobacco in which nearly half of the blend is strong tobacco, approximately 1/3 is strong and the remainder is oriental tobacco. The composition and relative amounts of the respective components of the composition can be modified to meet consumer preferences in the US and other markets.

According to the embodiment shown in FIG. 5A and 5B, a preferred method of manufacturing a tobacco web blank 66, in a form suitable for automatically manufacturing cigarettes 23, comprises a first series of steps 120 (shown in FIG. 5A) to convert a tobacco feedstock, preferably a tobacco web, into a continuous layer of tobacco web 66s. and a second series of steps 122 (shown in Fig. 5B) transforming the continuous tobacco web 66s into one or more wound tobacco web reels 66b that are in a condition for use in the automatic manufacture of cigarettes 23.

According to the embodiment shown in FIG. 5A, the process 120 of converting the tobacco feedstock into the continuous layer of the tobacco web 66 begins by subjecting the tobacco feedstock to an extraction step 124 (preferably using water) to separate the tobacco fiber from the soluble tobacco portions of the original feedstock. The tobacco feedstock preferably comprises a tobacco web, but other forms of tobacco and / or tobacco layer are also suitable for use in this process. The tobacco web preferably comprises a blend of strong and strong tobacco, and optionally may comprise oriental or other varieties. The tobacco fiber according to the extraction process 124 is subjected to a papermaking process 126 for forming a continuous layer 68b of the backing structure.

In process X2, the tobacco fiber from the extraction process 124 is dispersed in water, and by adding a predetermined amount of cellulosic fiber to serve as a reinforcing agent in the composition of said substrate structure 68. The cellulosic fiber preferably comprises shredded (pulp) wood, linen and / or pulp or tobacco stem. Once bonded, the blended dispersions of tobacco fiber and cellulose fiber are refined to form a slurry of structure 128. suitable for casting in the casting step 130. wherein the slurry of structure 128 is directed to the molding frame of the forming machine structure and casting. to a wire mesh (longitudinal mesh), or to an endless steel strip, preferably to the aforementioned mesh.

It is preferable to refine the dispersed mixture of tobacco fiber and reinforcing agent after mixing the two parts together. Alternatively, they can be cleaned separately and then combined.

After the casting step 130, the resulting structure 132 is then directed through one or more dryers in a drying step 134. This step preferably comprises passing the structure through a Yankee dryer and one or more drum dryers, although initial alternative arrangements and devices are known in the art and applicable to the drying step 134. At the conclusion of the drying step 134, a monitoring step 136 is performed to measure the moisture content and weight of the dried structure. The moisture content output 138 is used to adjust the drying operation 124 to achieve and maintain the desired final moisture level in the backing layer 68s for subsequent surface treatment (coating) 144. The backing layer 68b has in this operation preferably about 15% or about 15% by weight of moisture.

According to the already mentioned monitoring step 136, the layer weight output 140 of the backing structure 68b is used to adjust the operation of the casting step 130 to achieve the basis weight in the preferred backing layer 68 as described above. Said adaptations include changes in the amount by which the slurry of structure 128 is applied to the molding frame of the machine that forms the structure in the casting step 130.

Optionally, the structure formed by step 126 may further include a coating step 142 that covers one side of the alginate backing structure 68a at the level already described along one side of the backing structure 68b.

which is the opposite side that receives the tobacco flavor material 10. However, the process without applying alginate has priority in practice.

At the conclusion of the process that shapes the structure, the underlying structure is in the form of a continuous layer 68b. 144. As an alternative, it may be collected for subsequent off-line coating operations. Nevertheless, it is preferred that by forming a layer of the underlying structure 68b. 144 immediately.

The backing structure 68s preferably enters a coating operation 144 having a moisture content of approximately 12 to 17 times, more preferably with a humidity of 14.5 to 15.5 times.

In the extraction (leaching) step 124, the soluble tobacco portions leave the extraction step 124 in the form of a dilute solution containing about 5 to 10 percent dissolved tobacco components, more preferably 7 to 8 percent dissolved tobacco components. This dilute solution does not evaporate so (glow) to the solution.

preferably subjected to no treatment to minimize heat application The application of heat to the solution may have a flavor effect contributed by tobacco soluble ingredients when they are smoked as part of a cigarette 22 These soluble ingredients (also known as leached liquor) from the extraction step 124 are mixed in the mixing step 146 with additional, finely ground tobacco, glycerin and pectin, together with water, all in proportions which finally confer final relative contents, as already described for the dry state of the tobacco material

70. In conjunction with the mixing step 146, water is added (or retained) in an amount sufficient to form a dispersion having a solids content of about 20 to 35 percent, preferably a solids content of about 24 to 26 percent, at the end of the mixing step 124. The ground tobacco particles in the blend are preferably in the range of 60 to 400 Ôk, the term eye refers to the 95X rate of tobacco particles passing through a web having a given number of holes per square inch (6.45 cm ² ). More preferably, the ground tobacco particles are in the range of about 100 to 200 mesh, and most preferably about 120 mesh.

When the meshes of the ground tobacco particle are set above 120, more specifically at or about 180 to 220, the solids content of the slurry at the end of the mixing step 146 can be increased, for example to a level of about 28 to 31%.

At the conclusion of the mixing step 146, the resulting slurry of tobacco material is directed directly to the coating operation 144. although this coating operation can be effected at some subsequent time on the basis of a separate embodiment (α-line). In the surface treatment operation 144 the slurry of tobacco material should have a solids content of about 22-27% by weight, more preferably at or about 24-25%.

In the coating step 144, the slurry of tobacco material has a final weight percent tobacco soluble particle of 4 to 8 percent, more preferably 5.5 to 6.5 weight percent tobacco soluble particles. The pulpy tobacco material preferably enters a heat treatment operation 144 in the range of about 70 to 130 ° F (21.1 to 54.4 ° C, more preferably at or about 90 ° F (32.2 ° C), plus or minus 5 ° F.

The surface treatment step by means of standard treatment 128 is preferably performed by a reverse roller coating device which is located downstream of the Yankee dryer, behind the endless belt or the longitudinal (sintered) screen. This coating step may be performed by other suitable coating devices known and available to one of ordinary skill in the art of structure forming operations. The tobacco material 70 may instead be cast or extruded into the backing structure 68. Alternatively, the application step 128 may be taken offline, separate from the production of the backing layer 68s layer. During or after the coating step 128, flavors traditional in the cigarette industry are added, if desired.

At the end of the surface treatment operation 144, a continuous layer of tobacco web 66b is produced.

According to the embodiment shown in FIG. 5B, the process now proceeds from the steps 122 of transforming the tobacco web 66b into a wound tobacco web reel 66b that is suitable for the automatic production of cigarettes 23. Preferably, these conversion web steps 122 are made online by making a continuous web of tobacco web 66b. During the conversion step 122, the operator should avoid conditions that create cracks, cracks, or other imperfections in the tobacco web 66s so as to obtain a continuous winding of the tobacco web in the bobbin 66b with little or no connection. In addition, the layers of the tobacco web 66s are conditioned so that, at the end of the conversion steps 122, the tobacco web does not bind to itself and can be quickly wound and unwound from the reel 66b. without breaking.

Conversion steps 122 begin with a drying step 146, in which preferably the layer of tobacco web 66b is continuously promoted by a gaseous impact hot gas dryer, such as the type from Airtech Systems Corp.. of Stroughton, Maine, USA, or a hot air steam dryer. Instead, other dryers known in the art for forming structures may be used. The drying step 146 should be performed with minimal heat application, but in an amount sufficient to dry the tobacco web 68b from its original state (about 15% moisture content in the base layer and about 75% moisture content in the coating itself) to about a total of 8.5 Preferably, the dried tobacco web layer 66d has a moisture range of about 10-11%. This final moisture content is preferred for several reasons: to adjust the moisture content of the conversion process 122 at a later stage to facilitate longitudinal cutter operations; to about one where self-ignition will be self-ignition

If the material could be kept in balance during storage and / or shipment to the production facility; and to create a moisture level that avoids tackiness and bonding of the backing layer material to itself in the spool 66b.

Following the drying step 126, the dried layer of tobacco web 66d is cooled to ambient temperature, preferably one that is preferably equal to the site of likely storage and / or associated manufacturing equipment, usually in the range of 65 to 80 ° F (18.3 to 26.6). C). This cooling step 148 not only facilitates the equilibrium of the tobacco web 66 to the operating environment, but also avoids the risk of heat that is retained within the coil 66b. and this could otherwise initiate the process would not be controlled, lead to xtremic temperatures and degradation of the subjective nature of the tobacco structure

66. This cooling step, preferably performed using an ice-water impact air cooler, is available from Airtech System Corp. Stroughton, Maine, USA. Instead, other alternative cooling systems may be used, which are known to one of ordinary skill in the art of forming structures.

After the drying and cooling steps 146 and 148., the dried and cooled layer of the tobacco web 66cd passes through a dewatering device such as that offered by Thermo Elektron Web Systems, Inc. of Auburn, or other suitable fumigating equipment known and applicable to one of ordinary skill in the art of forming structures. At the conclusion of the deburring step 150, the tobacco structure 66 is substantially free of thermally induced collapsing along its edges and is ready for subsequent winding and cutting steps 152 and 154. However, it is preferable to monitor the temperature, humidity level and total weight of the tobacco layer 66b structure, leaving the de-flowing step 150 to provide feedback and control of the process, to fly off that the tobacco web layer 66b is ready for winding and cutting, and will result in desirable final temperature and humidity values and the total weight of the bobbin 66b.

In particular, when monitoring the tobacco web layer 66s, its total weight value is used to adjust the coating operation 144, for example, to the extent of supplying the slurry of tobacco material to the reverse roller coating device or the pinch gaps of the roller of the coating device. The moisture level value in the monitoring step 151 is used to control drying operations to achieve the final moisture level in the layer as described above. Similarly, the cooling step 148 is controlled in response to the temperature values of the tobacco web layer 66b in the monitoring step 151.

Thereafter, the tobacco web layer 66b is wound in a winding step 152 which is made by the structure winding devices known and available to one of ordinary skill in the fabricating technique. Subsequently, for this purpose, the tobacco web layer 66s is cut into individual bobbins 66b in which the cutting width of each bobbin corresponds to the desired circumference of the cigarette 23.

At the conclusion of the conversion step 122, the coil 66b is ready for automated cigarette manufacturing processes 23 / such as in the bonding operations shown with reference to FIG. 6 of commonly-assigned, commonly-pending U.S. application Ser. No. 07 / 943,504, filed September 11, 1952, the disclosure of which is incorporated herein by reference in its entirety.

