WO2012156705A1

WO2012156705A1 - A smoking article, a filter for a smoking article and an additive release component and a method of manufacturing

Info

Publication number: WO2012156705A1
Application number: PCT/GB2012/051049
Authority: WO
Inventors: David Morrison Russell; Wilbert Paulus Johanna Maria SCHOENMAKERS; Paul Barry FARENDEN; Darren Seymour; Mark Bailey
Original assignee: British American Tobacco (Investments) Limited
Priority date: 2011-05-13
Filing date: 2012-05-11
Publication date: 2012-11-22
Also published as: GB201108042D0

Abstract

A smoking article (200), wherein the smoking article comprises an additive release component (215). The additive release component (215) has a maximum lateral dimension of less than 3.5mm, and the smoking article (200) has a maximum lateral dimension of no more than 7.6mm.

Description

A smoking article, a filter for a smoking article and an additive release component and a method of manufacturing

Technical Field

Various embodiments of the invention relate to a smoking article comprising an additive release component, a filter for a smoking article comprising an additive release component, and methods of manufacturing the additive release component and filter. Background

As used herein, the term "smoking article" includes smokable products such as cigarettes, cigars and cigarillos whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes and also heat-not- burn products (i.e. products in which flavour is generated from a smoking material by the application of heat without causing combustion of the material). Typically, smoking articles are provided with a filter removing constituents from the gaseous flow.

It is known to provide a frangible spherical capsule containing a flavourant such as menthol, or water, inside the filter of a smoking article. By applying pressure to the outside of the filter, the smoker may break the capsule therein and release the flavourant. Thus, a smoker wishing to add flavour to the inhaled gaseous flow may do so by simply squeezing the filter. Individual spherical breakable capsules having a flavourant therein and methods of manufacture thereof are known per se and are described in, for example, WO 2007 / 010407.

The spherical capsule described can have a relatively large effect on flow of smoke, and/or cause a relatively large pressure drop, when used in smoking articles of the so- called "slim", "demi-slim", "superslim" and "microslim" formats, which typically have maximum lateral dimensions, or diameters, smaller than smoking articles with a "regular" format. Typically, cigarettes of a regular format have a circumference of about 24-25mm, corresponding approximately to a diameter in the range 7.6 to 8.0 mm. Cigarettes in the slim, demi-slim and superslim formats typically have circumferences of 22-24mm, i9-22mm and 16-19 mm respectively, corresponding approximately to diameters it the ranges 7.0-7.6, 6.0-7.0 and 5.1-6.0 respectively. Cigarettes in microslim formats have circumferences less than 16 mm, corresponding approximately to diameters of less than 5.1mm. If therefore a capsule is inserted for example in a superslim smoking article having a diameter of approximately 5.4mm, the capsule will occupy a relatively large proportion of the cross-sectional area of the smoking article and restrict the flow of smoke through the smoking article.

Summary

An embodiment of the invention provides, in a first aspect, smoking article comprising an additive release component contained within the smoking article, wherein the additive release component has a maximum lateral dimension of less than 3.5mm, and the smoking article has a maximum lateral dimension of no more than 7.6mm.

An embodiment of the invention provides, in a second aspect, a filter for a smoking article comprising: an additive release component, wherein the additive release component has a maximum lateral dimension of less than 3.5mm, and the smoking article has a maximum lateral dimension of no more than 7.6mm.

An embodiment of the invention provides, in a third aspect, a method of

manufacturing a smoking article or filter according to the invention, comprising: forming a plurality of additive release components connected in an elongate strip, and inserting the elongate strip into filtration material, and forming the smoking article or filter with the filtration material. An embodiment of the invention provides, in a fourth aspect, a method of

manufacturing a smoking article or filter according to the invention, comprising: providing a plurality of additive release component in a stack which extends at least partially perpendicularly to a longitudinal axis of filtration material, and inserting the additive release components consecutively into the filtration material, and forming the smoking article or filter with the filtration material.

An embodiment of the invention provides invention, in a further aspect, a smoking article comprising an additive release component, wherein the additive release component is elongate and has a maximum radial cross-sectional area of less than 50% of a radial cross-sectional area of the smoking article. An embodiment of the invention provides invention, in a further aspect, a filter comprising an additive release component, wherein the additive release component is elongate and has a maximum radial cross-sectional area of less than 50% of a radial cross-sectional area of the filter.

An embodiment of the invention provides invention, in a further aspect, an additive release component for a smoking article, wherein the additive release component is elongate and has a capacity of from 10 to 5θμΙ., and a maximum lateral cross- sectional area of less than 10 mm².

An embodiment of the invention provides invention, in a further aspect, an additive release component for a smoking article, wherein the additive release component is elongate and has a maximum lateral dimension of less than 4.5mm. Optionally, the maximum lateral dimension may be less than 3.5mm, or from 2mm to 3mm, or from 2.2mm to 2.9mm.

Brief Description of the Drawings

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

Figure 1 shows a perspective view of a filter and part of a smoking article according to a first embodiment of the invention and including an additive release component; Figure 2 shows a perspective view of an alternative additive release component invention;

Figure 3 shows schematically a process according to the invention for producing an additive release component assembly according to the invention;

Figure 4 shows a perspective view of a first embodiment of a partially formed filter produced according to a first method of the invention;

Figure 5 shows a perspective view of a second embodiment of a partially formed filter produced according to a second method of the invention.

Detailed description

Figure 1 shows a first embodiment of a smoking article and filter according to the invention. The smoking article 200 comprises a source of smokable material, which is preferably tobacco, in the form of a cylindrical tobacco rod 11. A filter 220 is coaxially attached to the tobacco rod 11. The filter 220 comprises one or more additive release components, which can be a single additive release component 215. The additive release component 2i5can be of any type described below. The additive release component is any component capable of storing an additive in non-operative condition, and selectively releasing the additive to modify the smoke of the smoking article. The additive release component is in the form of a capsule.

