`
`'
`
`.
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`
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`.
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`.
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`.
`4,513,756 4/1985 Pittman et a1.
`
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`.
`4,625,737 12/1986 Kenna et al.
`
`
`
`
`4,632,131 12/1986 Burnett et a1.
`.
`
`
`
`
`
`
`
`
`4’655'229 4/1987 sembaugh’ Jr‘ at 31‘
`
`
`
`4’708'151 1”1937 5119‘“ -
`
`
`4,714,082 12/1987 Banerjee et al.
`.
`
`
`
`
`4,724,850 2/1988 Graves .
`
`
`
`3/1988 Resce et a1.
`.
`4,732,168
`
`
`
`
`
`7/1988 Clearman et al.
`4,756,318
`
`
`
`9/1988 White et a1.
`.
`4,771,795
`
`
`
`
`
`4,793,365 12/1988 Sensabaugh, Jr. et al.
`
`
`
`
`4,858,630
`8/1989 Banerjee et 3.1.
`.
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`
`
`
`4,862,905 12/ 1987 Green, Jr. et a1.
`
`
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`
`
`
`3/1990 B°Yd at 31'
`'
`419431941
`
`
`
`FOREIGN PATENT DOCUMENTS
`9/1984 European Pat. Off.
`117355
`.
`
`
`
`
`
`
`
`3/1986 Euwpean Pan 011 -
`174645
`
`
`
`
`
`
`
`
`212234
`3/1987 European Pat Off- -
`
`
`
`
`
`3/1937 F4um Pat-0ft -
`232166
`
`
`
`
`
`322133 151333 E“°”“‘“‘ 5“? 8?? '
`
`
`
`
`
`254842
`2/1988 Egg: P2,: Off:
`1
`
`
`
`
`
`2/1988 European Pat. Off.
`254848
`.
`
`
`
`
`
`
`
`
`
`
`270738 1988 European Pat.
`.
`270916
`6/1988 European Pat. Off.
`.
`
`
`
`
`
`270944 6/1988 European Pat. Off.
`.
`
`
`
`
`
`271036 6/1988 European Pat. Off.
`.
`
`
`
`
`
`8/1988 European Pat. Off.
`277519
`.
`
`
`
`
`
`280262
`8/1988 European Pat. Off.
`.
`
`
`
`
`
`280990 9/1988 European Pat. Off.
`.
`
`
`
`
`
`2416876 9/1974 Fed. Rep. of Germany .
`
`
`
`
`
`
`8/1951 Switzerland .
`275420
`
`
`
`1185887
`3/1970 United Kingdom.
`
`
`
`
`1431045 4/1976 United Kingdom .
`
`
`
`
`1597106 9/1981 United Kingdom .
`
`
`
`
`Primary Examiner—V. Millin
`
`
`
`
`
`
`
`Attorney, Agent, or Firm—Robert M. Isackson
`ABSTRACT
`[57]
`
`
`.
`A flavor source to be used as a thermally releasable
`
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`
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`flavorant for smoking articles that do not combust to-
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`bacco. The material includes tobacco particles, an aero-
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`sol precursor that forms an aerosol upon exposure to
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`heat, and a filler material that absorbs and radiates heat
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`to minimize the likelihood that the flavor material will
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`ignite. The material is mixed in an extruder, extruded
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`through a die, and cut into pellets having a substantially
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`.
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`umform shape. The pellets are loaded into a chamber
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`1
`fl
`f
`.
`l
`.
`.
`.
`.
`t
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`
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`or me mm: m a smoking artlc e as a avor genera or.
