PL182861B1 - Cigarette and heater for use in an electric smoking simulator - 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

The invention relates to a cigarette for use in an electric smoking system, a cigarette foil used in such a cigarette and a method of making the cigarette foil used in such a cigarette.

EP-615411 discloses a cigarette intended to be burned in an electric smoking system, comprising a tobacco rod formed of a cigarette foil rolled into a tubular sheet, inside which a tobacco plug is provided, the cigarette foil having a base sheet on which it is located. there is a layer of tobacco material, the tobacco plug being disposed adjacent the free end of the tobacco rod and distanced from the opposite end of the tobacco rod, and there is an unfilled space between the tobacco plug and the opposite end of the tobacco rod, and a cigarette foil is known from this description, comprising a base sheet on which a layer of tobacco material is provided; and a method of making a cigarette film by forming a base sheet onto which a layer of tobacco material is applied.

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Traditional cigarettes impart flavor and aroma to the smoker by combustion, during which a mass of combustible material, mainly tobacco, is burned at temperatures that often exceed 800 ° C during puffing. Heat is drawn in by the adjacent mass of tobacco by puffing at the mouthpiece. On heating, insufficient oxidation of the combustible material causes the various gaseous combustion products and tobacco distillates to oxidize. As these gaseous products are drawn through the cigarette, they are cooled and condensed to form an aerosol which provides the flavor and aroma when smoked.

Conventional cigarettes therefore suffer from various disadvantages. One is the production of a sidestream of smoke when the cigarette smolders between puffs, which can be unpleasant for non-smokers. Once lit, these cigarettes must either be burned completely or discarded. It is possible to smoke a traditional cigarette again, however it is usually unpleasant for a thoroughbred smoker for subjective reasons (smell, taste, odor).

An alternative to more traditional cigarettes are those in which the material burned does not release tobacco aerosol by itself. Such smoking articles may include a flared carbon heating element (heat source) positioned adjacent to or near one end of the smoking article and a charge of tobacco loaded elements positioned adjacent to the above-mentioned heating element. The heating element is ignited with a match or cigarette lighter, and when a smoker takes a puff on the cigarette, the heat generated by the heating element is applied to the charge of tobacco-loaded elements so as to cause the charge to release tobacco aerosol. Although this type of smoking article produces little or no sidestream smoke, it still produces combustion products at the heat source, and as soon as its heat source is ignited it cannot readily be extinguished for later use in a practical sense.

In both the conventional and coal heated smoking articles described above, combustion occurs. This process naturally increases the amount of many intermediate products as the combusted material breaks down and interacts with the surrounding atmosphere.

U.S. Patent Nos. 5,093,894, 5,060,671, and 5,095,921 disclose cigarettes that significantly reduce sidestream smoke while allowing the smoker to selectively stop and restart smoking. However, the cigarettes disclosed in these patents are not very durable and may kink, tear or break with prolonged or inattentive handling. Under certain circumstances, these known cigarettes may crumble because they are even weaker and may tear or break when removed from the lighter.

The cigarette disclosed in U.S. Patent Nos. 08 / 380,718 and EP-A-0.615,411 comprises a tobacco-loaded tubular carrier, cigarette paper wrapped around the tubular carrier, an array of flow-through filter plugs at the mouth end of the carrier, and a filter plug at the free (distal) end of the carrier. The cigarette is inserted into the lighter and upon activation of the individual heaters for each puff, localized charring occurs at points around the cigarette where each heater touched the cigarette (referred to as the "warmer footprint"). Once all the heaters have been activated, these charred spots are spaced tightly apart from each other and surround the central portion of the cigarette carrier.

Depending on the maximum temperature and the total energy delivered to the heaters, the charred spots are more than just a discoloration of the cigarette paper. In most applications, charring will cause at least minor tears to the cigarette paper and the underlying support material, which tears will tend to mechanically weaken the cigarette. For a cigarette pulled from a lighter, the charred spots must be at least partially inserted beyond the heater. In extreme situations, such as with a damp, crumpled or twisted cigarette, the

This may be prone to tearing or may leave pieces of material on removal from the lighter. Pieces left in the lighter holder may interfere with proper operation of the lighter and / or create a sensation of disgust on the next cigarette. If a cigarette breaks in two while pulling, the smoker not only becomes frustrated with a damaged cigarette, but also has trouble clearing off the clogged lighter before smoking another cigarette.

Recommended Cigarette Solution according to US Ser. No. 08 / 380,718, EP-A-0.615,411 and Patent 5,388,594, provides a hollow tube between the filter plugs at the mouth end of the cigarette and the plug at the distal end. Such a design improves the delivery of the aerosol to the smoker by creating sufficient space for the aerosol from the carrier to penetrate with minimal impact and condensation of the aerosol on any adjacent surfaces.

When combining cut filler with the cigarette hollow structure of EP-A-0.615,411, it has been found that such cigarettes, when fully loaded with cut tobacco cut filler, tend to operate adequately with an electric lighter for the first few puffs. Subsequently, there is a tendency for the aerosol delivery to stop. The same phenomenon occurs with more traditional cigarettes that are fired in an electric lighter such as the electric lighter disclosed in EP-A-0,615,411.

Left unfilled, the hollow cigarette structures according to the recommended EP-A-0.615,411 also suffered from some degree of collapse due to improper or careless handling.

A cigarette for use in an electric smoking system comprising a tobacco rod formed of a cigarette foil rolled into a tubular sheet within which a tobacco plug is provided, the cigarette foil comprising a base sheet on which a layer of tobacco material is provided, the plug being the tobacco rod is disposed adjacent the free end of the tobacco rod and distant from the opposite end of the tobacco rod, and there is an unfilled space between the tobacco plug and the opposite end of the tobacco rod, according to the invention it is characterized in that adjacent the opposite end of the tobacco rod is a free flowing tubular an element that is spaced from the tobacco plug and an unfilled space is provided between the free flowing tubular element and the tobacco plug.

The tubular element is preferably a filter that comprises plasticized tow material or mouldable material.

The filter tip is adjacent the opposite end of the tobacco rod.

The tip of the filter includes a second free-flowing filter adjacent the opposite end of the tobacco rod that is connected to the opposite end of the tobacco rod by tipping paper.

Adjacent to the second free-flowing filter is a mouthpiece filter cartridge.

The first free flow filter comprises a first channel and the second free flow filter comprises a second channel, the channels connecting the unfilled space of the tobacco rod with the mouthpiece filter cartridge, and the inner radius of the second channel is greater than the inner radius of the first channel.

An additional backflow filter is located at the free end of the tobacco rod.

The first portion of the tobacco plug adjacent the free end of the tobacco rod has a greater density than the second portion of the tobacco plug remote from the free end.

A cigarette for use in an electric smoking system comprising a tobacco rod formed of a cigarette film in the form of a tubular base sheet with a layer of tobacco material, a flow restrictor at the opposite end of the tobacco rod and a tobacco rod adjacent the free end of the tobacco rod spaced from the flow restrictor which is tobacco

182 861 is in the form of tobacco cut filler that fills a portion of a tobacco rod leaving a blank space for the tobacco rod, according to the invention the flow restrictor is at the opposite end of the tubular sheet and the tobacco is spaced apart from the flow restrictor and unfilled the tobacco rod space is adjacent the flow restrictor.

The flow restrictor is preferably in the form of a tubular member that includes a first free flowing filter through which the first passage passes and the filter tip includes a second tubular free flowing filter disposed adjacent the first free flowing tobacco rod filter, through the second tubular free flowing filter passes through a second passage, and further, the first passage of the first free flowing filter is narrower than the unfilled space of a tobacco rod and narrower than the second passage of the second free flowing filter.

The cut tobacco is positioned at the free end of the tobacco rod and has a density greater than the remainder of the cut filler tobacco remote from the free end of the tobacco rod.

A mouthpiece filter is positioned adjacent to the second free-flowing filter.

The tubular sheet includes a cigarette wrapper around a tobacco rod that is connected to the tip of the filter by tipping paper.

The tobacco plug preferably comprises cut filler tobacco or a blend of cut filler tobacco of a combination of at least two grades of tobacco of light tobacco, burley tobacco and oriental tobacco.

A wrapper is provided around the cut filler tobacco.

The tobacco is disposed along the inner surface of the tubular sheet.

A wrapper is provided around the outer surface of the tobacco rod.

A cigarette foil having a base sheet on which a tobacco material layer is provided according to the invention is characterized in that the base sheet comprises combinations of tobacco fibers and cellulose fibers combined in a ratio ranging from about 2: 1 to 4: 1. , and has a specific weight of from about 35 to 45 g / m ² , and the tobacco material has a specific weight of at least twice that of the base sheet and contains finely ground tobacco and tobacco solids extract in a ratio of about 3: 1 to 9: 1 and a humectant in an amount of from about 5% to 20% by weight of the tobacco material.

The tobacco material has a specific weight of about 3 to 4 times that of the base sheet.

The tobacco material further comprises pectin in an amount up to about 2% by weight of the tobacco material.

The base sheet contains approximately 28 g / m ^{2 of} tobacco fiber and approximately 12 g / m ^{2 of} cellulose fiber from wood pulp, flax pulp or tobacco stem pulp.

The tobacco material comprises about 66 to 71% by weight of tobacco particles, about 16 to 20% by weight of tobacco solids extract, about 10 to 14% by weight glycerin, and about 1-2% pectin.

The cigarette foil used in a cigarette for use in an electric smoking system having a base sheet on which a layer of tobacco material is provided, according to the invention is characterized in that the base sheet comprises a combination of tobacco fibers with a specific weight of about 20 to 30 g / m 2. ² and carbon fiber with a specific weight of about 1 g / m ² , the tobacco material having a weight of 3 to 4 times the weight of the base sheet, and the tobacco material further comprises finely ground tobacco and a tobacco solids extract with a ratio in the range of about 3: 1 to 9: 1, and a humectant in an amount of about 5% to 20% by weight of the tobacco material.

The fiber base sheet tobacco has a specific gravity of about 25 to 28 g / m ^2, carbon fiber has a specific gravity of about 2 to 4 g / m ^2, and pectin has a specific gravity of 2.5 to 1.5 g / m ^2.

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The method of producing a cigarette film for use in a cigarette for use in an electric smoking system by forming a base sheet onto which a layer of tobacco material is applied, according to the invention, characterized in that soluble substances are separated from the tobacco fibers to form the base sheet. which are contained in a solution of the dissolved tobacco components, whereafter the separated tobacco fibers and the reinforcing agent are suspended, which slurry is poured into a base sheet forming machine and then 5 to 10% of the tobacco component solution is mixed with additional tobacco particles. a humectant and pectin to form a tobacco material dispersion, the water content is adjusted to keep the solids content of the dispersion in the range of about 20 to 30%, and the formed base sheet is then applied to the tobacco material dispersion in the form of and the layer which is then dried, cooled, straightened out the corrugations and rolled up.

A solution of tobacco solubles is used containing about 7 to 8% by weight of the dissolved tobacco components.

The amount of water is controlled to obtain a dispersion with a solids content of about 24 to 26%.

Tobacco particles having a mesh size in the range of about 100 to 220 are used.

Tobacco particles having a size corresponding to a screen number of approximately 120 are used.

The suspension enhancing agent is used in the form of at least one pulp selected from the group consisting of wood pulp, flax pulp and tobacco stem pulp.

The tobacco material dispersion is applied to a base sheet with a dry weight ratio of at least 2: 1.

The tobacco material dispersion is applied to a base sheet with a dry weight ratio of at least 3: 1.

The cigarette of the invention offers the advantage of being able to contain cut filler while being stable during combustion maneuvering as part of an electric smoking system, and provides satisfactory flavor and aerosol delivery with each puff.

The cigarettes of the invention can be easily manufactured and packaged in attractive packages, are physically strong, and minimize aerosol condensation and / or filtration within the cigarette and / or lighter. In addition, they resist breaking when the cigarette is withdrawn from the lighter, are less likely to collapse or rupture due to careless maneuvering by the consumer during cigarette manufacture or packaging, and allow for cost effective manufacturing processes, even at the manufacturing speeds employed.

When the cigarette of the invention is inserted into the lighter of an electric smoking system, the cigarette rests against a bumper positioned within the lighter heater holder (or some equivalent restraining member) so that the electric heating elements of the lighter are positioned predetermined along the side of the cigarette substantially therein. same position for each cigarette. Upon initiation of a puff, at least one of the lighter heaters is activated in response to heating the cigarette at a predetermined position along the tobacco rod. As the puff continues, the tobacco rod is heated and an aerosol is discharged from the tobacco web and filler. When an imprint of a heater shoe is applied to a void in the tobacco rod, the tobacco aerosol is released almost instantaneously into the space formed inside the unfilled portion of the tobacco rod and withdrawn from the cigarette. The majority of this fraction of the total aerosol delivered by the cigarette is derived from the tobacco agent, and its direct access favorably influences the type and extent of puffing of the cigarette by the smoker. Due to the greater weight of the tobacco at the filled portion of the tobacco rod, there is a slight delay in the release of the aerosol from the locations where the footprint of the heater is applied to the filled portion of the rod. The aerosol that comes out of the glued part of the tobacco rod has an additional, dominant flavor and character of the smoke.

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A further advantageous effect of the invention is the ability to control the aerosol delivery of a cigarette from an electric smoking system, in which the proportional amount of overlap between the filled and unfilled portions of the tobacco rod by the footprint of the heater influences the desired aerosol delivery setting depending on the type of cigarette or depending on the linear extension for the cigarette. the same kind.