The filter 220 comprises filtration material surrounded by a porous sheet material, preferably a porous paper, e.g. plug wrap. An additive release component 215 is located within the filtration material. In some aspects, the additive release component 215 comprises a breakable outer shell containing a a fluid which may be a volume of liquid or may optionally be held or absorbed in a substrate within the shell.

The filter 220 is covered by a covering layer 216. The covering layer is a sheet material wrapped around the filtration material, and forming an exterior of the filter 220. The covering layer 216 may connect the filter 220 to the tobacco rod 11, and is formed of a paper material, e.g. tipping paper. The covering layer 216 can be at least partially transparent. The covering layer 216 can define one or more transparent windows, e.g. a single transparent window 222 through which the additive release component 215 can be viewed. The window 222 comprises a transparent material attached to the covering layer 216. The transparent area of the covering layer allows viewing of the additive release component 215 from outside the filter 220. The covering layer 216 around the window 222 is opaque, and is patterned or coloured. The additive release component 215 is surrounded by filtration material 12. The one or more windows 222 may each comprise be aligned with a channel extending through the filtration material. In some aspects, a single longitudinally extending channel 223 extends through the filtration material, perpendicular to the longitudinal axis of the filter 220, and aligned with the window 222 in the covering layer. The window with channel allows viewing of the additive release component from the exterior of the filter.

The additive release component 215 is preferably elongate. The additive release component has a longitudinal axis which is parallel to an axial direction of the smoking article or filter in which the additive release component is located. The additive release component shown in Figure 1 is substantially tubular, and has a maximum cross-sectional area defined in a plane perpendicular to the longitudinal axis. The cross-sectional area of the additive release component is substantially constant along a majority of the length of the additive release component.

Alternatively, the cross-sectional area of the additive release component may vary along its length. The term "elongate" may be considered to mean that the dimension of the additive release component in one direction is substantially greater than the dimension of the additive release component in the two perpendicular directions. The longer dimension is beyond manufacturing tolerances for a substantially spherical additive release component. For example, the longer dimension may be at least 1.5 times the maximum lateral dimension, or at least two times the maximum lateral dimension.

The additive release component has an exterior surface which is substantially cylindrical. The longitudinal ends are rounded, for example, such that the ends are substantially hemispherical. The additive release component 215 comprises an outer wall and an inner volume filled with the fluid. The additive can be selectively released by the user of the smoking article into the adjacent filtration material 12 by squeezing the outside of the filter to deform or rupture the outer wall of the additive release component. The additive release component 215 is configured to release all of the additive contents when the outer wall is ruptured. Alternatively, additive release component 115 is configured to release only a part of the additive on inward pressure from a user, such that the additive release component 215 is configured to release the additive contents in a plurality of discrete deliveries.

A known smoking article can generally have a maximum lateral dimension, which is a diameter for a circular cross-section. In the case of a cigarette in the superslim format, or a filter therefor, the maximum lateral dimension, or diameter, may be 5- 6mm, for example, approximately 5.4mm, which may be known as a superslim. The filter will normally be marginally smaller in diameter than the filter, in order to accommodate wrapping paper. A spherical capsule may have a diameter which is a relatively large proportion of the cross-sectional area of the filter. The capsule may cause an adverse effect on smoke flow rate and/or pressure drop. The additive release component of the invention may have a relatively small diameter, such that the effect of the additive release component on the properties of the filter is reduced. The additive release component can be elongate, instead of spherical, such that a sufficient quantity of additive can be contained. The maximum lateral dimension of the additive release component is less than 4mm, or less than 3.5mm, and preferably from 2.2mm to 2.8mm. Elongate additive release components may have lengths of from 7mm to 11mm, e.g. from 8mm to 10mm or approximately 9mm. Alternatively, the length may be from 5mm to 7mm, e.g. approximately 5.5mm.

The combination of an elongate additive release component with a maximum lateral dimension (diameter) of less than 3.5mm, in a smoking article or filter having a slim, demi-slim or superslim format provides a required quantity of additive and affects the smoke flow rate and/or pressure drop within an acceptable threshold. The particular dimensions (lateral and length) of the elongate additive release component, in a smoking article of these small diameter formats provides an advantageous combination of parameters which provide the required quantity of additive without significantly affecting the pressure drop. Alternatively, the additive release component can have a shape which is not elongate. In some aspects, the additive release component may be spherical or substantially spherical. For a particular maximum lateral dimension (diameter), a spherical additive release component may be able to contain less quantity of additive than an elongate additive release component. For a smaller diameter of filter or smoking article, the reduced quantity of additive can be substantially as effective as a higher quantity of additive in a larger diameter filter or smoking article. The smaller diameter of filter or smoking article can have a maximum lateral dimension less than 7.6mm or less than 7mm, or any range specified in any embodiment. The diameter of the spherical additive release component is less than 3.5mm, or any range of diameter specified in any embodiment. The radial dimensions apply to both elongate and spherical additive release components.

The exterior maximum lateral extent, or diameter for a circular cross-section, of the additive release component of any type or embodiment may be within the range 1.5 - 4.5 mm. The maximum lateral extent can be less than 3.5mm, or less than 3mm, or less than 2.5mm, or less than 2mm, or less than 1.5mm, or less than imm. The maximum lateral extent may be from 2mm to 3mm, and more In some aspects, from 2.3mm to 2.9mm, 2.2mm to 2.8mm, or from 2.4 to 2.6mm, or approximately 2.5mm. Alternatively, the exterior maximum lateral extent may be from 2.0 to 2.4mm, or from 2.1mm to 2.5mm, or from 2.3mm to 2.7mm, or from 2.6mm to 3.0mm, or approximately 2.2mm, 2.3mm, 2.5mm or 2.8mm. In particular, the exterior maximum lateral extent can be one of: 2.3mm to 2.5mm, 2.5mm to 2.7mm or 2.7mm to 2.9mm. In some examples, the additive release components have a diameter of one of: 2.4mm, 2.6mm or 2.8mm.

