Patent Application
20120037172
Smoking articles, particularly cigarettes, generally comprise a tobacco rod of shredded tobacco (usually, in cut filler form) surrounded by a paper wrapper, and a cylindrical filter aligned in an end-to-end relationship with the tobacco rod. The tobacco rod is generally about 6.0 millimeters to about 10.0 millimeters in diameter and about 50 millimeters to about 125 millimeters in length.
Typically, the filter includes a plug of cellulose acetate tow attached to the tobacco rod by tipping paper. Ventilation of mainstream smoke can be achieved with a row or rows of perforations about a location along the filter.
When flavorants such as menthol are applied to cigarette filter in the form of a solution, staining or spotting of the outer surface of the cigarette can occur, particularly at high loadings of menthol in large amounts of solvent. Further, such a direct application of flavorants such as menthol to the cigarette filter does not allow for the regulation of menthol release during smoking and can lead to migration and loss of menthol during storage of the cigarette.
Accordingly, it would be desirable to provide a filter component for a smoking article, which provides added flavorant such as menthol to the mainstream smoke and can be easily manufactured and produced with existing filter forming equipment.
In accordance with an exemplary embodiment, a filter component for a smoking article, comprises: an upstream segment of filter material; a downstream segment of filter material in a spaced apart relation to the upstream segment of filter material so as to define a cavity therebetween; and a flavor bead disposed in the cavity. The flavor bead preferably has an outer diameter, which is at least 75% of the spaced apart relation of the upstream segment of filter material and the downstream segment of filter material and wherein the outer diameter of the flavor bead does not exceed an outer diameter of either the upstream or downstream segments of filter material.
In accordance with another exemplary embodiment, a smoking article comprises: a tobacco rod; and a multi-component filter comprising: an upstream segment of filter material; a downstream segment of filter material in a spaced apart relation to the upstream segment of filter material so as to define a cavity therebetween; a flavor bead disposed in the cavity, and wherein the flavor bead has an outer diameter, which is at least 75% of the spaced apart relation of the upstream segment of filter material and the downstream segment of filter material and wherein the outer diameter of the flavor bead does not exceed an outer diameter of either the upstream or downstream segments of filter material; and a filter wrapper which circumscribes the upstream segment of filter material, the downstream segment of filter material and the flavor bead.
In accordance with a further exemplary embodiment, a method of manufacturing a filter component comprises the steps of: dispensing a first filter segment having a first length onto a filter rod forming portion of a filter rod forming apparatus; dispensing a second filter segment having a second length in a spaced apart relationship to the first filter segment so as to define a cavity therebetween onto the filter rod forming portion; placing a flavor bead within the cavity; and circumscribing the first filter segment, the second filter segment and the flavor bead with a filter wrapper.
The drawings are exemplary only, and should not be construed as limiting the various embodiments set forth herein.
In accordance with an exemplary embodiment, as shown in
The smoking article 100 also includes a filter system 140 adjacent to the mouth end 114 of the tobacco rod 110 such that the filter system 140 and tobacco rod 110 are axially aligned in an end-to-end relationship, preferably abutting one another. The filter system 140 has a generally cylindrical shape, and the diameter thereof is essentially equal to the diameter of the tobacco rod 110. The ends (i.e., upstream end 146 (shown in
Herein, the “upstream” and “downstream” relative positions between filter segments and other features are described in relation to the direction of mainstream smoke as it is drawn from the tobacco rod 110 and through the filter system 140.
In accordance with an exemplary embodiment, the filter system 140 includes a plurality of filter segments 230, 240 (
In accordance with an exemplary embodiment as shown in
The downstream filter component 240 (or mouth end (buccal) component) is preferably in the form of a cellulose acetate plug 242 or other suitable fibrous or webbed material of moderate to low particulate efficiency. Preferably, the particulate efficiency is low, with the denier and grand total denier being selected such that the desired total RTD of the filter is achieved.
Preferably, one or more circumferential rows of perforations (not shown) are formed through the filter wrapper 280 and the tipping paper 290 at a location along the filter 220, preferably at an upstream end portion of the filter 220. In accordance with an exemplary embodiment, the placement of the one or more circumferential rows of perforations is at a maximum distance between the buccal end (or mouth end) 214 of the smoking article 200 and the perforations, which preferably is at least 12 mm (millimeters) or more, so that a smoker's lips do not occlude the perforations. Furthermore, because the introduction of diluting air flows at an upstream end portion of the filter 220, itself, lowers the particulate efficiency of the downstream portions of the segment, the upstream location of the ventilation along the filter component facilitates design of the component to provide a more elevated (yet moderate) RTD without a significant elevation of particulate efficiency, so as to help maintain a desired low particulate efficiency in the central component and throughout the filter.
In accordance with an exemplary embodiment as shown in
It can be appreciated that the upstream and downstream filter components 230, 240 are preferably of low particulate efficiency. Also preferably, amongst all the fibrous or web segments, the upstream end component is of lowest RTD and particulate efficiency, because it is upstream of the ventilation and therefore has greater effect upon the mainstream smoke. Unlike those other fibrous or webbed components, the upstream end component receives the mainstream smoke in the absence of a diluting air stream.