The subject of the invention is shown in an embodiment in the drawing, in which Figs. 1 and 2 show perspective views of an electric smoking system, Fig. 3 - a perspective view of a cigarette connected inside a heater holder of the smoking system shown in Fig. 1, Fig. 4A - sectional view. side view of a cigarette according to a preferred embodiment of the invention, Fig. 4B - detailed perspective view of the cigarette shown in Fig. 4a with some portions of the cigarette partially removed, Figs. 5A and 5B - flowcharts of steps in a preferred method of making the tobacco of the cigarette shown in Fig. 4A. and 4B, with Fig. 5A showing the steps of converting a tobacco web sheet to a tobacco web sheet and Fig. 5B showing the steps of converting a tobacco web sheet to a tobacco web sheet, Fig. 6A, cross-sectional side view of a substantially empty cigarette, Fig. 6B - graph. aerosol formation as a function of time during each draw produced by pr Fig. 6A, Fig. 6C - an illustration of the smoke measuring device used to determine the data shown in Figs. 6B, 7B and 8, Fig. 7A - cross sectional side view of a fully filled cigarette Fig. 7B - manufacturing diagram time versus time during each puff produced by a fully filled cigarette in Fig. 7A, Fig. 8 - Graphical comparison of the aerosol volume with each successive puff, delivered by each cigarette with reference to Figs. 4A, 6A and 7A, Fig. 9 - graph of the relationship between the total particle component (TPM) delivery and the amount of heater applied to the filled portion of a partially filled cigarette according to the embodiment (Fig. 4A), Fig. 10 - cross sectional side view of a cigarette according to a second preferred embodiment of the invention, Fig. 11 - sectional view from the side of a cigarette according to a third preferred embodiment of the invention, Fig. 12 - a side, sectional view of the heater holder, Fig. 13 a side view of the heater assembly, Fig. 14 - cross-sectional side view of the heater holder with an electrical insulator coating, Fig. 15 - cross-sectional side view of the heater holder using the electrical insulator shell forming the hub, Fig. 16 - cross-sectional side view of the heater holder with serpentine Fig. 17A - front sectional view of a heater blade having a flat underside facing the inserted cigarette; Fig. 17B - cross-sectional front view of a heater blade having an angled underside facing the inserted cigarette, Fig. 17C - cross-sectional front view of a heater blade having a curved underside facing the inserted cigarette, Fig. 18 - top view of a symmetrical arrangement of heater blades in a flat state prior to rolling, Fig. 19 - top view of an asymmetrical arrangement of heater blades in a flat condition before rolling, Fig. 20 is a radial sectional view Fig. 21 is a longitudinal sectional view of the cavity containing the aroma charge of the electric smoking system of Fig. 20 along the line AA of Fig. 20, Fig. 22, a radial sectional view showing a further alternative embodiment. of heater; and Fig. 23 is a longitudinal sectional view of the aroma-containing cavity of the electric smoking system of Fig. 22 along the line BB of Fig. 22.

Figures 1 and 2 show a smoking system 21 that includes a partially filled cigarette 23 according to the invention and a reusable lighter 25. The cigarette 23 is adapted to be inserted and removed from the slot 27 from the front end 29 of the lighter 25. As soon as the cigarette 23 has been inserted, the smoking system 21 is used in substantially the same way as with a more traditional cigarette, however without burning or smoking the cigarette 23. The cigarette 23 is removed after one or more puffs. Preferably, each cigarette 23 provides a total of eight puffs (a puff cycle) or more, however, may be adjusted at will for more or less of the total number of puffs available.

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The lighter 25 includes a housing 31 having front and rear housing portions 33 and 35. Within the rear housing portion 35 are removable one or more batteries 35a that provide power to a plurality of electrically resistive heating elements 37 that are disposed within the front housing portion 33 adjacent to the socket 27. The control circuit 41 in the front part of the housing 33 establishes an electrical connection between the batteries 35a and the heating elements 37. Preferably, the rear part 35 is adapted to be easily opened and closed, e.g. If desired, an electrical outlet or contacts may be provided to recharge the battery via a household electrical outlet or the like.

Preferably, the front housing portion 33 is removably attached to the rear housing portion 35, such as by a dovetail or a female fit. The housing 31 is preferably made of a hard, heat-resistant material. The preferred materials are metallic materials or more preferably polymeric materials. Preferably, the housing 31 has an overall dimensions of about 10.7 cm by 3.8 cm by 1.5 cm so that it can rest comfortably in the hand of the smoker.

The batteries 35a are sized to provide sufficient power for the operation of the heaters 37 and are preferably of a removable and rechargeable type. Alternative power sources such as capacitors can be used. Preferably, the power source is 4 nickel-cadmium battery cells connected in series to give a total unloaded voltage of approximately 4.8 to 5.6 volts. The desired power source characteristics are, however, received due to the characteristics of the other components of the smoking system 21, in particular the characteristics of the heating elements 37. U.S. Patent No. 5,144,962 discloses several types of power sources useful for the smoking system of the invention, such as rechargeable batteries. and circuits containing a capacitor that is recharged by the battery.

As shown in Fig. 3, the front portion of the housing 33 of the lighter 25 supports a substantially cylindrical heater holder 39 that slidably receives the cigarette 23. The heater holder 39 covers the heating elements 37 and is adapted to support an inserted cigarette 23 in a predetermined position relative to the heating elements 37 so that that these heating elements 37 are disposed along the sides of the cigarette at approximately the same position on each cigarette. The location where each heating element 37 abuts (or is in thermal contact) against the fully inserted cigarette 23 is referred to herein as the footprint of the heater.

To ensure a permanent positioning of the heating elements 37 relative to each cigarette 23, the heater holder 39 is provided with a stop 182 against which the cigarette rests when it is inserted into the lighter 25. Other means may be used to position the cigarette 23 relative to the lighter 25.

The front portion of the housing 33 of the lighter 25 also includes an electrical control circuit 41 that supplies a predetermined amount of power from the power source 35a to the heating elements 37. Preferably, the heater holder 39 includes 8 circumferentially spaced heating elements 37 that are concentric with the seat 27. and which are to be serpentine. The details of the heaters 37 are set forth and described in U.S. Common Patent Application No. 07 / 943,504 and U.S. Patent No. 5,388,594, both of which are hereby incorporated by reference. Additional heater mounts 37 that form part of the lighter are as disclosed in co-pending U.S. Patent Application filed January 6, 1995 (under the designation of Attorney PM 1729B CIP II) in Co-pending U.S. Application Serial No. 08 / 291,690 filed August 16, 1994, which are incorporated herein by reference. reference, and in the last part of this description with reference to figures 13 to 23. Preferably, the heaters 37 are individually powered by a power source 35a under the control of circuit 41 to heat the cigarette 23 preferably 8 times at positions spaced apart around the circumference of the cigarette 23. The heating is provided by eight puffs of the cigarette 23 as is the case with traditional smoking

182 861 cigarette. It may be beneficial to light more than one heater simultaneously for one or more puffs.

A further preferred heater design is set forth in co-pending US Patent Application Serial No. 08 / 224,842, filed April 8, 1994, incorporated herein by reference.

Returning to Figure 2, circuit 41 is preferably activated by a puff actuated sensor 45 which is sensitive to either pressure variations or variations in the amount of air flow that occur upon initiation of a puff 23 by a smoker. The puff actuated sensor 45 is preferably located within the front of the housing 33 of the lighter 25 and is connected to a space within the heater holder 39 adjacent to the cigarette 23 through a conduit extending through a spacer at the base of the heater holder 39 and, if desired, a puff sensor tube (not shown). A puff actuated sensor 45 suitable for use with a smoking system 21 is described in U.S. Common Patent No. 5,060,671, incorporated herein by reference. The puff sensor 45 is preferably a silicone sensor model 163PC01D35, manufactured by the Micro Switch division of Honeywell, Inc., Freeport, Illinois. Flow sensing devices, such as using the principles of hot wire anemometry, are useful for activating one of the heater elements 37 when a change in airflow is detected. As soon as it is activated by the sensor 45, the control circuit 41 directs the electric current to the corresponding one of the heating elements 37.

Indicator 51 is provided at a location along the exterior of lighter 25, preferably on the front of housing 33, to indicate the number of puffs remaining from cigarette 23. Indicator 51 is preferably a seven-segment liquid crystal display. Preferably, the indicator 51 displays the figure "8" when the detector 53 detects the presence of a cigarette in the heater holder 39. The detector 53 preferably comprises a light sensor at the base of the heater holder 39 that detects when a light beam is reflected from an inserted cigarette 23. Then the detector 53 provides a signal to circuit 41 which in turn sends a signal to indicator 51 in response. Displaying "8" on indicator 51 means that eight puffs can be made for each cigarette 23, i.e., that none of the heater elements 37 have been activated for warm the cigarette 23. After the cigarette 23 is completely burned, the indicator displays the number "0". When 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 turned off. The detector of the cigarette is modulated so that it does not emit a constant beam of light which would unnecessarily weaken the power source 35a. A preferred detector 53 suitable for use in smoking system 21 is a light sensor type OPR5005, manufactured by ΟΡΤΕΧ Technology, Inc., 1215 West Crosby Road, Carrollton, Texas 75006, USA.

As an alternative to displaying the remaining puff count, the detector display may indicate whether the system is active or not active ("on" or "off").

As one of several possible alternatives to using the detector 53 described above, a mechanical switch (not shown) may be used to detect the presence or absence of a cigarette 23, and a reset button (not shown) may be used to set the circuit 41 after inserting a new cigarette into the lighter 25, e.g. to cause indicator 51 to display the digit "8", etc. Power sources, circuits, puff actuated sensors and indicators useful in the smoking system 21 of the present invention are described in U.S. Common Patent No. 5,060,671, and in U.S. Patent Application No. 07 / 943,504. introduced here as a reference.

As shown in Figures 4A and 4B, a cigarette 23 according to a preferred embodiment of the invention comprises a tobacco rod 60 and a filter tip 62 which are joined together by a tissue 64.

The partially filled filled cigarette 23 preferably has a substantially constant diameter along its length and, like conventional cigarettes, has a diameter preferably between about 7.5 mm and 8.5 mm such that the smoking system 21 provides the smoker with a familiar feel. Preferably, the cigarette 23 has a total length of 62 mm, which facilitates the use of the convoy

181 861 optional cigarette wrapping machines 23. The combined length of the mouthpiece filter 104 and the free flowing filter 102 is preferably 30 mm. The wrapping paper preferably extends about 6 mm above the tobacco rod 60. The overall length of the tobacco rod 62 is preferably 32 mm. Other proportions, lengths, and diameters may also be selected instead of those given above for the recommended solution.

The tobacco rod 60 of a cigarette 23 preferably comprises a tobacco web 66 that has been coiled into a tubular (cylindrical) form.

The wrapper 71 tightly wraps around the tobacco web 66 and is held together along the longitudinal side seam as commonly used in making conventional cigarettes. The wrapper 71 holds the tobacco web 66 wrapped around the free flowing filter 74 and the tobacco plug 80.

Preferably, the wrapper paper 71 is tightly wrapped around the tobacco web 66 to provide the exterior appearance and feel of a traditional cigarette. Smoke with a better taste has been found to be obtained when the wrapping paper 71 is standard cigarette paper preferably flax paper having approx. 20 to 50 CORESTA (defined as the amount of air measured in cm ³ that passes through 1 cm ^{2 of the} material, e.g. . paper sheet, in one minute at a pressure drop of 1.0 kilopascala, and more preferably about 30 to 45 CORESTA, a specific gravity of approx. 23 to 35 g per m ² (g / m ^2), and most preferably approx. 23 to the - 30 g / m ^2, and a filler loading (preferably calcium carbonate) of approx. 23 to 35% by weight, benefit dare 28 to 33% by weight.

Wrapping paper 71 preferably contains little or no citrate or other burn modifiers, with recommended levels of citrate ranging from 0 to about 2.6% by weight of the wrapping paper 71, and more preferably less than 1%.

The tobacco web 66 preferably includes a base component 68 and a tobacco flavor layer 70 disposed along the inner surface of the base web 68. At the tip 72 of the tobacco rod 60, the tobacco web 66 and the wrapper 71 are wrapped around a tubular free flowing filter 74. A free-flowing filter 74 is provided. constructive restraint and support at the tip 72 for the tobacco rod 60 and allows the aerosol to be drawn from within the tobacco rod 60 with a minimal pressure drop. The free-flowing filter 74 also functions to restrict the flow at the tip 72 of the tobacco rod 60, which is believed to aid in the generation of an aerosol when puffing on the cigarette 23. The free-flowing filter has a length of at least 7 mm to facilitate machining and is preferably annular, however. Other shapes and types of low-capacity filters are also suitable, including cylindrical filter plugs.

At the free end 78 of the tobacco rod 60, the tobacco web 66 with the wrapper 71 are wrapped around the cylindrical tobacco plug 80. Preferably, the tobacco plug 80 is made separate from the tobacco web 66 and provides a relatively short column of tobacco cut filler that has been wrapped and held in the wrapper. 84.

Preferably, the tobacco plug 80 is made on a conventional cigarette rod machine on which the cut filler, preferably blended, is air formed into a continuous tobacco rod on a traveling belt and wrapped with a continuous web of wrapping 84 which is then glued along its seam. longitudinal and heat-sealed. However, according to a preferred embodiment of the invention, the wrapper 84 is preferably made of a cellulosic tape containing little or no filler, sticky or burn additives (each at less than 0.5% by weight) and preferably little or no adhesive. Preferably, the tobacco plug wrap 84 has a low specific gravity of less than 15 g / m ^2, and more preferably about 13 g / m ^2. The tobacco wrapper 84 preferably has a high permeability in the range of about 20,000. up to 35 thousand CORESA, and more preferably, in the range of about 25,000. up to 35 thousand CORESTTA, and is preferably made of softwood fibrous pulp, abaca cellulose or other long fiber pulp. These types of tissue paper are available from Papierfabrik Schoeller and Hoescht GMBH,

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Postfach 1155, D-76584, Gemsback, Germany, another tissue suitable for use as a wrapper 84 is TW 2000 from DeMauduit, Euimperle, France, with an addition of carboxy-methylcellulose of 2.5% by weight.

The machine for making a tobacco rod is activated such as to obtain a tobacco rod density of approximately 0.17 to 0.30 grams / cm ³ (g / m ^3), but more preferably in the range of at least 0.20 to 0.30 g / m ³ and most preferably between about 0.24 to 0.28 g / m ^3. Increased densities are recommended to avoid loose ends at the free end 78 of the tobacco rod 60. However, it should be recognized that lower rod densities allow the tobacco column 82 to contribute more to aerosol production and smoke flavor. Thus, the need for aerosol delivery (which is enhanced by the low density of the tobacco rod in the tobacco column 82) and the need to avoid loose ends (which is favored by elevated rod density ranges) must be balanced.