A length of the additive release component is from 4mm to 15mm. The additive release component has an exterior length from 7mm to 11mm, and more In some aspects, from 8mm to 10mm, or approximately 9mm.

Alternatively, the additive release component has an exterior length from 4mm to 15mm, and In some aspects, from 5mm to 7mm, or from 5mm to 6mm. In some aspects, the additive release component length is approximately 5.5mm. The additive release component maximum lateral extent is from 2.2mm to 2.8mm, and is preferably approximately 2.5mm.

Alternatively, the length of the additive release component is from 11mm to 15mm, or from 12 to 14mm, or approximately 13.6mm. The additive release component maximum lateral extent is from 2.2mm to 2.8mm, and is approximately 2.5mm.

Alternatively, the exterior maximum lateral extent, or diameter for a circular cross- section, of the additive release component of any type or embodiment may be within the range 4.5 mm to 7mm. The maximum lateral extent may be less than 7mm, less than 6mm, less than 5mm or less than 4mm. The maximum lateral extent may be between 3mm and 4mm. In particular, the maximum lateral extent of the additive release component may be between 3mm and 4mm (e.g. approximately 3.5mm) in combination with a filter/smoking article having a diameter of between 5mm and 6mm (e.g. approximately 5.4mm). The maximum lateral extent may be greater than imm, in combination with any upper limit, capacity or relative cross-sectional area.

These dimensions may apply to any type of additive release component. The larger length additive release component can be used with an additive release component comprising a substrate. The substrate may contain approximately 40% of additive by volume.

The diameter and length of the additive release component determines the maximum volume of additive which can be contained. Therefore, the selection of a relatively small diameter is used in combination with a relatively high length in order to contain a required quantity of additive. Any combination of dimensions, including dimensions outside of the ranges indicated, may be used. The outer shell of any embodiment of additive release component has a thickness of approximately 0.2mm.

The smoking articles or filters containing the additive release component can have a diameter of from 4mm to 10mm, for example from 5mm to 7mm, or y from 5mm to 6mm, or from 5.1mm to 6mm (superslim). In some aspects, from 5.2mm to 5.6mm,or from 5.3mm to 5.5mm, for example approximately 5.4mm. Where the smoking article or filter is in the slim, demislim, superslim or microslim format, it will have a diameter of less than about 7.6, 7.0, 6.0 and 5.1 mm respectively (corresponding approximately to circumferences less than 24, 22, 19 and 16 mm respectively). Where the smoking article or filter is in the regular format, it will have a diameter of 7.6-8.0 mm (corresponding approximately to a circumference of 24-25mm) So called "wide" formats have , diameters larger than 8.0mm (corresponding approximately to circumferences greater than 25mm).

The small lateral extent of the additive release component may be advantageous for reducing pressure drop in any diameter smoking article, although the advantage has a particular effect for the smaller diameter smoking article. The invention is applicable to any diameter of smoking article or filter in combination with a relatively sized additive release component. For example, the smoking article may have a diameter of from one of: 5mm, 5.3mm, 5.5mm, 6mm, 6.5mm, 7mm, 7.3mm, 7.5mm, 7.7mm, 8mm to one of 5.5mm, 6mm, 6.5mm, 7mm, 7.5mm, 7.9mm, 8.5mm, in an any combination.

The additive release component is located in a filter, within filtration material.

Alternatively, the additive release component is located in a tobacco rod.

Alternatively, the additive release component is located in a separate section of the smoking article, not surrounded by filtration material. For example, the additive release component may be located in a separate section located between the tobacco rod and filter. The diameters referred to is the diameter of the part of the smoking article in which the additive release component is located, i.e. filter, tobacco rod or separate section. The part of the smoking article generally has a circular cross- section. Alternatively, the cross-section may be elliptical, wherein references to diameter should be interpreted as maximum lateral extent. The additive release component has an additive capacity from 3μΙ, to 5θμΙ., or from to ΐθμΐ., or from ιομΐ- to 30μΙ., and optionally from Ι5μ1_^ to 25μΙ. or from 20μΙ. to 3θμΙ. or from 8μΙ. to 2θμΙ_^, or approximately 20μΙ. or approximately 3θμΕ. Any upper or lower value of capacity may be used in combination. In particular, the capacity of the additive release component may be from one of: 3μΙ_^, 5μΙ., 8μΙ., ιομΐ,, Ι5μ1-, 2θμΙ,, 25 ^ 3θμΙ., 35μΙ-, 40 L to one of: 5μΙ-, 8μΙ., ΐθμΐ,, Ι5μ1., 2θμΙ,, 25μ^ 3θμΙ., 35μΙ-, 40pL, 45 μΐ-, 50μ^