Glycerin in tobacco material ΖΏ. it serves as an aerosol precursor and facilitates the formation of a visible aerosol during smoking of the cigarette. 23 In addition, when glycerin is released into the atmosphere, it condenses and gives the look expected of cigarette smoke. Other moisture stabilizers suitable for use in the tobacco industry may be used in its place.

Optionally, after the casting step 123, the side of the structure 98 may be covered with alginate before, during, or after the surface treatment step 126. The alginate surface provides sufficient strength and film formation along one side of the backing layer 68 described in the commonly assigned patents. it has sufficient strength without alginate and it is preferred to practice forming the underlayer 68 without it.

The present invention can be practiced with another type of support structures comprising carbon-fibrous or metallic or mesh materials (mats, rugs, matrices) discussed and jointly in US applications, Serial No. 07/943 504 (PM 1550) and Serial No. No. 07/943 747 (PM 1655), and commonly assigned U.S. Pat. No. 5,388,549 (PM 1697), and European Patent Application EP-A-0 615 411, all of which are incorporated herein by reference in their entirety.

With respect to carbon-fiber structures as disclosed in EP-A-0 615 411, and co-assigned U.S. Pat. 5

388 549 (PM 1697). 08/380 718, filed 30.

discussed as September 1995 (PM 1697 Cont.), the matting structures comprising tobacco fiber in a preferred composition of said backing structure 68. ranges from 20 to 30 g / m ^2, preferably about 24 to 28 g / m ² , most preferably 26 g / m ² , a carbon fiber in the range of 2 to 9 g / m ² , preferably 2 to 4 g / m ² , and most preferably 3 g / m ² , and a pectin in the range of about 0.5 to 1.5 g / m ² , and most preferably about 1 g / m ² pectin. Preferably, the components are balanced to form a backing layer 68 having a basis weight of about 30 g / m ² . It is also preferred to use a carbon fiber having a strand length of 1/4 inch (6.35 mm) to facilitate its dispersion during the slurry forming portion of the process. Initiation of the carbon fiber feedstock dispersion is facilitated when processes such as those disclosed in U.S. Pat. 4,007,083 and 4,234,379.

In an alternative embodiment of the tobacco backing layer 66 (ie, carbon fiber mats), the total weight of the finished dry layer is approximately 160 g / m ² of which 30 g / m ² comprises the backing layer 68 and 130 g / m ² includes the tobacco material 70. more preferably, the carbon fiber-free tobacco backing 66 has a dried layer weight of approximately 170g / m ² , of which 40g / m ² comprises the backing 68 and 130g / m ² includes the tobacco material 70.

Although any type is used for the backing layer 68 (or carrier), the tobacco material 70 is preferably disposed on the inner surface of the backing layer 68 and releases the tobacco flavor aerosol (response) when heated. Such materials may also comprise continuous layers, foam gels, dried slurries, or dried, spray-applied slurries of tobacco material.

According to the embodiment shown in Fig. 3 and in conjunction with the teachings incorporated by reference in commonly assigned U.S. Pat. No. 5,388,594 (PM 1697) when the cigarette 23 of the preferred embodiment is inserted into the sleeve

27. is introduced into the heater 22 until the free end 78 of the cigarette 23 reaches the stop 182. fixedly in the base of the heater fixture 39. Once the cigarette is in place, the smoking process can begin, and accordingly, smoker pulls out of cigarette.

45. which, in cooperation, that the electric current is one of the heaters supplied through the electric 183 at one end recorded by the coating sensor with the control circuit 41 of the apparatus, supplied to the predetermined (heater fibers) 37. The current is a circuit that contains the leads of each heater fiber 37. a common ring 184 at the opposite end of each heater 37 and a common inlet 186. located from the common ring 184 back to the vicinity of the inlet 183. When each heater 22 is activated, thermal energy is transferred through the wrap 71 and the tobacco web 68 in sufficient quantity to cause that the tobacco flavor material 70 of the tobacco web 66 will release the tobacco aerosol within the confinement of the tobacco rod 60 that is drawn from the cigarette 23 in response to the action when the smoker withdraws from the cigarette at the tip end of the cigarette 23.

The smoker takes one coat of cigarette from 1.5 to 2.0 seconds, while the FTC cigarette testing procedures assume a duration of coating of 2.0 seconds.

Where the heater fingerprint 94 covers the hollow space 21, the aerosol is released directly from the heated tobacco flavor material 70 into the hollow space, and is accordingly drawn into and through the tip 52 with a very low pressure drop. On the other hand, where the heater fingerprint 94 overlaps Sfi. (heater / filler overlay 22), the tobacco plug 80 begins to heat the tobacco plug of the proximal portion B together with the proximal portions of the tobacco web 66. Accordingly, the blended tobacco plugs 80 contribute their own total aerosol fraction by contributing their flavor and other flavor. The aerosol released from the tobacco plug 80 in or around the heater / filler overlay 22 undergoes some filtration and pressure drop as it is drawn through the tobacco plug 80 and into the cavity 91.

The aerosol produced from heating the tobacco plug 80 has a character and taste that can be altered by the tobacco mixture, as well as adjustments in how many imprints of the heater 24 overlap the tobacco plug 80. The aerosol component that is produced near the hollow space 91 is released. cigarettes faster because there is less thermal inertia in the cavity 91 and because the thermally vaporized tobacco substance in the cavity 91 is not subject to a pressure drop of the tobacco plug 80 and is instead immediately transferred to the tip 62 by a free flow filter 74. released from the tobacco plug 80, since it is released predominantly from the tobacco flavor material 70 on the substrate structure 62. As will be explained in greater detail below, it has been found that, to satisfy the smoker, the aerosol delivered from the cigarette 22 preferably includes both the aerosol components to provide immediate delivery to the smoker and the flavor characteristics attributed to the blended filling tobacco. In the explanation that follows, it will be appreciated that the presence of the cavity 91 (and its instantaneous delivery) ensures consistent smoking, a coating from the coating of the cigarette 22, and promotes consistency (here coincidence) between cigarettes. This relationship is supported in the compared attributes of the pull-pull of the partially filled cigarette 23 formed in accordance with the preferred embodiment (which has a cut filler insert 80 and a hollow space 91). compared to cigarettes 23 * of the first alternative design of FIG. 6A having no cut filler within its rolled up tobacco structure, and the second alternative embodiment of FIG. 7A having a rolled tobacco structure fully filled with cut filler. In the description of these alternative designs, it should be understood that the tobacco web 66 ¹ and 66 includes a backing web and tobacco material 70 as in the preferred embodiment. The tobacco rods of these alternative designs also included repackaging 71.

A rotary type heater, with an energy setting of 15 joules, as shown in FIG. 6B and 7B, on the cigarettes shown in FIGS. 6A and 7A, respectively.

Referring to Fig. 6A, a cigarette adapted for smoking in an electrical smoking system of the first alternative design includes a tobacco rod 60 ¹ and a tip 62 *, each containing the components indicated by commas in the base numeral index, corresponding to the components shown in Fig. 4A. However, the tobacco rod 60 * of the cigarette 23 * does not encapsulate any cut filler within its tobacco structure fefe *, and the free end 78 * of the tobacco rod 60 * is provided with a backflow filter 200 *. The backing structure 68 * of the tobacco structure 66 * was of the carbon fiber-containing type as previously described. An embodiment of the cigarette 23 * is also detailed in commonly assigned U.S. Patent No. 5,388,594 (PM).

1697), which is incorporated herein by reference in its entirety. In the description that follows, reference will be made to this cigarette 23 * as a filler-free cigarette 23 *.

According to the embodiment shown in FIG. 6C, an otodetector was made

6V. Photosensor output 6 from light beam intensity Any tobacco aerosol, light diffusing effect attempts to use smoking devices in collaboration with the smoking system 21. The output of the smoking device was routed through each smoke measurement device 6v having a translucent chamber 6 where the light beam was illuminated. 6u from the source 6w passes through this translucent chamber 6v to 6z on the opposite side of the translucent chamber is treated to solve 6u. when it impinges on the sensor 6z that passes through the chamber 6v has a light beam on the light beam, so that any resulting change in the recorded light intensity in the forodetector 6z will in turn indicate the total particle mass (TMP) in the aerosol.

In accordance with PTC testing practices, it is preferred that the smoking device draws from the smoking system 21 Standard Two Second Coating.

The information graphically shown in FIG. 6B shows the intensity registered at the smoke measuring device relative to time as the smoking machine progressed through each of a succession of puffs on the cigarette 25 without the filler ¹ The data indicates the following trends: that with cigarettes 22 ^one filler-free first and second coating is consistent (here in accordance) with the remaining three draws, the latter three coatings being more consistent with each other, and that the aerosol is well delivered before the two second period for each coating. The filler-free cigarette 25 ¹ is less consistent in delivering the first few strokes, and consistency prevails only in the latter coatings. The first draw data is relatively consistent with the overall observation that the non-filler cigarette smoking device 23 ¹ delivers less aerosol during the first coating only if remedial action is taken such as perforation of the tobacco rod 60 ¹ or other measures as disclosed in US patent no. 5,388,594 (PM 1697).

According to the embodiment shown in FIG. design of an electric cigarette 23 ¹¹

7A, yet one includes a tobacco rod 60a tip 62 having components and arrangements similar to those of the preferred embodiment shown in FIG. 4A, with the same components indicated by a double dash in the base digit index. However, the cigarette 23 in FIG. 7A includes a rear flow filter 200 at the free end 78 and a column of cut filler 220 extending along the entire length of the tobacco rod 60 * between the rear flow filter 200 and the free flow filter 74 of the tobacco rod 60. and oriental tobacco, at a stick density of 0.275 grams per cubic centimeter. The backing structure 68 66 is a type of tobacco structure as already described with reference to the cigarette 23 filling the cigarette 23.

According to the embodiment of the illustrated intensity of the Light by the carbon fiber containing device 6v, in the discussion that follows, it will be guided as fully filled.

FIG. 7B, the smoke measurement measurement was correlated with the time passing of each coating of successive strokes, labeled from one to seven per fully filled filling cigarette 23. 7B are representative of the two recognizable trend in cigarette performance created in accordance with a fully filled 23 / pl fill cigarette, the first few puffs provide significant aerosol delivery, but then the supply decreases to such an extent that the last three draws provide substantially less delivery than the first draws. (unless corrective action is taken), and in a fully filled refill cigarette, the aerosol delivery delayed and the initial draws (puffs one, two and three) do not reach the maximum delivery unless a substantial portion of the two second period has elapsed.