`28 Claims, 5 Drawing Sheets
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`
`R.J. Reynolds Vapor
`IPR2017-01117
`
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`
`
`
`
`
`
`R.J. Reynolds Vapor v. Fontem
`Exhibit 1008-00001
`
`
`
`
`
`
`
`4,981,522
`[11] Patent Number:
`[19]
`United States Patent
`
`
`
`
` Nichols et a]. [45] Date of Patent: Jan. 1, 1991
`
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`[54] THERMALLY RELEASABLE FLAVOR
`
`
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`SOURCE FOR SMOKING ARTICLES
`
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`
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`Inventors: Walter A. Nichols, Richmond; Harry
`
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`
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`V.Lanzillotti, Midlothian; Richard A.
`
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`
`
`Thme R1°hm°nd§Alex 5- Ge’geb’v
`
`
`
`
`PQWhauén; Constance H- Morgana
`Midlothlan; Bruce E- Warmck,
`
`
`
`
`Prince George; D. Bruce Losee, Jr.,
`
`
`
`
`
`Richmond; John R. Hearn,
`
`
`
`
`Richmond; Johnny L_ Miller,
`
`
`
`Richmond, an of Va_
`
`
`
`
`
`
`
`[73] Assignee:
`Philip Morris Incorporated, New
`
`
`York, NY.
`
`
`[21] App]. No; 222,831
`
`
`
`
`[22] Filed;
`Jul, 22, 1933
`
`
`
`
`
`[51]
`Int. Cl.5 ........................ .. A24D 1/00; A24D 1/18
`
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`
`
`
`
`
`
`
`[52] US. Cl.
`............ 131/274; 131/275;
`
`
`
`
`
`
`131/194; 131/335; 131/359; 131/353; 131/370;
`
`
`
`
`131/375
`[58] Field of Search ............... 131/359, 369, 194, 370,
`
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`
`
`
`
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`
`
`131/372, 375» 353, 355: 356
`
`
`
`
`
`References
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`
`[75]
`
`
`
`
`U-S' PATENT DOCUMENTS
`
`
`-
`27.214 11/1971 Nakahara et a1.
`.
`
`
`
`
`3,098,492 7/1963 Wurzburg -
`
`
`
`3,219,041 11/1965 Bromberg -
`
`
`
`.
`3.404.690 10/1968 Mosby et a1.
`
`
`
`
`
`3,410,279 11/1968 Mosby etal- .
`
`
`
`
`
`3,447,539 6/1969 Briskin etal- -
`
`
`
`
`
`3,540,456 5/1969 McGlumphy etal. -
`
`
`
`
`3.550.598 6/1970 McGlumphy etal- -
`
`
`
`
`
`
`
`g’gg’ggg
`gifge't 31
`
`
`
`
`3:643:668 2/1972 Briskin et aL .
`
`
`
`
`1/1973 Bromberg .
`3,713,451
`
`
`
`3,738,374 6/1973 Bennett .
`
`
`
`.
`3,858,587
`1/1975 Cavelli et a1.
`
`
`
`
`
`3,885,574 4/1975 BOthWiCk et 31-
`
`
`
`
`3,902.504 2/1975 Owens, Jr- et 81-
`
`
`
`
`3,931,824
`1/1976 Miano et a1.
`.
`
`
`
`
`.
`4,008,723 2/1977 Bothwick et a1.
`
`
`
`
`
`4,286,604 9/1981 Ehretsmann et a1.
`
`
`
`9/1981 Berger
`4,291,711
`
`‘
`.
`.
`
`
`
`
`
`4’333’484 6/1982 K69“? ‘
`4,341,228 7/1982 Kentsxs et a1.
`
`
`
`
`
`
`
`4,391,285 7/1983 Burnett et a1.
`4,481,958 11/1984 Raine at 31.
`_
`
`
`
`
`
`4,510,950 4/1985 Keritsis et a1.
`
`
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`
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`
`.
`.
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`
`
`
`
`
`-
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`.
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`.
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`.
`
`