Although certain dimensions are disclosed with reference to the embodiments shown, such dimensions can be varied to provide different configurations related to the upstream and the downstream filter components 230, 240 and the flavor bead 260 within the filter 220.
The tobacco rod 210 may be wrapped with a conventional cigarette wrapper or banded paper can be used for this purpose. Banded cigarette paper has spaced apart integrated cellulose bands that encircle the finished tobacco rod of cigarette to modify the mass burn rate of the cigarette so as to reduce risk of igniting a substrate if the smoking article is left thereon smoldering. U.S. Pat. Nos. 5,263,999 and 5,997,691 describe banded cigarette paper, which patents are incorporated herein in their entirety for all purposes.
In accordance with an exemplary embodiment, the flavor bead 260 is in the form of a tobacco bead. In accordance with an exemplary embodiment, the flavor bead 260 consists essentially of tobacco particles, water and optional flavorants but without added binder ingredients. The flavor bead can be extruded and/or spheronized. In the alternative, the flavor bead 260 may further contain an added binder ingredient, wherein the binder is preferably a cellulosic material. A preferred cellulosic material is microcrystalline cellulose. Additional dry and liquid binders may be present in the beads as well as additional flavorants and fillers. If desired, the flavor bead 260 can include one or more coatings 262. Flavorants such as menthol crystals can be used to form a mentholated flavor bead, and/or other flavorants can also be added to the flavor bead 260 and/or to the coatings 262 of the bead 260. However, as noted above, the flavor bead 260 preferably is a bead comprising tobacco particles and water that is held together without addition of a binder additive other than water.
Not wishing to be bound by theory, at the downstream location of the flavor bead 260, the temperature of tobacco smoke passing through the filter is in a cooled condition, essentially at or about room temperature. Despite the absence of heat from the cigarette coal (or any addition of moisture), it has been found that a flavor bead 260 is effective in releasing flavor into the mainstream smoke so as to produce a flavored smoke. The flavors released from the flavor bead 260 are flavors specific to the tobacco source and/or flavors added to the bead 260 during their production. The organoleptic notes from using a flavor bead 260 are associated with enhanced tobacco character. Preferably, the flavors from the tobacco particulates and/or flavor components are released into the mainstream tobacco smoke under essentially ambient conditions.
In accordance with an exemplary embodiment, the flavor bead 260 can be a crushable capsule or bead, wherein the flavor bead releases at least a portion of the flavorant or additive material, such as menthol when the filter 220 is subjected to an external force.
In accordance with an exemplary embodiment, the flavor beads 260 are preformed. Flavorants can be included during the process of making the flavor or can be later added to the beads. Alternatively or in addition, flavorants can be added to a coating on the bead 260, said coating having perhaps the additional function of providing a controlled release of the components in the beads 260. Volatile flavorants can be added during the process of preparing the beads or to the preformed beads, depending on the process used for preparing the beads. Depending on the method of preparing the beads 260, it may be more preferable to add volatile flavorants to the preformed beads rather than during the process of preparing the beads. Liquid compounds can be added to the beads 260 by for example impregnating the beads with liquid formulations containing for example volatile flavors, diluents, and the like. Alternatively, compounds and compositions can be added to the beads by mixing the beads or by fluidized bed spraying of the beads or by other suitable methods.
It can also be appreciated that the functionality of the flavor bead 260 can be tailored to have more of controlled-delivery release of active compounds. For example, diffusion of the flavors from the bead 260 can be adjusted by bead porosity and density as well as by any controlled-release coating added to the beads. For instance, the beads 260 can be overcoated with polymeric coatings of different functionalities and or compositions (e.g., single or multiple overcoats depending on the application) to control the delivery and release of the active compounds.
In another aspect, the flavor bead 260 can act as a delivery system for delivering flavors naturally occurring in the components of the bead formulation. Alternatively, the flavor beads can act as a medium for creating and/or enhancing naturally occurring flavors through Maillard, enzymatic, or other types of reactions. It is further contemplated that the beads 260 can be altered or enhanced by thermal treatment of the beads 260 after formation. The thermal treatment can further enhance reactions such as Maillard reactions and enzymatic reactions and thereby flavors of the smoking article containing said beads.
