Note: Descriptions are shown in the official language in which they were submitted.
2026S38 RBP File No. 4109-080
Title: CIGARETTE AND SMOKABLE FILLER MATERIAL THEREFOR
FIELD OF THE lNVh~ 1 ION
The present invention relates to cigarettes and
other smoking articles, and in particular to cigarettes,
s which when smoked, yield relatively low levels of
incomplete combustion products, generate low amounts of
sidestream "tar" and odor, and are capable of sustaining
smolder during FTC smoking conditions.
Popular smoking articles, such as cigarettes, have a
substantially cylindrical rod shaped structure and
include a roll or charge of smokable material, such as
shredded tobacco material (e.g., in cut filler form),
wrapped in a paper wrapper, thereby forming a so-called
"smokable rod". Normally, a cigarette has a cylindrical
filter element aligned in an end-to-end relationship with
the smokable rod. Typically, a filter element includes
cellulose acetate tow circumscribed by plug wrap, and is
attached to the smokable rod using a circumscribing
tipping material.
Typically, cigarettes are employed by the smoker by
lighting one end thereof and burning the smokable rod.
As such, smoke normally is provided by burning smokable
material, which typically is tobacco cut filler. The
smoker then receives mainstream smoke (e.g., mainstream
tobacco smoke) into his/her mouth by drawing on the
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opposite end (e.g., the filter end) of the cigarette. As
such, the smoker is provided with the pleasures of
smoking (e.g., smoking taste, feel, satisfaction, and the
like).
During the time that the cigarette is burning,
sidestream smoke is generated. Sidestream smoke is smoke
which directly enters the atmosphere from the lit end of
the cigarette. Sidestream smoke diffuses into the
atmosphere, and the characteristic visible nature and
odor thereof may be perceived negatively by some
individuals. The relative amount of visible sidestream
smoke generated by a burning cigarette is related to the
amount of sidestream "tarl' generated by that burning
cigarette. Typical commercially available cigarettes
which burn tobacco cut filler, and have lengths of about
84 mm (e.g., having a smokable rod length of about 57 mm
and a filter element length of about 27 mm), often yield
about 25 to about 35 mg of sidestream "tar" per
cigarette. See, Proctor et al, Analyst, Vol. 113,
p. 1509 (1988), for an apparatus and technique for
determining the sidestream "tar" of a cigarette.
Numerous cigarettes which reportedly yield
relatively low levels of visible sidestream smoke have
been proposed. See, for example, U.S. Patent Nos.
4,637,410 to Luke; 4,624,268 to Baker et al; 4,407,308 to
Baker; 4,231,377 to Cline et al; 4,420,002 to Cline;
4,450,847 to Owens; 4,108,151 to Martin; 4,225,636 to
Cline; 4,433,697 to Cline; 4,461,311 to Mathews et al;
and 4,561,454 to Guess.
Through the years, there have been proposed various
methods for altering the composition of mainstream
tobacco smoke. For example, many tobacco substitute
materials have been proposed, and a substantial listing
of such materials can be found in U.S. Patent No.
4,079,742 to Rainer et al. In addition, tobacco
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substitute smoking materials having the LLad~..ames Cytrel
and NSM were introduced in Europe during the 1970's.
Numerous references have proposed articles which
generate flavored vapor and/or visible aerosol. Most of
such articles have employed a combustible fuel source to
provide an aerosol and/or to heat an aerosol forming
material. See, for example, the background art cited in
U.S. Patent No. 4,714,082 to Banerjee et al.
Smoking articles which are capable of providing the
pleasures associated with cigarette smoking, by heating
but not necessarily burning tobacco, and without
delivering considerable quantities of incomplete
combustion products, are described in U.S. Patent Nos.
4,714,082 to Banerjee et al; 4,756,318 to Clearman et al;
and 4,793,365 to Sensabaugh, Jr. et al. Such smoking
articles employ a combustible fuel element for heat
generation; and aerosol forming substances positioned
physically separate from, and in a heat exchange
relationship with, the fuel element. During use, heat
generated by the fuel element acts to volatilize the
aerosol forming substances, thereby providing an aerosol
which resembles tobacco smoke. Such smoking articles
yield extremely low levels of visible sidestream smoke as
well as low levels of FTC "tar".
It would be desirable to provide a good tasting
cigarette which provides good smoking satisfaction,
provides relatively low mainstream gas phase yields,
provides relatively low levels of incomplete combustion
products, is capable of sustaining smolder during FTC
smoking conditions, yields an ash having desirable
physical characteristics, and generates low levels of
sidestream "tar" and hence low levels of visible
sidestream smoke.
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SUMMARY OF THE INVENTION
The present invention relates to smoking articles
incorporating tobacco in cut filler form and/or in a
processed form. Preferred smoking articles have the form
of a cigarette having two essential components: (i) a
roll or charge of smokable material, and (ii) an outer
wrapping material (e.g., a paper wrapper) circumscribing
the roll of smokable material. Cigarettes of the present
invention incorporate a smokable filler material
(described in greater detail hereinafter) as at least a
portion of the smokable material thereof.
The preferred wrapping material, which surrounds the
roll of smokable material to thereby form a "smokable
rod", is a low air permeability cigarette paper wrapper.
Highly preferred wrappers having a low air permeability
or low porosity exhibit a porosity below about 5 CORESTA
units. A CORESTA unit is a measure of the linear air
velocity which passes through a 1 cm2 area of wrapper at a
constant pressure of 1 centibar. See CORESTA Publication
ISO/TC 126/SC I N159E (1986).
One form of smokable material is a
tobacco-containing smokable filler material. A smokable
filler material of the present invention comprises an
intimate mixture of (i) tobacco (e.g., shredded tobacco
laminae, milled tobacco laminae, pieces of tobacco stems,
tobacco fines, tobacco dust, or a tobacco extract or
other form of processed tobacco), and optionally (ii)
inorganic filler material. The smokable material
includes a relatively high level of aerosol forming
material (e.g., a polyol, such as glycerin and/or
propylene glycol). The smokable filler material includes
a binding agent, in order to maintain the components of
the smokable filler material together. An especially
preferred binding agent is an alginate, such as ammonium
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alginate. The tobacco-containing smokable filler
material also can include certain flavoring agents (e.g.,
cocoa, licorice, organic acids, menthol, and the like) in
intimate contact therewith. The tobacco-containing
smokable filler material can be cast as a sheet from an
aqueous slurry, or provided in extruded form. Such a
tobacco- containing smokable filler material can be a
form of reconstituted tobacco, and can be employed
individually as the sole smokable material of the
cigarette. Alternatively, such a tobacco-containing
smokable filler material can be physically mixed with
(i.e., blended) or otherwise employed with other smokable
materials, such as tobacco cut filler.
Another form of smokable filler material of the
present invention comprises a relatively high level of
aerosol forming material. The smokable filler material
includes a binding agent, in order to maintain the
components of the smokable filler material together. An
especially preferred binding agent is an alginate, such
as ammonium alginate. Such a smokable filler material
also can include certain flavoring agents in intimate
contact therewith. The smokable filler material can be
cast as a sheet from an aqueous slurry or provided in
extruded form. Such a smokable filler material can be
physically mixed with or otherwise employed with
tobacco-containing smokable materials and/or tobacco cut
filler.
BRIEF DESCRIPTION OF THE DRAWINGS
Figures 1 through 4 are longitudinal sectional views
of smoking articles of the present invention.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A preferred embodiment of a cigarette and a smokable
filler material of the present invention is shown in
Figure 1. The cigarette 10 includes a generally
cylindrical rod 15. The rod includes a roll of smokable
material 20 wrapped in at least one layer of
circumscribing outer wrapping material 25 (e.g., paper).
The rod 15 is hereinafter referred to as a "smokable
rod". The ends of the smokable rod 15 are open to expose
the smokable material. The smokable rod is used by
lighting one end thereof, and aerosol (e.g., smoke) is
provided as a result of the combustion of the burning
smokable material. As such, the smokable rod burns from
the lit end thereof towards the opposite end thereof.
The cigarette 10 also includes a filter element 30
positioned adjacent one end of the smokable rod 15 such
that the filter element and smokable rod are axially
aligned in an end-to-end relationship, preferably
abutting one another. Filter element 30 has a generally
cylindrical shape, and the diameter thereof is
essentially equal to the diameter of the smokable rod.
The ends of the filter element are open to permit the
passage of air and smoke therethrough. The preferred
filter element has at least two filter segments. As
shown in Figure 1, a first filter segment is positioned
adjacent the smokable rod, and preferably includes a
carbonaceous filter material 35 circumscribed by a
wrapping material 37; while a second filter segment is
positioned at the extreme mouthend of the cigarette, and
preferably includes a filter material 40, such as a
gathered non-woven polypropylene web or cellulose acetate
tow, circumscribed by a wrapping material 45. The filter
material 40 of the segment preferably is a material which
provides an aesthetically pleasing, white appearance.
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Each of the filter segments is manufactured using known
filter rod making machinery. The two segments are
combined using known plug tube combining techniques, and
are held together using circumscribing wrap 50 so as to
form the filter element.