`

`
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`
`
`US. Patent
`
`
`Jan.1, 1991
`
`
`
`Sheet 1 015
`4,981,522
`
`
`
`
`
`
`
`F/G‘./
`
`Exhibit 1008-00002
`
`
`
`
`

`

`
`
`US. Patent
`
`Jan. 1, 1991
`
`Sheet 2 of 5
`
`4,981,522
`
`F/Gi2b
`
`V1-
`
`0000000
`0000000
`0000000“
`in
`g}
`(x?!
`N)
`
`‘0
`Q
`“'3
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`
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`Q
`‘1‘
`
`FIG:20
`
`
`
`
`Exhibit 1008-00003
`
`

`

`
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`
`
`
`
`0f5
`4,981,522
`
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`
`
`
`Exhibi000000000 04
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`
`

`

`
`Us. Patent
`
`
`
`Jan. 1, 1991
`
`
`
`Sheet 4 0f 5
`
`
`
`rflflI/Ifdm§\\\§n
`”!”””’
`
`\
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`Ig
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`Sg~fig‘§.§‘~“~‘,fifii“!
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`v63‘
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`MN.\NWW
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` s‘; ‘5“..aVy’“"“"'4""a""“""““‘A"d".~‘-".“‘~‘~.‘-“~“~.~.‘~‘....~.."..‘.~".\I
`
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`Exhibit 1008-00005
`
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`
`

`

`
`
`
`US. Patent
`
`
`Jan. 1, 1991
`
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`
`Sheet 5 of 5
`4,981,522
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`
`Exhibit 1008-00006
`
`
`
`
`
`
`

`

`1
`
`4,981,522
`
`
`
`THERMALLY RELEASABLE FLAVOR SOURCE
`
`
`
`FOR SMOKING ARTICLES
`
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`
`BACKGROUND OF THE INVENTION
`
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`This invention relates to a thermally releasable flavor
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`source for use in smoking articles which produce sub-
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`stantially no smoke. More particularly, this invention
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`relates to a tobacco-containing thermally releasable
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`flavor source that provides the sensations associated
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`with the smoking of tobacco without the burning of
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`tobacco.
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`A substantial number of previous attempts have been
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`made to produce a smoking article which produces an
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`aerosol or vapor for inhalation, rather than smoke. For
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`example, Siegel U.S. Pat. No. 2,907,686 shows a smok-
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`ing article consisting of a charcoal rod and a separate
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`carrier impregnated with flavorants and a synthetic
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`“smoke” forming agent which is heated and volatized
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`by the burning charcoal rod. The charcoal rod is coated
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`with a concentrated sugar solution so as to form an
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`impervious layer during burning. It was thought that
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`this layer would contain the gases formed during smok-
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`ing and concentrate the heat thus formed, thereby ther-
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`mally releasing the flavorants.
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`Another smoking article, shown in Ellis et al. U.S.
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`Pat. No. 3,258,015, employs bunting tobacco in the
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`form of a conventional cigarette to heat a metallic cylin-
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`der containing a source of nicotine, such as reconsti-
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`tuted tobacco or tobacco extract. During smoking, the
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`vapors released from the material inside the metal tube
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`mix with air inhaled through an open end of the tube
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`which runs to the burning end of the smoking article.
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`Ellis et al. U.S. Pat. No. 3,356,094 shows a similar smok-
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`ing article in which the tube becomes frangible upon
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`heating, so that it will break off and not protrude as the
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`surrounding tobacco burns away.
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`European patent application 0 177 355 by Hearn et a1.
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`shows a smoking article which produces a nicotine-con-
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`taining aerosol by heating, but not burning, a flavor
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`generator. The flavor generator could be fabricated
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`from a substrate material such as almumina, natural
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`clays and the like, or tobacco filler. The flavor genera-
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`tor is impregnated with thermally releasable flavorants,
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`including nicotine, glycerol, menthol and the like. Heat-
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`ing of the flavor generator is provided by hot gases
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`formed as a result of the combustion of a fuel rod of
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`pyrolized tobacco or other carbonaceous material.
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`Banerjee et al. U.S. Pat. No. 4,714,082 shows a varia-
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`tion of the Hearn et al. device which employs a short
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`fuel element. The performance of the device is im-
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`proved by maximizing heat transfer between the fuel
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`element and the aerosol generator. This is effected by
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`preventing heat loss by insulation, and by enhancing
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`heat transfer between the burning fuel and the flavor
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`generator by a metallic conductor. A spun glass fiber
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`insulator surrounds the fuel element and aerosol genera-
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`tor assembly.
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`European Application No. 0 212 234 shows a smok-
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`ing article having an aerosol generating means abutting
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`a fuel element. The aerosol generating means is said to
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`include a thermally stable, porous particulate substrate
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`material, for example, carbon, tobacco, or mixtures of
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`carbon and tobacco formed into densified spherical