Alternatively, the maximum lateral extent of the additive release component is one of from : 1.5mm to 2.5 mm, 1.5mm to 3 mm, 1.5mm to 3.5 mm, 2mm to 2.5 mm, 2mm to 3 mm, 2mm to 3.5 mm, 2.5mm to 3 mm, 2.5mm to 3.5 mm, 3mm to 4mm, 3.5mm to 4mm. The maximum lateral extent of the additive release component may be from a lower lateral extent of one of 1.0mm, 1.1mm, 1.2mm, 1.3mm, 1.4mm, 1.5mm, 1.6mm, 1.7mm, 1.8mm, 1.9mm, 2.0mm, 2.1mm, 2.2mm, 2.3mm, 2.4mm, 2.5mm, 2.6mm, 2.7mm, 2.8mm, 2.9mm, 3.0mm, 3.1mm, 3.2mm, 3.3mm, 3.4mm, 3.5mm, 3.6mm, 3.7mm, 3.8mm, 3.9mm, 4.0mm, 4.1mm, 4.2mm, 4.3mm, 4.4mm and to a higher lateral extent of one of: 1.6mm, 1.7mm, 1.8mm, 1.9mm, 2.0mm, 2.1mm, 2.2mm, 2.3mm, 2.4mm, 2.5mm, 2.6mm, 2.7mm, 2.8mm, 2.9mm, 3.0mm, 3.1mm, 3.2mm, 3.3mm, 3.4mm, 3.5mm, 3.6mm, 3.7mm, 3.8mm, 3.9mm, 4.0mm, 4.1mm, 4.2mm, 4.3mm, 4.4mm, 4.5mm, 4.6mm, 4.7mm, 4.8mm, 4.9mm, 5.0mm, 5.1mm, 5.2mm, 5.3mm, 5.4mm, 5.5mm, 5.6mm, 5.7mm, 5.8mm, 5.9mm, 6.0mm, 6.1mm, 6.2mm, 6.3mm, 6.4mm, 6.5mm, 6.6mm, 6.7mm, 6.8mm, 6.9mm, 7.0mm, 7.1mm, 7.2mm, 7.3mm, 7.4mm, 7.5mm, 7.6mm, 7.7mm, 7.8mm, 7.9mm, 8.0mm in any combination.

These ranges are not, however, intended to be limiting and the skilled person would understand that larger or smaller filter or additive release component could be employed. References to diameter indicate the maximum lateral dimension of the additive release component. For an additive release component which is not circular in cross-section, the diameter values above indicate the maximum lateral dimension of the additive release component.

The additive release component has a maximum radial cross-sectional area. The area of the additive release component relative to the radial cross-sectional area of the section of the smoking article containing the additive release component may determine whether the restriction of smoke flow or pressure drop due to the additive release component is within acceptable limits. In some aspects, the additive release component is less than 50% of the radial cross-sectional area of the section

containing the additive release component, for example less than 45%, less than 40%, less than 35%, less than 30%, less than 25%, less than 20%, less than 15%, or less than 10%. Alternatively, maximum radial cross-sectional area of the additive release component may be less than 65%, less than 60%, or less than 55% of that of the section of the cigarette of filter containing the component. The cross-sectional area of the additive release component may be higher than 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, or 45% of the filter or smoking article, in combination with any upper limit.

Alternatively, the maximum radial cross- sectional area of the additive release component, expressed as a percentage of the radial cross-sectional area of the section of the smoking article or filter containing the additive release component, may be more than 50%. The ratio may be less than 55%, 60%, 65%, 70%, 75%, 80%, 85%,

90% or 95%. Alternatively, the ratio may be more than 5%, 10%, 15%, 20% 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90% or 95%.

The invention may comprise filters and smoking articles, particularly cigarettes, in which the maximum radial cross-sectional area of the additive release component expressed as a percentage of the radial cross-sectional area of the section containing the additive release component lies in a range between any two values described above. This range may be from 15% to 50%, or In some aspects, from 20% to 35%, or from 30% to 45%, or from 25% to 40%, or from 30% to 40%.

In particular, where an additive release component has the above area relative to a section of the smoking article containing the additive release component, the diameter of that section may be less than 8mm, less than 7.5mm, less than 7mm, or less than 6mm. For example, the section of the smoking article containing the additive release component may have a diameter of from 5mm to 6mm, or from 6mm to 7mm, or from 5mm to 7.5mm. Alternatively, the diameter of this section of the smoking article may be greater than 8mm.

The additive release component has a maximum lateral cross-sectional area of less than 40 mm², less than 30mm², less than 20mm², less than 15 mm², and more In some aspects, less than 10 mm², less than 8 mm², less than 6 mm², less than 5 mm². The lateral cross-sectional area may be greater than 1mm², 2mm², 3mm², 4mm², 5mm² or 6mm², in combination with any upper limit. The smoking article, filter, tobacco rod, and any section containing the additive release component will normally have substantially the same diameter. For ease of reference, the cross-sectional area of the smoking area is referred to as the cross- sectional area of the section in which the additive release component is located. This cross-sectional area may refer to the cross-sectional area of the smoking article, filter, tobacco rod, or any section containing the additive release component. The cross- sectional area of the smoking article, filter, tobacco rod, or any section containing the additive release component are generally elongate, defining a longitudinal axis. The cross-section is taken in a radial or lateral direction, i.e. perpendicularly to the longitudinal axis. Any dimension described for one of the smoking article, filter, tobacco rod, or any section containing the additive release component may be applicable to any of the smoking article, filter, tobacco rod, or any section containing the additive release component. The invention can be defined in terms of the proportion of the cross-sectional area of the additive release component to the cross-sectional area of a section of the smoking article containing the additive release component. Alternatively, the invention may be defined in terms of the maximum lateral dimension of the additive release

component, optionally in combination with the lateral dimension of the smoking article. Alternatively, the invention may be defined in terms of the relative cross- sectional areas of the additive release component and smoking article/filter, in combination with lateral dimension of the smoking article and/or additive release component, and/or any other property (e.g. capacity, absolute cross-sectional area) of the smoking article and/or additive release component.

In a first type of additive release component, the outer shell is frangible on

compression, and breaks or ruptures to allow full release of the additive.

Alternatively, each additive release component may be configured to release the additive contents in a plurality of discrete deliveries. The outer wall or shell may be formed of gelatin, hydroxypropyl methylcellulose (HPMC) or any other suitable material. The additive release component defines a cavity having a volume which is filled with additive.