The filter element 30 normally is attached to the
smokable rod 15 by tipping material 55, which
circumscribes both the entire length of the filter
element and an adjacent region of the smokable rod. The
inner surface of the tipping material 55 is fixedly
secured to the outer surface of the plug wrap 50 and the
outer surface of the wrapping material 25 of the smokable
rod, using a suitable adhesive. The cigarette 10 can be
manufactured using known cigarette making techniques and
equipment. Optionally, a ventilated or air diluted
cigarette is provided with an air dilution means such as
a series of perforations 65 which extend through the
tipping material 55, plug wrap 50 and wrapping material
37. Such ventilation can be provided to the cigarette
using known techniques, such as laser perforation
techniques.
Another preferred embodiment of a cigarette and
smokable filler material of the present invention is
shown in Figure 2. The cigarette 10 is generally similar
to the cigarette described with reference to Figure 1,
except that the smokable material has the form of a blend
which is provided in a segmented fashion. At one end of
the smokable rod 15 (i.e., at the end of the cigarette to
be lit) is located a first segment 70 of smokable
material. At the other end of the smokable rod 15 (i.e.,
at the end of the smokable rod adjacent the filter
element) is located a second segment 75 of smokable
material. Each segment is defined or identified in terms
of its composition (i.e., the composition of each segment
is different). The segments are aligned in an abutting,
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end-to-end relationship; however, there can be a certain
amount of intermixing of smokable materials in the region
where the two segments meet. The length which each
segment of smokable material extends along the smokable
rod can vary. However, the relative longitudinal length
of the first segment relative to the second segment
normally ranges from about 1:2 to about 2:1, with about
1:1 being preferred. Such smokable rods can be
manufactured using apparatus described in U.S. Patent
Nos. 4,009,722 to Wahle et al and 4,516,585 to Pinkham.
For preferred cigarettes of the type shown in Figure
2, the first segment 70 normally includes tobacco in some
type of smokable form. Such a form of tobacco includes
tobacco cut filler (e.g., tobacco laminae, processed
tobacco materials, volume expanded tobacco filler,
reconstituted tobacco filler materials, and the like, and
blends thereof), and blends thereof with other smokable
materials. Examples of processed tobacco materials are
deproteinated reconstituted tobacco materials described
in U.S. Patent Nos. 4,887,618 to Bernasek et al and
4,941,484 to Clapp et al. Preferred cigarettes also have
a second segment 7~ which includes a smokable material or
blend of smokable materials different in overall
composition from the overall composition of the smokable
material(s) of the first segment 70. The first segment
70 and/or the second segment 75 include at least one form
of smokable material of the present invention.
Another preferred embodiment of a cigarette of the
present invention is shown in Figure 3. The cigarette 10
is generally similar to the cigarette described with
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reference to Figures 1 and 2, except that the smokable
material 20, which incorporates the smokable filler
material of the present invention, is wrapped or
contained in a processed tobacco sheet 80, or other inner
wrapper material. The processed tobacco sheet 80
normally is a reconstituted tobacco sheet which is
manufactured using a paper-making process, and a single
layer of the sheet circumscribes the smokable material
20. The smokable material 20 wrapped in the processed
tobacco sheet 80 is in turn wrapped in a single layer of
circumscribing outer wrapping material 25 (e.g.,
cigarette paper).
Another preferred embodiment of a cigarette of the
present invention is shown in Figure 4. The cigarette 10
is generally similar to the cigarette described with
reference to Figures 1, 2 and 3, except that the filter
element includes three segments. Segment 85, positioned
between first filter material 35 and filter material 40,
preferably is composed of a particulate matter such as
activated carbon granules, magnesium silicate granules,
silica gel particles, or the like.
The smokable material employed in the manufacture of
the smokable rod can vary, and most preferably has the
form of cut filler. As used herein, the term "cut
filler" in referring to smokable materials is meant to
include smokable materials which have a form suitable for
use in the manufacture of smokable rods for cigarettes.
As such, cut filler can include smokable materials which
are blended and are in a form ready for cigarette
manufacture. Smokable materials normally are employed in
the form of strands or shreds as is common in cigarette
manufacture. For example, cut filler can be employed in
the form of strands or shreds cut from sheet-like or
"strip" materials. Such strip materials are cut into
widths ranging from about 1/5 inch to about 1/60 inch,
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preferably from about 1/25 inch to about 1/35 inch.
Generally, the resulting strands or shreds have lengths
which range from about 0.25 inch to about 3 inches. Cut
filler also can have an extruded form (e.g., extruded
strands) or other physically processed form.
The smokable rods of cigarettes of the present
invention include smokable filler material of the present
invention. The smokable filler material can be employed
in cut filler form.
One preferred type of smokable filler material of
the present invention normally includes at least about
15, usually at least about 20, often at least about 25,
frequently at least about 30, and sometimes at least
about 40 weight percent aerosol forming material.
Typically, the smokable filler material includes up to
about 70, and usually up to about 60 weight percent
aerosol forming material. The smokable filler material
also typically includes up to about 20, preferably about
3 to about 15 weight percent binding agent; and up to
about 80 percent, preferably about 40 to about 75 weight
percent filler component. In particular, the filler
component can include inorganic filler materials (e.g.,
precipitated calcium carbonate) and/or an organic filler
material (e.g., tobacco dust or milled tobacco laminae).
Amounts of flavoring agent sufficient to provide the
desired flavor characteristics to the smokable filler
material can be incorporated into the smokable material.
If desired, a carbonaceous material (e.g., pyrolyzed
alpha cellulose) can be incorporated into the smokable
material, freguently up to about 10 weight percent, based
on the total dry weight of the smokable material.
However, such carbonaceous material is not a necessary
component of the smokable material, and the smokable
material can be absent of such carbonaceous material.
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The smokable filler material can be combustible, and can
be blended with other smokable materials.
One preferred type of smokable filler material of
the present invention is a reconstituted tobacco
including some form of tobacco and aerosol forming
material. Such a smokable filler material typically
includes an amount of aerosol forming material relative
to tobacco of about 4:1 to about 1:2, preferably about
2:1 to 1:2, and often about 1.5:1 to about 1:1.5, on a
weight basis. Such a smokable filler material includes
an amount of aerosol forming material and tobacco such
that the total combined weight thereof in the smokable
filler material provides at least about 25, often at
least about 30, frequently at least about 35, usually at
least about 40, preferably at least about 45, and more
preferably at least about 50 percent of the weight of the
smokable filler material. Usually, the total combined
weight of the aerosol forming material and tobacco does
not exceed about 95, often does not exceed about 90, and
frequently does not exceed about 85 percent of the weight
of the smokable filler material. An example of a
preferred smokable filler material includes about 50 to
about 70 percent aerosol forming material and tobacco,
based on the total weight of the smokable filler
material. If desired, flavoring agents, inorganic
fillers, etc., can be incorporated into the smokable
material.
The tobacco-containing smokable filler materials of
the present invention have some form of tobacco
incorporated therein during manufacture. The tobacco
which is employed to provide such a tobacco-containing
smokable filler material can have a variety of forms,
including tobacco extracts, tobacco fines or dust,
shredded or comminuted tobacco laminae, tobacco stems,
volume expanded tobacco filler and other processed forms
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of tobacco, and the like, and combinations thereof.
Tobacco extracts are processed forms of tobacco and are
provided by extracting a tobacco material using a solvent
such as water, carbon dioxide, a hydrocarbon, or a
halocarbon, as well as various other organic and
inorganic solvents. Tobacco extracts can include spray
dried extracts; freeze dried extracts; heat treated
extracts; tobacco essences, such as those essences
described in European Patent Publication No. 0326370
published August 2, 1989; and aroma oils and extracts
described in U.S. Patent No. 4,506,682 to Mueller and
Canadian Patent Application No. 596,617 filed April 13,
1989.
The smokable filler materials of the present
invention incorporate a binding agent. Especially
preferred~binding agents include the alginates, such as
ammonium alginate, propylene glycol alginate, potassium
alginate and sodium alginate. The alginates, and
particularly the high viscosity alginates, can be
employed in conjunction with controlled levels of free
calcium ions. Other suitable binding agents include
hydroxypropylcellulose such as Klucel H from Aqualon Co.;
hydroxypropylmethylcellulose such as Methocel K4MS from
The Dow Chemical Co.; hydroxyethylcellulose such as
Natrosol 250 MRCS from Aqualon Co.; microcrystalline
cellulose such as Avicel from FMC; methylcellulose such
as Methocel A4M from The Dow Chemical Co.; and sodium
carboxymethylcellulose such as CMC 7HF and CMC 7H4F from
Hercules Inc. Other binding agents include starches
(e.g., corn starch), guar gum, carrageenan, locust bean
gum, pectins and xanthan gum. Combinations or blends of
binding agents (e.g., a mixture of guar gum and locust
bean gum) can be employed.
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The smokable filler materials of the present
invention can have at least one aerosol forming material
incorporated therein. The preferred aerosol forming
materials include polyols (e.g., glycerin, propylene
glycol and triethylene glycol), and any other materials
which yield a visible aerosol, and combinations thereof.