The tobacco column 84 preferably comprises tobacco blend cut filler typically used in the tobacco industry, including blends including pale tobacco, burley tobacco, and oriental tobacco optionally together with processed tobacco and other blended components, including traditional cigarette flavorings, but preferably, cuttable. tobacco column filler 84 is a blend of pale, burly, and oriental tobacco in a ratio of about 45:30:24 in the US market, with no reconstituted tobacco or any flavorings included. Optionally, a swollen tobacco component may be included in the blend to adjust the rod density, and flavorings may be added.

A continuous tobacco rod formed as described above is cut into predetermined lengths of the tobacco plug 80. The length is preferably at least 7mm to facilitate on-machine processing. However, the length may vary from about 7mm to 25mm or more, depending on preferences placed on the cigarette design that emerge from the following description, in particular with reference to Figures 4A and 4B.

In general, the length 86 of the tobacco plug 80 is preferably set with respect to the total length 88 of the tobacco rod 60 such that a void 90 is formed along the tobacco rod 60 between the free flowing filter 74 and the tobacco plug 80. The void 90 corresponds to the unfilled portion of the tobacco rod. 60 and remains in direct fluid communication with the wrapper 62 via the free-flowing filter 74 of the tobacco rod 60.

As shown in Figure 4A, the length 86 of the tobacco rod 80 and its relative position along the tobacco rod 60 are also selected with respect to the features of the heating elements 37. When the cigarette is properly positioned relative to the stop 182 of the heater holder 39, a portion 92 of each heating element 37 will make contact with the tobacco rod 60 along the area of the rod 60. This area of contact is referred to as the footprint of the heater foot 94. The footprint of the heater foot 94 (as shown by the double arrow in Fig. 4A) is not itself part of the structure of the cigarette, but is a representation of the cigarette. area of the tobacco rod 60 likely to reach the expected operating heating temperature of the heating element 37 while smoking a cigarette 23. Since the heating elements 37 are at a constant distance 96 from the stop 182 of the heater holder 39, the footprint of the heater 94 consequently is located along the tobacco rod 60 the same j a predetermined distance 96 from the free end 78 of the tobacco rod 60 for each cigarette 23 that will be fully inserted into the lighter 25.

Preferably, the length of the tobacco plug 80, the length of the footprint of the heater 94 and the distance between the footprint of the foot of the heater 94 and the stop 182 are selected such that the footprint of the foot of the heater 94 extends beyond the tobacco plug 80 and overlaps a portion of the void 90 by a distance 98. Distance 98. by which the footprint 94 extends beyond the void 90 (the unfilled portion of the tobacco rod 60) is also referred to as "applying a warmer over the void" 98. The distance that the remainder of the foot footprint 94 extends beyond the core insert is referred to as "covering the filler by the heater" 99.

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Tip 62 preferably includes a free flowing filter 102 disposed adjacent to tobacco rod 60 and a mouthpiece filter plug 104 at the distal end of tip 62 relative to tobacco rod 60. Preferably, free flowing filter 102 is tubular and communicates air with a very low pressure drop. However, other standard configuration low capacity filters may be used in place of such a filter. The inside diameter of the free flowing filter 96 is preferably between 2 to 6 mm and preferably larger than the diameter of the free flowing filter 74 of the tobacco rod 60.

The mouthpiece filter 104 seals the free end of the tip 62 for appearance reasons and if necessary to provide some filtration, although the mouthpiece filter 104 is preferably a low efficiency filter, preferably about 15 to 25% efficiency.

The free-flowing filter 102 and the mouthpiece filter plug 104 are preferably joined together as an interconnected plug 110 by means of a wrapper 112. The wrapper 112 is preferably a porous, light weight wrapper that is conventionally available in the cigarette product industry. The interconnected plug 110 is attached to the tobacco rod 60 by means of an endcap 64 having properties standard and conventionally used in the cigarette industry. The tissue paper 64 may be cork, white or any other color according to selected decorative preferences.

Preferably, a cigarette 23 made according to the preferred embodiment of the invention has an overall length of about 62 mm, of which 30 mm is the combined plug 110 of the tip 62. Thus, the tobacco rod 60 is 32 mm long. Preferably, the free-flowing tobacco rod 60 filter 74 is at least 7mm in length and the void 91 between the in-line filter 94 and the tobacco plug 80 is preferably at least 7mm in length. Preferably, the footprint of the heater shoe 94 is approximately 12mm long and is positioned to cover at location 98 a distance of 3mm the void of the cigarette, leaving a 9mm footprint of the heater shoe 94 applied to the tobacco plug 80.

The length of the void 91 and the length of the tobacco rod 80 can be adjusted to facilitate manufacture, and more importantly, to control the combustion characteristics of the cigarette 23, including taste, draw, and aerosol delivery. The length of the void 91 and the amount of heater applied to the filler (as well as the amount of heater applied to the void) may also be varied to regulate the puff sensation, to enhance the quality of aerosol delivery (on a puff-to-puff basis as well as between cigarettes), and to control aerosol condensation at or near heaters.

In the preferred embodiment, the void 91 (the unfilled portion of the tobacco rod 60) extends about 7 mm to provide adequate clearance between the footprint of the heater 94 and the free-flow filter 74. Thereby, a margin is created so that the footprint 94 does not heat up. the free-flowing filter 74 during smoking. Other lengths are also suitable, for example if manufacturing tolerances permit it, so the void 91 may be only 4mm or less in length or at the other extreme may extend beyond 7mm to define an elongated unfilled portion along the tobacco rod 60. Recommended length range for unfilled part (void 91) is from about 4 mm to 18 mm, and preferably 5 to 12 mm.

Base sheet 68 physically separates the heating elements 37 from the tobacco flavor material, transfers the heat generated by the heating elements 37 to the flavor material 70, and maintains the physical integrity of the tobacco rod during maneuvering, insertion into lighter 25, and removal from the cigarette after combustion.

In the following description, certain percentages and / or relative weights will be given for the various components that make up the tobacco sheet 66.0 unless otherwise stated, or of course for those skilled in the art, the weight percentages given are based on the base weight when dry, i.e. the added levels. the percent and / or relative weights do not contain the moisture component.

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The method of manufacturing the tobacco sheet 66 is carried out preferably without the addition of carbon fibers, as will be described below. According to a preferred method of manufacturing the base sheet 68 has a preferred total basis weight of about 35 to 45 g / m ^2, and more preferably about 40 g / m ^2.

And a weight of 40 g / m ^2, the base sheet 68 preferably comprises approximately 28 g / m ² tobacco fiber and approximately 12 g / m ² cellulosic fiber such as from wood pulp or flax. The cellulosic fibers function as a cellulosic reinforcing agent in the sheet composition 68. It is recommended that the amount of cellulose fiber in the base sheet be minimized for subjective reasons (to avoid giving the cigarette a paper flavor). In general, the ratio of tobacco fiber to cellulose fiber in base sheet 68 on a dry weight basis should be in the range of about 2: 1 to 4: 1. The preferred cellulose mat is bleached softwood kraft cellulose, although most wood and flax pulp can also be used.

An alternative reinforcing agent for base sheet 68 is cellulose fiber derived from the tobacco stem.

Although not recommended, one side of the base sheet 68 may be coated with alginate at a level of about 1 g / m ^2. If an alginate is used, then it is preferable to apply it to the side of the base sheet 68 that is opposite the side holding the tobacco flavor material 70.

The tobacco material 70 is preferably applied to the sheet 68 at levels weight in the dry state amounting to at least twice, preferably about three or four times the weight of the base sheet 68. In the preferred embodiment, the tobacco material has a basis weight of about 130 g / m ^2, preferably that the total weight of the base sheet 66 is about 170 g / m ² . On a dry weight basis, the tobacco material 70 comprises a fraction of the ground tobacco and a solids extract in a ratio ranging from 3.5 to 1 (5.3: 1) to 5 to 1 (5: 1) by weight, however the ratio is this may range from about 3: 1 to 9: 1. In a preferred embodiment, the ratio is approximately 4: 1.

Glycerin is added to the tobacco material 70 as a humectant and an aerosol precursor at levels of about 10-14%, preferably about 12%, by weight of the dry tobacco material 70, however this level of additives may be varied from about 5% to 20% or more. based on dry tobacco material 70. When the amount of glycerin is reduced to only 5 to 7% of the dry weight of the composition, the tobacco sheet 66 may be somewhat stiffer and more resistant to collapse when rolled into a tubular form.

Pectin is also added to the tobacco material 70 in percentages based on the dry weight of about 0.5 to 2%, preferably about 1.4%. Pectin is added as a coating agent. In its absence, the tobacco material 70 may tend to penetrate excessively into the base sheet 68 during the coating operation, imparting a granular surface texture to the coated side of the tobacco sheet 66. Too much pectin inhibits penetration and weakens the bond between the tobacco material 70 and the base sheet 68. At about 1%, the pectin promotes penetration and bonding between the layers, respectively, so that the base sheet 68 can withstand the rigors of automated cigarette manufacturing.

Most preferably, the tobacco material 70 on the base sheet 68 comprises about 16-20% by weight on a dry basis of tobacco solid extracts, 66-71% by weight by weight of tobacco particles, 8-14% glycerin, and about 1.4% pectin. Commercially available in the United States of America, the ground tobacco incorporated into tobacco material is preferably a blend of light burley tobacco and oriental tobacco, with nearly half of the blend being pale tobacco, about 1/3 burley tobacco and the remainder oriental tobacco. The composition and relative amounts of the blend components can be advantageously selected to meet consumer preferences in the US and other markets.

As shown in Figures 5A and 5B, a preferred method of making a starting tobacco sheet 66 in a form suitable for the automated manufacturing of cigarettes 23 includes

The 182 861 has a first series of steps 120 (shown in Figure 5A) for converting a tobacco stock, preferably a tobacco belt, into a continuous tobacco sheet 66s and a second series of steps 122 (shown in Figure 5B) for converting the continuous tobacco sheet 66s into one or more more wound tobacco sheet drums 66b suitable for use in automated cigarette manufacturing 23.

As shown in FIG. 5A, a method 120 for converting a tobacco stock to a continuous tobacco sheet layer 66s begins with subjecting the tobacco stock to an extraction step 124 (preferably with water) to separate the tobacco fibers from the soluble tobacco materials of the initial stock. The tobacco stock preferably comprises tobacco strips, however other forms of tobacco and / or tobacco sheet are also suitable for use in this process. Preferably the tobacco strips are a blend of pale tobacco and burley tobacco, and may optionally contain oriental tobacco or other grades.

The tobacco fiber collected from the extraction process 124 is subjected to a papermaking process 126 to produce a continuous base sheet layer 68s.

In process 126, the tobacco fiber from extraction step 124 is dispersed in water with the addition of a predetermined amount of cellulose fiber which serves as a reinforcing agent in the base sheet composition 68. Preferably, the cellulose fiber is pulp-like cellulose derived from wood, flax and / or tobacco stalks. Shortly after combining, the blended dispersion of tobacco fiber and cellulose fiber is refined to obtain a castable slurry 128 in a casting step 130 in which the slurry 128 is directed to the headbox of the sheet making machine and poured onto the web of a flat screen or closed paper mill. a steel belt, preferably a template.

It is more preferred to clean the dispersed mixture of tobacco fiber and the reinforcing agent after the two components have been mixed together. Instead, they can be cleaned separately and then combined.

Following the casting step 130, the resulting sheet 132 is then passed through one or more dryers in a drying step 134, which step preferably includes passing the sheet over a Yankee dryer and one or more can dryers, although many alternatives and devices may be used to carry out the drying step 134. known in the art. Upon completion of the drying sheet step 134, the monitoring step 136 begins to measure the moisture content and the dried sheet weight. The moisture content measurement output 138 is used to adjust the drying operation 134 to achieve and maintain the desired final moisture level in base sheet 68s for the next coating operation 144. Base sheet 68s preferably has about 15% moisture by weight at the time of coating 144.

Returning to the monitoring step 136, the output 140 determining the weight of the base sheet 68s is used to adjust the operation of the casting step 130 to achieve the recommended base sheet weight 68 as described above. Such adjustments include variations in the rate at which the slurry 128 enters the casting box of the sheet making machine during the casting step 130.

The sheet forming step 126 may optionally further include a coating 142 step in which one side of the base sheet 68s is coated with alginate at the levels previously described along one side of the base sheet 68s opposite that side which contacts the tobacco flavor material 70. However, recommended practice is omitting the use of alginate.

Upon exiting the sheet forming step 126, the base sheet is in the form of a continuous sheet 68s which is amenable to being subjected to the coating operation 144. Alternatively, it may be collected for subsequent coating operations upstream of the run. Preferably, however, it is transferred directly to the coating operation 144 after the production of the base sheet 68s.

Preferably, the base sheet 68s is transferred to the coating step 144 having a moisture content of about 12 to 17%, and preferably 14.5 to 15.5% moisture.

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Returning to the extraction stage 124, the soluble tobacco materials exit the extraction stage 124 as a dilute solution containing about 5 to 10% dissolved tobacco components (solutes), and preferably 7 to 10% dissolved tobacco components. Preferably, the diluted solution does not undergo any evaporation treatment so as to minimize the application of heat to the solution. The application of heat may have a negative effect on the taste of the dissolved tobacco substances when smoking a cigarette 23.

These solubles (also known as "liquid extract") from the extraction step 124 are mixed in a blending step 146 with additional finely ground tobacco, glycerin, and pectin along with water all in relative amounts that give a final proportional content as described above for state dry tobacco material 70. In step 146, water is added (or contained) in amounts sufficient to provide a dispersion of about 21 to 35% solids, more preferably about 24 to 26% solids, from the mixing step 124. The ground tobacco particles in the mixture have a size preferably in the range of 60 to 400, defined by the screen number, which corresponds to 95% passage of the tobacco particles through a screen having a given number of holes per square inch. More preferably, the additional milled tobacco particles have a screen size in the range of about 100 to 200, and most preferably about 120.