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`particles in a one step process (e.g., as described in U.S.
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`Pat. No. Re 27,214) in a “Marumerizer” type machine.
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`The substrate materials carry one or more aerosol form-
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`ing materials and may include one or more volatile
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`5
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`10
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`15
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`20
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`25
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`30
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`35
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`45
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`50
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`55
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`65
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`2
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`flavoring agents. The smoking article may include op-
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`tionally a plug of tobacco at the month end of the fuel
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`element whereby hot gases passing through the tobacco
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`may vaporize volatile components in the tobacco with-
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`out combustion.
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`European Application 0 254 848 shows a substrate
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`material having a decreased retentive capacity for use
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`as a carrier for aerosol materials, e.g., alumina or modi-
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`fied carbon.
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`The prior art devices that rely on thermally releas-
`able flavorants have not heretofore adequately pro-
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`vided a flavor source for smoking articles that will
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`provide the smoker with the taste and satisfaction that
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`has become expected of a conventional tobacco-bum-
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`ing smoking article. Accordingly, there is a continuing
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`need for a flavor source that can be heated to provide an
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`acceptable taste comparable to a conventional smoking
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`article without being burned. Further, there is a con-
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`tinuing need to provide such a flavor source containing
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`tobacco.
`
`SUMMARY OF THE INVENTION
`
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`It is an object of this invention to provide a process
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`for making a thermally releasable flavor source for a
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`smoking article in which the sensations of smoking of
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`tobacco are achieved without the burning of tobacco.
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`It is a further object of this invention to provide a
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`tobacco-containing flavorant material
`that can be
`
`
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`heated to provide a flavored aerosol to the smoker.
`
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`It is another obJect of this invention to provide a
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`tobacco-containing flavorant material having a low
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`mass and high surface area that is adapted to optimize
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`
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`heat exchange for providing a flavored aerosol upon
`
`
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`being heated.
`
`
`
`It is another object of this invention to provide a
`
`
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`
`
`
`tobacco-containing material in the form of substantially
`
`
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`
`
`uniform pellets that can be easily processed, stored in
`
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`
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`bulk, and packaged in a flavor generator of a smoking
`
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`article.
`
`
`In accordance with this invention, there is provided a
`
`
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`flavor material for use in a smoking article having a heat
`
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`source that is capable of heating the flavor material to
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`generate therefrom a flavored aerosol and/or vapor for
`
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`delivery to the smoker. Broadly, the invention concerns
`forming a flavorant material by combining particular-
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`ized tobacco, an aerosol precursor, and a finely divided
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`filler material, thoroughly mixing the components, ex-
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`truding the mixture out a die orifice into a strand, and
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`cutting the extruded strand into lengths, preferably of
`uniform length, thereby forming pellets. The pellets
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`preferably comprise a mixture of about 15 to 95% to-
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`bacco material, 5 to 35% aerosol precursor, and 0 to
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`50% filler material. Optionally, conventional flavoring
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`agents may be added to the mixture prior to or subse-
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`quent to extrusion, e.g., menthol, oil of peppermint,
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`tobacco extract, nicotine, and other tobacco flavoring
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`agents known to those of skill in the art. In the preferred
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`embodiment, the die contains a plurality of orifices to
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`form a plurality of strands simultaneously at a relatively
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`uniform flow velocity.
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`The extrusion conditions are such that the materials
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`are adequately mixed at low temperatures with low
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`shear and a minimum amount of work to provide a
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`homogeneous mixture The extruding equipment may be
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`any conventional extruder machine and related control
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`apparatus such as that used in the food processing indus-
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`Exhibit 1008-00007
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`