During the first puffs, the fully-filled cigarette 23 tends to deliver a greater total volume of aerosol than 23 cigarette ¹ without fillers. A comparison of the data shown in FIG. 7B and FIG. 6B substantiates this overall remark (observation) in that the total areas above the line of the first few moves in FIG. 7B of the fully filled filling cigarette 23 / are larger than the total area above the first lines

The structures 66 are through the fact that during the first few moves in FIG. 6B with a cigarette 23i without filler. The area above the line of each coating in FIG. 7B and 6B indicate the total delivery during this thrust.

However, it is believed that the delay in delivery of the fully filled filling cigarette 23 leads the smoker to make an additional, stronger puff in response to the fact that he or she does not receive an immediate flavor response from the cigarette 23. This stronger coating in turn causes the heated portions of the package Z1. and the tobacco becomes completely consumed (oxygenated) of additional, through-drawn air so that several strokes cause more significant cracking and possibly localized spillage of the tobacco column 220. In addition, it is assumed that once in a fully filled filling cigarette, the 23-initiated pyrolysis has this tends to be more cohesive because it contains more flammable tobacco and / or because the tobacco is in a compact state. In any case, since air can be more easily drawn into the tobacco rod through the broken burnt points of the first few coatings, Ba assumes that localized breaks shorten the circumference of the desired air flow directions for subsequent coatings. Thereafter, the delivery is reduced during the later strokes of the fully filled filling cigarette 23. The data shown in FIG. 7B and the above explanation is based on a general note (comparison) that a fully filled refill cigarette 23 or a traditional cigarette, when smoked by electronic lighters, tends to deliver fewer products by the next draw.

With its delayed, even more self-sustaining pyrolysis, a fully filled cigarette 23 tends to generate large amounts of aerosol in the later stages of the draw, and at those times it can continue to produce the amount of aerosol when the smoker is actually coating the cigarette. The latter can result in the production of a post-coating which can persist within the lighter housing 33, particularly in or around the heater 39.

A portion of such a post-coating aerosol will be problematic to precipitate on the elements of the heater 33 or persist long enough until it is drawn into the cigarette 22 during the subsequent coating. One or the other consequence is detrimental to imparting a pleasant and lasting taste.

According to the embodiment shown in Fig. 6B, the filler lines of the traditional cigarette 23 * filler are evidence that the supply of aersol is maximized (where the stroke lines decrease most) before the two-second (2) duration of the standard stroke has passed, and the supply is at least later. stages of the puff, so that aerosol postpotiahnutia is not such a problem cigarettes 22 ¹ without fillers. However, as noted, a filler-free cigarette 22 ^l delivers less total aerosol volume than a fully filled fill cigarette 22, suffers from inconsistency during delivery for the first few coatings, and does not have the subjective attributes and flexibility that a smoker would surely enjoy if blended. (or even unmixed) cut filler.

Fig. 8 depicts comparative smoking data on a smoking device that uses smoke measuring devices 6y as described above using cigarettes made in accordance with a cigarette 22 ¹ without a filler; a fully filled filling cigarette 22i and a partially filled filling cigarette 22, constructed in accordance with the teachings of the preceding embodiment (as shown in Fig. 4A) of the present invention. In all these cigarettes, a carbofibrous material was used as a layer (the roof, shown in Fig. 8, partially filled 22 of the present invention provides a more consistent delivery during smoking. Avoid a drop in delivery that occurs during the previously mentioned strokes of the fully filled filling cigarette 22, and is more consistent in delivery than the filler-free cigarette 23 * during the first few coatings.

A partially filled refill cigarette 22 'which has been tested to obtain the data used in FIG. 8, was the backing mat). As a discussion of the data, the filling cigarette was filled halfway with the filler so that the heater over the hollow space in this cigarette design was relatively large, approximately 6 mm. The heater elements 37 used to generate the data shown in FIG. 8 were of the rotary type, with an energy of 15 joules per heater cycle.

According to the embodiment shown in particular in FIG. 8, the data there is presented by the amount of aerosol (in milligrams) generated during the first two seconds of each coating in a successive sequence of strokes during smoking of each particular type of cigarette. Referring to the data shown in FIG. 6B and 7B, the amount of aerosol indicated in FIG. 8 will analytically correspond to the integration (area already defined) of each coating line from 0 to 2 seconds in FIG. 6B and 7B.

The data presentation in FIG. 8 clearly illustrates the drop in delivery that occurs in a fully filled refill cigarette 23. when the smoker continues from the first draw to the next draw. In contrast, a non-filler cigarette does not suffer from a drop in delivery as in a fully filled refill cigarette.

The data presentation in FIG. 8 also clearly illustrates that čiaetočne filled cigarette provides consistency in delivery comparable to the cigarette 23 without the filler ¹ in the six puffs. In addition, it does so to its taste and subjective impression by contributing the cut filler.

According to Table II, there has been gathered data that indicate that changes in the size of the cavity heater overlap in a cigarette formed in accordance with the cigarette 23 can affect delivery. The data presented in Table II was produced by a device partially filled with cigarettes having a 32 mm tobacco rod and a 7 mm high flow filter at the tip of the tobacco rod and a 30 mm long tip in which the heater (heater fiber) imprint was 12 cm long and centered on the middle point of the tobacco rod of each cigarette.

Table II

Hollow space length (mm) 4 7 10

Heater overlap along the cavity (mm)

Heater overlap along the tobacco insert (mm) 11 8 5

Average TPM 4.9 5.5 7.0

Corrected average TPM (lowest value omitted) 5.2 5.9 7.3

Standard deviation of corrected diameter 0.34 0.53 0.5

Fig. 9 provides a graphical representation of total particulate matter (TPM) versus filler heater overlap (in millimeters). Data shown here was generated using standard testing techniques to determine the tar level of the FTC, using Cambridge pillows at two second stroke intervals on standard smoking devices. The cigarettes tested were partially filled, filling cigarettes having a carbon fiber backing structure and a total length of 58 mm, except that data appearing along the coordinate in FIG. 9 were obtained from a cigarette without a filler having a carbon fiber backing structure and the same overall length. When the tobacco overlap by the heater changed, the heater fingerprint remained constant and centered on the tobacco rods

Accordingly, any heater has created space for the center point of the tobacco overlap to increase the overlap proportionally to reduce the overlap of the hollow heater. The heater was of the rotary type having a heater imprint of approximately 10 mm. All data taken together suggest that in these circumstances there is a second series relationship between the total particulate matter delivered and the amount of filler overlap by the heater.

The data shown in FIG. 9 and the separate dataset in Table II show that the filler heater overlay size can be adjusted to achieve the desired (final) delivery level in the partially filled refillable cigarette. 22 Setting the filler heater overlay is the way that Ba prefers and achieves the desired the level of tar in partially filled fill cigarettes for reasons that state that the filler heater has a more controllable supply effect than the changes in rod density in the tobacco plug 80. This approach also allows to select the rod density in the tobacco plug 80 for a different purpose tar level, e.g. to control the free end and / or to produce the desired degree of pressure drop and / or filtration at the free end 78 of the tobacco rod 60, or otherwise facilitate manufacture. This also provides the capacity to change tar supply between related cigarette products, without having to change either the tobacco structure 66 or the tobacco plug 80.

It is also advantageous to assemble the proportional dimensions of the partially filled, refill cigarette 22 and the heater fixture 39 of the lighter 21 so that, by inserting the cigarette 23 into the lighter 21, each heater element 37 is disposed along the tobacco rod 6 such that heater imprint, covers only the filled portion of the tobacco rod (through the fifl tobacco insert). In such embodiments, the cavity 21 still facilitates aerosol formation and helps to cool the smoke. It is assumed. That the free pass filter Z4 helps to promote aerosol formation by constituting a restriction of the flow through the aerosol constituent when drawn from the wider cavity 21. In this respect, it should be noted that the free pass filter 74 of the tobacco rod Zfl represents the edges 22 and 75 in the passages between them and the hollow space 21 on the one hand and between it and the free pass filter 102 on the other hand, as already mentioned. These openings 22 and 75 are formed because the free flow filter 74 has a smaller inner radius than one or both of the other two opposing regions (the void cavity 91 and the space encapsulated within the filter b by the free passage 102). These edges 73 and 75 (and possibly other adjacent portions of the filter b through the free passage 74) are believed to promote turbulence and other flow conditions favoring aerosol formation from the gas phase and particulate phase constituents released from the heated portions of the tobacco rod tobacco. 10, the cigarette 23a is formed in accordance with b by yet another preferred embodiment of the present invention, having components and arrangements the same as those set forth in the discussion of the cigarette 23 in FIG. 4A, but with the addition of a rear flow filter 200a. located at the free end 78a of the tobacco rod 60a. This back flow filter 200a prevents tobacco from the tobacco plug 110 from escaping at the free end 78a. The free flow filter 200a may also be colored to indicate that the cigarette 23a for use with an electric smoking device, instead of being used with a match or a traditional cigarette lighter as with traditional cigarettes. Although the rear flow filter 200a is shown as a separate (separate) component of the wrapped tobacco plug, it is advantageous to connect the tobacco plug 80a to the rear flow filter 200a with the insert wrapper (not shown) to produce a cigarette 23a. With the rear flow filter insert 200a, the cigarette 23a may be provided with a tobacco insert 80a. having a low rod density, without risking problems such as loose ends or tobacco falling out of the tobacco rod 60a. As disclosed in EP-A-0 615 411, and co-pending and co-assigned US patent application Ser. 07/943 504, filed

On September 11, 1992 (PM 1550) and commonly assigned U.S. Pat. No. 5,388,594 (PM 1697), the rear flow filter 200a is configured to restrict or prevent aerosol release from the free end 78a of the tobacco rod 60a at the end of the coating and to create a pressure drop across the free end 78a so as to favorably limit the amount of air drawn in. into the cigarette 23a from the free end 78a relative to the proportional amount of air admitted along the sides of the tobacco rod 60a.

With respect to the filler cigarette techniques 22, preferably, the heater energy of the partially filled design that is given and the amount of filler overlap by the heater can be used to create and / or adjust the supply to the desired tar level. Accordingly, when designing a new partially filled, refill cigarette 22, it is generally applicable to select the density of the rod in the tobacco plug 80 to achieve the desired degree of pressure drop at the free end ZS. and / or for controlling the backflow or backflow in the same way as Ba achieves by the backflow filter 200a of the alternative embodiment 23a.

Referring to FIG. 11, one more cigarette 23b. made in accordance with yet another preferred embodiment of the present invention, comprises a tobacco plug 80b. comprising a low density portion 310b. adjacent to the free end 78b of the cigarette rod The cigarette 23b is formed such that the heater fingerprint 94b overlaps the low density portion 310b of the tobacco plug 80b so as to achieve increased delivery that is achieved by a lower rod density. The high density region of the cut filler 320b is configured to prevent loose ends and to limit the transfer of air axially through the rod B in a manner analogous to the rear flow filter 200a.