If the sieve size of the ground tobacco particles is set above 120, and in particular about 180 to 220, then the solids content of the tobacco material suspension may be raised after the mixing step 146 exits the mixing step 146 to levels of about 28 to 31%.

Upon exiting from the mixing step 146, the resulting slurry material is passed directly to the coating step 144, although this coating step may also optionally be performed later outside the run. In the coating step 144, the slurry tobacco material should have a solids content of about 22 to 27% by weight, and preferably about 24 to 25%.

In the coating step 144, the slurry tobacco material has a target weight of tobacco solubles of 4 to 8%, and more preferably 5.5 to 6.5% by weight of tobacco solubles. Preferably, the slurry tobacco material enters the coating step 144 at a temperature in the range of about 70 to 130 ° F, and more preferably about 90 ° F plus or minus 5 ° F.

The coating step 128 is preferably carried out with a standard reverse roll coater located downstream of a Yankee dryer above the closed belt or belt of a papermaking machine. The coating step may be performed by any other suitable coating equipment known and available to those skilled in the sheet forming art. The tobacco material 70 may instead be cast or extruded into base sheet 68. Alternatively, the supplying step 128 may be performed out of the run separately from the production of base sheet 68s. Flavorings conventionally used in the cigarette industry may be added during or after the coating step 128 as desired.

Upon exiting the coating step 144, a continuous web of tobacco sheet 66s is obtained.

As shown in Figure 5B, this process continues with steps 122 of converting the tobacco sheet web 66s into a wound tobacco sheet web drum 66b that is suitable for automated cigarette manufacturing 23. Preferably, the conversion steps 122 are performed in series to produce a continuous web of tobacco sheet 66s. . During the conversion steps 122, the operator should avoid conditions that cause cracks, tears, or other damage to the tobacco sheet 66s, so as to obtain a continuous roll of the tobacco sheet on drum 66b with no or little tangles. In addition, the tobacco sheet web 66 should be conditioned so that, upon exiting the processing step 122, the tobacco sheet does not overlap and can be quickly wound and unwound from drum 66b without breaking.

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The conversion steps 122 begin with a drying step 146 in which preferably the tobacco sheet web 66s is fed continuously through a gas fired hot air dryer such as that obtained from Airtech Systems Corp. Stroughton, Maine or with a steam heated hot air jet dryer, Other dryers known in the art for drying the sheet may also be used. The drying step 146 can be conducted with minimal heat input, in amounts sufficient only to dry the tobacco sheet 68s from its initial state (about 15% moisture content in the base sheet and about 75% moisture level in the coating) to about 8.5 to 12%. the moisture content exiting the drying step 146. More preferably, the dried tobacco sheet web 66d has a moisture content in the range of about 10 to 11%. This final moisture content is recommended for several reasons: to facilitate cutting at a later stage in the conversion process, 122, to set a moisture level that is close to the equilibrium level of the material after stocking and / or shipment to a factory, and to establish a moisture level that is it will prevent the base sheet material from sticking to and sticking together on drum 66b.

Following the drying step 126, the dried tobacco sheet web 66d is cooled to ambient temperature, preferably that of the storage site and / or factory, typically in the range of 65 to 80 ° F. This cooling step 148 not only helps to balance the tobacco sheet 66 to the operating environmental conditions, but also avoids the risk of heat being trapped in drum 66b, which would initiate the self-heating process. Unless this temperature is controlled, the phenomenon of self-heating could lead to the development of temperature extremes and consequently the degradation of the properties of the tobacco sheet 66. Preferably, the cooling step is carried out with a cold water cooler operated by an air stream, obtained from Airtech Systems Corp., Stroughton. Maine, although many alternative cooling systems known to those skilled in the art may be used.

Following the drying and cooling step of the sheet 146 and 148, the dried and cooled tobacco sheet web 66dc is passed through a wrinkle suppression device, such as that offered by Thermo Electron Web Systems, Inc., Aubum, Maine or any other suitable strip straightener known to those skilled in the art. fields. Upon exiting from the flattening of the ripples 150 step, the tobacco sheet 66 is substantially free of thermally induced ripples along its edges and is in a condition suitable for subsequent winding and cutting at steps 152 and 154. However, it is preferable to monitor the temperature, moisture level, and moisture level prior to carrying out these steps. and the total weight of the tobacco sheet web 66f as it exits the ripple flattening step 150 so as to provide process control to obtain the tobacco sheet web 66s in a punching and slitting condition, and to obtain the desired temperature and moisture target value and total weight. drums 66b.

Specifically, when monitoring the tobacco sheet web 66, its total weight reading is used to set the conditions of the coating step 144, such as the feed rate of the slurry tobacco material to the reverse roller coater or to the nip at the coater nip. The moisture level readings in the monitoring step 151 are used to control the drying operation so as to obtain target moisture levels in the belt as previously described. Similarly, the cooling step 148 is controlled in response to the temperature readings of the tobacco sheet web 66 in the monitoring step 151.

Thereafter, the tobacco sheet web 66 is wound on a winding step 152 which is performed by strip winding machines known and available in the sheet processing art. Thereafter, the wrapped tobacco sheet web 68s is cut into individual drums 66b, the width cut for each drum being selected to match the desired circumference of the cigarette 23.

Upon exiting the conversion steps 122, drum 66b is in a state adapted for automated cigarette manufacturing 23, such as the combined operations disclosed.

Referring to Fig. 6 of co-pending US Application Serial No. 07 / 943,504, filed September 11, 1992, incorporated herein by reference.

The glycerin in the tobacco material 70 serves as an aerosol precursor and facilitates the formation of a visible aerosol when the cigarette 23 is burned. Additionally, when glycerin is released into the atmosphere, it condenses and has an appearance typically found in cigarette smoke. Other humectants suitable for use in the tobacco industry may be used instead.

Optionally, after the casting step 123, an alginate may be coated along one side of sheet 68 before, during or after the coating step 126. The alginate coating provides additional strength and forms a film along one side of the substitute sheet 68. However, this base sheet 68 has sufficient strength without alginate, and it is recommended practice to make base sheet 68 without an alginate coating.

The present invention may be practiced with other types of base sheets (carriers), including carbon fiber layers, or metallic or mesh layers, as described in co-pending US Patent Applications Serial No. Ser. at 07 / 943,504,07 / 943,747, U.S. Patent No. 538,8594, and European Patent Application EP-A-0615411, incorporated herein by reference.

The fiber layers disclosed in EP-A-0615411 and in U.S. Patent No. 538,8594, continuation of which is co-pending application Serial No. 08/380 718, filed September 30, 1995, have the preferred composition of which is a base sheet 68 containing tobacco fibers in the range 20-30 g / m ^2, more preferably about 24 to 28 g / m ^2, and most preferably 26 g / m ^2, carbon fiber in the range of 2-9 g / m ^2, more preferably 2 to 4 g / m ^2, and most preferably about 3 g / m ^2, and pectin in the range of about 0.5 to 1.5 g / m ^2, and most preferably about 1 g / m ^2. Preferably, these constituents are balanced if so, to establish a base sheet 68 having a total basis weight of about 30 g / m ^2. It is also preferable to use 1/4 inch strand carbon to aid in dispersing it during the slurry step. The initiation of the carbon fiber dispersion is facilitated by using procedures such as those disclosed in US Patent Nos. 4,007,083 and 4,234,379.

In another embodiment of the tobacco base sheet 66 (i.e., the layer of carbon fiber), the total weight of the finished sheet of dry is preferably about 160 g / m ^2, of which 30 g / m ² of the base sheet 68, and 130 g / m ² of tobacco material 70. a more preferred embodiment of the tobacco base sheet 66, which does not contain carbon fiber sheet has a weight in the dry state of about 170 g / m ^2, of which 40 g / m ² of the base sheet 68, and 130 g / m ² of material tobacco 70.

Regardless of which type of base sheet 68 (or carrier) is used, tobacco material 70 is preferably placed on the inner surface of base sheet 68 and releases tobacco flavor aerosol (reaction) when heated. Such materials may also include continuous sheets, foams, gels, dried suspensions, or spray-dried deposited tobacco material suspensions.

As shown in Figure 3, and in conjunction with the teachings of U.S. Patent No. 5,388,594, when a cigarette 23 of the preferred embodiment is inserted into the socket 27, it is guided to the heating holder 39 until the free end 78 of the cigarette 23 rests against the stop 182 permanently attached to the base of the heater holder 39. Once the cigarette is in place, smoking can commence, and each puff of the cigarette by the smoker is detected by a puff sensor 45 which, in conjunction with control circuit 41, supplies electric current to a preselected one of the smoker. heaters 37. Power is provided by an electrical circuit that includes conduits 183 at one end of each heater 37, a common ring 184 at the opposite end of each heater 37, and a common conduit 186 extending from common ring 184 back near conduits 183. is energized, then the thermal energy is transferred being consumed by the wrapper 71 and the tobacco sheet 68 in an amount sufficient to cause the tobacco flavor material 70 of the tobacco sheet 66 to release an aerosol.

The tobacco inside the tobacco rod 60 that is drawn from the cigarette 23 in response to the puff of the cigarette by the smoker covered with the paper end of the cigarette 23.

A smoker's puff duration is typically about 1.5 to 2.0 seconds, and the FTC cigarette testing procedures assume a puff duration of 2.0 seconds.

Where the imprint of the heater shoe 94 covers the void 91, the aerosol is released directly from the heated tobacco flavor material 70 into the void 91 from where it is drawn into the tip 62 with a very slight pressure drop. Conversely, where the footprint of the heater 94 covers the tobacco plug 80 (filler cover 99 / heater), proximate portions of the tobacco rod 80 are heated along with adjacent portions of the tobacco sheet 66. Thus, the mixed grades of tobacco in the tobacco rod 80 have their own fraction in the total. aerosol so as to give it its own flavor and other subjective qualities. Aerosol discharged from the tobacco plug 80 near the filler / heater cover 99 undergoes some filtration and pressure drop as it is drawn through the tobacco plug 80 into the void 91.

The aerosol produced by heating the tobacco plug 80 has a property and taste that can be varied by the tobacco blend as well as a control of the extent to which the footprint of the heater boot 94 covers the tobacco plug 80. The aerosol component produced in the vicinity of the void 91 is released more quickly from the cigarette because there is less of it. the thermal inertia in the void 91 and because the thermally vaporized tobacco material in the void 90 is not subject to the pressure drop of the tobacco plug 80 and is instead delivered more rapidly to the tip 62 through the free flowing filter 74. However, it has a property different from that of the released component of the tobacco plug 80 as it is released predominantly from the tobacco flavor material 70 on the base sheet 68. As will be explained in detail below, it has been found that to satisfy the smoker, the aerosol delivered from the cigarette 23 preferably comprises both aerosol components to provide to deliver directly to the smoker and to contain a taste sensation corresponding to a tobacco filler mixture. As can be seen from the following recommendations, the presence of void 91 (and the immediate initial delivery) ensures continuous combustion from puff to puff of the cigarette 23 and results in proper cigarette consistency. This relationship contributes to the comparable properties of each puff when burning a partially-filled cigarette 23 made of the preferred embodiment (having a cut filler 80 and void 90) compared to the first alternate cigarettes 23 '(Fig. 6A) having no cut filler inside. rolled tobacco sheet, and with a second alternative (Fig. 7A) having the rolled tobacco sheet completely filled with cut filler. In these alternative embodiments, it will be appreciated that the tobacco sheets 66 'and 66 include a sheet 68 and a layer of tobacco material 70 similar to the preferred embodiment. The tobacco rods 60 'of these alternatives also include a wrapper 71.

For comparative data as shown in Figs. 6B and 7B, a serpentine heating element set at 15 µl energy was used in the combustion of the cigarettes shown in Figs. 6A and 7A, respectively.

As shown in Fig. 6A, a cigarette to be burned in an electric combustion system according to a first alternative comprises a tobacco rod 60 * and a tip 62 ', each of which includes components denoted by © with the numeral' corresponding to the components of the preferred embodiment shown in Fig. 4A. . However, the tobacco rod 6 (Y cigarette 23 does not contain any cut filler within the tobacco sheet 66 ', and the free end 78' of the tobacco rod 60 'is provided with a backflow filter 200'. The base sheet 68 'of the tobacco sheet 66' comprises carbon fiber as well as The structure of the cigarette 23 'is also detailed in US Patent No. 5,388,594, incorporated herein by reference, For the purposes of the following description, this cigarette 23' will be referred to as a fillerless cigarette 23 '.

182 861

As shown in Fig. 6C, a smoking machine was tested in conjunction with the smoking system 21. The smoking machine output was directed during each puff through a measuring device 6y having a transparent chamber 6v, where a beam of light 6u from source 6w passes through the transparent chamber 6v. to the photodetector 6z on the opposite side of the transparent chamber 6v. The output of the photosensor 6z is evaluated to determine the intensity of the light beam 6u hitting the sensor 6z. Any tobacco aerosol passing through chamber 6v will have a light scattering effect on the light beam 6u such that any resulting change in the light intensity found at the photodetector 6z will indicate the overall molecular composition (TPM) of the aerosol. In line with FTC cigarette testing practice, it is recommended that the smoking machine perform the standard two-second puffs from the smoking system 21.

The information graphically represented in Fig. 6B shows the intensity recorded at the smoke measurement device versus the time the smoking machine took each of the puffs during combustion of the unfilled cigarette 23 '. These data show the following trends: that for a deflated cigarette 23 ', the first and second puffs are not consistent with the remaining three puffs because the three later puffs are much more consistent with each other, and that the aerosol is delivered for a long time before the two-second expiration. time period of each puff. The unfilled cigarette 23 'has a less consistent aerosol delivery on the first few puffs, and delivery consistency is only present in the last puffs. The data for the first puff is consistent with the general finding that machine combustion of deflated cigarette 23 'provides less aerosol during the first puff, unless additional measures such as perforating the tobacco rod 60 * or other measures set forth in US Patent No. 5,388,594 are taken.