The aerosol forming material can be provided as a portion
of the binding agent (e.g., when the binding agent is
propylene glycol alginate). Combinations of aerosol
forming materials can be employed.
The smokable filler materials of the present
invention can have at least one flavoring agent
incorporated therein. The flavoring agents can vary, and
include menthol, vanillin, citric acid, malic acid,
cocoa, licorice, and the like, as well as combinations
thereof. See, Leffingwell et al, Tobacco Flavorinq for
Smokinq Products (1972).
If desired, a caramelizing material can be
incorporated into the smokable filler materials of the
present invention. Caramelizing materials can act to
improve (i) the integrity of the ash and fire cone of the
cigarette, (ii) the appearance of the smokable filler
material, and (iii) the flavor characteristics of the
mainstream smoke of the cigarette. The caramelizing
material can be incorporated into the smokable filler
material during the preparation of that material and/or
applied to the surface of that material (e.g., as a
powder) after the manufacture thereof. Normally, the
amount of caramelizing material which is employed to
treat a particular smokable filler material is such that
the resulting material which incorporates the
caramelizing material includes up to about 20 weight
parts of caramelizing material and greater than about 80
weight parts of the smokable material which is treated.
Examples of suitable caramelizing materials include
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sugars, such as glucose, fructose and sucrose; and
compositions such as Carob Powder Code 1739 from M. F.
Neal, Inc.
The smokable filler materials of the present
invention can be surface treated with certain substances.
For example, the smokable filler materials can have
powdered substances applied to the surface thereof.
Exemplary substances include cocoa powder, licorice
powder, powdered inorganic materials (e.g., potassium
carbonate or iron oxide), tobacco dust, finely divided
tobacco laminae, or the like, or blends thereof. The
surface treatment of the smokable filler materials can
provide to those materials improved color and appearance,
improved ash characteristics, and improved flavor
characteristics.
Inorganic materials can be incorporated as fillers
in the smokable filler materials of the present
invention. Such invrganic materials often have a
fibrous, flake, crystalline, amorphous, hollow or
particulate form. Examples of inorganic filler materials
include calcium carbonate, calcium sulfate particles,
magnesium oxide, magnesium hydroxide, perlite, synthetic
mica, vermiculite, clays, thermally stable carbon fibers,
zinc oxide, dawsonite, low density hollow spheres of
calcium carbonate, glass spheres, glass bubbles,
thermally stable carbon microspheres, calcium sulfate
fibers, hollow ceramic microspheres, alumina, calcium
carbonate agglomerated using a carbonaceous component,
calcium carbonate agglomerated using an organic material,
low density processed calcium carbonate, and the like.
The smokable filler material of the present
invention can include an agglomerated matrix filler of an
inorganic component and a carbonaceous component. The
inorganic component can include particles of calcium
carbonate, calcium sulfate, magnesium oxide, and the
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, _
like. A particularly preferred agglomerated matrix
filler is agglomerated calcium carbonate, and most
preferably, agglomerated precipitated calcium carbonate.
Such an agglomerated matrix filler can be prepared by
providing an aqueous slurry of calcium carbonate
particles and a binding material, and drying the slurry
to form an agglomerated matrix of calcium carbonate
(i.e., a matrix of a plurality of calcium carbonate
particles spaced within a continuous or semi-continuous
phase of binding material). If desired, the slurry can
be volume expanded by incorporating a foaming agent
therein. Examples of suitable foaming agents include
linear sodium benzene sulfonates, linear alkyl sulfonates
and linear alkyl ethoxy sulfates. Calcium carbonate
particles which are employed to provide the agglomerated
matrix typically exhibit a surface area of less than
about 20 m2/g, frequently less than about 10 m2/g, and
sometimes less than about 1 m2/g, as determined using the
Brunauer, Emmett and Teller (BET) method described in
J. Am. Chem. Soc., Vol. 60, p. 309 (1938). Typical
binding materials are organic materials, such as
cellulosic derivatives (e.g., sodium carboxymethyl-
cellulose), and preferably are sugar containing
materials, such as molasses, high fructose corn syrup, or
Carob Powder Code 1739 from M. F. Neal, Inc. Other
organic materials, such as pectins and alginates, also
can be employed.
Preferably, a high solids content aqueous slurry
(e.g., about 40 to about 55 weight percent solids content
slurry) of calcium carbonate and binding material is
spray dried to provide agglomerated particles (e.g.,
normally spherical particles) of calcium carbonate
particles and binding material. Alternatively, the
slurry can be dried by the application of heat to provide
a solid mass of agglomerated calcium carbonate and
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binding material, and the solid mass can be ground to
yield particles of the desired size. Preferably, the
amount of calcium carbonate relative to binding material
ranges from about 20:1 to about 2:1, more preferably
about 15:1 to about 4:1, on a dry weight basis.
Normally, the inorganic particles agglomerated using
saccharide and polysaccharide materials tend to lose
their agglomerated character when contacted with water
under ambient conditions, as a result of the propensity
of the saccharide and polysaccharide materials to be
soluble in water.
The agglomerated matrix of inorganic component and
organic binding material is subjected to heat treatment.
As such, volatile components from the organic binding
material are expelled, and the organic binding material
is calcined to form an essentially water insoluble, clean
burning carbonaceous component. Normally, the heat
treatment of the agglomerated matrix filler is provided
under controlled atmosphere, in order to minimize or
prevent oxidation of the binding material. Preferably,
the heat treatment provides a binding material which is
in the form of a carbonaceous material, and in turn,
provides a means for agglomerating the particles of
inorganic filler component into a matrix form.
In particular, the particles of agglomerated calcium
carbonate and binding material can be heat-treated (e.g.,
to a temperature of up to about 625C, and usually up to
about 600C) using an oven, a fluidized bed, rotary
calciner, belt calciner, or the like. For example,
particles of spray dried calcium carbonate particles
agglomerated using molasses can be heated in a
fluidized bed having gaseous nitrogen flowing
therethrough, heated at temperatures sufficient to heat
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the particles to about 300~C to about 425C flowing
therethrough, and collected. The agglomerated matrix of
inorganic component and organic binding material can be
subjected to heat treatment sufficient to calcine the
organic binding material by subjecting the agglomerated
matrix to very high temperatures (e.g., up to about
900C) for a short time period and under conditions
sufficient to avoid decomposition of the inorganic
component (e.g., when the inorganic component is calcium
carbonate). However, if the inorganic component is
calcium carbonate, and the calcium carbonate undergoes
some decomposition during the calcining step, the
agglomerated material can be re-carbonated by (i)
exposing that material to carbon dioxide atmosphere, or
(ii) dispersing that material in water and bubbling
carbon dioxide into the dispersion.
After the calcining process, the agglomerated
calcium carbonate particles normally have a calcium
carbonate content of greater than about 80, frequently
greater than about 90 weight percent and a carbon content
of greater than about 3 weight percent. Normally, the
resulting agglomerated particles are screened to sizes of
about -50/+325 US Mesh, and often about -80/+200 US Mesh.
Preferred agglomerated calcium carbonate particles which
have been calcined are essentially insoluble in water,
are spherical in shape, are free flowing, and exhibit a
bulk density of about 0.1 g/cm3 to about 1.1 g/cm3,
frequently about 0.3 g/cm3 to about 1 g/cm3, using mercury
intrusion techniques. As such, calcined agglomerated
calcium carbonate particles provide an inorganic material
having a bulk density less than about 2 g/cm3, and
preferably less than about 1 g/cm3, which includes an
inorganic component having a bulk density greater than
about 2.5 g/cm3. Normally, such calcined agglomerated
calcium carbonate particles exhibit a surface area of
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less than about 30 m2/g, and often about 10 m2/g to about
25 m2/g, as determined using the BET method.
If desired, the bulk density of the calcined
agglomerated inorganic filler can be lowered by digesting
away part of the inorganic component with an acidulant.
For example, calcined agglomerated can be dispersed in
water, and an aqueous hydrochloric acid solution can be
added to the resulting slurry which is agitated. The
acid reacts with the calcium carbonate, and essentially
does not react with the carbonaceous component. Thus,
the carbonaceous component acts to hold together the
remaining calcium carbonate, while a portion of the
calcium carbonate reacts to produce carbon dioxide gas
and water soluble calcium chloride.
Another type of filler which can be incorporated
into smokable filler materials of the present invention
is a low density inorganic filler. Such a filler is
provided by providing particles of a calcium salt,
decomposing the anion of the salt and contacting the
particles with carbon dioxide. Examples of suitable
salts include calcium propionate, succinate, tartrate,
stearate, salicylate, palmitate, oleate, lactate,
gluconate, citrate, ascorbate, acetylsalicylate and
benzoate. Other suitable salts include calcium salts of
saccharides and polysaccharides. Such salts are
subjected to conditions sufficient to decompose the anion
thereof, which usually involves subjecting the salt to
heat treatment under carbon dioxide atmosphere.