A second type of additive release component comprises an outer shell which is resiliently deformable. The outer shell functions as a single part, wherein the material of the outer shell is deformable. The outer shell may be formed from one part, or two (or more) parts sealed together. Preferably an outer shell formed from two parts is configured to rupture at a weakened region, for example along a longitudinal or circumferential seam joining the two parts, which opens under pressure to define a slit. The outer shell contains the additive, preferably flavourant or water, in an inner volume, i.e. hollow cavity. The outer shell surrounds and encapsulates the additive, and does not initially contain an aperture.

Regardless of the number of parts from which it is made, the outer shell may be configured to rupture in a predetermined area, over only part of the surface area, and preferably rupture to form one or more slits or apertures, when compressed. In some aspects, the outer shell defines a single slit (or a line of weakening that opens under pressure to form a single slit) which preferably extends longitudinally. The additive release component is configured to release only a part of the contents through the slit when the additive release component is compressed. The resiliently deformable additive release component at least partially returns to its original shape, when the compression of the additive release component 15 ceases. After the compression has ceased, the slit defined by the additive release component effectively closes, and no further contents are released from the additive release component. On a further compression, the additive release component deforms such that the resilient slit opens, and a further discrete delivery of the contents is released. In general, the outer shell may be configured to define an outlet having any shape, and is not limited to the slit described. For example, the outlet may be a pin-hole, or a region of weakening that opens to form an outlet under pressure. Alternatively, the outlet may not form in a pre-determined area, but may form on any part of the outer shell when a force is applied. The location of the outlet may depend on the exact force applied, and any inherent (i.e. not controlled) variation in the thickness of the outer shell.

In a third type of additive release component, the additive release component comprises an outer shell which is frangible. The outer shell is configured to break apart over substantially the whole surface of the outer shell, or alternatively rupture only in a predefined area when compressed. The outer shell surrounds the additive, and does not initially contain an aperture. The outer shell contains the additive, preferably flavourant or water, in a substrate within the outer shell. The substrate is preferably a body of absorbent material impregnated with the additive. The substrate is a porous matrix with an open structure, in particular, an open cell structure, e.g. an open cell foam structure. The description refers to a foam, but applies to any type of matrix with an open cell structure. The substrate is configured to be progressively compressible and configured to release at least a part, and preferably only a part, of the additive contents when partly compressed. The additive is distributed within the substrate, and In some aspects, absorbed by the substrate. The substrate is preferably formed of a filtration material, for example, cellulose acetate. The filtration material may be in the form of a known tow of filtration material suitable as a filter. The outer shell does not inhibit release of the additive once ruptured. The substrate may be at least partially resiliently deformable and may at least partially return towards the original shape, when the compression of the additive release component ceases. In the partial expansion of the substrate following release of the compressive force, the substrate may re-absorb a part of the released additive. References to release of the additive are intended to refer to the net release of additive after the compressive force has ended. On a further partial compression, the substrate releases a further discrete delivery of the contents.

In a fourth type of additive release component, the additive release component comprises an outer shell which is deformable. The outer wall is preferably plastically deformable, such that a deformation is maintained after the deforming force ceases. The outer shell contains the additive, preferably flavourant or water, in an inner volume. The outer shell surrounds the additive, and does not initially contain an aperture. The outer shell is configured to rupture in a predetermined area over only a part of the surface, and preferably rupture to form one or more slits or apertures of other shapes e.g. pin-holes, when compressed. In some aspects, the outer shell defines a single slit, which preferably extends longitudinally. The outer shell functions as a single part, wherein the material of the outer shell is deformable. The outer shell may be formed from one part, or two (or more) parts sealed together. Preferably an outer shell formed from two parts is configured to rupture along a longitudinal seam joining the two parts to define a slit. The additive release component is configured to release only a part of the contents through the slit when the additive release component compressed. The plastically deformable additive release component does not return towards its original shape, when the compression of the additive release component ceases. The additive release component and/or additive is configured such that no further contents are released from the additive release component 15. On a further compression, the additive release component 15 deforms further such that a further discrete delivery of the contents is released. In a fifth type of additive release component, the additive release component comprises a matrix with a closed cell structure, in particular, a closed cell foam substrate. The description refers to a foam, but applies to any type of matrix with a closed cell structure. The closed cell foam defines a matrix having a plurality of small cavities which contain additive. The cavities are closed by the foam material, retaining the additive until selective release. On application of a compressive force, the closed cell foam is configured to release additive. The compressed substrate develops cracks and/or openings, which allow release of the additive. The substrate preferably plastically deforms on compression.

The substrate can be formed by extrusion of the material containing the additive. The extruded closed cell foam is then cut to a suitable length.

The closed cell foam substrate does not require an outer shell to retain the additive, and so forms the additive release component without an outer shell. Alternatively, the additive release component may comprise the closed cell foam substrate encapsulated in an outer shell.

Alternatively, the substrate is fibrous, e.g. formed of cellulose acetate fibres, with additive dispersed therein as droplets or as microcapsules. The droplets or microcapsules are distributed within the matrix or fibres. The substrate is optionally surrounded by a frangible, elastically deformable or plastically deformable outer shell. The substrate is configured such that the additive can be released in a plurality of discrete deliveries, by a plurality of separate compressions. This differs from a conventional capsule having a frangible outer shell, in which all the additive is released at once when the outer shell is ruptured. Alternatively, any type of the additive release component comprises a substrate within the outer shell. The additive is distributed within the substrate. The substrate is an open cell foam material, which is compressible and configured to release only a part of the additive contents when compressed. The substrate is formed of a filtration material, for example, cellulose acetate tow. The substrate may be at least partially resiliently deformable, contained within a plastically deformable outer wall which prevents the substrate from expanding when compression ceases. Alternatively, the sponge substrate may actuate or follow a resilient outer wall at least partially towards its original shape when compression ceases. Alternatively, the open cell foam substrate may not resiliently return towards to its original size, and can plastically deform when compressed. The outer encapsulation comprises an outer wall which is frangible, resiliently deformable or plastically deformable, as described above for the additive release components. The outer encapsulation may have the same or different type of outer wall than the additive release components, in any combination.