Figure 7A shows a further embodiment of an electrically burned cigarette 23 that includes a tobacco rod 60 and a tip 62 having components and an arrangement similar to the preferred embodiment shown in Figure 4A, with like components being doubled '. However, the cigarette 23 of Fig. 7A includes a backflow filter 200 at the free end 78 and a column of cut filler 220 extending the entire length of the tobacco rod 60 between the backflow filter 200 and the free-flow filter 74 of the tobacco rod 60. The tobacco column 220 of the cigarette 23 contains a burley blend of tobacco. , light and oriental tobacco with a rod density of 0.270 g / cm ³ . The base sheet 68 of the tobacco sheet 66 'comprises carbon fiber as described above. In the following description, the cigarette 23 will be defined as a fully filled cigarette 23.

Figure 7B shows the results of light intensity measurements from the smoke measuring device 6y correlated with the elapsed time of each puff for consecutive puffs numbered 1 to 7 on a fully filled cigarette 23. The data shown in Figure 7B shows two trends in the quality of the cigarette made. such as a fully filled cigarette 23: that the first few puffs give a significant aerosol delivery, however thereafter delivery slows down to the point that the last three puffs give significantly less aerosol delivery than the first few puffs (unless corrective measures are taken), and that with the cigarette 23 fully full, aerosol delivery is delayed and the initial puffs (1st, 2nd, 3rd puff) do not give maximum delivery until after a significant fraction of the two-second period.

During the first few puffs, a fully full cigarette 23 provides a greater total volume of aerosol than a de-filtered cigarette 23 '. Comparing the data in Figures 7B and 6B supports this general observation that the total areas above the first few puff lines in Fig. 7B for a fully filled cigarette 23 are greater than the total areas above the first few puff lines in Fig. 6B for po.

182 861 saved cigarette filler 23 '. The area above each puff line in Figures 7B and 6B is indicative of complete aerosol delivery during a puff.

However, it is believed that the delay in aerosol delivery by the fully filled cigarette 23 causes the smoker to take a prolonged, more abrupt puff in response to no direct gustatory response from the cigarette 23. This prolonged puff may in turn cause the heated portions of the wrapper 71 and tobacco to be puffed. of the sheet 66 are utilized (oxidized) more by the additional air drawn in through the cigarette so that there is a more significant breakage and possibly localized collapse of the tobacco column 220 during the first few puffs. Additionally, it is believed that as soon as pyrolysis is initiated in a fully filled cigarette, it becomes more self-supporting due to the presence of a greater amount of tobacco to be burned and / or due to its more compact condition. In any event, because air can be drawn into the tobacco rod more easily through the bifurcated "burn" sites during the first few puffs, these localized branches shorten the path of the desired air path in subsequent puffs. Consequently, for a fully filled cigarette 23 ', the aerosol delivery decreases during the final puffs. The data shown in Fig. 7B and the above explanation is consistent with the general finding that a fully filled cigarette 23 'or a conventional cigarette, when burned with electric lighters, tends to decrease aerosol delivery with subsequent puffs.

In this type of delayed but more self-sustaining pyrolysis, a fully filled cigarette 23 'tends to generate a large amount of aerosol in the final puff stages so that aerosol generation may continue beyond the time the smoker is currently puffing on the cigarette. The latter situation may result in the production of an "out-of-puff" aerosol which may penetrate inside the housing 33 of the lighter 25, particularly near the heater holder 39. This type of "puff" aerosol will condense on the heating elements 33 or circulate long enough to be drawn into the cigarette 23 'during the next puff. In any case, this has the disadvantage of delivering a pleasant and consistent taste.

Returning to Fig. 6B, the puff lines of the unfilled cigarette 23 'show that aerosol delivery is maximum (where the puff lines are at the highest) for a long time prior to the two-second standard puff duration, and that delivery is minimal at the last puff stages, such that in the case of without filler cigarette 23 ', aerosol generation "after puff" is not a big problem. However, as stated above, a deflated cigarette 23 provides a lower total aerosol volume than a fully-filled cigarette 23, and inconsistent delivery during the first few puffs and loses the subjective qualities and flavor gamut found with cut filler blend (or even unblended filler). .

Figure 8 shows comparative combustion data with a combustion machine using a smoke measurement device 6y as described above for cigarettes made as a unfilled cigarette 23, a fully filled cigarette 23 and a partially filled cigarette 23 made according to a preferred embodiment of the invention (such as shown in Fig. 4A). All of these cigarettes use a carbon fiber layer as the base sheet. By considering the data shown in Figure 8, it has been found that a partially filled cigarette 23 of the invention provides a more stabilized aerosol delivery through the smoke. It does not experience the drop in aerosol delivery that occurs with the last puffs of a fully filled cigarette 23, and has a more stabilized aerosol delivery than a defilled cigarette 23 'during the first few puffs. The partially filled cigarette 23 tested for the data collection used in Fig. 8 was a half filled cigarette with cut filler such that the cover of the heater above the void in the cigarette was relatively large, about 6 mm. Heating elements adapted to receive da

The 182,861 units shown in Figure 8 were serpentine type and operated at an energy of 15 µl per heating cycle.

Figure 8 shows the amount of aerosol (in milligrams) generated during the first two seconds of each puff of the puff cycle while each particular type of cigarette is smoked. With respect to the data shown in Figs. 6B and 7B, the amount of aerosol indicated in Fig. 8 corresponds analytically to the integral (area formed above) of each puff line from 0 to per second in Figs. 6B and 7B.

The data shown in Figure 8 illustrate the drop in aerosol delivery for a fully filled cigarette 23 from the first puff to the following puffs. In contrast, a defilled cigarette does not exhibit a decrease in aerosol delivery as with a fully filled cigarette 23.

The data in Figure 8 also clearly illustrates that a partially filled cigarette 23 provides a stabilized aerosol delivery compared to a defilled cigarette 23 'over six puffs. In addition, the contribution of cut filler to taste and subjective perception is noted here.

Table II summarizes how the variation in the void volume of the cigarette 23 by the heater may affect aerosol delivery. The data shown in Table II were obtained from a machine for burning partially filled cigarettes having a 32 mm long tobacco rod, a 7 mm long free-flow filter at the paper wrapped end of the tobacco rod and a 30 mm long tissue paper, with the footprint length of the heater being 12 cm, and was centered on the center of the tobacco rod on each cigarette.

Table II

Void length (mm) 4 7 10 Heater is applied along the void (mm) 1 4 7 Applying a heater along the tobacco plug 11 8 5 Average TPM 4.9 5.5 7.0 TPM diameter set (lowest reading omitted) 5.2 5.9 7.3 Standard deviation of the set mean 0.34 0.53 0.50

Figure 9 is a graphical illustration of the total particle component (TPM) of the delivered aerosol as a function of filler-heater cover size (mm). Data shown here was obtained using a standard test technique for determining FTC "tar" levels using Cambridge shims and two second puff intervals on standard smoking machines. The test cigarettes were partially filled cigarettes having a carbon fiber base sheet and a total length of 58 mm, with the data along the ordinate in Figure 9 obtained from a unfilled cigarette having a carbon fiber base sheet and the same overall length. When changing the cover of the tobacco with the heater, the footprint length of the heater remained constant and was centered on the center point of the tobacco rod. Thus, each increase in coverage of the tobacco with heater resulted in a proportional reduction in coverage of the void heater. The heater was of the serpentine type and its imprint length was about 10 mm. Taken together, these data indicate that there is a secondary relationship between the total molecular component delivered and the amount of coverage of the filler by the heater. The data shown in Figure 9 and the separate data set shown in Table II show that the amount of coverage of the filler by the heater can be adjusted to achieve the desired (target) level of aerosol delivery in a partially filled cigarette 23.

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Adjusting the amount of filler coverage by the heater is the preferred way to obtain the desired level of "tar" in partially filled cigarettes as variations in heater coverage of filler have been found to have a more pronounced and controlled effect on aerosol delivery than rod density variations in the tobacco rod 80. This allows for density adjustments. rod in tobacco rod 80 for purposes other than tar level selection, for example to control loose ends and / or to obtain the desired degree of pressure drop and / or filtration at the free end 78 of tobacco rod 60 or to otherwise facilitate manufacturing. It is also possible to alter the tar delivery of the cigarette products without having to change the tobacco sheet 66 or the tobacco plug 80.

It is also advantageous to select the relative dimensions of the partially filled cigarette 23 and the dimensions of the heater holder 39 of the lighter 21 such that upon insertion of the cigarette 23 into the lighter 21, each heating element 37 is disposed in the tobacco rod block 60 such that at least some, if not all, footprints of the heater they only overlap the filled part of the tobacco rod 60 (above the tobacco plug 80). In such a configuration, the void 91 facilitates aerosol generation and helps to cool the smoke. The free-flowing filter 74 is believed to assist in aerosol generation by restricting the flow of aerosol components drawn from the wider void 91. In this regard, it should be noted that the free-flowing filter 74 of the tobacco rod 60 has edges 73 and 75 at the transition points therebetween. and a void 91 on the one hand, and between a free-flowing filter 102 on the other hand. The edges 73 and 75 result from a smaller inner radius of the free flowing filter 74 than each of the other two adjacent areas (the void 91 and the confined space within the free flowing filter 102). It is believed that these edges 73 and 75 (and possibly other adjacent portions of the free flowing filter 74) promote turbulence and other flow conditions favorable to generating vapor phase aerosol and molecular phase components released from the heated tobacco portions of the tobacco rod 60.

As shown in Fig. 10, a cigarette 23a made according to a further preferred embodiment of the invention has the same components and structure as that shown in the consideration of cigarette 23 in Fig. 4A, but with the addition of a backflow filter 200a disposed at the free end 78a of the tobacco rod 60a. The backflow filter 200a prevents tobacco from escaping from the tobacco plug 80a at the free end 78a. The free-flowing filter 200a may also be colored to indicate that the cigarette 23a is a cigarette for use in an electric combustion apparatus in place of a cigarette to be lit with a match or a conventional cigarette lighter as is the case with conventional cigarettes. While the backflow filter 200a is shown as a separate component of the wrapped tobacco plug 80a, for the convenience of cigarette manufacture 23a, the tobacco plug 80a may be joined to the backflow filter 200a by a wrapper (not shown). In the case of a backflow filter, cigarette 23a may be provided with a tobacco plug 80a having a rod density without the risk of problems such as loose ends or tobacco falling out of the tobacco rod 60a. As reported in EP-A-0.615,411, and in U.S. Patent Application Serial No. 07,943,504, and U.S. Patent No. 5,388,594, the backflow filter 200a restricts or completely prevents aerosol release from the free end 78a of tobacco rod 60a upon puff and produces a drop. pressure at the free end 78a so as to advantageously limit the amount of air that is drawn into the cigarette 23a from the free end 78a side to the proportion of air admitted along the sides of the tobacco rod 60a.

Due to the design of the partially filled cigarette 23 as preferred, the energy of the heaters and the amount of filler cover by the heater can be used to establish and / or control the delivery of the aerosol to the desired "tariness" level. Thus, when designing a new partially filled cigarette 23, for

To achieve the desired degree of pressure drop at the free end 78 and / or to control backflow, selection of the rod density in the tobacco plug 80 can be used in the same manner as for the backflow filter 200a in alternative 23a.

As shown in Figure 11, another cigarette 23b of another preferred embodiment of the invention includes a tobacco plug 80b that has a low density portion 31bb adjacent to void 91b and a high density portion 320b adjacent free end 78b of cigarette rod 60b. The configuration of the cigarette 23b is such that the imprint of the boot of the heater 94b covers the low density portion 31bb of the tobacco rod 80b so as to obtain the enhanced aerosol delivery achieved with lower rod densities. The high-density area of cut filler 320b is intended to avoid loose ends and to limit air transfer axially through the rod 60b in a manner analogous to the backflow filter 200a.

Figure 12-21 shows the currently recommended heater solutions. These heaters are useful for any of the cigarette designs described above, that is, the full, partially filled, and deflated cigarette of Figures 4a, 4b, 6a, 7a, 10, and 11, and for modifying these cigarettes.

These heaters improve the mechanical strength for repeated insertions, adjustments and withdrawals 23, and significantly improve the generation of aerosols from a heated cigarette while maintaining energetic conditions. It was found that the generated aerosols tend to flow radially inward from the pulsed heater.

In general, eight heater blades 121 are preferably used to obtain eight puffs upon successively lighting the heater blades 121, thereby simulating the number of puffs from a conventional cigarette. In particular, heater blades 121 extend from hub 110 to form a cylindrical array of heater blades receiving an inserted cigarette 23. Preferably, a gap 129 is formed between adjacent heater blades 121.

It may be desirable to vary the number of puffs, and thus the number of heater blades 121, when a cigarette is inserted into the cylindrical receptacle CR. This desired number is obtained by creating the desired number of heating blades 121. This can be achieved by using uniformly or non-uniformly sized blades.

A heater holder is seated in an opening 27 of a lighter 25. A cigarette 23, possibly first through a backflow filter 200, is inserted into an opening 27 of a lighter 25 into a substantially cylindrical space of a heater holder 39 defined by an annular shaped cap 83 having an open end to receive a cigarette. a cylindrical air duct sleeve 87, a heater assembly 100 including heater blades 121, an electrically conductive pin or common conductor 104A that serves as a common conductor for heater elements in the heater unit, electrically conductive studs or conductors 104B, and a spacer. The lower inner surface 81 of the spacer holds the cigarette 23 in the desired position in the heater holder 39 such that the heater vanes 121 are positioned adjacent a cavity 79 in the cigarette and preferably are positioned as described above with reference to Figures 1 to 11.

Essentially the entire heater holder 39 is internally located and secured in place by a sliding fit with the housing 31 of the front portion 33 of the lighter 25. The front edge 93 of the cap 83 is preferably positioned at the first end 29 or extends slightly out of the first end 29 of the lighter 25 and preferably includes an internally chamfered or a rounded portion to facilitate the passage of a cigarette 23 into and out of the heater holder 39. Pins 104A and 104B are preferably positioned in corresponding seats (not shown) thereby supporting a heater holder 39 in the lighter 25, and wires or printed circuits lead from the receptacle to the cigarette lighter. various electrical components. Other pins may provide additional support to strengthen the pin assembly. Pins 104A and 104B may be made of any suitable material and are preferably bronze

182 861 tin-phosphorus. Channel 47 in the spacer and base 50 are connected to a puff-actuated sensor 45, and a light sensor 53 senses the presence or absence of a cigarette 23 in the lighter 25.