Currently preferred embodiments of the heater are shown in FIG. These heaters are suitable for any embodiment of the cigarette described herein, i. fully filled, partially filled and refilled cigarettes in FIG. 4a, 4b, 6a, 7a, 10, and 11, and modifications to these cigarettes. These heaters provide increased mechanical strength to re-insert and remove cigarettes 23, and greatly increase the generation of aerosols from the heated cigarette, while maintaining energy requirements. It has been found that the generated aerosols tend to flow radially away from the pulse heater.

In general, Ba favors eight heater blades 121 to provide eight coatings based on the sequential heater of the heater blades 121, and thus simulating the coating (s) of a traditional cigarette, the heater blades 121 are positioned away from the throat 110 to form a cylindrical receptacle 22- Preferably, a gap 129 is defined between adjacent heater blades.

It may be desirable to vary the amount of strokes, i.e. the number of heater blades 121. In & 3, the cigarette is inserted into the cylindrical sleeve CB. This desired number is achieved by providing the desired number of heater blades 121 This can be achieved by providing blades of equal or uneven size.

The heater fixture is arranged in the lighter throat 27, 25. The cigarette 23 is retracted, an optional 2flD rear flow filter. a first, in the neck 25, of the lighter 25 into the substantially cylindrical space of the heater fixture 39 defined by the annular cap 83 having an open end for receiving a cigarette, a cylindrical air channel sleeve 87, a heater assembly 100 including heater blades 121 or electrically conductive plug; lead 104A. which serves as a common supply of the heater elements of this heater assembly, electrically conductive, positive pins or leads 104B and a certain spacer. The lower inner surface S1 of the spacer drives the cigarette 23 in the desired position in the heater fixture 39 such that the heater blades 121 are disposed adjacent the cavity 78 in the cigarette, and are preferably arranged as described with respect to FIG. 1 and 11.

Essentially, the entire heater 22 is disposed inside and secured in position by a tight fit with the housing 31 of the front portion 23 of the lighter 25. The forward edge of the cap S2 is preferably disposed in or slightly spaced apart from the first end 22 of the lighter 22 and preferably to facilitate insertion of the cigarette 22 into and out of the heater fixture 22. Pins 104A

4Ί defines an overall throat 365. which and 104B are predeterminedly received in corresponding sleeves (not shown), thereby providing support for the lighter clamp 22, and wires or printed connections extend from the sleeve to various electrical elements. Other pegs may provide additional support for peg system reinforcement. Pins 104A and 104B may include any suitable material and preferably comprise tinned phosphor bronze. Pass 47 in the spacer and SO base. they are connected to the activated sensor 45 and the light sensor 53 senses the presence or absence of the cigarette 23 in the lighter 25.

As shown in FIG. 12 and 13, the heater assembly 100 preferably has a monolithic structure that includes eight heater blades 121 disposed from the central throat 111 in a symmetrical configuration or as already described in reference to Figs. 19, in an asymmetrical configuration. As best seen in FIG. 13, the heater assembly has a circular insertion opening 360 having a retracted cigarette toward a coaxially defined cylindrical sleeve R having a diameter smaller than the insertion opening 360. The insertion opening 360 is delimited by respective end portions 118B of the connecting portions 118 of the heater blades 121 and the neck 365 is defined by a portion of the sections 118 between the connecting edge 118A and 118B. The insertion end 360 preferably has a diameter that is larger than the inserted cigarette 23 to guide the cigarette towards the sleeve, and the sleeve has a diameter approximately equal to the cigarette 23 to ensure a tight fit for good thermal energy transfer. The cigarette 23 preferably has a diameter that is approximately equal to the range of diameters known in the art. Taking acceptable manufacturing tolerances for the cigarette 23 / the gradually tapered surface or neck 365 in the passageway between the distal end and the collar CB may also serve to slightly squeeze the cigarette, to increase thermal contact with the surrounding blades 121 serving as the inner wall of the collar. By way of non-limiting example, the insertion tip 360 preferably has an inside diameter of about 0.356 inches ± 0.02 inches (0.9 cm ± 0.05 cm), and the sleeve CR preferably has an inside diameter of about 0.278 inches ± 0.02 inches (0.02 inches). 7 cm ± 0.05 cm). The blades 120 may be bent inward to increase thermal contact with the cigarette by limiting the diameter of the cylindrical sleeve.

Each U-shaped heater blade 121 includes a first section or arm 116A disposed at a first end from the neck 111. a connecting portion 118 coupled to the opposite second end of the first section or arm 116A, and a second section or arm 116B positioned at a first end from the connecting portion 118 The first and second arms 116A and 116B are separated by a gap 125, which may be relatively constant, preferably being substantially parallel in any unwound state as in FIG. 18 and 19, as discussed below, are continuous in the insertion direction of the cigarette to reduce unwanted cigarette retention and are oriented towards the definition of the cylindrical sleeve 6 of the inserted cigarette 23.

The connecting portion 118 has a curved connecting edge 118A for connecting the opposed inner edges of the blade arms 116A and 116B such that a formed U-shaped elongated resistive path is substantially parallel to the longitudinal axis of the inserted cigarette along the cigarette, as discussed in more detail below. The curved connecting edge 118A preferably has a curvature of approximately 180 ° ± 20 ° so that it is formed into a U-shaped blade and has a curvature that is concave towards the neck 111 and convex towards the sliding opening 360. The first end of the first blade arm 116A at the neck H1. may have an increased width, with approximately the same thickness, in the portion 115 relative to the remainder of the first arm 116A to reduce the current and energy density in the portion 115 to limit the resistive heating of the portion 115. This extension also increases the mechanical integrity of the blade 121 in the throat 111 .

The second end 122 of the second blade arm 116B is preferably raised relative to the main portion of the second blade arm 116B in a stepped form to facilitate electrical connection to the respective positive pin 104B. More specifically, as shown in FIG. 12 and 13, termination

122C. and, therefore, for resistance heating 122C, it is preferably switched

122 includes three sections, namely, Part 122A. which is a substantially planar continuation of the main portion of the second blade arm 116B, a transition portion 122B that rises at the angle shown, and connecting an end portion 122C that is parallel to the portion 122A. These end portions 122 may have a greater width than the second blade arm 116B. to increase strength, to provide adequate contact area for positive connection in the connecting end portion, to reduce the current density and termination 122. The end portion is welded, or electrically and mechanically coupled by other techniques to the positive pin 104B.

Yet another embodiment for achieving positive connections of the heater blades 121 is shown in FIG. 14 and 15. The connecting end 122 is preferably not stepped shaped as in FIG. 12 and 13, but is a substantially planar extension of the second blade arm 116B. and this simplifies the fabrication discussed below. To reduce the possibility of short connections arising from contact between the positive end 122 and the neck 111 and / or the portion 115 of the first arm 116A. when, for example, the inserted cigarette is rotated or otherwise adapted to the smoker, at the end 122, the neck 111 and the 1X5 portion, an electrically insulating ceramic surface 300 is applied, in particular to the respective facing edges of these elements.

Preferably, the ceramic surface is applied by any conventional technique, for example, by plasma spraying on the throat 111 connecting the end 122 and the part 115 of the first arm 116A. The respective ceramic preferably has a relatively high dielectric constant. Other suitable electrical insulators such as alumina, zirconia, mulite, corderite, spinel, fosterite, combinations thereof, etc. may also be used. Preferably, zirconium oxide or other ceramics having a thermal expansion coefficient that is very close to that of an economically located metal heater structure is used to avoid differences in expansion and contraction sizes during heating and cooling, and thus prevent operation during operation. cracks and / or delamination. This ceramic layer remains physically and chemically stable when the heater element is heated. The thickness of the electrical insulator is preferably, for example, about 0.1 to 10 mils (0.0025 to 0.25 mm), or about 0.5-6 mils (0.00127 to 0.152 mm), and more preferably 1-3 inch inches (0.025-0.076 mm). The end portion 122 is preferably not covered. The positive pins 104B are then attached as shown to the exposed part. To simplify the masking, the corresponding part of the portion 15 is not similarly coated with the ceramic.

The ceramic may also be applied, for example, in the same plasma spraying step, at a gap 127 between the ends 122 and portions 115 of the first arms 116A and a gap 126 between the ends 122 and the throat 110 to form the ceramic throat structure to enhance the mechanical integrity of the heater assembly. this shown in FIG.

15. The size of the ceramic neck assembly may be larger than shown. With or without this additional ceramic application, the ceramic surface electrically insulates the positive splice ends 122, and the gaps of widths 127 and 125 can be reduced while providing protection against short splices. Accordingly, the end portion 122 and the portion 115 of the first leg 116A may have an elevated area, and so further strengthen the skeletal structure and further strengthen the heater assembly. In addition, such a ceramic surface smoothes the sharp edges of the diffusing gaps 125 and 12LZ to reduce the potential for catching damage to the cigarette especially during insertion, withdrawal and any treatment by the smoker. Alternatively, the entire blade 121, and in particular the first and second arms 116A and 116B. are completely covered on one surface, for example the outer surface facing away from the cigarette, both on the inner and outer surfaces, and / or the edges defining said gaps by a ceramic layer, for example approximately 2 mils of zirconium, to strengthen the heater blades maintaining gaps when desired. Accordingly, the blades 121 may be thinner, for example, about 2 to about 6 mils (0.05 to 0.15 mm), thus increasing the heat path section and allowing the blades to be wider to increase the thermal interface b by the cigarette 22. While maintaining the same overall blade resistance. This increased blade width, together with the ceramic layer, further strengthen the heater structure. Also, the ceramic surface on the outer surface of the blades 121 facing away from the inserted cigarette can prevent heat loss from the heater blade to the environment. The ceramic is preferably applied by plasma spraying or other method described in the related applications and is preferably applied by electron beam vapor precipitation to avoid introducing residual loads that may be introduced during processing by plasma spraying from surface treatment and / or particle impact.

Each blade 121 forms a resistive heater element. More specifically, the first end 115 of the first blade portion 116A is electrically coupled to the negative ends of the power supply, and more specifically, is an integral neck extension 111. or is mechanically and electrically coupled to the neck 111 that is electrically and mechanically connected to the negative end pin 104A via weld or other technique such as brazing or soldering. Preferably, the two end pins 104A are used to provide a balanced support since the positive and negative connections also serve to mechanically support the heater. The neck 111 thus functions as electrically common to all heater blades 121. In any embodiment, the negative connection of each heater (heater filament) can be made individually by, for example, a suitable negative contact located at the end of the heater, opposite to the respective positive contact surfaces 122.