The closed cell foam substrate does not require an outer shell to retain the additive, and so may form the additive release component without an outer shell. Alternatively, the additive release component may comprise the closed cell foam substrate encapsulated in an outer shell. The outer shell may be frangible, plastically

deformable or resiliently deformable on compression.

The substrate is formed by extrusion of the material containing the additive. The extruded closed cell substrate is then cut to a suitable length. The closed cell substrate can be made from cellulose acetate.

The outer wall or shell or any type of additive release component is configured as a structural part, which provides strength to allow handling of the additive release component. For example, the outer wall or shell may have a thickness of

approximately 0.2mm. Alternatively, the outer wall or shell may be a coating on the exterior of the substrate, which does not provide structural strength.

Figure 2 shows a further additive release component 35invention. The additive release component 35 may be of substantially the same construction any of the embodiments described above and comprises an elongate tube, having a

substantially circular or elliptical cross-section. The elongate shape allows each additive release component 35 to be of a smaller diameter than an equivalent single spherical additive release component 35 containing the same quantity of liquid. The additive release component 35 can therefore be located in a smaller diameter filter than the equivalent spherical additive release component 35, or, the filter 20 may comprise an increased radial depth of filtration material 12 around the additive release component 35 than the equivalent spherical capsule.

The additive release component 35 is substantially tubular with curved ends. In some examples, a flange 34 extends at the curved ends, which may comprise excess material for forming the outer shell. The additive release component 35 comprises a line of weakening 37. The line of weakening extends longitudinally, preferably extends substantially the whole length of the additive release component 35. The additive release component 35 may rupture only along the line of weakening, or may rupture initially at the line of weakening and immediately rupture over substantially the whole area of the additive release component 35. The line of weakening 37 defines a longitudinal slit which resiliently opens on compression of the additive release component 35, as described above. The line of weakening may be formed by a joint between two parts of the additive release component, or may be defined in an independent process in a selected area, e.g. by scoring the surface of the outer wall.

Figure 3 shows an assembly 80 comprising a plurality of additive release components 85 during manufacture. The additive release components 85 is of substantially the same construction any of the embodiments described above. Each additive release component 85 is formed containing an additive, according to any suitable method, examples of which are described below. The assembly 80 comprises additive release components 85 connected together in an elongate chain, with longitudinal ends attached to adjacent additive release components 85. The elongate additive release components 85 have a longitudinal axis extending parallel to the longitudinal axis of the assembly 80.

An additive release component 85a being formed is held between first and second pairs of retaining members or pinches 82, 84. The first pair of retaining members 82 holds or defines a first longitudinal end of the additive release component 85a. The second pair of retaining members 84 is shown separated, prior to compressing a second longitudinal end of the additive release component 85a. The additive is located in a tube of outer shell material, which is arranged substantially vertically. One or both of the retaining members 82,84, preferably upstream member 84, forms a seal in the tube. The seal is preferably a heat seal. The upstream pinch heat seals the tube, capturing the liquid downstream to the last seal. Formed additive release components 85 are shown connected to each other and the partially formed additive release component 85a by a web 86. The web 86 may be formed by connected flanges 34, as described with respect to Figure 2. The tube is then cut into individual units through the seal at a station further downstream. Alternatively, the manufacturing apparatus may comprise only a single pair of pinches for forming all of the seals in the tube. The additive release component can be formed by a blow-fill-seal method. An elongate tube of material for forming the outer tube is formed, preferably by extrusion. A gas is blown into the tube through a needle, in order to inflate the tube and form the outer shell. The additive is inserted through a needle into the outer shell. The outer shell is then sealed to form a completed additive release component. The blow-fill-seal method may be used for any embodiment for which it is suitable.

Alternatively, the additive release component can be formed by a bag-fill-seal method. The outer shell is formed by any known method. For example, two half bags may be stamped out and connected, e.g. by welding. Alternatively, two sheets may be heat sealed together. The additive is inserted into the outer shell, and the outer shell sealed.

Alternatively, the additive release component can be formed by freezing the additive, e.g. a solution of menthol in water, and subsequently coating this with material for the outer wall, e.g. gelatin. Alternatively, the additive release component may be formed by co-extrusion or any other suitable method.

Figure 4 shows a first method of forming a plurality of filters 90 according to the invention. A plurality of additive release components 85 of any type or embodiment are provided, connected together in a chain 80 extending parallel with the longitudinal axes of the additive release components 85. The additive release components 85 are inserted into a rod of filtration material 82 to form a plurality of filters. The chain 80 is inserted in a direction substantially parallel to a longitudinal axis of the filtration material 82 and assembly 80. As shown, the additive release components 85 are inserted into filtration material during forming of the filtration material into a cylindrical rod. In a machine (not shown), filter tow is drawn from a source of tow (not shown), and is compressed through a nozzle (not shown) and through a tongue of a garniture (not shown).

The chain 80 is drawn from a reel or hopper (not shown) and fed through the tongue so as to incorporate the chain 80 into the flow of tow. The chain 80 is a string of additive release components located within strands of filtration material tow. The tongue is configured such that the additive release components 85 are centrally disposed inside the eventual rod. In the garniture, the tow and the chain 80 therein are wrapped in a plug wrap (not shown), so as to form an elongate filter rod. An endless garniture tape (not shown) travels along a garniture bed, and drags the plug wrap, the tow, and the chain 80 through the garniture. The garniture tape curves inwardly as it travels through the garniture, thereby shaping the plug wrap such that the tow and chain 80 therein are cylindrically paper wrapped. An adhesive, such as hot melt glue or polyvinyl acetate (PVA) is applied to the plug wrap. Further details of the method of manufacturing are described in WO2010/03899, which is incorporated herein by reference.