As shown in Figures 12 and 13, heater assembly 100 is preferably a monolithic structure that includes 8 heater blades 121 extending from center hub 111 symmetrically or as described below with reference to Figure 19 in an unsymmetrical arrangement. As shown in Figure 13, the heater assembly defines a substantially circular insertion opening 360 having an inlet 365 that directs a inserted cigarette toward a defined coaxially cylindrical receptacle CR having a diameter that is smaller than insertion opening 360. Insertion opening 360 is defined by respective end portions. 118B of the joining section 118 of the heater blades 121, and the inlet section 365 is defined by a portion of the section 118 between the joining edge 118A and the tip 118B. The insertion end 360 preferably has a diameter that is larger than the insertion cigarette 23 to guide the cigarette towards the CR socket, and the CR socket has a diameter approximately equal to the cigarette 23 to provide a sliding 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. With suitable cigarette manufacturing tolerances 23, the progressively tapering region or inlet 365 during the transition between the distal end and the seat CR may also serve to slightly compress the cigarette to increase thermal contact with the surrounding vanes 121 serving as the inside wall of the seat. The insertion end 360 preferably has an inside diameter of about 0.356 inches. + -. 0.02 inches and the CE receptacle preferably has an inside diameter of about 0.278 inches. + -. 0.02 inches. The paddles 120 may be tilted inward to increase thermal contact with the cigarette by limiting the diameter of the cylindrical seat.

Each U-shaped heater blade 121 includes a first section or leg 116A extending from a first end of hub 111, a joining section 118 connected to the opposite second end of the first section or leg 116A, and a second section or leg 116B extending at a first end from the interconnecting section 118. towards hub 111. First and second legs 116A and 116B are separated by a slot 125, which may be relatively constant, preferably substantially parallel in any of the unrolled states as shown in Figures 18 and 19 below, continuous in the cigarette insertion direction to reduce undesirable jamming. of the cigarette, and are oriented so as to form a cylindrical receptacle CR for an inserted cigarette 23. The connecting section 18 has a curved connecting edge 118A to join the opposite inner edges of the paddle legs 116A and 116B such that an elongated U-shaped path is formed which is substantially parallel to the longitudinal axis of the inserted cigarette and which runs along the side of the cigarette, i k is detailed below. The curved connecting edge 118A preferably has a curvature of about 180 ° ± 20 ° such that a U-shaped blade is formed and has a curvature that is concave towards the hub 11ii and convex towards the insertion opening 360. The first end of the first blade leg 116A at the hub 111 may have an increased width, with the same approximate thickness, at portion 115 with respect to the remainder of the rest of the first leg 116A to reduce the current density and power density at portion 115 to reduce ohmic heating of portion 115. Likewise, this widening increases the mechanical integrity of the blade 121 at hub 111.

The second end 122 of the second blade leg 116B is preferably raised relative to the main portion of the second blade section 116B in a stepped shape to facilitate electrical connection to the corresponding positive pin 104B. Specifically, as shown in Figs. 12 and 13, tip 122 includes three sections, namely sections 122A which is a substantially planar continuation of the main section of the second blade leg 116B, a transition section 122B which rises at an angle as shown, and connecting end sections. 122C, which is substantially parallel to section 122A. The end sections 122 may be wider than the second leg of the blade 122B to provide increased strength, to provide a suitable contact area for positive joining at the connecting end section 122C, and to lower the current density, and so on.

The end section 122C is preferably welded or electrically and mechanically connected in any other way to the positive pin 104B.

Another solution for achieving positive joints of heater blades 121 is shown in Figures 14 and 15. Connecting end 122 preferably does not have a stepped shape as in Figures 12 and 13, instead is a substantially flat extension of the second heater leg 116B which simplifies its manufacture as in Figs. described below. To reduce the possibility of short circuits due to contact between the positive end 122 and the hub 111 and / or the first leg section 115A 116A, such as when a cigarette is inserted twisted or otherwise positioned by a smoker on tip 122, hub 11a, section 115 is provided with an electrically insulating ceramic coating 300, in particular over the respective protruding edges of these elements.

Preferably, the ceramic coating is applied in any known manner, for example by plasma spraying, to the hub 111, the connecting end 122 and the first leg section 115A 116A. The ceramic material preferably has a relatively high dielectric constant. Any suitable electrical insulator may be used, such as alumina, zirconia, mullite, cordierite, spinel, fosterite, combinations thereof, etc. Preferably, zirconia or other ceramic material having a thermal expansion factor closely matched to that of the underlying structure is used. a metal heater to avoid differences in expansion and the consequent amounts of shrinkage during heating and cooling, thereby avoiding cracks and / or delamination during operation. The ceramic layer remains physically and chemically stable as the heating element is heated. For the electrical insulator, a recommended thickness is, for example, about 1.0 to 10 mils, or about 0.5-6 mils, and most preferably 1-3 mils. Preferably, a portion of tip 122 is uncoated. The positive pins 104B are then connected as discussed above to this exposed portion. To simplify masking, the corresponding part of the section 115 is likewise not coated with ceramic material.

Ceramic material may also be used, e.g., in the same plasma spray step, in the gap 127 between the ends 122 and sections 115 of first legs 116A and in the gap 126 between ends 122 and hub 110 to form a ceramic hub structure enhancing the mechanical integrity of the heater unit as shown. in Fig. 15. The size of this ceramic hub structure may be larger than shown. With or without the use of this additional ceramic material, the ceramic coating electrically isolates the positive connecting ends 122, and the width of the gaps 127 and 125 can be reduced while still being protected against short circuits. Thus, the end section 122 and the first leg section 115A may have an increased area, thereby further strengthening the socket and, in the case of a ceramic hub, increasing the carcass structure! further strengthening the heating unit. Moreover, this type of ceramic coating smoothes the tip of the edges forming the gaps 125 and 127 to reduce the risk of jamming and damage to the cigarette, especially during insertion, removal, or any adjustment by a smoker. Alternatively, the entire paddle 121 and in particular the first and second legs 116A and 116B are fully coated on one surface, e.g. zirconium, to strengthen the heating blades, keeping gaps if necessary. The paddles 121 can thus be thinner, e.g., about 2 to about 6 miles, thereby increasing the resistance of the heating track and allowing the heater blades to be used for an increased indirect thermal surface with the inserted cigarette 23 while keeping the overall blade resistance the same. This increased width of the blades, together with the ceramic layer, additionally strengthens the structure of the heater. Likewise, the ceramic coating on the outer surface of the blades 121, farther away from the inserted cigarette, can prevent thermal losses from the heated blade to the environment. The ceramic is applied by plasma spraying or by any other method described in the related applications, and is preferably applied by physical electron beam vapor deposition to avoid fumes.

To induce residual stresses that may be induced during plasma spray treatment due to surface treatment and / or due to particle impingement.

Each blade 121 forms a resistive heating element. In particular, the first end 115 of the first blade section 116A is electrically connected to the negative terminal of the power source, and in particular is an integral extension of the hub 111, or is mechanically and electrically connected to the hub 111, which in turn is electrically and mechanically connected to the negative pin 104A by welding. or other technique such as braze welding or soldering. Preferably, two terminal pins 104A are used to create a balanced support as the negative and positive connections also serve to mechanically support the heater. The hub 111 thus functions as an electrical component common to all heater blades 121. In either embodiment, the negative connection to each heater may be made individually, e.g., with a suitable negative contact located at the end of the heater opposite the corresponding positive contact 122.

A corresponding positive connection for each heater blade 121 is made at the joining end section 122C of the second blade section 116B as discussed above. The interconnecting end section 122C is electrically insulated or insulated from the common hub 110 through the slot 127, from the first section of the blade 116A, particularly the first end 115 of the associated heater blade 120 through the slot 125, and from the adjacent heater blade through the slot 131 to avoid short circuits and to allow expansion. thermal. In addition, the ceramic coatings discussed above are optionally applied. Alternatively, interconnecting end sections 122C are properly connected to ground.

The positive and negative connections discussed form a resistive path, and in particular a circuit through which current flows from an electrical power source, for example a control circuit, to a given vane and / or vane 120 upon activation of the combustion system due to the puff of the cigarette by a smoker. The primary blade heating region includes a first blade leg 116A, an edge portion 118A, and a second blade leg 116B. Thus, the portion of the inserted cigarette 23 lying below and in contact with a given actuated paddle 121 along the side of the cigarette will be heated according to an outer surface pattern corresponding to the heated part of the paddle, i.e. in an elongated U-shape corresponding to the overlying paddle, mainly by conduction and radiation. and partly also by convection. In addition, the portion of the cigarette inserted between the legs, i.e., the gap below the gap 125, is heated by overlapping or cutting as a result of the cumulative radial and conductive heat transfer from both legs 116A and 116B. If the slit 125 is too large, then the desired overlap will not occur and the portion of the inserted cigarette below the slit 125 will not be adequately heated. Likewise, radiant heat and conduction heat will heat the portions of the inserted cigarette located somewhat on the outer edges of the legs 116A and 116B of the heater blades. The various heated portions together form a heated area of the cigarette 23 that extends from just beyond the outer edge of leg 116A, below leg 116A through slit 125, below leg 116B and slightly beyond leg 116B to the actuated vane 121, which corresponds to puffing of smoke with a produced tobacco flavor. The size of the heated portion is dependent on the geometry of the blade and the heating properties as well as the size and duration of the energy pulse. Preferably, the heated vane is sized and thermally designed to directly heat an insertion segment of a cigarette having a sufficient size, e.g., 8 mm ² , to produce a proper puff from a smoker in response to a puff-actuated energy pulse.

The relatively larger end regions of the blades 115 and 122 forming part of the current path are not heated to these operating temperatures because their relatively larger volumes lower the current density and thus lower ohmic heating. Likewise, the connecting end section 118 is not heated to these operating temperatures because this heating tends to mimic edge 118A and this section creates a relatively larger volume and accordingly has a lower current density, and thus has less ohmic heating than the edge.

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118Α and directly adjacent sections. To further reduce undesirable heating of the remainder of the connecting portion 118, one may (1) increase the thickness of the monolithic material of portion 118 relative to the curved portion 118A in region 118C to further reduce the current density and ohmic heating as shown in Figure 5, (2) perforate portion 118 to reduce ohmic and / or conductive heat path, and / or (3) add additional heat sink material 119 to portion 118 to reduce thermal transfer to that portion as shown in Fig. 6. To achieve this heat absorption, a non-conductive material may be used. thermally, i.e. a thermal insulator such as a ceramic material. Examples of suitable ceramics are alumina, zirconium oxide, a mixture of alumina and zirconium oxide, mullite, etc., such as in the case of heating blade coatings. Each of these modifications should be evaluated for any effect on the mechanical integrity of the connecting portions 118 that support the heater assembly 100 and define an opening for insertion and withdrawal of a cigarette.

After the heating blade 121 is pulsed, there is a predetermined minimum time before the next puff can be made. Prematurely heating the cigarette part can also cause undesirable and / or partial aerosol generation or heat induced degradation of the cigarette part prior to the desired heating. Subsequent overheating of the previously heated part may result in the development of an undesirable smell and taste.

When a longer puff than that obtained by pulsing a single vane is desired, then a controlled logic is used to ignite the next heater or additional heater blades immediately after pulsing the initial heater blade, or during the initial portion of the initial pulse, to heat the next cigarette segment. The additional heater blade may be a radially consecutive heater blade or another heater blade. The heater blades should be sized to obtain the total number of puffs desired of the desired duration.

In a first embodiment, the number of heater blades 121 corresponds to the number of puffs desired, e.g., 8. In a further embodiment, the number of heater blades 121 formed is twice the number of puffs, e.g., there are 16 heaters for a cigarette for eight puffs. Such a configuration allows a variety of firing sequences as compared to normal sequential firing for about 2 seconds, and preferably a radially sequential firing sequence for a solution where the number of heater blades 121 corresponds to the number of puffs. For example, the logic so that two circumferentially opposing blades 121, i.e., blades separated by 180 ° on the tube, light up simultaneously to heat the appropriate portion of the cigarette together to produce a puff. Alternatively, the first order of lighting each other blade 121 for a cigarette entails a second order of lighting the remaining blades of the heater 121 for the next cigarette. Alternatively, this first lighting sequence may be repeated for a predetermined zinc of smoking a plurality of cigarettes and then initiating a second lighting sequence. Any combination of heater blades may be used. The number of paddles may be less than, equal to, or greater than the number of puffs of a single use cigarette. For example, a nine-blade system may be used for a six-puff cigarette with a different set of six heaters being ignited for each subsequent cigarette and the accompanying set of the remaining three heaters not igniting.

The heater assembly 100 is electrically and mechanically secured at one end by welding or pins 104A to the hub 110 and pins 104B to the ends 122. Pins 104A and 104B are preferably pre-pressed into, or otherwise permanently connected to, the plastic hub, preferably for air leakage is minimized. Preferably, this affixed end is opposite the cigarette insertion opening 360. The connecting sections 118, and in particular the opposite ends 118B, opposite the connecting edges 118A, define an insertion opening 360. The end sections 118B may flare outward to form an inlet section 365. Thereafter, the vanes 121 taper in that inlet section for a second time.

An inner diameter which is slightly smaller than the outer diameter of the inserted cigarette 23, for example at the center of the paddle, to achieve the desired thermal contact, i.e., compression forces, between the paddles and the cigarette, is required. End sections 118B are free to expand when heated, that is, sections 118B are not attached. Specifically, each end 118B is disposed within a corresponding channel 210 provided in the inner wall 201 of end cap 83 of the lighter. Specifically, the radially outward movement of the end portions 118B of the inwardly deflected blades 121 is restrained by ends 118B contacting the radially outer walls of the channel 210, thereby establishing limits for deflection and internal deflection. This internal variation may be supplemented by an internal factory variation as discussed above. As shown, the inner wall 201 is flared outwards to allow part of the tips of the blades 118B to be inserted. The radially outer wall of channel 200 contacting tip 118B is sized and shaped to insert the appropriate extent of blade tip 118B such that the tip of blade 118B will not extend from channel 210 as the blade is heated or cooled, or when a cigarette is inserted or removed. If desired, this radially outer channel wall is provided with a stopper, e.g., a trapezoid, which contacts ends 118B. In an alternative embodiment, the tip portion 118D of the vane 118B is rounded, particularly elliptical, in front of the inserted tip 118B. This rounded portion 118D allows the inserted portion to tilt within the channel 210 in response to thermally or mechanically induced moments, thereby keeping the inserted portion of the blade tip within the channel 210. Additionally or alternatively, the tips of the blade 118 are more rounded.