A respective positive connection of each heater blade 121 is made at the connecting end portion 122C of the second blade portion 116B as discussed herein. The connecting end portion 122C is electrically insulated or insulated from the common throat 110 by a gap 127 from the first electrical in the particular smoking blade portion 116A. and in particular the first end 115 and the adjacent heater blade through a gap 131 to avoid short connections and thereby allow thermal expansion. In addition, the ceramic surfaces discussed are optionally applied. Alternatively, the connecting end portions 122C are respectively connected to ground.

The positive and negative connections described provide a resistive path, and more specifically a circuit of the applied current from the power source, for example, through the control circuit, the blades (s), upon activation of the system by a smoker pull. The primary blade heater surface includes a first blade arm 116A. the edge portion 118A and the second blade arm 116B. Accordingly, the portion of the inserted cigarette 22 lying below and contacting the activated blade 121 positioned longitudinally will be heated by the pattern of the outer surface of the corresponding heated portion of the blade, i.e. in the elongated U shape corresponding to the overlapping blades primarily by conduction and radiation. In addition, a portion of the inserted cigarette between said arms, i.e., an economical gap 125, is heated by overlapping or intersecting the cumulative radiant and conductive heat transfer, such as from the arm 116A. and the arms 116B. If the gap 125 is too large, the desired overlap will not occur and the portion of the inserted cigarette lying below the gap 125 will not be adequately heated. Also, radiant and conductive heat will heat the tape portions of the inserted cigarette slightly beyond (outside) the outer edges of the heater blade arms 1Χ & Δ and 116B. The various heated portions together form a heated (hot) region of the cigarette 22, which is located slightly beyond the outer edge of the arm 116A. under arm 116A. through the gap 125. below the shoulder 116B. and slightly beyond the arm 116B of the activated blade 121 and which corresponds to the coating of the generated tobacco flavor. The size of this heated region depends on the blade geometry and heater characteristics as well as the magnitude and duration of the energy pulse. The heater blade is preferably sized and is thermally designed to ultimately heat the Begment of a mounted cigarette having a sufficient size, e.g. 18 mm ² , to generate an acceptable smoker coating in response to a pull-activated energy pulse.

The relatively larger blade and the surfaces 115 and 122 forming part of the current path are not heated to these operating temperatures because their relatively larger volumes reduce the current density and thus reduce the resistance heating. Also, the portion joining the end portions 118 is not heated to these operating temperatures because the heater heating path tends to follow the edge 118A and this portion generates a relatively larger volume and accordingly has a lower current density and thus less resistive heating than the edge 118A and the immediately adjacent portions. . To further reduce unwanted heating of the remainder of the joining portion 118, it is possible to: (1) increase the thickness of the monolithic material of the portion 118 relative to the curved edge 118A in the region 118C to further reduce current and resistive heating density, as shown in FIG. 5, (2) perforate the resistive and / or heat conduction path portion 118, and / or (3) add additional heat dissociating material 119 to the heat transfer material limiting material 118 as shown in FIG. 6. A thermally non-conductive material is applied to achieve this heat-separating function, i. j. a thermal insulator such as ceramics. Examples of suitable ceramic materials include alumina, zirconia, mixtures thereof, mullite, etc., as is the case with the heater blade surface. Each of these modifications should be evaluated for any adverse effect on the mechanical integrity of the connecting portions 118 that support the heater assembly 10 and define the cigarette insertion and withdrawal opening.

Following the impulse of the heater blade 121, a predetermined minimum time exists before the next thrust is allowed. Premature heating of a portion of the cigarette could also lead to unwanted and / or partial generation of the aerosol, or heat-induced degradation of a portion of the cigarette prior to the desired heating. Subsequent reheating of the already heated portion can lead to undesirable developed odors and flavors.

If a longer coating is desired than is achieved during a single blade operation, then the control logic is designed to trigger yet another heater or additional heater blade (s) immediately after the initial heater blade pulse, or during the final portion of the initial pulse, to heater yet another. segment of the cigarette. The additional heater blade may be a radially following heater blade or another heater blade. The heater blades should be sized to achieve the total required number of strokes in the required duration (length).

In one embodiment, the number of heater blades 121 corresponds to a number of desired coatings (strokes), that is, eight. In yet another embodiment, the number of heater blades 121 is twice the number of strokes, for example, sixteen strokes per eight cigarette strokes. Such a configuration allows different heating sequences than normal, consecutive heating of approximately two seconds, and preferably radial sequential heating to an embodiment in which the number of heating blades 121 corresponds to the number of strokes. For example, the logic circuit may dictate that two peripheral opposing heater blades 121, t. j. heater blades separated by 180 ° on the pipe, simultaneously burning together an adequate cigarette size for generation of pull. Alternatively, the first heater sequence of each second heater blade 121 of the cigarette is followed by a second heater sequence of intervening heater blades 121 of another cigarette. Alternatively, the first sequence may be repeated in a predetermined cigarette life cycle and then initiated a second run sequence. Any combination of heater blades may be used. The number of heater blades may be less than or equal to, or may be greater than the number of strokes of a single smoking cigarette. For example, a nine blade system may be used for a six-stroke cigarette in which a different set of six heaters is heated to each subsequent cigarette and the associated set of three heaters is not hot.

numerous heating

The heater assembly is relatively fixed to weld pins 104A to end 122. Contact pins, i. The end parts are heated, i.e. more specifically,

100 is electrically and mechanically terminated by one end 110, and pins 104B to 104A and 104B are preferably preformed into or otherwise rigidly connected to the plastic socket, preferably in a manner to minimize air leakage. Preferably, the fixed end is opposite the sliding opening 360. The connecting portions 118 and the specifically opposite ends 118B opposite the connecting edges 118A. the end portions 118B may be funnel-shaped to extend outwardly and define a portion of the neck 365. The blades 121 then taper away from this portion of the neck and define an inner diameter that is slightly smaller than the outer diameter of the inserted cigarette 23 in, for example, at the point of the blade, to provide the desired thermal compression forces between the blades and the cigarette. 118B are free to extend when the end portions 118B are not fixed, each end 118B being disposed within a corresponding channel 210 located in the inner wall 201 of the end cap of the lighter 22. More specifically, the radial outward movement of the end portions 118B within the tapered blades 121 is enclosed by the ends 118B contacting the radial outer walls of the channels 210, thereby forming a taper boundary and defining (defining) the inner taper. This inward bevel may be supplemented by an inward bevel, as discussed above. As shown, the inner wall 210 extends outwardly in a funnel-like manner to allow for the insertion of a portion of the blade ends 118B. The radial outer wall of the channel 200 contacting the end 118B is sized and shaped to allow insertion of an appropriate size of the end of the blade 118B so that the end of the blade will not leave the passage 210 while heating or cooling the blade or inserting or withdrawing the cigarette. If desired, this radially outer channel wall is provided with an abutment, for example, a trapezoid contacting the end 118B.

In an alternative embodiment, the blade end portion 118D is rounded and more particularly elliptical in front of the end portion 118B. This rounded portion 118D allows the slidable portion to rotate within the channel 210 in response to thermally or mechanically induced moments, thereby maintaining a retracted blade tip portion within the channel 210. Additionally or alternatively, the blade ends 118B are more rounded.

In the first embodiment shown in FIG. 3, the channel 210 is sized such that the blade end 118B of the heater blade 121 can be expanded in a translational manner, i. toward the end portion 202 of the channel 2 '' by inserting the cigarette 23 and / or heating the blade so that the desired contact between the cigarette and the blades is achieved. Such an arrangement in which one blade tip is loose relative to the opposing throat allows mechanical displacement and / or thermal expansion and contraction of the heater blades in the longitudinal direction with appropriate blade insertion / recess and / or annealing / cooling, thus limiting loads .

In the second embodiment shown in FIG. 14, an abutment 20, which may be trapezoidal, may be positioned within the channel 210 such that when the heater blade 121 expands thermally by heating (shifting) or displacement when the cigarette is inserted. End 118B contacts abutment 204 to form a pin point to allow the blade 121 to bevel inwardly toward the inserted cigarette 22, thereby reducing the load on the blade and increasing the desired thermal contact, i.e., the compressive force between the blade and the cigarette. The pivot point is the point where the blade 121 is free to rotate, but not for translation, in this bearing 204.

Thus, the heater assembly 100 is preferably a monolithic structure that is optionally coated with ceramics as mentioned. The throat 111 and the heater blade 121 are made of a material having the required electrical resistance and strength. For example, materials having an electrical resistance in the range and more preferably such that temperatures of about about to about 500 µohm.cm, 100 to about 200 gohm.cm are preferred,

200 ° C to about 1000 C ©, and preferably about 400 ^Q C. to about 950 DEG C., and preferably about 300 ° C to about 850 ° C., Are reached by the activated blade 120 in approximately 0.2 to about 2.0 seconds, , with a pulse of about 10 to about 50 Joules, more preferably about 20 Joules. The material should be able to withstand approximately 1,800 to approximately suffer from an unwanted bending disorder

000 such pulses, without significant degradation, or.

The materials from which the heater blades 121 are made are preferably selected to provide reliable reuse for at least 1,800 on / off cycles. The heater fixture 39 is preferably disposable, separate from the lighter 25 comprising a power supply 37 and circuits, which is preferably discarded after a single use after 3600 cycles or more. The heater materials and other metallic components are also selected based on their oxidation resistance and overall low reactivity to ensure that they do not oxidize or otherwise react with the cigarette 22 at any temperature they are likely to encounter when desired. The heater blades 121 and other metallic components are encapsulated in an inert, heat-conducting material, such as a suitable ceramic material, to further prevent oxidation and reaction.

More preferably, however, the heater blades 121 and other metallic components are made of a heat resistant alloy that exhibits a combination of high mechanical strength and resistance to surface oxidation, corrosion and degradation at high temperatures. Preferably, the heater blades 121 are made of a material that exhibits high strength and surface stability at temperatures up to about 80% of their melting points. Such alloys are referred to as superalloys and are generally based on nickel, iron or cobalt. For example, alloys primarily of iron or nickel with aluminum and yttrium are suitable. Preferably, the heater blade alloys 121 comprise aluminum to further enhance the performance of the heater element, for example, by providing resistance to oxidation.

Preferred materials include iron and nickel aluminides and most preferably alloys disclosed in commonly assigned, commonly pending U.S. patent applications Ser. 08/365 952, filed on December 29, 1994, and in particular Serial No: _ (not shown), filed at the same time as this, entitled "Iron-aluminum alloys, useful as electrical resistance heater elements" (Meeting No PM 1769), they are incorporated here by reference.

