R.j. Reynolds Tobacco Company

Andrew J Sensabaugh, Jr

Henry T Ridings

Chandra K Banerjee

Michael D Shannon

Ernest G Farrier

Mark L Raker

John H Reynolds, Iv

Gary R Shelar

Dennis Lee Potter

Alan B Norman

James L Resce

James L Harris

Amos E Westmoreland

Thomas L Gentry

Richard L Lehman

Joseph J Chiou

Donna K Woods

Arvol C Marsh, Jr

Jack F Clearman

James W Pryor

Stephen W Jakob

Ronald Lewis Parks

George W Fearrington, Jr

Henry A Hauser

Dewitt C Crepps

William Y Rice, Jr

William P Mangan

Woods, Donna K

Electrochemical heat sources, materials used to make electrochemical heat sources and methods of forming electrochemical heat sources are disclosed. The electrochemical heat sources includes at least two metallic agents capable of interacting electrochemically with one another, such as magnesium and iron or nickel. The metallic agents may be provided in a variety of forms, including a frozen melt, a bimetallic foil, wire of a first metal wrapped around strands of a different metal, and a mechanical alloy. The metallic agents may be in the form of a powder filling a straw, or small particles extruded with a binder or pressed to form a rod. The powder filled straw or rod may be placed in a heat chamber surrounded by tobacco in a smoking article. An electrolyte solution contacts the metallic agents in the heat chamber to initiate the electrochemical interaction, generating heat which in turn may be used to volatilize nicotine and flavor materials in the tobacco. The heat sources may also be used to heat foods or beverages, in hand warmers, and to heat equipment or materials.

Electrochemical heat source

A smoking article with an electrochemical heat source is disclosed. The non-combustion heat source includes at least two metallic agents capable of interacting electrochemically with one another, such as magnesium and iron or nickel. The metallic agents may be provided in a variety of forms, including a frozen melt, a bimetallic foil, wire of a first metal wrapped around strands of a different metal, and a mechanical alloy. The metallic agents may be in the form of a powder filling a straw, or small particles extruded with a binder or pressed to form a rod. Preferably, the heat source is self-extinguishing if ignited. The powder filled straw or rod may be placed in a heat chamber surrounded by tobacco. An electrolyte solution contacts the metallic agents in the heat chamber to initiate the electrochemical interaction, generating heat which in turn volatilizes the nicotine and flavor materials in the tobacco. Preferably, any gases from the heat chamber are directed away from air intake holes through which air enters the smoking article.

Tobacco smoking article with electrochemical heat source

Processes for producing flavor substances from tobacco are disclosed. The processes involve heating tobacco during a first staged heating to a first toasting temperature to drive off volatile materials; increasing the toasting temperature during a second staged heating to a second toasting temperature and separately collecting, as flavor substances, at least portions of the volatile materials driven off at the first and second toasting temperatures. Another aspect of the present invention involves reducing the moisture content of the tobacco without removing volatile flavor components, such as by freeze drying the tobacco, and then heating the dried tobacco. Preferably the tobacco is heated in a flowing gas stream and at least portions of the volatile materials are separately collected as flavor substances as the gas stream passes sequentially through a moderate temperature trap, a cold temperature trap and a filter capable of collecting submicron sized particles. It has been discovered that better flavor release can be obtained from smoking articles that incorporate extracted tobacco flavor substances applied to a substrate if the substances are separately extracted and are then applied separately to a plurality of individual segments of the substrate. Thus one aspect of the present invention is a smoking article comprising separately extracted tobacco flavor substances applied to a plurality of individual segments of a carrier within the smoking article.

Processes for producing flavor substances from tobacco and smoking

The present invention is directed to a smoking article which produces an aerosol that resembles tobacco smoke but which preferably contains no more than a minimal amount of incomplete combustion or pyrolysis products. The preferred smoking article of the present invention provides an aerosol 'smoke' which is chemically simple, consisting essentially of air, oxides of carbon, water, and the aerosol which carries any desired flavor or other desired volatile materials as well as trace amounts of other materials. In addition to a mouthend piece, an especially preferred embodiment of the present smoking article comprises a short combustible carbonaceous fuel element which is less than about 30 mm in length prior to smoking. The fuel element is disposed longitudinally relative to a physically separate aerosol generating means which comprises a porous nonparticulate substrate. The substrate includes one or more aerosol forming substances.