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`3
`try, including single screw extruders and preferably
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`twin screw extruders.
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`In the preferred embodiment, the several ingredients
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`are added at different locations or mixing zones along
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`the extruder barrel mixing chamber, for example, first
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`feeding in the aerosol precursor, adding in the filler
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`material downstream to the aerosol precursor, and f1-
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`nally adding the tobacco particles and any added flavor-
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`ing agents downstream of the filler material, each at a
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`controlled feed rate. Altemately, the ingredients may be
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`mixed in a conventional mixing device and then fed into
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`the mixing chamber of the extruder apparatus.
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`The aerosol precursor preferably also acts as a lubri-
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`cant to aid in reducing the work required to mix the
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`ingredients and so to maintain the temperature of the
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`mixing barrel at or below a selected operating tempera-
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`ture. In circumstances where the amount of aerosol
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`precursor does not alone adequately lubricate the mix-
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`ture, an additional lubricant may be added, e.g., water
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`or alcohol.
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`In the preferred embodiment, the extrudate is main-
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`tained at a temperature below about 170' F., preferably
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`at about 150' F. A cooling fluid may be circulated about
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`the extruder mixing barrel to absorb heat generated
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`during mixing. For example, a conventional heat trans-
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`fer fluid, e.g., propylene glycol, at —-4‘ C. may be used.
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`Further, the relative proportions and feed locations of
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`the components of the mixture, particularly of any lu-
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`bricating material and other dry materials, can be ad—
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`justed to provide the desired degree of mixing and tem-
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`perature inside the extruder barrel and to produce the
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`desired pellets in accordance with the abilities of one
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`skilled in using such extrusion apparatus.
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`The extruded strands are severed to form pellets
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`having a substantially uniform surface area and a low
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`mass. These characteristics advantageously provide
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`efficient heat exchange with the heat source of the
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`smoking article and improve the ability of the smoking
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`article to generate the desired flavors. Further,
`the
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`pellets are flowable and substantially incompressible,
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`but not friable. Thus, the pellets can be stored and
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`shipped in bulk storage containers, e.g., 50 gallon
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`drums, without significantly damaging the pellets
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`stored on the bottom of the container, and be with-
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`drawn from bulk storage containers for inclusion into
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`the smoking articles in metered amounts or continu-
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`ously.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`The above and other objects and advantages of the
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`invention will be apparent upon consideration of the
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`following detailed description,
`taken in conjunction
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`with the accompanying drawings, in which like refer-
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`ence characters refer to like parts throughout, and in
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`which:
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`FIG. 1 is a schematic perspective view of an extruder
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`illustrating the process of the present invention;
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`FIG. 2a is a front view of the extruder die of FIG. 1;
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`FIG. 2b is a side view of the extruder die of FIG. 1;
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`FIG. 3 is an exploded perspective view of an embodi-
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`ment of a smoking article incorporating the pellets of
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`the present invention;
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`FIG. 4 is a longitudinal cross-sectional view of the
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`smoking article of FIG. 3, taken from line 2—2 of FIG.
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`3;
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`FIG. 5 is an end view of the smoking article of FIGS.
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`3 and 4, taken from line 3—3 of FIG. 4;
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`FIG. 6 is a radial cross-sectional view of
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`10
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`15
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`20
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`25
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`30
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`35
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`45
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`50
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`55
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`60
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`65
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`The pellets of this invention comprise a thermally
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`releasable flavorant material produced by an extrusion
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`process that provides for the homogeneous mixture of
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`the components and a substantially uniformly sized end
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`product. Thus, high speed mass production apparatus
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`and techniques can be used to make and process the
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`pellets and form thermally releasable flavor generators
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`for smoking articles.
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`The tobacco material may be comminuted tobacco
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`selected from the group consisting of bright, burley,
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`oriental,
`sun-cured. air-cured bright and mixtures
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`thereof, reconstituted tobacco, comminuted stems or
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`tobacco dust or fines. The tobacco may have been pre-
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`viously subjected to a stiffening or expansion process to
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`increase its filling power, or to other conventional to-
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`bacco treatment processes, for example, to reduce the
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`alkaloid or nicotine content of the tobacco. Whatever
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`the source of the tobacco particles, the particles em-
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`ployed in the present invention will have a particle size
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`in the range of from about 20 to about 400 mesh, prefer-
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`ably about 150 mesh.
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`The aerosol precursor forms an aerosol upon being
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`subjected to heat. It is a material that, during the mixing
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`process, becomes widely dispersed among and absorbed
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`by the tobacco particles. Advantageously, absorption
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`by the tobacco and filler material minimizes migration
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`or wicking of the aerosol precursor so that it remains
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`widely dispersed. The aerosol precursor also serves as a
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`lubricant to facilitate mixing of the components. The
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`preferred aerosol precursor material is glycerine, pref—
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`erably U.S.P. grade glycerine, added in a liquid state
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`containing substantially no water. Other aerosol precur-
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`sor materials may be selected from propylene glycol,
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`1,3-butanediol and the like.
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`The filler material aids in controlling the dessication
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`and pyrolization of the pellets by presenting a thermal
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`load to the heat source of the smoking article. Thus, the
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`pellets may be subjected to gas temperatures above the
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`ignition temperature, yet the pellets will not heat up 0
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`ignition temperature. The filler material also may re-
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`duce the ashing tendency of the pellets as they are pyro-
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`lized. The preferred filler material is calcium carbonate
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`in a fine precipitated grade, typically about 0.8—1.0 mi-
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`crons in diameter. It is believed that calcium carbonate
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`having a particle size less than about 1(1) mesh can be
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`used satisfactorily. Other filler materials may be se-
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`lected from inert fillers, e.g., alumina. The filler material
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`also becomes widely dispersed among the components
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`of the mixture by the mixing process.
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`The equipment for making pellets may be any con-
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`ventional extruder machine and control apparatus, for
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`example, extruders such as those used in the food pro-
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`cessing industry. Twin screw extruders are preferred
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`over single screw extruders because they provide more
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`uniform mixing, a more uniform flow velocity at the
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`die, and, hence, a more uniform product. A preferred
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`twin screw extruder is the model MPF-SO, manufac-
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`tured by APV Baker, of Grand Rapids, Michigan, hav-
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`4,981,522
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`4
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`the smoking article of FIGS. 3—5, taken from line
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`4—4 of FIG. 4;
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`FIG. 7 is a radial cross-sectional view of the smoking
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`article of FIGS. 3—6, taken from line 5——5 of FIG. 4; and
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`FIG. 8 is a radial cross-Sectional view of 390 the
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`smoking article of FIGS. 3—7, taken from line 6—6 of
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`FIG. 4.
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`DETAILED DESCRIPTION OF THE
`
`
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`INVENTION
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`Exhibit 1008-00008
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`