In the first embodiment shown in Fig. 3, the passage 210 is dimensioned such that the tip 118B of the heater blade 121 can expand in a progressive manner, i.e., towards the end surface 202 of the passage 210 after inserting the cigarette 23 and / or heating the blade such that the result is contact between the cigarette and the paddles is desirable. Such an arrangement where one end of the vane is free from the opposite of the inserted hub allows the blades 1212 to mechanically displace and / or expand and contract in a longitudinal direction upon insertion / removal of a suitable cigarette and / or heating / cooling of the vane, thereby reducing stresses. In the second embodiment packaged in Figure 14, a stopper 204 is provided inside the conduit 210, which may have a trapezoidal shape such that when the vane 121 thermally expands upon heating or displacement upon insertion of the cigarette 23, end 118B contacts the stop 204 and establishes a position. a tilting point to allow the paddle 121 to deflect inwardly toward the inserted cigarette 23, thereby reducing stresses on the paddle and increasing the desired thermal contact, i.e., compression forces between the paddle and the cigarette. The heel point is understood to mean the freedom of rotation of the blade 121, but preferably no translational movement, at the stop 204.

The heater assembly 100 therefore preferably has a monolithic structure which is optionally coated with a ceramic material. Hub 111 and blades 121 are made of a material having the desired electrical resistance! resilience. For example, materials having an electrical resistance in the range of about 50 to about 500 pohm cm, and more preferably about 100 to about 200 pohm cm, are suitable, and the activated blade 120 achieves temperatures of about 200 ° C to about 1000 ° C, and preferably about 400 ° C. ° to about 950 ° C, and most preferably about 300 ° C to about 850 ° C in about 0.2 to about 2.0 seconds, for a pulse of 10 to about 50 µL, more preferably about 10 to about 25 µL, and most preferably about 20 Juli. The material should be able to withstand about 1,800 to about 10,000 such pulses without showing damage, significant deterioration, or undesirable bending of the blades 121.

The materials of the blades 121 are preferably selected so as to ensure that at least 1800 on / off cycles are reliably repeatedly performed without failure. The heater holder 39 is preferably replaceable separately from the lighter 25 containing the power source 37 and the circuit, which is preferably replaced after 3600 cycles or more. Heater materials and other metallic components are also selected based on them

Resistance to oxidation and general non-reactivity to ensure that they will not oxidize or otherwise react with the cigarette 23 at any temperature attained. If desired, the heater blades 121 and other metallic components are encapsulated in an inert heat-conducting material, such as a suitable ceramic, to further avoid 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 blades 121 are made of a material that exhibits high strength and surface stability at temperatures up to about 80% of their melting point. Such alloys include those commonly referred to as lap alloys which are generally nickel, iron or cobalt based. For example, alloys containing mainly iron or nickel with aluminum and yttrium are suitable. Preferably, the alloy of the heater blades 121 comprises aluminum to further improve the quality of the heating element, e.g. by providing oxidation resistance.

Preferred materials include iron and nickel aluminides, and most preferably the alloys disclosed in U.S. Patent Application Serial No. 08 / 365,952, filed December 29, 1994 and in the co-pending application titled "Aluminide Iron Alloys Useful As Electroresistive Heater Elements" (Agent Designation No. PM 1769), introduced here as a reference.

Several elements can be used as additives to Ni _{3 Al alloys.} The main additions are B and Si for the alloy for the heater layer 122. The task of B is to increase the strength at the grain boundary and this additive is most effective when Ni ₃ Al is nickel-rich, e.g. Al <24% At. No Si is added in large amounts to Ni ₃ Al alloys, because addition of Si over a maximum of 3% by weight will form nickel silicides and, when oxidized, will result in the formation of SiO _x . The addition of Mo improves the strength at low and high temperatures. Zirconium helps improve the shock resistance of the oxides during cyclic thermal processes. In addition, Hf may be added to improve high temperature strength, a preferred Ni ₃ Al alloy for use as substrate 300 and resistive heater 122 is designated IC-50 and contains about 77.92% Ni, 21.73% Al. 0.34% Zr and 0.01% B as reported in "Treatment of Intermetallic Alumina" by V. Sikka, Intermetallic Metalurgy and Processing Intermetallic Compounds. ed. Stoloff et al., Van Nestrand Reinhold, NY, 1994, Table 4. A variety of elements can be added to the ferric aluminide. Possible additives include elements such as Nb, Cu, Ta, Zr, Ti, Mn, Si, Mo and Ni. The heater material may be Haynes® 214 alloy (Hynes® alloy No. 214, i.e. nickel-based, containing 16.0% chromium, 3.0% iron, 4.5% aluminum, traces of yttrium and the rest (about 75%) nickel, commercially available from Haynes International, Kokomo, Indiana), Inconel 702 alloy, MCrALY alloy, Nichrome® type FeCrALY alloys (54-80% nickel, 10-20% chromium, 7-27% iron, 0-11% copper, 0- 5% manganese, 0.3-4.6% silicon and sometimes 1% molybdenum and 0.25% titanium, Nichrome I alloy contains 60% nickel, 25% iron, 11% chromium and 2% manganese, Nichrome II alloy contains 75 % nickel, 22% iron, 11% chromium and 2% manganese and an alloy of nichrome III, which is a heat resistant alloy containing 85% nickel and 15% chromium), as described in Patent Application Ser. No. 08 / 380,718, issued Jan. 30, 1995 and US Patent No. 5,388,594, or materials having similar properties.

As shown in Fig. 12, the blades 121 project symmetrically from the hub 111. Alternatively, asymmetric arrangements may be used. For example, a plurality of, e.g., 6 or 8, 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 slots 131 as discussed above. The subgroups are separated by a wider gap 135, as shown in Fig. 19, in an non-rolled flat condition. The slit 135 is formed in such a way that conduction, especially radiant heat transfer, from adjacent vanes 121 of adjacent subgroups to the portion of the cigarette 23 lying beneath the slit 135 is minimized. Thus, the slit 135 forms a wider unheated and substantial portion of the cigarette that is stronger than unheated part

The cigarette ends are located beneath the narrower gaps 131 whereby the column strength of the cigarette 23 is increased to aid cigarette removal upon lighting and consequently heating and weakening of the respective parts of the cigarette. If desired, the logic circuit can activate more than one heater simultaneously in a symmetrical or unbalanced configuration.

The solution of the present invention, which uses two heater legs 16A and 116B separated by a gap 125, provides a significant improvement in the amount of aerosol produced compared to the amount produced by a fixed heater.

The solid heater provides good heat transfer to the cigarette, however the mass transfer of the aerosol to the drawn airflow is a compromise to the solid structure blocking optimal entrainment of air outside the cigarette to the cigarette, especially if a post-burn system housing made with perforations to communicate air is used from the outside of the casing to the outer surface of the cigarette. The heater of the invention having the same volume as the fixed heater but having a larger circumference results in a better air entrapment, e.g. due to the slot 125, and consequently results in an improved flavor delivery per unit of energy input into the blade 121. As already discussed, the slot 125 should be be sized to ensure optimal application of radiation for a given blade geometry. As larger amounts of aerosol are produced, the required weight of the paddles while producing the same desired amount of flavor can be reduced, resulting in a lighter assembly and a reduction in the amount of energy required to adequately heat the paddles 121 and the inserted cigarette, further reducing the weight of the assembly as it can be smaller power source such as batteries. For example, but not limited to, slit 125 may be about 0.020 inches ± about 0.005 inches wide, blade legs 116A and 116B may be about 0.0125 inches to about 0.017 inches ± about 0.005 inches and about 0.55 inches long, ± about 0.005 inches long. 0.005 inches, and a thickness of about 0.008 inches to about 0.010 inches. + -. About 0.005 inches, and the length from the edge of hub 110 to the top of connection section 118 may be about 1.062 inches. + -. About 0.625 inches.

It has been found that a predominantly lateral or radial flow of air relative to an inserted cigarette results in a more desirable production of smoke than a predominantly longitudinal flow. The slots 125, 127 and 131 provide flow paths for the air drawn in into contact with the inserted cigarettes. Additional air channels were used to optimize the lateral air flow by perforating the heater blade section.

Figure 16 shows a further embodiment of the blade geometry in which both the first leg 116A and the second leg 116B are serpentine shaped. The serpentine shapes of the legs 116A and 116B are parallel so that the legs are evenly spaced and the slit 125 is also serpentine in shape. Such a serpentine shape increases the circumference of the blade and thus improves aerosol delivery. This serpentine shape is described in more detail in EP-A-0.615,411 and in patent application Ser. 08 / 380,718, filed January 30, 1995 and in US Patent No. 5,388,594.

Referring to Figs. 18 and 19, a first preferred method for producing a system according to the invention will now be described. The manufacturing steps can be carried out according to any desired method to obtain suitable manufacturing speeds, material savings, etc.

A sheet of suitable material is produced having a thickness, e.g., about 2 to about 20 mils, e.g., about 10 miles, to form a plurality of vanes 121 extending substantially perpendicularly through respective sections 116A, and more particularly through the respective end section 115, from substantially straight section 111A in a contour. comb. The blades 121 are substantially parallel to each other, and have slots 131 located between opposite edges of the second blade section 116B, but the blades and the first section 16A of the adjacent blade. As stated above, the vanes 121 are either symmetrically spaced with equal slots 131 located between the vanes as shown in Fig. 18, or they are asymmetrically spaced.

E.g. with equal gaps 131 between adjacent blades 121 forming the blade subgroups 121A and 12IB, and a greater distance 133 between two subgroups of width X as shown in Fig. 19. Note that straight section 111A has two end portions of at least half the length of one half of X to form a second distance 133 after folding. These end portions can be longer than X to achieve an overlap for joining. As a non-limiting example, slit 131 may be about 0.040 inches 6 0.005 inches wide in any one embodiment and slit 135 may be about 0.125 inches 6 0.005 inches wide in an unsymmetrical embodiment.

The blades have a configuration as discussed above to form the connecting section 118 and the legs 116A and 116B.

Such informing of the sheet or strip of material in the configuration described is carried out by any conventional technique such as stamping or cutting, e.g. with a CO ₂ or a Yag laser. If a strip format is used, then the number of blades 121 formed from the strip may exceed the required number for a single cylindrical heater system. The straight strip is then cut as needed to form sections 111A having the desired number of projecting blades 121. If desired, a step of shaping sections 122A, 122B, and 122C by stamping is used.

If necessary, the ceramic coating 300 is then applied by masking the extruded profile and, e.g., spraying a thermal coating on the 11 ', 115, 122 or all of the blade or any part of it to form the desired pattern, as discussed above. Alternatively, the ceramic coating is applied after the winding step by this procedure or before forming the blades as needed. As is known, prior to each of the steps of producing the heater and depositing the ceramic material, appropriate masks are applied to define the application areas.

Subsequently, section 111A is folded to form a circular hub 111. Section 111A may be folded in any direction. Preferably, section 111A is rolled up such that the positive contacts 122C at the end section 122 are provided on the outer surface of the cylindrical heater formed, i.e., on the side opposite the cigarette, to simplify engagement with pins 104B and to avoid damage during cigarette insertion and removal. The rolled section may be rolled to a diameter smaller than the desired diameter and may be inserted into the holder. The collapsed section then expands and is held in shape by the electrical connection. Alternatively, the rolled section is joined, e.g., by any welding technique such as spot welding or laser welding, to form hub 111.

Preferably, each paddle 121 is given a bias such that legs 116A and 116B and joining edge 118A will exert a compressive force on the inserted cigarette after formation of the heater assembly as shown in Fig. 13. This bias preferably occurs prior to winding, however it may be. made after collapsing. This bias increases the thermal contact between the heater blade and the inserted cigarette to improve the heat transfer efficiency.

The heat transfer efficiency is also improved by optimizing the size of the surface area of the legs of the blades 116A and 116B which are in an effective thermal relationship with the underlying cigarette. As shown in Fig. 17A, the lower sides 117 of legs 116A and 116B (for example, leg 116A is shown) are flat, i.e., flat in the transverse direction of the legs in these embodiments. To improve heat transfer, the underside 117 is formed with various non-planar geometries, e.g., an angular or a curved shape to maximize the surface area of the heated leg relative to the cigarette without undesirable expanding in volume, and thus without undesirably reducing the current density and resulting ohmic leg heating. a heater as shown in Figures 17B and 17C, respectively. The shaped underside 117 preferably does not pierce any portion of the cigarette 23 to avoid weakening and possible tearing of the cigarette during insertion, alignment, or removal. The bottom mid point or vertex 117 contacts or is located

The 182 861 is in thermal proximity to the cigarette 23 and the remainder of the bottom 117 is in a radiant thermal relationship with the cigarette 23.

Preferably, this underside shape is obtained by pressing the legs 116A and 116B of the blades 121 in an unfolded state. This embossing can occur simultaneously as an embossing to achieve the above-discussed deviation. This underside embossing also increases the strength of the legs 116A and 116B thereby avoiding undesirable short circuits and distortions.

The second production method will be described below. A tube of suitable material is provided. The blades 121 are then formed by any technique such as laser cutting. Alternatively, the blades are formed by profile forging in which an internal pin is inserted into the pipe to form the vane profiles discussed, and then a second die is applied, internally or externally, to cut the profile. If necessary, a ceramic coating 300 is applied to the profiled pipe.

The present invention also minimizes potentially harmful thermally induced stresses. As the blades 121 and hub 111 are monolithic, stresses that arise from interconnecting discontinuous parts of the heater elements are avoided.