Smoking article with improved substrate

The present invention is directed to a smoking article which is capable of producing substantial quantities of aerosol, both initially and over the useful life of the product, without significant thermal degradation of the aerosol former and without the presence of substantial pyrolysis or incomplete combustion products. Preferred embodiments of the present smoking article comprises a short combustible carbonaceous fuel element, a short heat stable, preferably carbonaceous substrate bearing an aerosol forming substance and disposed longitudinally behind the fuel element, an efficient insulating means, and a relatively long mouthend piece. Preferably, the fuel element is provided with a plurality of longitudinally extending passageways which act to control the heat transferred from the burning fuel element to the aerosol generating means, thus preventing the thermal degradation of the aerosol former. The aerosol generating means comprises a conductive, preferably metallic chamber, which at least partially surrounds or encloses the substrate, and is in a conductive heat exchange relationship with the fuel element, and which contains an aerosol forming material.

Smoking article with conductive aerosol chamber

The present invention relates to a smoking article which produces an aerosol that resembles tobacco smoke, but contains no more than a minimal amount of incomplete combustion or pyrolysis products. The smoking article of the present invention provides an aerosol 'smoke' which is chemically simple, consisting essentially of oxides of carbon, air, water, and the aerosol which carries any desired flavorants or other desired volatile materials, and trace amounts of other materials. The aerosol 'smoke' has no significant mutagenic activity as measured by the Ames Test. In addition, the article may be made virtually ashless so that the user does not have to remove any ash during use. One embodiment of the present smoking article comprises a short combustible carbonaceous fuel element; a short heat stable, preferably carbonaceous substrate bearing an aerosol forming substance, and a relatively long mouthend piece. The fuel element and the substrate are arranged in a heat exchange relationship, thereby causing aerosol formation without significant degradation of the aerosol former.

Smoking article

The present invention relates to fuel elements useful in smoking articles which produce an aerosol that resembles tobacco smoke, but contains no more than a minimal amount of incomplete combustion or pyrolysis products. Preferred embodiments of the present invention comprise a short combustible carbonaceous fuel elements, usually less than about 20 mm in length, preferably from about 5 to 15 mm in length, and most preferably about 10 mm in length. The diameter of the fuel elements of the present invention generally is less than about 8 mm, preferably from about 3 to 7 mm, and most preferably from about 4 to 6 mm. Smoking articles utilizing the fuel elements of the present invention are capable of providing an aerosol 'smoke' which is chemically simple, consisting essentially of air, oxides of carbon, water, and the aerosol which carries any desired flavorants or other desired volatile materials, and trace amounts of other materials. The aerosol 'smoke' from the preferred embodiments has no significant mutagenic activity as measured by the Ames Test. In addition, the fuel element may be made to be virtually ashless so that the user does not have to remove any ash during use.

Making an aerosol generating cartridge useful for a smoking article is described. The method comprises filling a non-combustible elongated capsule, open at one end, with a substrate bearing an aersol forming material, and applying a fuel element to the open end of the capsule to enclose the substrate within the capsule.

Method for making aerosol generating cartridge

The present invention preferably relates to an insulated smoking article which is capable of producing substantial quantities of smoke, both initially and over the useful life of the product, without significant thermal degradation of the aerosol former and without the presence of substantial pyrolysis or incomplete combustion products or sidestream smoke. Thus, the article of the present invention is able to provide the user with the sensations and benefits of cigarette smoking without burning tobacco. In addition, the article may be made virtually ashless so that the user does not have to remove any ash during use. Preferred embodiments of the present smoking article comprise a short i.e., 30 mm or less (prior to smoking), combustible carbonaceous fuel element, a short heat stable, preferably carbonaceous, substrate longitudinally disposed relative to the fuel element bearing an aerosol forming substance, an efficient insulating means surrounding at least a portion of the fuel element and a relatively long mouthend piece. The fuel element, insulator and substrate are arranged in a heat exchange relationship, providing aerosol formation without significant degradation of the aerosol former.