One method for providing a low density inorganic
filler involves heating calcium lactate particles
screened to -80/+170 US Mesh at about 600-C for about 8
hours under a steady 228 ml/min. flow of carbon dioxide
gas, so as to provide a material which has undergone
about a 65 percent weight loss. About 20 weight parts of
the material is charged into about 80 weight parts water
Y-119B-R&D:18
._ - 19 - 2026538
and the resulting slurry is contacted with sufficient
hydrochloric acid solution to lower the pH thereof to
about 6.8. The material then is removed from the water,
washed with water, dried, and screened to a particle size
of -80/+170 US Mesh. Such material is greater than about
95 weight percent calcium carbonate, and exhibits a bulk
density of about 0.4 g/cm3, as determined using mercury
intrusion techniques.
The agglomerated matrix filler can have the form of
an inorganic component and an organic component. Other
inorganic components include calcium sulfate, magnesium
oxide and magnesium carbonate. Calcium carbonate
agglomerated using ammonium alginate is an example of an
agglomerated matrix filler having an inorganic component
in an alginate component. Such an agglomerated matrix
filler can be provided by providing an aqueous slurry of
calcium carbonate particles and hydrated alginate, and
drying the slurry to form an agglomerated matrix of
calcium carbonate (i.e., a matrix of a plurality of
calcium carbonate particles spaced within a continuous or
semi-continuous phase of alginate). If desired, the
slurry can be volume expanded by incorporating a foaming
agent therein. Examples of suitable foaming agents
include linear sodium benzene sulfonates, linear alkyl
sulfonates and linear alkyl ethoxy sulfates. Preferably,
a high solids content aqueous slurry of calcium carbonate
and alginate is spray dried to provide agglomerated
particles (e.g., normally spherical particles) of calcium
carbonate particles and alginate. Alternatively, the
slurry can be dried by the application of heat to provide
a solid mass of agglomerated calcium carbonate and
alginate, and the solid mass can be ground to yield
particles of the desired size. Preferably, the amount of
calcium carbonate relative to alginate ranges from about
99:1 to about 2:1, preferably about 20:1 to about 5:1, on
Y-119B-R&D:lg
- - 20 - 2026538
a dry weight basis. Typically, the particles of calcium
carbonate agglomerated using alginate are essentially
insoluble in water. In particular, the essentially
insoluble character of the alginate in the agglomerated
matrix filler tends to limit to a great degree any
propensity of the agglomerated matrix filler to lose its
agglomerated character when contacted with water under
ambient conditions. The agglomerated matrix filler is
rendered insoluble due to the interaction of the alginate
with calcium ions of the calcium carbonate. If desired,
the agglomerated matrix filler can be treated with a
dilute solution of acid to decompose a portion of the
calcium carbonate and liberate calcium ions, and the
resulting calcium ions can act to render insoluble the
alginate component of the agglomerated matrix filler.
The agglomerated matrix filler having an inorganic
component and an organic component can incorporate a
variety of other organic components. For example, the
organic component can be pectin, which has a tendency to
become essentially water insoluble upon interaction with
calcium ions. Alternatively, agglomerated matrix filler
having a polysaccharide organic component can be treated
with divalent ions (e.g., calcium, barium, cobalt, iron
or manganese ions) or trivalent ions (e.g., iron or
aluminum ions) to render the polysaccharide essentially
water insoluble. As yet another example, a slurry of
polysaccharide material (e.g., ethylcellulose) and
inorganic component particles can be provided in a non-
aqueous solvent (e.g., alcohol) and dried, resulting in
the formation of an agglomerated matrix filler which is
essentially water insoluble.
Typically, the smokable filler materials of the
present invention are provided by forming an aqueous
slurry of aerosol forming material, binding agent and the
other components of that smokable filler material,
Y-119B-R&D:20
- 21 ~ 2~26538
casting the slurry as a sheet, and drying the cast
material to form a relatively, dry workable sheet.
Techniques and equipment for casting a slurry as a sheet
will be apparent to the skilled artisan. Other
materials, such as calcium acetate, potassium carbonate,
pH control agents, urea, amino acids, potassium chloride
and/or calcium hydroxide, can be incorporated into the
slurry. Sequestering agents (e.g., diammonium hydrogen
orthophosphate, sodium citrate, potassium
hexametaphosphate or tetrasodium pyrophosphate) can be
incorporated into the slurry in amounts sufficient to
control the free calcium ion concentration in the slurry.
The cast material can be dried at ambient temperatures or
at elevated temperatures. Further, an aqueous solution
of calcium salts can be applied to the cast slurry. The
resulting dried sheet can be cut or broken into "strip"
form, and later can be cut or shredded into cut filler
form.
The smokable filler materials of the present
invention can be extruded into the desired shape using
suitable extrusion techniques. See, for example, the
types of processes described in U.S. Patent No. 4,880,018
to Graves, Jr. et.al. Preferably, an aqueous slurry of
the components of the smokable material and an alginate
binding agent is extruded into an aqueous solution of
calcium ions (e.g., an aqueous solution of calcium
chloride), collected and dried. If desired, extruded
smokable filler materials can be physically processed
(e.g., subjected to treatment using rollers, etc.) and
formed into the desired shape.
The smokable rods of cigarettes of the present
invention often include a physical mixture or blend of
smokable materials. The blend can include at least one
type of smokable filler material of the present invention
Y-b-R&D:21
- 22 - 2026538
and at least one other smokable material. The blend can
include two or more smokable filler materials of the
present invention, or a physical mixture of at least one
smokable filler material of the present invention with at
least one other smokable material. Certain cigarettes
include within such a blend, a sufficient amount of at
least one of the smokable filler materials of the present
invention such that the smokable material within each
cigarette comprises at least about 1 percent of the
carbonaceous material, based on the total weight of the
blend. Typically, such an optional blend incorporates
carbonaceous material as the carbonaceous component of
the calcined agglomerated matrix filler. In particular,
cigarettes having such types of smokable filler materials
and having low porosity paper outer wrappers (e.g.,
having outer wrappers having less than about 5 CORESTA
units) have the propensity to sustain smolder (e.g., not
self-extinguish), when smoked under FTC smoking
conditions. FTC smoking conditions consist of 35 ml
puffs of 2 second duration, taken every 60 seconds.
The smokable filler materials of the present
invention can be blended with tobacco cut filler. The
type of tobacco can vary, and can include flue-cured,
Burley, Maryland and Oriental tobaccos, as well as the
rare and specialty tobaccos, and blends thereof. Such
tobacco cut filler can be provided in the form of tobacco
laminae; volume expanded or puffed tobacco laminae;
processed tobacco stems such as cut-rolled or cut-puffed
stems; reconstituted tobacco materials, such as (i)
deproteinated tobacco materials described in U.S. Patent
Nos. 4,887,618 to Bernasek et al and 4,941,484 to Clapp
et al, (ii) a phosphate-containing reconstituted tobacco
material described in U.S. Patent Nos. 3,353,541 and
3,420,241 to Hind et al, and 3,386,449 to Hind,
Y-119B-R&D:22
~ - 23 - 2026538
(iii) a reconstituted tobacco material described in
Tobacco EncYclo~edia, edit. by Voges, p. 389, TJI (1984),
or blends thereof.
Smokable materials can be cased and top dressed as
is conventional during various stages of cigarette
manufacture. For example, flavoring agents can be
applied to the smokable material as is commonly performed
when cigarette cut filler is processed. Suitable
flavoring agents include vanillin, cocoa, licorice,
menthol, and the like. Flavor modifying agents can be
applied to the smokable material. A flavor modifying
agent in the form of levulinic acid can be applied to the
smokable filler material (e.g., in amounts ranging from
about 0.01 to about 2 percent, normally from about 0.1 to
about 1 percent, preferably about 0.2 to about 0.6
percent, based on the dry weight of the smokable
material). Another flavor modifying agent in the form of
potassium carbonate can be applied to the smokable
material (e.g., in amounts of less than about 5 percent,
normally about 2 to about 3 percent, based on the dry
weight of the smokable material). Aerosol forming
materials and humectants, such as glycerin and propylene
glycol, can be applied to the smokable material. Such
components conveniently are applied to the smokable
filler material as casing and top dressing components.
The preferred wrapping material which provides the
smokable rod is a cigarette wrapping material having a
low air permeability value. Such a wrapping material
normally has an air permeability of less than about 5
CORESTA units, often less than about 3 CORESTA units, and
Y-119B-R&D:23
- 24 - 2026S38
frequently less than about 1 CORESTA unit. Typical
wrapping materials are cigarette paper wrappers.
Suitable wrapping materials are cigarette paper wrappers
available as DD-71-1, DD-71-6, MTR-1021, P-2831-60-2,
P-2831-60-3, P-2831-60-4, P-2831-60-5, P-2674-110,
P-2831-60-1 and DD-100-2 from Ximberly-Clark Corp.
Suitable low porosity cigarette paper wrappers are
commercially available, and can have various levels of
burn chemicals, fluxing agents, etc., incorporated
therein. Particularly preferred are cigarette paper
wrappers which include an amount of a polymeric film
forming agent sufficient to provide a paper having the
desirably low air permeability value. For example, a
sufficient amount of a solution of a polymeric (e.g.,
carboxymethylcellulose or ethylcellulose) film forming
agent can be applied to a paper wrapper. The selection
of the polymeric film forming agent will be apparent to
the skilled artisan.