`

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`Exhibit 1008-00009
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`4,981,522
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`5
`ing a 25:1 length to diameter ratio. Extruders having
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`smaller length to diameter ratios, e.g., of about 15:1,
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`may be used.
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`Referring to FIG. 1, extruder barrel 300 has several
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`input ports spaced along the mixing barrel for feeding
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`materials to be mixed into the barrel. Conventional
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`product feed apparatus may be provided for controlling
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`the rate at which the liquid or finely divided ingredients
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`of the pellets are added to obtain the desired propor-
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`tions. For example, metering pump 350 may be used for
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`metering the flow of a liquid aerosol precursor from
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`supply reservoir 341 into the extruder barrel at port 342
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`at a rate of about 20 lbs per hour. Similarly, funnel 344
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`may be used for receiving and passing finely divided
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`filler material from supply 343 into port 345 at a rate of 15
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`about 25 lbs per hour, and funnel 357 may be used for
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`receiving and passing finely divided tobacco from sup-
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`ply 346 into port 348 at a rate of about 55 lbs per hour.
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`Conventional means for metering the flow of the partic-
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`ulate materials (not shown) may be provided.
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`The extruder barrel is preferably cooled in a conven-
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`tional manner, e.g., by passing cooling fluids at about
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`—-4 degrees centigrade through ports 310 of extruder
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`305 so that the cooled fluids circulate in the jacket of the
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`extruder barrel (not shown). The cooling fluids absorb
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`heat generated by the mixing action and thus minimize
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`the likelihood of the heat adversely affecting the subjec-
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`tive qualities of the tobacco material. It is desired that
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`the temperature of the material be kept below 175° E,
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`which temperature will minimize any thermal degrada-
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`tion of the tobacco material and further will permit the
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`addition of flavoring agents to the extrudate in the mix-
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`ing barrel. The preferred maximum temperature in the
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`barrel is about 150' F. and the preferred minimum tem-
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`perature is about 140° F. The relative proportions of the
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`mixture, particularly the lubricant and other dry materi-
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`als, and the temperature of the circulating cooling liquid
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`can be adjusted to provide the desired temperature
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`inside the extruder barrel. The flow rate and tempera-
`ture of the cooling liquid also can be adjusted to control
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`the temperature. Further, the extruder jacket may be
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`divided into compartments so that different flow rates
`of coolant and different (or the same) temperatures can
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`be maintained in different compartments along the mix-
`4s
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`ing barrel, independently of any difference in heat being
`created by mixing.
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`Referring to FIGS. 1, 2a, and 2b, extruder die 320 has
`a plurality of orifices 325, preferably about two hundred
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`and sixty-four orifices. Each orifice is preferably about
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`50
`1.0 mm in diameter. The extruded material thus forms
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`. spaghetti-like strands 328 that are about the same diame-
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`ter as the die orifices, e.g., 1.0 mm. Die 320 is preferably
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`configured so that orifices 325 are arranged into four
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`groupings of orifices (See FIG. 2a). Within each group-
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`ing the orifices are spaced about the same distance
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`apart, and the groups are separated by solid material.
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`This grouping facilitates cutting of strands 328 into
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`pellets 329 and minimizes pellets from interfering with
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`the extrusion or cutting steps. Means for catching the
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`pellets (not shown) also are provided, for example, a
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`vibratory conveyor or a basket under the die.
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`It is desirable to extrude the extrudate out the die at a
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`substantially uniform flow velocity. This will provide
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`an extruded material that will have substantially uni-
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`form dimensional characteristics, particularly with re-
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`spect to surface area. The rheology of the materials may
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`be adjusted to provide the desired uniform flow veloc-