Insulated smoking article

The present invention preferably relates to a smoking article which is capable of producing substantial quantities of aerosol, both initially and over the useful life of the product, without significant thermal degradation of the aerosol former and without the presence of substantial pyrolysis or incomplete combustion products of sidestream aerosol. The article of the present invention is able to provide the user with the sensations and benefits of cigarette smoking without the substantial combustion products produced by burning tobacco in a conventional cigarette. In addition, the article may be made virtually ashless so that the user does not have to remove any ash during use. Preferred embodiments of the present smoking article comprise a short combustible carbonaceous fuel element, preferably less than 30 mm in length prior to smoking and less than about 8 mm in diameter a short, heat stable, preferably carbonaceous substrate bearing an aerosol forming substance, an efficient insulating means, and a relatively long mouthend piece. The fuel element is provided with a plurality of longitudinally extending passageways which act to control the heat transferred from the burning fuel element to the aerosol generating means.

Smoking article with improved fuel element

A cigarette provides tobacco flavor by heating tobacco, but not burning tobacco or any other material. A heat source which includes a metal oxide (e.g., calcium oxide), an anhydrous metal sulfate (e.g., magnesium sulfate), an inorganic salt and a sugar, generates heat upon contact of water therewith. The heat produced by the heat source heats tobacco in a heat exchange relationship therewith. Flavors volatilize from the tobacco and are drawn into the mouth of the user of the cigarette. Typical heat sources heat the tobacco to a temperature within 70.degree. C. to 200.degree. C. for 4 to 8 minutes.

Tobacco containing cigarette filter plugs comprise strands of tobacco material which are bound with an activated binding agent. The filter plugs exhibit good firmnless and integrity, and provide cigarettes exhibiting a unique tobacco taste. Filter plugs are prepared by forming an intimate admixture of tobacco material and binding agent, forming rods and activating the binding agent.

Tobacco rods and filters

A drug delivery article provides a dose of a volatilized drug by heating a drug carrying substrate, but not burning any material. A heat source which includes a metal oxide (e.g., calcium oxide), an anhydrous metal sulfate (e.g., magnesium sulfate), an inorganic salt and a sugar, generates heat upon contact of water therewith. The heat produced by the heat source heats the drug in a heat exchange relationship therewith. The drug volatilizes and is drawn into the mouth of the user of the article. Typical heat sources heat the drug to a temperature within 70.degree. C. to 200.degree. C. for 4 to 8 minutes.

Drug delivery article

A flavor delivery article provides volatilized flavor by heating a flavor carrying substrate, but not burning any material. A heat source which includes a metal oxide (e.g., calcium oxide), an anhydrous metal sulfate (e.g., magnesium sulfate), an inorganic salt and a sugar, generates heat upon contact of water therewith. The heat produced by the heat source heats flavor in a heat exchange relationship therewith. Flavors volatilize and are drawn into the mouth of the user of the article. Typical heat sources heat the flavor to a temperature within 70.degree. C. to 200.degree. C. for 4 to 8 minutes.

Flavor delivery article

Rods are manufactured by shredding strips of sheet-like reconstituted tobacco material into a plurality of strands of about 1/32 inch width. The strands are gathered into a rod-like shape and circumscribed by paper wrap in order to provide a continuous rod. The continuous rod is severed at regular intervals to provide a plurality of rods of the desired length. The resulting rods have a plurality of substantially longitudinally extending strands provided from shredded sheet-like material. The rods are useful as cigarette rods or in the manufacture of cigarette filter elements.

Growing community of inventors

Winston-Salem, NC, United States of America

Andrew J Sensabaugh, Jr