Some elements may be used as additives to NiaAl ea alloys. B and Si are the main additives to the alloy of the heater layer 122. It is believed to increase the grain strength of the grain and is most effective when NiaAl is rich in nickel, for example, Al <at. %. Si is not added to the NiaAl alloy in large quantities because the Si additive forms a maximum of 3 weight percent nickel silicides and will lead to Si povedχ by oxidation. Mo adds strength at low and high temperatures. Zirconium helps to increase the resistance to cracking by oxidation during thermal cycling. Hf may also be added to increase high temperature strength. A preferred NigAl alloy for use as substrate 300 and resistance heater 122 is designated IC-50 and is reported to include approximately 77.92 X Ni, 21.73 * Al, 0.34% Zr, and 0.01 * B in processing intermetallic aluminides, V. Sikka, Intermetallic Metallurgy of Intermetallic Compound Processing, ed. Stoloff et al., Van Nestrad Reinhold, NY, 1994, Table 4. Various elements may be added to the iron aluminide. Possible additives include Nb, Cu, Ta, Zr, Ti, Mn, Si, Mo and Ni. The heater material may be a Haynes ^R 214 alloy (Haynes ^R No. 214 alloy, nickel based alloy containing 16.0 X chromium, 3.0% iron, 4.5 X alumina, traces of yttrium and the rest (approximately 75 *), commercially available available from Haynes International of Kokomo, Indiana), Inconel 702, assigned 08/380 718, MCrAlY, FeCrAlY, Nichrome ** (54-80% nickel, 10-20 * chromium, 7-12% iron), 0-11% copper, 0-5 * manganese, 0.3-4.6% silicon, and sometimes 1% molybdenum and 0.25 * titanium, Nichrome I is reported to contain 60% nickel, 25% iron, 11 X of chromium and 2% manganese, Nichrome II has 75 X of nickel, 22 X of iron, 11 X of chromium and 2 X of manganese, and Nichrome III, a heat resistant alloy, contains 85 X of nickel and 15 X of chromium) as described in the jointly original U.S. Patent Application Ser.

filed Jan. 30, 1995, and U.S. Patent No. 5,388,594, or materials having similar properties.

As shown in FIG. 12, the heater blades 121 are arranged to be symmetrically positioned from the throat 111. Alternatively, asymmetrical arrangements are used. For example, the amount, e.g. six or eight. The heater blades 121 may be divided into, e.g. two equally numbered subgroups of e.g. three or four heater blades. The heater blades in each subgroup are separated by gaps 131 as described above. These subgroups are separated by a wider gap 135, as shown in FIG. 19, in an unrolled, flat condition. The gap 135 is defined as follows. That the heat transfer of the conductive and in particular radiant heat from the adjacent blades 121 of the adjacent subgroups is minimized to the portion of the cigarette 23 lying below this gap 135. Accordingly, the gap 135 provides a wider unheated and thick portion of the cigarette that is stronger than the unheated portions narrower gaps 131, and so the strength of the cigarette column 23 is increased to assist in removing the cigarette after smoking and subsequent heating, and weakening portions thereof. If desired, the logic can activate more than one heater simultaneously in a symmetrical or unsymmetrical configuration.

The present invention, having two heater arms 116A and 116B separated by a gap 125, results in a substantial increase in the amount of aerosol generated compared to the amount generated by the solid heater achieves a good heat transfer element. Fixed heater in cigarette, but mass transfer of aerosol into the drawn air stream is limited by solid

As noted above, gap 125 provided for optimal radiation and sliding of the cigarette, and units, because of the power supply structure blocking optimal withdrawal of air outside the cigarette into the cigarette, especially when the smoking system housing is provided with perforations to communicate air outside the housing with the outer surface of the cigarette. The heater of the present invention has the same volume as the solid heater, but results in a larger circumference at a greater draw-in opportunity, for example due to gap 125, and accordingly results in an increased supply of flavor per unit of energy to the blade 121.

should be sized to overlap the blade geometry. Since more aerosols are generated, the desired weight of the blades can be reduced while generating the same desired amount of flavors, resulting in a lighter unit and reducing the energy required to adequately heat the heater blades 121, further reducing the weight of this source, e.g. the battery may be smaller. By way of non-limiting example, the gap 125 may be about 0.020 inches (0.5 mm), ± about 0.005 inches (0.1 mm) wide, the blade arms 116A and 116B may be about 0.0125 inches (0.3 mm) to about 0.017 inches (0.4 mm), ± about 0.005 inches (0.1 mm) wide, and about 0.55 inches (13.9 mm), ± about 0.005 inches (0.1 mm) long, and about 0.008 inches (0.2 mm) to about 0.010 inches (0.25 mm) thick, ± about 0.005 inches (0.1mm), and the length from the edge of the neck 110 to the tip of the connecting portion 118 may be about 1.062 inches (26.9 mm) ± about 0.626 inches (1.58 mm).

the primary transverse or radial flow of the inserted cigarette results in more smoke than the primary longitudinal flow.

JL2Z and 131 provide air paths that will contact the inserted cigarettes. additional

It was found that the air in relation to the desired

The gaps 125 drawn into the generation of air passages are provided to optimize the transverse air flow by perforating the portions of the heater blades.

A further embodiment of the blade geometry is shown in FIG. 16, on which the first arm 116A is shown. and the other arm

116Β are parallel so that the arms are equidistant from each other and the gap 125 also has a circular shape. Such a circular shape increases the perimeter of the blade and thus increases the drawing in of the aerosol. This circular shape is described in more detail in EP-A-0 615 411 and co-assigned the original patent application Ser. No. 08 / 380,718, filed Jan. 30, 1995, and U.S. Patent No. 5,388,594.

The first preferred method of manufacture (fabrication) will now be described with reference to Figs. 18 and 19. The steps defined herein may be performed in any desired order to achieve manufacturing speeds, materials, savings, and so on.

A layer or strip of suitable material is formed having a thickness, for example, of about 2 to about 20 mils (0.05 to 0.5 mm), for example 10 mils, for defining the amount of blades 121 positioned. perpendicularly through respective first blade portions 116A. and in particular through respective first end portions 115, of a generally straight portion 111A in a ridge configuration. The blades 121 are substantially perpendicular to each other, with gaps 131 positioned between opposite edges of the second blade portion 116B of one blade and the first blade portion 116A of the adjacent blade. As mentioned, the blades 121 are either symmetrically arranged, with the same gaps between each other as shown in FIG. 18, or are arranged asymmetrically, for example with the same gaps 131 between adjacent blades 121 defining blade subgroups 121A and 121B and a greater distance 133 between the two subgroups of width K as shown in FIG. It should be noted that the straight portion 111A has two end portions of at least half the length of one half X to form the second spacing 133 when rolled. These end portions should be longer than X to provide an overlap for connection. By way of non-limiting example, the gap 151 may be approximately 0.040 inches (1 mm) ± 0.005 inches (0.1 mm) wide in any embodiment, and the gap 135 may be approximately 0.125 inches (3.1 mm) ± 0.005 inches (0). , 1 mm), wide in asymmetrical design.

The blades are configured as previously described to form part 118 and arms 116A and 116B.

This formation of a layer or web of material into the described embodiment is accomplished by any conventional technique such as punching or cutting, for example using CO 2 or a Yag laser. When using the FIU format, the plurality of heater blades 121 formed from this band may exceed the required number of a single cylindrical heater arrangement. The straight web is then cut, if desired, to form the portion 111A. having the desired number of heater blades 121 extending therefrom. When the stepped shape of Section 122A is used. 122B and 122C are formed by punching.

If a ceramic protective surface 300 is used then it is applied by masking the embossed profile and, for example, by heat spraying the coating on the portion 111A. 115. 122. or all or any part of the blade, to form the desired pattern as described. Alternatively, the ceramic surface is applied after the winding step by this process or, if desired, before forming the blades. As is known, the respective masking is applied prior to each of the filament and ceramic deposition steps to define the areas of application.

The portion 111A is then wound to form a circular neck 111. The portion 111A can be wound in both directions. Preferably, the portion 111A is wound such that the positive contacts 122C at the end portion 122 are on the outer surface of the formed cylindrical heater, i.e., on the side opposite the cigarette, to facilitate attachment to the pins 104B and to avoid damage during insertion and removal of the cigarette. The winding portion may be wound to a smaller diameter than its final desired diameter and is slid into the fixture. The coiled part is then expanded and kept in shape by electrical connections. Alternatively, the coiled portion is joined, for example, by any welding technique, such as spot or laser welding, to form the neck 111.

Preferably, a bevel is applied to each blade 121 such that the arms ULEA and 116B and the connecting edge 118A exert a compressive force on the inserted cigarette when the heater assembly is formed as shown in FIG. 13. Preferably, the bevel occurs prior to winding, but may be made after winding. This skew increases the thermal contact between the heater blade and the extended cigarette to increase heat transfer efficiency.

The heat transfer efficiency is also enhanced by optimizing the surface area of the blade arms 116A and 116B. which are in an effective thermal relationship with cigarettes lying at the bottom. As shown in FIG. 17A, the lower portions 117 of the arms 116A and 116p (the arm 116A is shown by way of example) are planar, i. flat in the transverse direction of the blade arm in the embodiments. To improve the heat transfer relationship, the underside 117 is shaped in various non-planar geometries, such as an angle or curve, to maximize the surface area of the glowing arm relative to the cigarette without undesirably increasing the volume and thus undesirably reducing the current density and resulting resistance heating of the glowing arm. as appropriately emphasized in FIG. 17B and 17C. The shaped bottom portion 117 preferably does not penetrate any portion of the cigarette 22 to prevent weakening and possibly tearing of the cigarette during insertion, adjustment or removal. Rather, the center point of the lower portion 117 contacts or is in close thermal proximity to the cigarette 23, and the remainder of the lower portion 117 is in a radiant thermal relationship with the cigarette 22.This bottom shape is preferably achieved by knocking the arms 116A and 116B with the blade 12L. This punching may occur at the same time as the punching to achieve the chamfer described above. This embossment for shaping the bottom portion also increases the strength of the arms 113A and 116B. thus avoiding unwanted short connections and deformations.

A second fabrication method will now be described. A tube of suitable material is secured. The blades 121 are then formed by any technique such as laser cutting.

Alternatively, the blades are formed by a die-forging technique in which an internal thrust is inserted into the tube to form said blade profiles and then further forging is used, either from inside or outside to cut the profile. If desired, the profiled tube is provided with a ceramic surface 800.

The present invention also minimizes potentially harmful, thermally induced loads. Since the heater blades 121 and the throat 111 are monolithic, the load resulting from the interconnections of discrete parts of the heater elements is prevented.