All the various embodiments of the invention are capable of delivering an effective amount of tobacco-flavored smoke under standard conditions of use. In particular, it is now considered desirable to deliver between 5 and 13 mg, and preferably between 7 and 10 mg, of an aerosol for a smoker performing 8 puffs, each puff being 35 ml in volume and lasting 2 seconds. It has been found that in order to achieve such aerosol delivery, heater elements 121 should be temperature transmittable as discussed above when placed in a heat transfer relationship with the cigarette 23. In addition, the blades 121 should preferably draw the energy discussed above. Lower energy requirements for the blades 121 are provided when the blades are curved inwardly towards the cigarette 23 to improve heat transfer.

Of course, the heater resistance is also dictated by the particular power source 37 used to obtain the necessary electrical energy to heat the blades 121. For example, the above heater resistances correspond to solutions where power is provided by 4 nickel-cadmium battery cells connected in series at total voltage. an unloaded power source of approximately 4.8 to 5.8 volts. Alternatively, if 6 or 8 such series-connected batteries are used, the blades 121 should preferably have a resistance of about 3 ohms and 5 ohms, or about 5 ohms and about 7 ohms.

Figures 20 and 21 show a further embodiment 450 of the invention that employs a plurality of heating elements 451. Each heating element 451 has an oblong "U" shape and each has both ends 452,453 of the respective legs attached to the side wall of the recess 430 in adjacent to the end wall 443 of the cavity 430. Each respective end 452 is individually connected to the control circuit and simultaneously to an electric power source for individually activating the heating elements 451, the ends 453 being jointly grounded. Although the ends 454 adjacent to the mouth of the recess 430 are not electrically connected and thus need not touch the side wall of the recess 430, they are twisted towards the side wall of recess 430 as shown in Figs. 20 and 21 to guide the removable part, i.e. cigarette to be inserted as discussed above. It should be noted that in Fig. 21 the upper and lower members 451 are shown intersected by their U-shaped vertices 454.

In a further embodiment 470 shown in Figs. 22 and 23, the heating elements 471 are spaced a little further away from the cavity wall 430, and each is provided with a slightly sharper "V" shaped tip 472 as well as a fold 473 to increase their height. stiffness. In this way, the heating elements 471 actually pierce and enter the removable portion to obtain the desired near thermal contact.

182 861

In such a solution, the open-cell foam structure is particularly adapted. In this solution, since the heating elements 471 are further spaced from the side wall of the cavity 430, the ends 452,453 are not connected to the side wall of the recess 430, but to an end wall 443. Preferably, the connections of the ends 452,453 to the end wall 443 are via spacers 480. which are neither thermally nor electrically conductive. In this way, the rubbing action causes the residue to rub off the ends 452,453 and to the spacers 480, where the residue does not reheat, as described in US Patent No. 5,249,586. Perforations 412 are provided in the wall to allow outside air to be drawn through portion 420, as described in US Patent No. 5,249,586, incorporated herein by reference.

Various modifications, changes and improvements will be apparent to those skilled in the art without departing from the spirit and scope of the present invention as described and defined in the following claims. For example, prior to the cooling step, an unfolding step may be performed to modify part of the process described above with respect to Fig. 5B.

182 861

182 861

Oh aj

182 861

ο what

182 861

TOBACCO

FEEDSTOCK

TOBACCO FIBER

ĘXTRACTION

TOBACCO SOLUBLES

DISPERSE TOBACCO FIBER AND CELLULOSIC FIBER

126 n

124

'PULPĘD (CELLULOSE

120

140

138

REFINE WEB SLURRY

WEB SLURRY

CAST SLURRY ONTO WEB FORMING MACHINE

WEB

DRY WEB

MONITOR ^ MDISTURE CONTENT -oWEIGHT

128

132

134

136

ΜΙΧ SOLUBLES WITH ° GROUND TOBACCO -GLYCERIN • PECTIN o WATER

146

SLURRIED TOBACCO MATERIAL

142

SHEET OF BASE WEB

COAT WEB WITH alginate <OPTIONAL)

COATING OPERATION

144

WEB

SHEET

182 861

FIG. 5B.

182 861

62 '

23 '

FIG.6A.

Maln Stream Aerosol Productlon

Transmission Intensity

Time (sec)

FIG. 6B.

182 861

FIG. 6C.

182 861

182 861

Maln Stream Aerosol Production

0.275 g / cc out filier, base mat, backflow filter

Transmissive Intensity

250

Time (sec>

FIG. 7B

182 861

MAIN STREAM AEROSOL VOLUME CONSTRUCTION COMPARISON Serpentine Heater, 15 Joules

AEROSOL VOLUME

2,500

2,000

1.500

1,000

0.500

------ O ------ FLUEH FREB CIOARETTC 23 · ----- □ ----- FULLY FLLED CMAHETTE 33

------ »PARTIAUY FB.LED CłOARETIt 23

0.00040

1 ------------------------------------------------- 1 ------------------------------------------------- 1 ------------------------------------------------- 1 ------------------------------------------------- -1 ------------------------------------------------ --- 1

2 3 4 5 6

PUFF #

FIG. 8.

182 861

TPM (mg)

FIG. 9.

182 861

182 861

182 861

182 861

FIG. 13.

182 861

Ο

182 861

182 861

182 861

FIG.17A

FIG.17B

FIG.17C.

182 861

182 861

182 861

182 861

Publishing Department of the Polish Patent Office. Circulation of 70 copies. Price PLN 6.00.

Claims (36)

Patent claims A cigarette for use in an electric smoking system comprising a tobacco rod formed of a cigarette foil wrapped into a tubular sheet within which a tobacco plug is provided, the cigarette foil comprising a base sheet bearing a layer of tobacco material, and the tobacco plug is positioned adjacent the free end of the tobacco rod and distanced from the opposite end of the tobacco rod, and an unfilled space is provided between the tobacco plug and the opposite end of the tobacco rod, characterized in that adjacent the opposite end (72) of the tobacco rod (60) there is a free flowing tube element (74) spaced from the tobacco plug (80) and a blank space (91) is provided between the free flowing tube element (74) and the tobacco plug (80). 2. A cigarette according to claim 1 The tube as claimed in claim 1, characterized in that the tubular element (74) is a filter. 3. A cigarette according to claim 1 The method of claim 2, wherein the filter comprises plasticized tow material. 4. A cigarette according to claim 1 The method of claim 2, wherein the filter comprises a mouldable material. 5. The cigarette according to claim 1 A filter tip (62) as claimed in claim 1, characterized in that adjacent the opposite end (72) of the tobacco rod (60) is a filter tip (62). 6. A cigarette according to claim 1 The filter tip (62) of Claim 5, characterized in that the filter tip (62) comprises a second free flowing filter (102) adjacent an opposite end (72) of the tobacco rod (60) that is connected to the opposite end (72) of the tobacco rod (60) by a tipping paper. (64). 7. The cigarette of claim 1 The method of claim 6, characterized in that adjacent the second free-flowing filter (102) is a mouthpiece filter cartridge (104). 8. A cigarette according to claim 1 The method of claim 7, characterized in that the first free flow filter comprises a first channel (75) and the second free flow filter (102) comprises a second channel, the channels communicating an unfilled space (91) of a tobacco rod (60) with a mouthpiece filter cartridge (104). and the inner radius of the second channel is greater than the inner radius of the first channel (75). 9. A cigarette according to claim 1 The method of claim 8, characterized in that an additional backflow filter (200) is provided at the free end (78) of the tobacco rod (60). 10. A cigarette according to claim 1 The method of claim 1, wherein the first portion (320b) of the tobacco plug (80b) adjacent the free end (78) of the tobacco rod has a greater density than the second portion (310b) of the tobacco plug remote from the free end (78). 11. A cigarette for use in an electric smoking system comprising a tobacco rod formed from a cigarette film in the form of a tubular base sheet with a layer of tobacco material, a flow restrictor at the opposite end of the tobacco rod and a flow restrictor adjacent the free end of the tobacco rod. a tobacco arrangement spaced from the flow restrictor, which tobacco is in the form of tobacco cut filler filling a portion of the tobacco rod to leave the tobacco rod space unfilled, characterized in that the flow restrictor (74) is at the opposite end (72) the tubular sheet (66) and the tobacco (80) is spaced from the flow restrictor (74), and an empty space (91) of the tobacco rod (60) is adjacent the flow restrictor (74). 182 861 12. A cigarette according to claim 1 A tube as claimed in claim 11, characterized in that the flow restrictor (74) is in the form of a tubular element. 13. A cigarette according to claim 1, The tube element as claimed in claim 12, characterized in that the tubular element comprises a first free-flowing filter through which the first passage (75) passes, and the filter tip (62) includes a second free-flowing tubular filter (102) disposed adjacent the first free-flowing tobacco rod filter (60). the second passageway through the second tubular free flow filter (102), and the first passage (75) of the first free flow filter being narrower than the unfilled space (91) of the tobacco rod (60) and narrower than the second passage of the second free flow filter (102). 14. The cigarette of claim 1 The cut tobacco as claimed in claim 11, characterized in that the cut tobacco (80) is positioned at the free end (78) of the tobacco rod (60) and has a density greater than that of the remainder of the cut filler tobacco distal from the free end (78) of the tobacco rod (60). . 15. The cigarette of claim 1 A mouthpiece filter (104) as claimed in claim 13, characterized in that adjacent the second free-flowing filter (102) is a mouthpiece filter (104). 16. A cigarette according to claim 16 The method of claim 11, characterized in that the tubular sheet (66) comprises a cigarette wrapper (71) around a tobacco rod (60) that is connected to the tip (62) of the filter by tipping paper (64). 17. The cigarette of claim 1 The tobacco plug (80) as claimed in claim 11, wherein the tobacco plug (80) comprises cut filler tobacco. 18. A cigarette according to claim 1, The tobacco plug of claim 11, wherein the tobacco plug (80) comprises a blend of cut filler tobacco that is a combination of at least two of light tobacco, burley tobacco and oriental tobacco. 19. A cigarette according to claim 1 The method of claim 17 or 18, characterized in that a wrapper (84) is provided around the cut filler tobacco. 20. A cigarette according to claim 1 The method of claim 17 or 18, characterized in that the tobacco (80) is disposed along the inner surface of the tubular sheet (66). 21. A cigarette according to claim 1 The method of claim 11, characterized in that a wrapper (71) is provided around the outer surface of the tobacco rod (60). A cigarette foil comprising a base sheet upon which a layer of tobacco material is disposed, characterized in that the base sheet (68) comprises a combination of tobacco fibers and cellulose fibers combined in a ratio ranging from about 2: 1 to 4: 1. and has a specific gravity of from about 35 to 45 g / m ^2, and the smoking material (70) has a specific gravity of forming at least twice the specific gravity of the base sheet and containing a finely ground tobacco, and extract solids tobacco present in a ratio of about 3: 1 to 9 : 1 as well as a humectant in an amount of about 5% to 20% by weight of the tobacco material (70). 23. The cigarette foil of claim 1; The tobacco material of claim 22, wherein the tobacco material (70) has a specific weight of about 3 to 4 times that of the base sheet (68). 24. The cigarette foil of claim 24 The tobacco material of claim 22 or 23, wherein the tobacco material (70) further comprises pectin in an amount up to about 2% by weight of the tobacco material (70). 25. The cigarette foil of claim 25 24, characterized in that the base sheet (68) comprises about 28 g / m ² tobacco fiber and approximately 12 g / m ² cellulosic fiber of wood pulp, flax pulp, or tobacco stem pulp. The cigarette foil of claim 26. The tobacco material of claim 25, wherein the tobacco material (70) comprises about 66 to 71% by weight of tobacco particles, about 16 to 20% by weight of tobacco solids extract, about 10 to 14% by weight glycerin and about 1-2% pectin. 27. A cigarette foil for use in a cigarette for use in an electric smoking system comprising a base sheet on which a layer of tobacco material is provided, characterized in that the base sheet (68) comprises a combination of tobacco fibers with a specific weight of about 20 to 30 g. / m ² and carbon fiber with a specific weight of about 1 g / m ² , the tobacco material (70) having a weight of 3 to 4 times that of 182,861 base sheet (68), and the tobacco material (70) further comprises finely ground tobacco and an extract of tobacco solids in the range of about 3: 1 to 9: 1, and a humectant in an amount of about 5% to 20% by weight tobacco material (70). 28. The cigarette foil of claim 28 27, characterized in that the tobacco fiber base sheet (68) has a specific gravity of about 25 to 28 g / m ^2, carbon fiber has a specific gravity of about 2 to 4 g / m ^2, and pectin has a specific gravity of 2.5 up to 1.5 g / m ² . 29. A method of producing a cigarette film for use in an electric smoking cigarette by forming a base sheet onto which a layer of tobacco material is applied, characterized in that, to form the base sheet, soluble substances are separated from the tobacco fibers, which are present in a solution of the dissolved tobacco components, and the separated tobacco fibers and the reinforcing agent are slurried, which slurry is poured into a base sheet forming machine, and then a 5 to 10% solution of the tobacco components is mixed with additional tobacco particles with an agent humectant and pectin to form a tobacco material dispersion, the water content is adjusted to keep the solids content of the dispersion in the range of about 20 to 30%, and then the tobacco material dispersion is applied to the formed base sheet as a layer followed by the trunks are dried, cooled, straightened out folds and rolled into a roll. 30. The method according to p. The process of claim 29, wherein the tobacco soluble solution comprises about 7 to 8% by weight of dissolved tobacco ingredients. 31. The method according to p. The process of claim 29, wherein the amount of water is adjusted to obtain a dispersion with a solids content of about 24 to 26%. 32. The method according to p. The process of claim 29, wherein the tobacco particles have a screen size in the range of about 100 to 220. 33. The method according to p. The method of claim 32, wherein the tobacco particles have a size corresponding to a screen number of about 120. 34. The method according to p. The process of claim 29, wherein the suspension enhancing agent is in the form of at least one pulp selected from the group consisting of wood pulp, flax pulp and tobacco stem pulp. The method according to p. 35. The process of claim 29, wherein the tobacco material dispersion is applied to the base sheet with a dry weight ratio of at least 2: 1. 36. The method according to p. The process of claim 35, wherein the tobacco material dispersion is applied to the base sheet with a dry weight ratio of at least 3: 1. * * *