Figure 5 shows a second method and arrangement of forming filters 95 according to the invention. The additive release components 85 of any embodiment or type are arranged in a stack 97 extending substantially perpendicularly to the longitudinal axes of the additive release components 85 in the stack. The additive release components 85 may be connected together in the stack 97, or may be individually retained in the stack by a retaining assembly (not shown) . The additive release components 85 are fed consecutively into filtration material, and the filtration material is then closed around the additive release components 85. The method is substantially as described above, and with reference to WO2010/03899, except with the additive release components 85 fed in substantially perpendicularly to the axis of the filter formed. The filter has been described as having a covering layer with one or more transparent windows. Alternatively, the covering layer 216 may not have a transparent window, and may be opaque over the whole exterior surface.

By applying pressure to the outside of the part of the filter which surrounds the additive release component, the user may deform the one or more additive release component and release the additive therein.

The additive release components are capsules having an outer shell, containing additive fluid (liquid or powder) in an interior cavity. The outer shell of each additive release component is frangible to release all of the additive on application of pressure.

The filter may comprise a reaction surface against which the additive release component can be urged, in order to facilitate release of additive. In particular, the additive release components may be located on a periphery of the filter. The radially adjacent filtration material may provide a reaction surface against which the additive release component can be urged. In some aspects, the filtration material may be relatively hard (e.g. by containing an increased amount of plasticiser) to form the reaction surface, and may have a hardness on the Filtrona scale of more than 90%. The additive release components may be located within the filtration material, or may be located in a cavity adjacent to the filtration material. The cavity may be formed by an elongate inner rod of filtration material, which one or two annular outer sections of filtration material surround. A covering layer forming an exterior of the filter is attached to one or both of the outer sections of filtration material, and spaced from the inner rod to define a cavity. In some aspects, the inner rod is harder than the annular outer sections, optionally by containing more plasticiser.

Alternatively, each additive release component can release its additive contents in a plurality of discrete doses, preferably actuated by a plurality of separate applications of pressure. This type of additive release component may comprise a resiliently or plastically deformable outer shell, preferably configured to release additive through a slit formed in a pre-determined area. Alternatively, this type of additive release components may comprise a porous absorbent substrate having an open cell structure (e.g. open cell foam), in which the additive is contained. The substrate may be at least partially resiliently deformable. The substrate is surrounded by an outer shell to retain the additive, which may be frangible, resiliently deformable, plastically deformable, or a thin coating. The substrate may form discrete additive release components, or may be in the form of an annulus in the first filter section.

Alternatively, this type of additive release component may comprise a porous matrix containing the additive in discrete cavities and having a closed cell structure (e.g. closed cell foam), which is plastically deformable to release the additive.

The additive release components can be individually attached to the filter or substrate. Alternatively, the additive release components may be connected by a web, and may be connected between laminated strips of sheet material. Alternatively, the strips of sheet material may form the additive release components, such that the additive release components do not have a separate outer shell, and the strips of sheet material contain the additive.

The additive release components have been described as manually manipulated to release the additive. Alternatively, a movable part may be configured such that movement of the movable part around an exterior of the smoking article releases additive from at least one of the additive release components. The movement is preferably sliding or rotation, by a ring or C-shaped clip, over an external surface of the filter. The filter may provide a reaction surface, against which the additive release components are urged by the movable part. The additive release components may be located in one or more grooves, extending circumferentially, longitudinally or helically. Alternatively, the movable part comprises a covering layer defining two adjacent surfaces, wherein the additive release components are located between the adjacent surfaces such that relative movement of the adj acent surfaces of the covering layer releases additive from at least one of the additive release components.

The additive release components have been described as individually located in the smoking article. Alternatively, a plurality of the additive release components may be surrounded by an outer wall or outer encapsulation. The outer encapsulation may be porous or configured to rupture or deform to allow release of additive on

compression. The outer encapsulation may itself be contained within a further encapsulation. The additive may be contained within a plurality of discrete cavities within an open cell substrate, or a closed cell substrate. The open cell substrate, and optionally the closed cell substrate, have an outer encapsulation. One or more additive release components may be affixed to an exterior of a substantially larger additive release component. Alternatively, a plurality of additive release components, of the same or different sizes, may be affixed together. Any of these embodiments may be considered as a plurality of components connected in a unitary structure.

The additive released from the additive release components has been described as being entrained by ventilating air and/or gaseous flow from the tobacco rod.

Alternatively, flow containing additive may be selectively released from the filter. The filter comprises a selecting means, preferably in the form of a movable element, preferably rotatable, at a mouthpiece end of the filter. The selecting means, at least a part of which is movable in relation to the first and second flow paths, is configured to select a first flow path, a second flow path, or optionally, an adjustable proportion of the first and second flow paths. The first flow path may correspond to an annular, radially outer flow path, and the second flow path may correspond to a radially inner flow path within the first flow path. Alternatively, first and second half-cylindrical filter parts respectively define the first and second flow paths, the first and second filter parts arranged together to form a cylindrical filter part. The additive may be initially encapsulated within one or more additive release components (i.e. capsules), prior to being selectively released. The additive release component is located in a filter, within filtration material.

Alternatively, the additive release component is located in a tobacco rod.

Alternatively, the additive release component is located in a separate section of the smoking article, not surrounded by filtration material. For example, the additive release component is located in a separate section located between the tobacco rod and filter.

The outer shell can be formed of a gellable material, e.g. gelatine. For example, an additive release component is manufactured by a known co-extrusion process. In the co-extrusion process, two fluids may be extruded together so that an additive release component is created by surface tension. Alternatively, a soft-gel process is used, which is known for making soft-gel type capsules. The additive release components are manufactured by a known co-extrusion process, for a capsule size of 5θθμηι to 10 mm. In the co-extrusion process, two fluids may be extruded together so that an additive release component is created by surface tension.