Various embodiments of the present invention are all designed to allow the delivery of an effective amount of a flavored tobacco response to a smoker under standard conditions of use. In particular, it is currently considered desirable to deliver between 5 and 13 mg, preferably between 7 and 10 mg, of an aerosol to a smoker for 8 puffs, each with a 35 ml stroke, lasting two seconds. In order to achieve such a supply, it has been found that the heater elements 121 should be able to transmit the temperature as indicated when they are in thermal relationship with the cigarette 23. Further, the heater blades 121 should preferably consume said energy. Lower energy requirements require heater blades 121 that are bent inwardly toward the cigarette 23 to increase the heat transfer relationship.

The heater resistor is also dictated by the particular power supply 37 that is used to provide the necessary electrical energy to heat the heater. For example, the heater element resistors of the embodiment wherein the power is supplied by four nickel-cadmium battery cells connected in series with the total unpowered voltage about 4.8 to 5.8 volts. In an alternative, when using Seeet or eight such Battery-connected Batteries, the heater blades 121 should preferably have a resistance between aBi of 3 Ohms and about 5 Ohms, or about 5 Ohms and about 7 Ohms.

In one embodiment 450 of the present invention, a blade 121 is shown. 20 and 21, and includes a plurality of heater elements 451. Each heater element 451 is U-shaped, each having two ends 452, 453 of respective arms connected to a side wall of cavity 430 adjacent to end wall 443 of cavity 430. Each respective end 452 is individually connected to the control circuit, and finally to the power source, to individually activate the heater elements 451, while the terminals 453 are connected together to ground. Although the endings 454 adjacent the end of the throat of the cavity 430 are not electrically connected and thus do not have to contact the side wall of the cavity 430. they are rotated toward the side wall of the cavity 430 as shown in FIG. 20, and FIG. 21, to secure the inward displacement of the disposable portion, i. slipped cigarettes as mentioned above. It should be noted that in FIG. 21, the uppermost and lowermost elements 451 are shown cut (omitted) into the U-shaped tips 454.

In yet another embodiment 470 shown in FIG. 22 and 23, the heater elements 471 are spaced further away from the wall of the cavity 430, and each is provided with a sharper tip V, as well as a deflection 473, to increase their stiffness. In this way, the heating elements 471 actually penetrate into the disposable portion to provide the desired tight thermal contact. The open-celled foam structure is particularly suitable for such an embodiment. In that embodiment, since the heater elements 471 are spaced a little further from the side wall of the cavity 430, the endings 452, 453 are not connected to the side wall of the cavity 430 but to its end wall 443. Attaching the endings 452. 453. to the end wall 443 it is made through spacers 480 which conduct neither heat nor electric current. In this manner, the swab wipes residues (beyond) away from the ends 452, 453, and into the spacers 480, where those residues are not heated again, as described in more detail in U.S. Pat. Perforations 412 are provided in the wall to allow the outside air to be drawn through the portion 420. As described in more detail in U.S. Pat. No. 5,249,586, which is incorporated herein by reference in its entirety.

It will be apparent to those skilled in the art that many modifications, replacements and improvements may be made without departing from the scope of the invention as described and defined in the following claims. For example, the de-aging step may be performed prior to the cooling step, as a modification of a portion of the respective process already described with reference to FIG. 5B.

Claims (86)