The optional polymeric film forming agent can be
applied to the paper wrapper during the manufacture of
the paper, or applied as a print or paint after
manufacture of the paper is complete. Typically, the
film forming agent is applied to the paper as a dilute
solution (e.g., at a concentration of about 0.2 to about
5 weight percent relative to the solvent) for ease of
processing. The amount of film forming agent applied to
the paper wrapper depends upon factors such as the
permeability of the paper and the film forming
capabilities of the film forming agent. Typically, the
amount of film forming agents employed ranges from about
1 to about 10 percent, based on the dry weight of the
paper. For example, a 5 weight percent solution of
ethylcellulose in ethanol or sodium carboxymethyl-
cellulose in water can be applied to cigarette paper
using a size press, and the paper can be dried to provide
Y-119B-R&D:24
~ - 25 - 202C538
a non-wetting, moisture resistant paper wrapper having a
porosity of less than about 1 CORESTA unit, preferably
less than about 0.5 CORESTA unit.
The smokable rods and the resulting cigarettes can
be manufactured in any known configuration using known
cigarette making techniques and equipment. Smokable rods
often include smokable material wrapped in a single layer
of wrapping material, although a double layer of two
types of wrapping materials can be employed.
Cigarettes having smokable rods which are double
wrapped with two layers of wrapping material preferably
include one of the previously described low porosity
paper wrappers as the outer wrappers. The inner wrapper
can vary, but typically is a tobacco-containing wrapping
material. Exemplary inner wrappers are paper wrappers
which include about 3 parts Java tobacco stem parts and
about 1 part wood pulp, and are available from
Kimberly-Clark Corp. as P-2249-115 and P-2831-23-3.
Other suitable inner wrapping materials include tobacco
parts and carbonaceous materials, and are available from
Kimberly-Clark Corp. as P-2540-94-A, P-2540-94-C and
P-2540-94-D. The inner wrapping materials (i) can
include burn chemicals (e.g., potassium citrate,
potassium acetate or potassium succinate), and/or (ii)
act as a substrate for flavors (e.g., menthol or
vanillin) or flavor precursors (e.g., vanillin glucoside
or ethylvanillin glucoside).
Typically, the smokable rod has a length which
ranges from about 30 mm to about 70 mm, preferably about
35 to about 60 mm: and a circumference of about 17 mm to
about 27 mm, preferably about 22 mm to about 25 mm.
Short smokable rods (i.e., having lengths from about 30
Y-119B-R&D:25
~ 21~6538
- 26 -
to about S0 mm) can be employed, particularly when
smokable materials having a relatively high packing
density are employed.
The packing density of the smokable material
contained within the outer wrapping material can vary.
Typical packing densities for smokable rods of cigarettes
of the present invention range from about 150 to about
400 mg/cm3. Normally, packing densities of such smokable
rods range from about 200 to about 380 mg/cm3, frequently
about 250 to about 360 mg/cm3, particularly when
relatively short (i.e., less than 50 mm long) smokable
rods are employed.
The cigarettes of the present invention preferably
include a filter element, and most preferably a filter
element having more than one segment. For example, a
preferred filter element has two or more filter segments.
Typically, the segments of the preferred filter elements
each have lengths which ranges from about 10 mm to about
30 mm; and circumferences of about 17 mm to about 27 mm,
preferably about 22 mm to about 25 mm. The plug wrap
which circumscribes the filter material of each filter
segment typically is a conventional paper plug wrap, and
can be either air permeable or essentially air
impermeable.
Preferred filter materials of one of the filter
segments include carbonaceous materials (e.g., activated
carbon particles, charcoal particles, or carbon paper).
An example of a particularly preferred filter material is
provided by gathering a tobacco/carbon paper available as
P-144-BAC from Kimberly-Clark Corp. Such filter
materials reduce the levels of certain gas phase
components from the mainstream smoke which passes to the
mouth of the smoker. As such, preferred filter materials
of that segment act to reduce the levels of any smoke
Y-119B-R&D:26
- 27 _ 202~538
components which may provide an off-taste or other
undesirable characteristics to the mainstream smoke.
Preferred filter materials of another of the filter
segments normally include fibrous materials. An example
of a suitable filter material is a gathered nonwoven
polypropylene web. A particularly preferred nonwoven
polypropylene sheet-like web is available as PP-100-F
from Kimberly-Clark Corp. Another example of a suitable
filter material is a cellulose acetate tow. Particularly
preferred cellulose acetate tow items include (i) 8
denier per filament/40,000 total denier, and (ii) 8
denier per filament/15,000 total denier, (iii) 8 denier
per filament/25,000 total denier, and (iv) 8 denier per
filament/30,000 total denier. Plasticizers, such as
triacetin, propylene glycol or triethyl citrate, can be
combined with the filler materials.
Another filter segment can have a filter material in
the form of a gathered web of nonwoven thermoplastic
(i.e., hydrophobic) fibers in intimate contact with a
water soluble tobacco extract so as to provide an
extract-containing filter material. A highly preferred
web is a nonwoven web of polypropylene fibers available
as PP 200 SD from Kimberly-Clark Corp. Such segments can
provide enhanced flavor characteristics to the mainstream
smoke which passes therethrough.
Yet another filter segment can include a tobacco
paper material as the filter material. For example, a
filter material can have the form of a gathered web of
tobacco paper available as P-144-B from Kimberly-Clark
Corp.
The filter element segments suitable for use in this
invention can be manufactured using known cigarette
Y-119B-R&D:27
- 28 - 2n2c538
filter making techniques. Filter elements can be
manufactured from cellulose acetate tow using known
techniques. Filter elements can be manufactured from
carbon paper, tobacco paper and a sheet-like nonwoven
polypropylene web using filter making techniques
described in U.S. Patent No. 4,807,809 to Pryor et al.
Alternatively, particles of charcoal or activated carbon
can be incorporated into the filter element using a so-
called "triple filter' configuration by positioning the
particles between two segments of suitable filter
materials.
The filter elements can have low, moderate or high
filtration efficiencies. Preferred filter elements have
minim~l mainstream aerosol (i.e., smoke) removal
efficiencies while maintAining the desirable draw
characteristics of the cigarette. Such minimal smoke
removal efficiencies are provided by "low efficiency'
filter elements. Low efficiency filter elements have a
minimal ability to remove mainstream smoke particulates.
See, Keith in Schemeltz~s The Chemistry of Tobacco and
Tobacco Smoke, p. 157 (1972). Generally, low efficiency
filter elements pr~vide less than about 40 weight percent
mainstream smoke particulate removal efficiency.
Tipping material circumscribes the filter element
and an adjacent region of the smokable rod such that the
tipping material extends about 3 mm to about 6 mm along
the length of the smokable rod. Typically, the tipping
material is a conventional paper tipping material.
Tipping materials of varying porosities can be employed.
For example, the tipping material can be essentially air
impermeable, air permeable, or treated (e.g. by
mechanical or laser perforation techniques) so as to have
a region of perforations, openings or vents thereby
providing a means for providing air dilution to the
Y-119B-R&D:28
21~26538
- 29 -
cigarette. The total surface area of the perforations
and the positioning of the perforations along the
periphery of the cigarette can be varied in order to
control the performance characteristics of the cigarette.
For air diluted or ventilated cigarettes of the
present invention, the amount of air dilution can vary.
Typically, the amount of air dilution for an air-diluted
cigarette is greater than about 25 percent, and
frequently greater than about 40 percent. The upper
limit for air dilution for a cigarette typically is less
than about 75 percent, more frequently less than about 65
percent. As used herein, the term "air dilution" is the
ratio (expressed as a percentage) of the volume of air
drawn through the air dilution means to the total volume
of air and aerosol (i.e., smoke) drawn through the
cigarette and exiting the extreme mouthend portion of the
cigarette. See, Selke et al, Beitr. Zur Tabak. In.,
Vol. 4, p. 193 (1978).
Cigarettes of the present invention, when smoked,
provide a flavorful mainstream aerosol. The mainstream
aerosol of such cigarettes can yield low levels of
incomplete combustion products as well as low levels of
gas phase components. The cigarettes burn at an
acceptable rate, and maintain static smolder, at least
when smoked under FTC smoking conditions. The
cigarettes, when smoked, have an ash and fire cone which
is not overly cohesive, and hence, is not overly long.
However, the cigarettes also provide an ash and fire cone
which exhibit good integrity.
Cigarettes of the present invention, when smoked,
generally yield less than about 20 mg, preferably less
than about 10 mg of sidestream "tar" per cigarette, as
determined using the apparatus and techniques described
by Proctor et al, Analyst, Vol. 113, p. 1509 (1988).
Such cigarettes normally provide more than about 5 puffs,
Y-119B-R&D:29
_ 30 _ 2026~38
. _
preferably more than about 6 puffs per cigarette, when
smoked under FTC conditions. Normally, cigarettes of the
present invention provide less than about 20 puffs, and
often less than about 15 puffs, when smoked under FTC
conditions.
The following examples are provided in order to
further illustrate the invention but should not be
construed as limiting the scope thereof. Unless
otherwise noted, all parts and percentages are by weight.