The shell fluid can be a warm gelatin solution, and liquid contents, e.g. menthol, are respectively delivered under pressure from separate tanks into a two-fluid nozzle. The shell fluid and liquid contents flow from a nozzle where they form droplets in a carrier fluid, the droplets having an outer shell of shell fluid and an inner core of liquid contents. A cooling mechanism is provided to cool and solidify the shell fluid. Alternatively, the shell material may be alginate, agar-agar, gum arabicum, latices or waxes. Alternatively, the additive release components may be formed by any suitable process for encapsulating a fluid (liquid) . For example, the capsules may be formed by interfacial polymerisation, which may produce a capsule size of ο.2μηι to a few millimetres. The shell may be made of a polymer, for example, polyester, polyamide, polyurea, polyurethane, or a biodegradable polymer e.g. protein, polysaccharides or oligosaccharides.

Alternatively, the additive release components may be formed by complex

coacervation, which may produce a particle size of lopm to a few millimetres. The outer shell may be made from gelatine and gum arabic. Alternatively, the additive release components can be formed by single extrusion, which may produce a particle size of 2θθμιη to a few millimetres. The shell may be made from alginate, chitosan, carrageenan, cellulose derivatives, or waxes. Alternatively, the additive release components can be formed by melt extrusion, which may produce a particle size of 3θθμηι to a few millimetres. The shell may be made from gelatine, sugars, maltodextrins, corn syrup, food polymers or modified starches. Alternatively, the additive release components can be formed by melt injection, which may produce a particle size of 2θθμιη to a few millimetres. The shell may be made from carbohydrate materials, e.g. sucrose, glucose syrups and modified starches.

Alternatively, the additive release components may be formed by a spray drying microencapsulation process, which may produce a particle size of ιομιη to a few millimetres. The capsule shell may be made from polysaccharides (starch, alginate, agar, pectin, carrageenan, gums), proteins (gelatine, casein), fats and fatty acids, cellulose derivatives, lipids (waxes, shellac, carnuba or beeswax) . Any materials for the additive release component or filter must be safe to use, and are subject to regulatory approval. Embodiments of the invention may be configured to comply with applicable laws and/or regulations, such as, by way of non-limiting example, regulations relating to flavours, additives, emissions, constituents, and/or the like. For example, the invention may be configured such that a smoking article implementing the invention is compliant with applicable regulations before and after release of an additive or additives.

Any of the features described in any embodiment may be used in combination with any other features of any other embodiment.

Materials for the additive release components or filter comply with and/or are subject to applicable regulatory requirements/approvals. They may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple,

Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamon, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, oil, liquid, or powder.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior containment of additive. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/ or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims

Claims l. A smoking article comprising an additive release component contained within the smoking article,

wherein the additive release component has a maximum lateral dimension of less than 3.5mm, and

the smoking article has a maximum lateral dimension of no more than 7.6mm. 2. The smoking article as claimed in claim 1 wherein the smoking article has a maximum lateral dimension selected from one of: from 5mm to 6mm, from 6mm to 7mm, and from 5.2mm to 5.6mm.

3. The smoking article as claimed in any one of the preceding claims wherein the additive release component has a maximum radial cross sectional area as a proportion of a radial cross-sectional area of the smoking article which is selected from one of: less than 80%, less than 70%, less than 60%, less than 50%, less than 40%, less than 30%, and, less than 25%. 4. The smoking article as claimed in any one of the preceding claims wherein the maximum lateral dimension of the additive release component is selected from one of: from 2mm to 3mm, from 2.2mm to 2.9mm, less than 3mm, less than 2.5mm, less than 2mm, less than 1.5mm, and less than imm. 5. The smoking article as claimed in any one of the preceding claims wherein the additive release component has a maximum lateral cross-sectional area of less than 10 mm².

6. The smoking article as claimed in any one of the preceding claims wherein the additive release component has a capacity selected from one of: from 3μΙ, to 5θμΙ. and from 5μΙ, to Ι5μ1.. η. The smoking article as claimed in any one of the preceding claims wherein the additive release component is elongate.

8. The smoking article as claimed in claim 7 wherein a length of the additive release component is selected from one of: between 4mm and 15mm, between 7mm to iimm, 8mm to lomm, approximately 9mm, from 5mm to 7mm, from 5mm to 6mm, and approximately 5.5mm.

9. The smoking article as claimed in any one of the preceding claims wherein the additive release component comprises an outer shell containing the additive.

10. The smoking article as claimed in any one of the preceding claims wherein the outer shell is frangible, resiliently deformable or plastically deformable. 11. The smoking article as claimed in any one of the preceding claims wherein the additive release component is configured to define an aperture to release the additive, wherein the aperture is defined by a rupture of an outer shell in a pre-determined area. 12. The smoking article as claimed in any one of the preceding claims wherein the smoking article comprises only a single one of the additive release component.

13. The smoking article as claimed in any one of the preceding claims comprising one or more windows configured to view the additive release component.

14. The smoking article as claimed in claim 13 wherein the or each window comprises a channel extending through filtration material surrounding the additive release component. 15. A filter for a smoking article comprising:

an additive release component, wherein the additive release component has a maximum lateral dimension of less than 3.5mm, and

the smoking article has a maximum lateral dimension of no more than 7.6mm. 16. A method of manufacturing a smoking article as claimed in any one of claims 1 to 14, comprising:

forming a plurality of additive release components connected in an elongate strip, and

inserting the elongate strip into filtration material, and

forming the smoking article with the filtration material.

17. A method of manufacturing a smoking article as claimed in any one of claims 1 to 14, comprising:

providing a plurality of additive release component in a stack which extends at least partially perpendicularly to a longitudinal axis of filtration material, and

inserting the additive release components consecutively into the filtration material, and

forming the smoking article with the filtration material.