(in the wording of the replacement letters under Rule 26 and as corrected by the claims received by the International Bureau on 10 February 1977 (modifying the original Articles Nos. 39 and 48-50)) Cigarette (23) comprising a tobacco rod, said tobacco rod (60) comprising a tubular tobacco structure (66) and a tobacco plug (80) disposed within said tubular tobacco structure, the tobacco rod having a loose end (78) and an opposite end (72) The tubular tobacco structure comprises a backing structure (68) and a tobacco flavor material layer (70) supported by the backing structure, the backing structure being adapted to transfer heat from the electrical heater element (37) to the tobacco flavor material, the tobacco rod (60) being adapted to operably receiving an electric heater element (37) along the tobacco rod (60) at a location between the free end (78) and the opposite end (72), the tobacco plug (80) being positioned adjacent to said free end and positioned away from said opposite end so that delimits the unfilled space / 91 / honey with said tobacco insert and said opposite ends. The cigarette of claim 1, wherein the location of the electric heater element (37) along said tobacco rod is such that the location overlaps at least a portion of the unfilled space (91) and overlaps at least a portion of the tobacco plug (80). The cigarette of claim 1 or 2, wherein said tobacco rod comprises a free flow filter (74) adjacent said opposite end, said free flow filter being spaced apart from the tobacco plug (80) so as to define an unfilled space (91). between this free flow filter and the tobacco plug. 4. A cigarette and lighter adapted to cooperate as an electric smoking system, the cigarette comprising a tobacco web, partially filled with cut filler tobacco to define a filled portion of the tobacco rod and an unfilled portion of the tobacco rod (91), the cigarette (23) and the lighter. (25) are arranged to overlap at least one of the filled and unfilled portions of the tobacco rod when the cigarette is in its lighter position. The cigarette of claim 4, wherein said filled tobacco rod portion comprises a tobacco plug, and the electric heater overlaps at least a portion of the unfilled space and overlaps at least a portion of the tobacco plug when the cigarette is in the lighter position. The cigarette of claim 4 or 5, wherein the cigarette has a free end, the tobacco plug is positioned adjacent to the free end, the cigarette comprising a tubular element spaced apart from the tobacco plug so as to define an unfilled portion of the tobacco rod between the free flow filter. and the tobacco plug. A cigarette according to any preceding claim, wherein the tubular element (74) is a filter. The cigarette of claim 7, wherein the tubular member (74) is made of a plastic pull material. The cigarette of claim 7, wherein the free flow filter (74) is made of molded material. A cigarette according to any preceding claim, further comprising a filter tip (62) adjacent the opposite end. The cigarette of claim 10, wherein the tip (62) comprises a second free flow filter (102) adjacent the opposite end, the cigarette further comprising tip paper (64) connecting the second free flow filter (102) to the opposite end. . The cigarette of claim 11, wherein the tip further comprises a mouthpiece filter insert (104) adjacent the second free flow filter (102). A cigarette according to claim 12, wherein the free-flow filter (74) of the tobacco rod (66) comprises a first passage (75) and the second free-flow filter (102) comprises a second passage, the first and second passage connecting the unfilled space. 91), the second passage has a second inner radius greater than the first inner radius of the first passage (75). The cigarette of claim 12, wherein the free end tobacco rod further comprises a backflow filter (200). The cigarette of claim 12, wherein the tobacco plug (80b) comprises a first portion (320b) adjacent the free end (78b) having a greater density than the second portion (310b) of the tobacco plug distal to the free end. A cigarette (23) comprising a tobacco rod (60) having a free end (78) resistant to back flow and an opposite end (72), the tobacco rod comprising a tubular tobacco structure (66) comprising a layer of tobacco material (78), flow restriction (74) (operating at the opposite end of the tubular tobacco structure and the tobacco (78, 80) functionally positioned adjacent the free end and located from the flow restriction, the tobacco comprises cut filler tobacco partially filling the tobacco rod so that it defines the filled portion of the tobacco rod and the unfilled portion the unfilled portion is positioned adjacent the flow restriction, the tubular structure is arranged to sell the heat received by the tubular structure to tobacco, the tobacco rod (60) is arranged such that during the coating of the heat cigarette along the region of the tubular structure releases with the application of the structure is the tobacco flow. an aerosol that is drawn through the restriction A cigarette according to claim 16, wherein the flow restriction (74) is defined by a tubular element. The cigarette of claim 17, wherein the tubular element comprises a first free flow filter (74), the first free flow filter defining a first passage (75) therein, the cigarette further comprising a tip (62) comprising a second free flow tubular filter. (102) positioned adjacent the first free-flow tobacco rod filter, the second free-flow tube filter defines a second passage therein, the first pass of the first free-flow filter is narrower than the unfilled portion (91) of the tobacco rod and narrower than a second passage of the second free flow filter (102). The cigarette of claim 18, wherein the cut filler tobacco forms a backflow resistant liner. The cigarette of claim 19, wherein a portion of the cut filler tobacco (80) is disposed at the free end (78) and has a density greater than the remainder of the cut filler tobacco distal to the free end. The cigarette of claim 20, wherein the tip (62) further comprises a mouthpiece filter (104) adjacent the second free flow filter (102). A cigarette according to claim 20, wherein the tubular structure comprises a cigarette wrapper (71) around the tobacco rod (60), the tip being attached to the tobacco rod by the tip paper (64). The cigarette of any preceding claim, wherein the tobacco or tobacco plug (80) comprises cut filler tobacco. The cigarette of claim 23, wherein the tobacco or tobacco plug (80) comprises a blend of cut filler tobacco, the blend comprising a combination of at least two distinctive, strong and oriental tobacco. A cigarette according to claim 23 or 24, wherein the tobacco plug comprises an insert wrap (84) arranged around the cut filler tobacco (80). A cigarette according to claim 23 or 24, wherein tobacco (70) is disposed along the inner surface of the tubular tobacco structure (66). The cigarette of claim 26, wherein the tobacco rod comprises a wrapper (71) disposed around the outer surface of the tubular tobacco rod or a portion thereof. A method of improving the delivery of smoke from a cigarette (23) actuated (or operable with) an electronic lighter, the cigarette comprising a tubular structure (66) having a free end (78) and an opposite end (72), the smoke being retractable from the opposite termination, this method includes the steps of: forming an unfilled portion along the tubular structure at the location adjacent the opposite end, and the tobacco filled portion along the tubular structure at the location adjacent the free end, and overlapping the electric heater element of the electronic lighter at least partially over the tobacco filled structure of the tubular structure. to release the smoke components from the tobacco. The method of claim 28, wherein the overlapping step comprises overlapping the electric heater element partially over both the filled portion and the unfilled portion of the tubular structure while the electric heater element is activated. The method of claim 28 or 29, further comprising the step of passing the released tobacco ingredients through an embodiment positioned adjacent the opposite end. A tobacco web adapted to be rolled into a tubular tobacco rod (60) of a cigarette (23) operable with an electric cigarette lighter (25), said tobacco web comprising a backing structure (68) and tobacco material (70) arranged along the first side of said backing structure, the backing structure comprising a combination of tobacco and cellulose fibers bonded in a ratio of about 2: 1 to 4: 1, the backing layer having a basis weight in the range of about 35 to 45 g / m ² , the tobacco material having at least twice the basis weight, than the backing structure, the tobacco material comprises finely divided tobacco and extracted tobacco solids in a ratio ranging from about 3: 1 to 9: 1, and a moisture stabilizer at about 5% to 20% by weight of the material. The tobacco structure of claim 31, wherein the tobacco material has a basis weight approximately three to four times greater than that of the backing structure. The tobacco structure of claim 31 or 32, wherein the tobacco material further comprises pectin at a level of up to about 2 X the weight of the tobacco material. The tobacco structure of claim 33, wherein the backing structure comprises about 28 g / m ^{2 of} tobacco fiber and about 12 g / m ^{2 of} cellulose fiber of wood or flax pulp, or of tobacco stem pulp. The tobacco structure of claim 34, wherein the tobacco material comprises about 66 to 71% by weight of tobacco 20% by weight extracted about 10 to 14% by weight of particles, about 16 to tobacco solids. glycerin and about 1-2 X pectin. A tobacco web adapted to be rolled into a tubular tobacco rod (60) of a cigarette (23) operable with an electric cigarette lighter (25), said tobacco web comprising a backing structure (68) and tobacco material (70) disposed along a first side of said backing structure, the backing structure comprises a combination of tobacco fiber in a basis weight of component of about 20 to 30 g / m ² , carbon fiber in a basis weight of component of about 2-9 g / m ² , and pectin in a basis weight of component of about 1 g / m ² , tobacco the material has a basis weight three to four times that of the backing structure, the tobacco material comprising finely divided tobacco and extracted tobacco solids in a ratio of about 3: 1 to 9: 1, and a moisture stabilizer at a level of about 5% to 20% % by weight of this material. A cigarette operable with an electric cigarette lighter, the cigarette comprising a tubular tobacco rod (60) made of a tobacco web according to any one of claims 31 to 36. The cigarette of claim 37, further comprising a cut filler tobacco insert (80) adjacent the free end (78) of the tobacco rod (60), at least one free flow tubular filter (74) adjacent the opposite end (71) of the tobacco rod and hollow space (91) without filler, located between the cut filler tobacco insert and the free flow filter. A method of manufacturing a tobacco web (66), comprising a backing web (68) and a layer of tobacco material (70), the tobacco web being bendable into a tubular mold as part of a cigarette (23) operating with an electric cigarette lighter (25), : separating the soluble substances (124) from the tobacco plug fibers, the soluble substances being in a solution containing 5 to 10% by weight of the dissolved tobacco components, producing (128) a backing structure by forming a slurry from the separated tobacco fiber; forming the slurry and pouring (130) of the slurry into a structure forming apparatus, producing tobacco material (146) by mixing a 5 to 10% solution of tobacco ingredients with additional tobacco particles, glycerin and pectin to form a dispersion of the tobacco material and adjust the water content so to achieve a solids content of about 20 to 30% in the dispersion, applying (144) this tobacco material dispersion along the backing to form a tobacco web, drying (146) the tobacco web to a moisture content of about not 8.5 to 12%, cooling (148) this tobacco web, de-spoiling (150) this tobacco web, winding (152) this tobacco web to form a roll of tobacco web, and cutting (154) this web of the tobacco web so as to form a bobbin of the tobacco web. The method of claim 39, wherein the solution of tobacco soluble substances comprises about 7 to 8% by weight of the dissolved tobacco ingredients. The method of claim 40, wherein the water content is adjusted such that a dispersion having about 24 to 26% solids content is reached at the end of the mixing step. The method of claim 41, wherein the tobacco particles have a size in the range of 100 to 220 mesh. The method of claim 42, wherein the tobacco particles have a size of about 120 meshes. A method according to any one of claims 40 to 43, wherein the slurry firming composition comprises at least one of wood pulp, flax pulp and tobacco stalk pulp. The method of any one of claims 40 to 44, wherein the application step comprises applying a dispersion of tobacco material to the backing structure in a dry weight ratio of at least 2: 1. The method of any one of claims 40 to 45, wherein the application step comprises applying a dispersion of tobacco material to the support structure in a dry weight ratio of at least 3: 1. The tobacco web of claim 36, wherein the tobacco fiber is at a basis weight of the component of about 24 to 28 g / m ² , the carbon fiber at a basis weight of the component of about 2-4 g / m ² , and pectin in a basis weight of the component of about 2.5 to 1.5 g / m ² . A heater (39) for use in a smoking system or a power source for heating a cigarette, the heater comprising: a plurality of electrically resistive heater blades defining a receptacle for receiving an inserted cigarette and disposed along the inserted cigarette, each blade including a first heater blade arm having a first end and a second end, a second heater blade arm having a first end; a second end (112), and a connecting portion (118) connecting the second end of the first heater blade arm and a first end of the second heater blade arm, wherein the first and second heater blade arms of each heater blade are separated by a respective gap (125); the first heater blade arms are adapted to be in electrical contact with an electrical power source in which paths are formed comprising a first respective resistive heater blade heater arm connecting the portion, and a second heater blade arm, e.g. by properly heating each of the electrically resistive heater blades along the first and second blades, which in turn heat the inserted cigarette, the first ends of the first blades having a common connection. The heater of claim 48, wherein the first ends of the first heater blade arms (116A) are grounded. A heater according to claim 48 or 49, wherein the joint connection of the first ends of the first heater blade arms is a throat. A heater according to any one of claims 48 to 50, wherein the gap (125) separating the first and second heater blade arms is sized such that, upon being coated by a smoker, it allows air to flow into the heated cigarette. The heater of any one of claims 48 to 51, further comprising a support throat (110), the first end of each of the first heater blade arms (116A) extending from said support throat, wherein the support throat is adapted to be in electrical contact with a power source and forms a common connection of the first end of the first heater blade arms. The heater of claim 52, wherein the second ends of the second heater blade arms (116B) are adapted to be in a respective electrical connection or a power source in which respective resistance heating circuits comprising a first heater blade arm connecting the edge portion are formed. and a second heater blade, for respectively heating each of the electrically resistive heater blades (121), which in turn heat the inserted cigarette. A heater according to claim 52 or 53, wherein the second ends (122) of the second heater blade arms (116B) are directed towards the support throat (111) and are electrically insulated therefrom. The heater of claim 52 or 53, wherein the second ends (122) of the second heater blade arms (116B) are separated from the throat by a gap. The heater of claim 52, further comprising an electrical insulator applied to at least one throat and a second end of the second heater blade arms. The heater of claim 52, further comprising an electrical insulator applied to at least one of the second ends of the second heater blade arms and the first ends of the first heater blade arms. The heater of claim 52, further comprising an electrical insulator (300) forming a ceramic neck support structure around the support neck (111), second ends (112) of the second heater blade arms (116B), and first jaws of the first heater blade arms (116A). A heater according to any one of claims 52 to 58, wherein the throat and blades are monolithic. The heater of any one of claims 48 to 59, wherein the connector portion (118) further comprises a free end (118B) to compensate for thermal expansion (expansion) when said heater element is heated. The heater of claim 60, further comprising a support structure (83) stationarily disposed within the smoking system and defining channels (210) for receiving free ends (118B) connecting portions of the blades (121). The heater of claim 61, wherein the channels (210) are configured to allow translational thermal expansion and contraction of the heater blades. The heater of claim 61 or 62, further comprising a pivot point (204) disposed in each of said channels, the point being positioned such that the associated free end (118B) of the connecting portion rotates about these points to bevel the first and second heater blades. of the arms (116A, B) inwardly towards the inserted cigarette while heating the composite heater blade. A heater according to any one of claims 48 to 63, wherein portions of at least one of the first heater blade arm (116A) and the second heater blade arm (116B) are covered with ceramic (300) to strengthen and electrically insulate the at least one first heater blade arm and a second heater blade arm. The heater of claim 64, wherein a portion of the second heater blade arm (116B) is adjacent the ceramic to be in electrical contact with the power source. A heater according to any one of claims 48 to 65, wherein the blades (121) are arranged to receive longitudinally the inserted cigarette. A heater according to any one of claims 48 to 66, wherein the second end of the second heater blade arm has a stepped shape, the stepped shape including an end portion (1220) adapted to be in electrical contact with the power source. A heater according to any one of claims 48 to 67, wherein the first and second heater blade arms (116A, B) of the respective heater blade (121) are substantially parallel. A heater according to any one of claims 48 to 68, wherein the connecting edge has a curvature between about 160 ° and 200 °. A heater according to any one of claims 48 to 69, wherein the underside of at least one of the first and second heater blade arms (116A, B), facing the inserted cigarette, is substantially non-planar in the transverse direction of the heater blade arm. The heater of claim 70, wherein the lower portion is curved. The heater of claim 70, wherein the lower portion has a sharp edge. A heater according to any one of claims 48 to 72, wherein the plurality of electrically resistive heater blades (121) are arranged in groups, wherein the gaps (133) between the groups are sized to provide the unheated portions of the inserted cigarette with strength to facilitate cigarette removal. after smoking. A heater according to any one of claims 48 to 73, wherein at least one of the first and second heater blade arms (116A, B) has a spiral shape. The heater of claim 74, wherein both the first and second blade arms are rotary and parallel to each other such that the space between the arms is serpentine. The heater of claim 48, wherein the at least one end of the at least one blade (121, 122) is wider than the adjacent active portion of the at least one arm, wherein the end of the arm has a lower current density and lower resistance heating than the active portion. this arm. A heater according to any one of claims 48 to 76, wherein the connecting portion (119) is perforated. The heater of any one of claims 48 to 77, wherein the first and second heater blade arms (116A, B) are angled toward the inserted cigarette. The heater of any one of claims 48 to 78, wherein the first and second heater blade arms (116A, B) and the connecting edges have a resistance of about 100 to about 200 µm-cm. A heater according to any one of claims 48 to 80, wherein the first and second heater blade arms (116A, B) and the connecting edges have a resistance of about 50 to about 500 µm-cm. The heater of any one of claims 48 to 80, wherein the first and second heater blade arms (116A, B) and the connecting edges have the ability to reach a temperature of about 200 ° C to about 1000 ° at about 0.2 to about 2.0. seconds with pulses of about 10 to about 50 Joules. The heater of claim 81, wherein the first and second limbs (116A, B) and the edges joining may be pulsed to these temperatures after approximately 1800 to 10,000 such pulses. The heater of claim 48, wherein the gap (125) separating the first and second heater blade arms (116A, B) is sized to maximize the cumulative radiant heating from each of the first and second heater blade arms of the associated heater blade to a portion of the inserted cigarette. lying below this gap. The heater of any one of claims 48 to 83, wherein the first and second heater blade arms (116A, B) and the connecting edge portion (B) may comprise an electrically resistive material selected from the group consisting of iron and nickel aluminides. An electrical smoking system comprising a cigarette according to any one of claims 1 to 3 and a lighter, said lighter having a plurality of resistive glowing blades defining a glow blade receptacle, and thereby using these blades at least partially overlapping the tobacco plug when the cigarette is inserted into the socket. 86. The electrical smoking system of claim 85, wherein the heater blades are located along the length of the tobacco plug and partially overlap the unfilled space. An electrical smoking system according to claim 85 or 86, wherein said lighter comprises a heater according to any one of claims 48 to 84.