Another embodiment contemplates that the flavor bead 260 can be further enhanced by adding additives during the bead making process. This can include additives such as flavors as well as components which would enhance the formation of flavors by reactions such as Maillard reactions between the components to naturally enhance the smoke. The optional flavorant includes flavor materials that are practically unlimited, although water-soluble, alcohol-soluble and oil-soluble flavors are preferable. Typical flavors include lavender, cinnamon, cardamom, apium graveolens, fenugreek, cascarilla, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, mint oils, cassia, caraway, cognac, jasmine, chamomile, menthol, cassia, ylang-ylang, sage, spearmint, ginger, coriander, and coffee. Each of the flavors can be used singly or mixed with others. If desired, diluent agents can be added to the tobacco beads. Diluent agents which can be used for this purpose include powdered starch, such as but not limited to corn starch and potato starch, rice powder, calcium carbonate, diatomaceous earth, talc, acetate powder, and pulp flock. The optional flavorant can also be in the form of a solid matrix (liquid flavorants spray dried with a starch). The optional flavorant can also be in the form of solids, liquids or gels. The optional flavorant can be present in the tobacco beads in an amount of up to about 50% by weight (e.g., 0.1 to 5%, 5 to 10%, 10 to 15%, 15 to 20%, 20 to 25%, 25 to 30%, 30 to 35%, 35 to 40%, 40 to 45% or 45 to 50%).
For tobacco particles containing additive binder such as a non-tobacco cellulosic material, microcrystalline cellulose (MCC) is the preferred cellulosic material in combination with tobacco particles. Whereas various flavor carriers may need heat or water to release volatile flavor compounds into mainstream smoke, cellulosic binder containing flavor beads and/or tobacco beads 260 can release such flavor constituents under ambient conditions.
The flavor beads 260 are preferably in the form of “spheroids” having diameters in the range of about 3.5 to about 10.0 mm, more preferably from about 4.0 to about 7.0 mm and most preferably from about 4.5 to about 5.0 mm (and any 0.1 value in between these ranges). The flavor bead 260 (or spheroids) can be round or oval in structure. In accordance with an exemplary embodiment, the flavor bead 260 preferably has an outer diameter, which is at least 75% of the spaced apart relation of the upstream segment of filter material (or upstream filter segment) 230 and the downstream segment of filter material (or downstream filter segment) 240 and wherein the outer diameter of the flavor bead 260 does not exceed an outer diameter of either the upstream or downstream segments of filter material 230, 240.
It can be appreciated that the flavor bead 260 in the form of a tobacco bead can be used to flavor mainstream smoke in cigarettes, which allows a standard tobacco mixture to be used in the tobacco rod of a standard lit-end cigarette and the desired taste attributes of different cigarette products (e.g., regular, mild, full flavor, etc.) to be provided by a tobacco bead 260, which contain flavorant effective to achieve the desired taste of the mainstream smoke.
The preferred embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is given by the appended claims, rather than the preceding description, and all variations and equivalents which fall within the range of the claims are intended to be embraced therein. Moreover, the present invention may be practiced with cigarettes of various circumferences, narrow cigarettes as well as wide. Also, while the present invention is preferably practiced with unflavored tobacco rods, flavored tobacco filler is also contemplated.
As used herein, the term “about” and/or “approximately” when used in conjunction with a stated numerical value or range denotes somewhat more or somewhat less than the stated value or range, to within a range of ±10% of that stated.
It can be appreciated that the filter 220 can be manufactured by making and filling upstream and downstream plug-space-plug sections in sequence or simultaneously. For instance as shown in
As shown in
In accordance with an exemplary embodiment, the flavor bead 260 has an outer diameter 264, which is at least 75% of the spaced apart relation of the upstream segment of filter material 230 and the downstream segment of filter material 240 and wherein the outer diameter 264 of the flavor bead 260 does not exceed an outer diameter 224 of the filter component 200 and/or the upstream or the downstream segments of filter material 230, 240. For example, for a cavity 250 which is about 6 mm in length, the flavor bead 260 preferably has an outer diameter 264 of about 4.5 mm or greater.
In accordance with another embodiment, as shown in
As shown in
As shown in
In accordance with another exemplary embodiment,
It can be appreciated that the flavor beads 632 can be placed or positioned within the cavity by any known method including dispensing, the flavor bead by gravitation force, vacuum assisted method, such as a vacuum wheel and/or other known methods of placing a spherical object or bead within a cavity.
The continuous filter rod 650 before cutting preferably includes at least two segments of the first filter segment 612, at least two segments of the second filter segment 622, and at least two flavor beads 632 in the cavity formed between the first filter segment and the second filter segment. The filter segments 612, 622 are then wrapped in a filter paper or plug wrap 652 and cut into a plurality of filter components 660 having at least one flavor bead 630 therein. The individual filter components 660 are assembled with a tobacco rod to form a smoking article 670.
In accordance with another exemplary embodiment, an additional hopper 680 can include a recessed filter segment 682, which is placed adjacent to either the first filter segment and/or the second filter segment as described and shown in
It should be understood that the foregoing description is of the preferred embodiments, and is merely representative of the article and methods of manufacturing the same. It can be appreciated that variations and modifications of the different embodiments in light of the above teachings will be readily apparent to those skilled in the art. Accordingly, exemplary embodiments, as well as alternative embodiments, may be made without departing from the scope of the articles and methods set forth in the attached claims.
This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application No. 61/318,248, filed on Mar. 26, 2010, the entire content of which is incorporated herein by reference thereto.
| Number | Date | Country | |
|---|---|---|---|
| 61318248 | Mar 2010 | US |