EXAMPLE 1
A. Preparation of a Tobacco-Containing Smokable Filler
Material
An agglomerated matrix filler is provided as
follows:
Into a low shear mixer are charged about 832 parts
tap water at ambient temperature, about 757 parts
precipitated particulate calcium carbonate available as
Albacar 5970 from Pfizer Inc., and about 267 parts
molasses. The calcium carbonate has a rosettic structure
and an average particle size (i.e., diameter) of about 2
microns. The molasses is available as Refiner's Syrup
from Savannah Sugar Co., and has a solids/water content
of about 3.7:1. The resulting mixture is agitated for
about 5 to about 10 minutes to provide a slurry having a
solids content of about 52 percent and a viscosity of
about 1,200 cps as measured by a Brookfield LVT
viscometer with cylindrical LV spindle No. 4.
The slurry is spray dried by continuously pumping
the slurry at about 6 lbs./min. at a feed pressure of
about 475 to about 500 psig to a spray dryer. The spray
dryer is a Bowen Type commercial unit equipped with an
SD-046 nozzle, and operated in a commercial mode. The
Y-119B-R&D:30
- 31 - 202653~
inlet temperature is about 470F, and the outlet
temperature is about 260F. The resulting spray dried
particles have a generally spherical shape, and a
moisture content of below about 2 percent. The particles
are screened to a particle size of -70/+200 US Mesh.
The spray dried particles are placed on a 12 inch by
36 inch steel tray to a thickness of about 2 cm. The
tray then is passed into a continuous belt furnace at a
rate of about 8 to about 12 inches/min., and is subjected
to heating under nitrogen atmosphere at above about 600C
for about 10 minutes, and at above about 400C for about
20 minutes. The tray is subjected to a maximum air
temperature of about 670C during that time. The heated
particles are removed from the furnace into a cooling
zone for about 1 hour under nitrogen atmosphere, and
cooled to ambient temperature.
The calcined particles so collected are black, are
spherical in shape, are free flowing, and resist wetting.
The particles are about 93 percent calcium carbonate, and
exhibit a bulk density of about 0.5 g/cm3. The particles
each are an agglomerated matrix of a plurality of
precipitated calcium carbonate particles spaced within a
carbonaceous material.
The smokable filler material is provided as follows:
Into about 720 parts tap water is charged about 12
parts of a high viscosity ammonium alginate available as
Amoloid HY from Kelco Division of Merck & Co., Inc.,
followed by about 48 parts glycerin, and finally about 40
parts of the previously described calcined agglomerated
calcium carbonate. The resulting slurry is agitated
using an egg beater type mixer, until the slurry exhibits
a smooth texture. The slurry is cast onto a high density
polyethylene sheet at a thickness of about 0.015 inch and
air dried. The resulting dried sheet has (i) a thickness
of about 0.007 inch, (ii) exhibits a density of about
Y-119B-R&D:31
-
_ - 32 - 2026~3~
0.503 g/cm3, and (iii) a flexible and pliable character.
The sheet is provided in strip form, about 2 inches by
about 3 inches in size. The strips are shredded at about
32 cuts per inch to provide a tobacco-containing smokable
cut filler.
B. Preparation of a Cigarette
Cigarettes substantially as shown in Figure 1 are
provided as follows:
The cigarettes each have a length of about 84 mm and
a circumference of about 24.8 mm, and include a smokable
rod having a length of about 57 mm, a first filter
segment having a length of about 15 mm and a second
filter segment having a length of about 12 mm. The first
and second filter segments form a filter element. Each
filter segment is attached to each smokable rod using
nonporous tipping paper. For each cigarette, the tipping
paper circumscribes the filter element and about a 4 mm
length of the smokable rod in the region adjacent the
filter element. The filter elements are not ventilated.
The smokable rod includes the previously described
smokable filler material in cut filler form. The
smokable filler material is positioned within two layers
of wrapper. The inner surface of the outer wrapper
directly contacts the outer surface of the inner wrapper.
The inner wrapper circumscribes the smokable filler
material.
The first filter segment is provided by gathering a
11.75 inch wide web of tobacco and carbon paper available
as P-144-BAC from Kimberly-Clark Corp. using the filter
rod forming apparatus described in Example 1 of U.S.
Patent No. 4,807,809 to Pryor et al. The plug wrap for
the filter segment is available as Reference No. 5831
Y-lls~-R&D:32
_ _ 33 - 2026538
from Ecusta Corp. The first filter segment is positioned
adjacent the smokable rod.
The second filter segment is provided by gathering a
11.75 inch wide web of non-woven polypropylene web
available as PP-100-F from Kimberly-Clark Corp. using the
filter rod forming apparatus described in Example 1 of
U.S. Patent No. 4,807,809 to Pryor et al. The plug wrap
for the filter segment is available as Reference No. 5831
from Ecusta Corp. The second filter segment is
positioned adjacent the first filter segment, at the
extreme mouth end of the cigarette.
The cigarette paper outer wrapper exhibits an air
permeability of about 0 CORESTA unit. The cigarette
paper is available as P-2831-60-1 from Kimberly-Clark
Corp.
The inner wrapper is a reconstituted tobacco, paper-
type wrapper containing Java tobacco stem parts and wood
pulp. The inner wrapper is available as P-2831-23-3 from
Kimberly-Clark Corp.
Smokable cigarette rods are provided using known
techniques. In particular, the smokable material is
circumscribed by a single layer of paper wrap. The
weight of the smokable material within each cigarette rod
is about 0.9 g.
The cigarettes are employed by burning the smokable
rod such that the smokable material within the paper
wrapper burns to yield smoke. When employed, such
cigarettes yield very low levels of visible sidestream
smoke and essentially no sidestream odor.
EXAMPLE 2
A smokable filler material is prepared as follows:
Into about 300 ml tap water at ambient temperature
is hydrated about 5 g of the ammonium alginate described
Y-119B-R&D:33
2026S38
- 34 -
in Example 1. To this is charged about 20 g glycerin,
and then about 40 g of the calcined agglomerated calcium
carbonate described in Example 1. The resulting slurry
is mixed gently for about 15 minutes using an egg beater
type mixer. The resulting slurry is extruded at ambient
temperature using a 50 ml syringe through a die having a
generally circular orifice having a diameter of about
1 mm. The extrudate exits the die into a solution of
about 98 parts tap water and about 2 parts calcium
chloride at ambient temperature. Within about 30
seconds, extrudate is removed from the aqueous calcium
chloride solution, and resembles a cylinder having a
diameter of about 1 mm. The extrudate is dried under
ambient conditions. The extrudate is passed through the
nip of two closely spaced, smooth surfaced metal rollers
to produce ribbon about 2 mm wide and about 0.4 mm thick.
The resulting material is suitable for use as a smokable
filler material.
EXAMPLE 3
A smokable filler material is provided as follows:
Into about 240 parts tap water is charged about 4
parts of the ammonium alginate described in Example 1,
followed by about 17.5 parts glycerin, then about 17.5
parts propylene glycol, and finally about 61 parts of the
calcined agglomerated calcium carbonate described in
Example 1. The resulting slurry is agitated using an egg
beater type mixer, until the slurry exhibits a smooth
texture. The slurry is cast onto a high density
polyethylene sheet at a thickness of about 0.015 inch and
air dried. The resulting dried sheet has a thickness of
about 0.011 inch, an exhibits a density of about
0.745 g/cm3.
Y-119B-R&D:34
- _ 35 _ 2026538
EXAMPLE 4
A smokable filler material is provided as follows:
Into about 720 parts tap water is charged about 12
parts of the ammonium alginate described in Example l,
followed by about 24 parts glycerin, then about 24 parts
propylene glycol, and finally about 40 parts of the
calcined agglomerated calcium carbonate described in
Example 1. The resulting slurry is agitated using an egg
beater type mixer, until the slurry exhibits a smooth
texture. The slurry is cast onto a high density
polyethylene sheet at a thickness of about 0.015 inch and
air dried. The resulting dried sheet has a thickness of
about 0.007 inch, and exhibits a density of about
0.47 g/cm3.
EXAMPLE 5
A tobacco-containing smokable filler material is
provided as follows:
Into about 400 ml tap water at ambient temperature
is charged about 24.2 g glycerin and about 12.1 g
propylene glycol, and the resulting mixture is agitated
at high speed using the blender. To the resulting
mixture is added about 7.2 g of the ammonium alginate
described in Example 1, and the mixture which results is
agitated using the high shear blender for about 15
minutes in order to disperse the alginate in the liquid
and hydrate the alginate. About 10 g precipitated
calcium carbonate available as Code No. 2A from Pfizer
Corp. is dispersed in about 100 ml of tap water; charged
into the aqueous slurry of glycerin, propylene glycol and
alginate; and the resulting mixture is agitated until a
smooth slurry results. The resulting slurry is
transferred to an egg beater type mixer, and about 10 g
Y-119B-R&D:35
20~6538
- - 36 -
of the calcined agglomerated calcium carbonate described
in Example 1 is added to the slurry while the mixture is
gently agitated. Into the slurry is added about 36.4 g
of a mixture of volume expanded flue-cured and Burley
tobacco laminae which has been ground to a particle size
of -35/+80 US Mesh, and the mixture is gently agitated.
About 3 g diammonium hydrogen orthophosphate is dissolved
in about 200 g water; charged into the slurry; and the
resulting slurry is gently agitated for about 5 minutes.
The resulting slurry is cast to about a 0.03 inch
thickness on a high density polyethylene sheet and air
dried for about 30 minutes. Then, an aqueous solution of
l percent calcium chloride is sprayed onto the top side
of the cast slurry so as to apply about 1 percent calcium
chloride to the cast slurry, on a dry weight basis. The
slurry then is allowed to air dry to provide a relatively
stiff sheet. The resulting sheet is shredded at about 32
cuts per inch to provide a smokable filler material.
EXAMPLE 6
A smokable filler material is provided as follows:
Into about 480 ml tap water at ambient temperature
is dispersed about 8 g of the ammonium alginate described
in Example l. To this is charged about 48 g glycerin,
and then about 44 g of a precipitated calcium carbonate
available as Code No. 2A from Pfizer, Inc. The resulting
slurry is mixed in a high shear blender for about 15
minutes. The pH of the resulting slurry is about 9.2.
Upon standing, the slurry forms into a livery gel, but
reverts back to a sol upon further mixing. The slurry is
transferred to a 50 ml syringe, and extruded through a
die having an orifice about 0.015 inch by 0.06 inch. The
extrudate exits the die into a mixture or bath of about
99 parts tap water and about l part of a spray dried
Y-119B-RhD:36
_ ~ 37 ~ 2026538
aqueous Burley tobacco extract. The water/tobacco
extract mixture is at ambient temperature and exhibits a
pH of about 5.4. The extrudate is removed from the bath
after about 5 minutes. The resulting extrudate resembles
a continuous ribbon having cross-sectional dimensions
which approximate the dimensions of the die orifice. The
extrudate appears to have tiny air bubbles trapped
inside. The extrudate is air dried. The resulting
material is suitable for use as a smokable filler
material.
EXAMPLE 7
A smokable filler material is provided as follows:
Into about 480 ml tap water at ambient temperature
is dispersed about 8 g of the ammonium alginate described
in Example 1. To this is charged about 48 g glycerin,
and then about 44 g of a precipitated calcium carbonate
available as Code No. 2A from Pfizer, Inc. The resulting
slurry is mixed in a high shear blender for about 15
minutes. The pH of the resulting slurry is about 9.2.
Upon standing, the slurry forms into a livery gel, but
reverts back to a sol upon further mixing. The slurry is
transferred to a 50 ml syringe, and extruded through a
die having an orifice about 0.015 inch by 0.06 inch. The
extrudate exits the die into a bath of tap water and
hydrochloric acid at ambient temperature and exhibiting a
pH of about 5.4. The extrudate is removed from the bath
after about 5 minutes. The resulting extrudate resembles
a continuous ribbon having cross-sectional dimensions
which approximate the dimensions of the die orifice. The
extrudate appears to have tiny air bubbles trapped
inside. The extrudate is air dried. The resulting
material is suitable for use as a smokable filler
material.
Y-119B-R&D:37
_ 38 - 2026538
EXAMPLE 8
A. Preparation of a Tobacco-Containing Smokable Filler
Material
Into about 547 ml tap water at ambient temperature
is mixed about 24.2 g glycerin and about 12.1 g propylene
glycol. The mixture is agitated using a Waring Blender.
To this is added, with agitation, about 7.2 g of the
ammonium alginate described in Example 1, and then pieces
of about 36.4 g of Turkish tobacco leaf provided at an
approximate particle size of -25/+80 US Mesh. Finally,
about 20 g of a precipitated calcium carbonate available
as Code No. 2A from Pfizer, Inc. is added to the mixture.
The resulting mixture is agitated for about 5 minutes,
cast onto a flat high density polyethylene sheet at about
a 0.04 inch thickness, and allowed to air dry. The
resulting dried tobacco-containing sheet has a textured
appearance and has the feel of tobacco laminae. The
resulting tobacco-containing sheet is shredded at about
25 cuts per inch. The resulting cut filler is dried at
about 75C for about 25 minutes to provide a tobacco-
containing smokable cut filler.
B. Preparation of a Cigarette
Cigarettes substantially as shown in Figure 1 are
provided as follows:
The cigarettes each have a length of about 84 mm and
a circumference of about 24.8 mm, and include a smokable
rod having a length of about 57 mm, a first filter
segment having a length of about 15 mm and a second
filter segment having a length of about 12 mm. The first
and second filter segments form a filter element. Eachfilter segment is attached to each smokable rod using
Y-119B-R&D:38
- 2~26~8
- 39 -
nonporous tipping paper. For each cigarette, the tipping
paper circumscribes the filter element and about a 4 mm
length of the smokable rod in the region adjacent the
filter element. The filter elements are ventilated to
about 60 percent air dilution by providing a ring of
perforations through the tipping paper and plug wrap of
the filter element, circumscribing the cigarette about
12 mm from the extreme mouthend thereof.
The smokable rod includes the previously described
tobacco-containing smokable material in cut filler form.
The first filter segment is provided by gathering a
11.75 inch wide web of tobacco and carbon paper available
as P-144-BAC from Kimberly-Clark Corp. using the filter
rod forming apparatus described in Example 1 of U.S.
Patent No. 4,807,809 to Pryor et al. The plug wrap for
the filter segment is available as Reference No. 5831
from Ecusta Corp. The first filter segment is positioned
adjacent the smokable rod.
The second filter segment is provided by gathering a
11.75 inch wide web of non-woven polypropylene web
available as PP-100-F from Kimberly-Clark Corp. using the
filter rod forming apparatus described in Example 1 of
U.S. Patent No. 4,807,809 to Pryor et al. The plug wrap
for the filter segment is available as Reference No. 5831
from Ecusta Corp. The second filter segment is
positioned adjacent the first filter segment, at the
extreme mouth end of the cigarette.
The cigarette paper wrapper exhibits an air
permeability of about 0 CORESTA unit. The cigarette
paper includes about 4.2 percent potassium citrate and
about 1.1 percent sodium carboxymethylcellulose. The
cigarette paper is available as P-2831-60-1 from
Rimberly-Clark Corp.
Smokable cigarette rods are provided using known
techniques. In particular, the smokable material is
Y-119B-R&D:39
_ 40 _ 202~538
circumscribed by a single layer of paper wrap. The
weight of the smokable material within each cigarette rod
is about o.9 g.
The cigarettes are employed by burning the smokable
rod such that the smokable material within the paper
wrapper burns to yield smoke. When employed, such
cigarettes yield very -low levels of visible sidestream
smoke and essentially no sidestream odor. Cigarettes
smoked and tested in this manner each yield 17 puffs,
19.6 mg wet total particulate matter (WTPM), 0.165 mg
nicotine, 2.5 mg water, 6.7 mg glycerin and 2.7 mg
propylene glycol, under FTC smoking conditions. The
cigarettes do not self-extinguish during the smolder
period experienced during FTC smoking conditions.
EXAMPLE 9
Particles of calcium carbonate agglomerated with an
alginate are provided as follows:
Into a blender is charged about 750 ml tap water,
and then about 20 g glycerin. While the mixture is
gently agitated, about 10 g of the ammonium alginate
described in Example 1 is slowly added thereto, so as to
disperse the alginate in the water. The resulting
mixture is transferred into a 1 liter jar, sealed, and
gently rolled overnight to hydrate the alginate.
A slurry of 250 g precipitated calcium carbonate
available as Code No. 2A from Pfizer Inc. in 250 g tap
water is provided. Then, the slurry is added to 200 g of
the water/glycerin/alginate mixture. The resulting
slurry is agitated gently so as to provide a slurry
having a smooth texture.
The slurry is cast onto a high density polyethylene
sheet at a thickness of about 0.04 inch, and air dried to
provide pieces of dried sheet about 6 inches by about 6
Y-119B-R&D:40
- 41 - 2026538
_.
inches in size. The resulting dried sheet is hand ground
to a fine particle size and screened to -50 US Mesh.
A tobacco-containing smokable filler material is
prepared as follows:
Into a high shear blender is charged about 225 ml
tap water, and into the water is dispersed about 5 g of
the ammonium alginate described in Example 1. The
resulting mixture is gently agitated at ambient
temperature for about 15 minutes, until the alginate is
hydrated. Then, about 20 g glycerin is added to the
mixture, followed by about 25 ml tap water. To the
mixture is added about 16.7 g of an "American blend" of
tobacco cut filler which has been ground to a powder.
Then, about 25 ml tap water is added to the mixture. The
resulting mixture is agitated until a smooth slurry
results. To the slurry is added a mixture of about
13.8 g of the calcined agglomerated calcium carbonate
described in Example 1 and about 13.8 g of the calcium
carbonate agglomerated with ammonium alginate. The
resulting slurry is agitated until the slurry exhibits a
smooth texture. The resulting slurry is cast onto a high
density polyethylene sheet at a thickness of about 0.025
inch and air dried.
EXAMPLE 10
A tobacco-containing smokable filler material is
provided as follows:
Into about 225 parts tap water in a mixer is added
about 5 parts of the ammonium alginate described in
Example 1. To the alginate/water mixture is added about
20 parts glycerin.
The resulting slurry is cast as a sheet, and air
dried. The resulting cast material is elastic in nature
and is somewhat tacky to the feel. The material is
Y-119B-R&D:41
~ - 42 - 2026538
surface treated with about 5 parts tobacco dust which is
provided by grinding an "American blend" of tobacco cut
filler.
EXAMPLE ll
A smokable filler material is provided as follows:
Into tap water in a mixer is added about 13 parts of
the ammonium alginate described in Example l in
essentially the manner described in Example 10. To the
alginate/water mixture is added about 51 parts glycerin
and about 16 parts particles of precipitated calcium
carbonate.
The resulting slurry is cast as a sheet, and air
dried. The resulting smokable filler material is surface
treated with about 20 parts tobacco dust, in the manner
described in Example 10.
EXAMPLE 12
A smokable filler material is provided as follows:
Into tap water in a mixer is added about 9 parts of
the ammonium alginate described in Example 1 in
essentially the manner as described in Example 10. To
the alginate/water mixture is added about 37 parts
glycerin and about 34 parts particles of precipitated
calcium carbonate.
The resulting slurry is cast as a sheet, and air
dried. The resulting smokable filler material is surface
treated with about 20 parts tobacco dust, in the manner
described in Example 10.
Y-119B-R&D:42
2026538
- 43 -
EXAMPLE 13
A smokable filler material is provided as follows:
Into tap water in a mixer is added about 6 parts of
the ammonium alginate described in Example 1 in
essentially the manner described in Example 10. To the
alginate/water mixture is added about 26 parts glycerin
and about 48 parts particles of precipitated calcium
carbonate.
The resulting slurry is cast as a sheet, and air
dried. The resulting smokable filler material is surface
treated with about 20 parts tobacco dust, in the manner
described in Example 10.
EXAMPLE 14
A tobacco-containing smokable filler material is
provided as follows:
Into tap water in a mixer is added about 12 parts of
the ammonium alginate described in Example 1. To the
alginate/water mixture is added about 48 parts glycerin
and about 40 parts of tobacco laminae dust.
The resulting slurry is cast as a sheet at about a
0.03 inch thickness, and air dried.
EXAMPLE 15
A tobacco-containing smokable filler material is
provided as follows:
Into tap water in a mixer is added about 12 parts of
the ammonium alginate described in Example 1. To the
alginate water mixture is added about 24 parts glycerin,
about 24 parts propylene glycol and about 40 parts of
to~acco laminae dust.
Y-119B-R&D:43
2026~38
- 44 -
The resulting slurry is cast as a sheet at about a
0.03 inch thickness, and air dried.
EXAMPLE 16
A tobacco-containing smokable filler is provided as
follows:
Into tap water in a mixer is added about 10 parts of
the ammonium alginate described in Example 1. To the
alginate/water mixture is added about 38 parts glycerin,
about 32 parts tobacco laminae dust and about 20 parts
particles of precipitated calcium carbonate.
The resulting slurry is cast as a sheet at about a
0.03 inch thickness, and air dried.
EXAMPLE 17
A tobacco-containing smokable filler is provided as
follows:
Into tap water in a mixer is added about 7 parts of
the ammonium alginate described in Example 1. To the
alginate/water mixture is added about 29 parts glycerin,
about 24 parts tobacco laminae dust and about 40 parts
particles of precipitated calcium carbonate.
The resulting slurry is cast as a sheet at about a
0.02 inch thickness, and air dried.
EXAMPLE 18
A. Preparation of a Tobacco-Containing Smokable Filler
Material
Into a high shear blender containing about 1,000
parts tap water and about 13 parts of the ammonium
alginate described in Example 1, and the mixture is
Y-119B-R&D:44
_ - 45 - 202653~
agitated for about lS minutes. Then, about 10 parts
glycerin and about 10 parts propylene glycol is added to
the mixture. To the resulting mixture is added about 5
parts diammonium hydrogen orthophosphate. Then, about 10
parts milled Amarelinho tobacco leaf, about 7 parts
milled flue-cured tobacco leaf and about 15 parts of a
spray dried aqueous Burley tobacco extract. Then, about
20 parts of particles of precipitated calcium carbonate
available as Code No. 2A from Pfizer Corp. and about 10
parts of the calcined precipitated calcium carbonate
described in Example 1.
The mixture is agitated to provide a smooth slurry,
cast on a polyethylene sheet at 0.04 inch thickness, and
force air dried at a temperature of about 150F. The
resulting reconstituted tobacco sheet is shredded into
strands at about 25 cuts per inch. The strands are
conditioned overnight at about 24C and about 40 percent
relative humidity.
B. Preparation of a Cigarette
- 20 Cigarettes substantially as shown in Figure 3 are
provided as follows:
The cigarettes each have a length of about 78 mm and
a circumference of about 24.8 mm, and include a smokable
rod having a length of about 38 mm, a first filter
segment having a length of 16 mm and a second filter
segment having a length of about 24 mm. The first and
second segments form a filter element. Each filter
segment is attached to each smokable rod using nonporous
tipping paper. For each cigarette, the tipping paper
circumscribes the filter element and about a 4 mm length
of the smokable rod in the region adjacent the filter
element. The filter elements are ventilated to about 60
percent air dilution by providing a ring of perforations
Y-119B-R&D:45
2026538
- 46 -
through the tipping paper and plug wrap of the filter
element circumscribing the cigarette about 24 mm from the
extreme mouthend thereof.
The smokable rod includes the smokable filler
material wrapped within two layers of wrapper. The inner
surface of the outer wrapper directly contacts the outer
surface of the inner wrapper. The inner wrapper
circumscribes the smokable material.
The first filter segment is provided by gathering a
11.75 inch wide web of tobacco and carbon paper available
as P-144-BAC from Kimberly-Clark Corp. using the filter
rod forming apparatus described in Example 1 of U.S.
Patent No. 4,807,809 to Pryor et al. The plug wrap for
the filter segment is a paper plug wrap. The first
filter segment is positioned adjacent the smokable rod.
The second filter segment is cellulose acetate tow
(8 denier per filament/40,000 total denier) which is
plasticized with triacetin, and is circumscribed by
nonporous paper plug wrap. The second filter segment is
positioned adjacent the first filter segment, at the
extreme mouth end of the cigarette.
The cigarette paper outer wrapper of the smokable
rod is a calcium carbonate/flax paper available as
Reference No. 854 from Kimberly-Clark Corp.
The inner wrapper of the smokable rod is available
as P-2674-157 from Kimberly-Clark Corp.
The cigarettes are employed by burning the smokable
rod such that the smokable material within the paper
wrapper burns to yield smoke. When employed, such
cigarettes yield very low levels of visible sidestream
smoke and essentially no sidestream odor. The cigarettes
do not self-extinguish during the smolder period
experienced during FTC smoking conditions.
Y-119B-R&D:46
_ 47 _ 20265 38
EXAMPLE 19
A cigarette is provided in the manner described in
Example 18, except that the cigarette paper outer wrapper
is available as P-2831-60-1 from Kimberly-Clark Corp.
EXAMPLE 20
A smokable filler material is provided as follows:
Into about 225 parts tap water is mixed about 2.8
parts sodium carboxymethylcellulose available as CMC 7HF
from Hercules Inc. To the mixture is added about 25
parts glycerin and about 25 parts propylene glycol.
Then, about 47 parts of the calcined agglomerated calcium
carbonate described in Example 1 is added to the mixture.
The resulting slurry is cast as a sheet and air
dried.
EXAMPLE 21
A tobacco-containing smokable filler material is
provided as follows:
Into about 400 ml tap water at ambient temperature
is dispersed about 7.2 g of the ammonium alginate
described in Example 1, and the mixture is agitated at
high speed using the blender. To the resulting mixture
is added about 24.2 g glycerin and about 12.1 g propylene
glycol, and the mixture which results is further agitated
for about 5 minutes using the high shear blender. About
2 g diammonium hydrogen orthophosphate is dissolved in
about 20 g water and is charged into the mixture. About
10 g precipitated calcium carbonate available as Code No.
2A from Pfizer Corp. and about 10 g of the calcined
agglomerated calcium carbonate described in Example 1 are
dispersed in about 100 ml of tap water; charged into the
Y-119B-R&D:47
- 2026538
- 48 -
aqueous slurry of glycerin, propylene glycol and
alginate; and the resulting mixture is agitated until a
smooth slurry results. Into the resulting slurry is
added about 36.4 g of a mixture of volume expanded flue-
cured and Burley tobacco laminae which has been ground toa particle size of -35/+80 US Mesh, and the mixture is
gently agitated.
The resulting slurry is cast to about a 0.04 inch
thickness on a high density polyethylene sheet and air
dried for about 30 minutes. Then, an aqueous solution of
1 percent calcium chloride is sprayed onto the top side
of the cast sheet so as to apply about 1 percent calcium
chloride to the cast sheet, on a dry weight basis. The
slurry then is allowed to air dry to provide a relatively
stiff sheet. The resulting sheet is shredded at about 32
cuts per inch to provide a smokable filler material.
Y-119B-R&D:48