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`ity for the particular die and extrusion apparatus being
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`6
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`applied. A flow velocity of about 100 to about 250
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`pounds per hour is preferred.
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`Referring to FIGS. 1 and 2b. knife 400 may be placed
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`in close proximity to and preferably in frictional contact
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`with die orifice 320 and rotated to cut the strands as
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`they are extruded into segments of substantially the
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`same length, e.g., preferably in the range from about 0.5
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`to about 1.5 mm, thereby forming pellets of substan-
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`tially uniform configuration. The strands may be cut
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`perpendicular to the longitudinal axis of the strands or
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`at an angle thereto, for example, to increase the surface
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`area of the pellets. Preferably knife 400 has a plurality of
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`blades 410, e.g., six blades. The rate at which knife 400
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`rotates may be in the range of from about 200 to about
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`1800 revolutions per minute for a flow velocity of from
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`100 to about 250 pounds per hour, but may be adjusted
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`cutting edges on the knife. The cutting edges of the
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`knife blades preferably ride on the surface of the die
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`orifice.
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`The mixture in the extruder barrel and the resultant
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`pellets have a moisture content that depends upon the
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`0V content (as defined, for example, in US. Pat. No.
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`Re 32,013) of materials being mixed together. In the
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`preferred embodiment, the tobacco is added at about an
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`equilibrated 0V content of from about 7 to about 20%
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`0V, and the aerosol precursor and the filler material are
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`added in a substantially dry condition. Thus, the com-
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`ponents of the pellets are essentially dry mixed and the
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`pellets formed can be packaged in bulk immediately
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`following extrusion. Flavoring agents that optionally
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`may be added are typically provided in a liquid carrier
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`solution of water, alcohol or propylene glycol. The
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`carrier liquids tend to be absorbed by the tobacco or the
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`glycerine and so disperse the flavoring agent. The
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`amount of liquid carrier is usually not significant to
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`affect the 0V level or capacity of the pellets.
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`When glycerine is used as the aerosol precursor, the
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`proportion of glycerine in the pellets effects the equili-
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`brated OV content of the pellets because of the known
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`propensity for glycerine to absorb water. Thus, at
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`higher glycerine levels, e.g., at about 30 wt. % glycerv
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`ine, the equilibrated OV level may be at about 18% and
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`that might cause the pellets to be soft or sticky after
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`they have equilibrated. In such case, the residence time
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`of the pellets in the ambient atmosphere may be con-
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`trolled so that the still hard pellets can be packaged and
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`stored in, for example, sealed containers, prior to equili-
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`bration or significant water absorption. At lower glyc-
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`erine levels, e.g., 5 wt. %, the equilibrated 0V content
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`will be at about 12%, which is sufficiently dry to permit
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`longer residence times and may permit storage in non-
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`airtight containers in all but the more humid of environ-
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`ments.
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`In circumstances where water or other volatile lubri-
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`cant may be added to the mixture, appropriate measures
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`may be taken to remove the lubricant or moisture to
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`provide the hard, non-tacky pellets for use or for stor-
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`age. For example, means for drying the pellets for use
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`or for storage may be provided such as ovens (radiant,
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`convection or microwave), subjecting the pellets to a
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`dessicant environment, or the like.
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`Uniformity of the tobacco particles is important to
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`producing pellets having consistent structural and sub-
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`jective characteristics. The size of the particles added to
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`the extruder can have an affect on the uniformity of the
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`product. Tobacco particles that approach the size of the
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`orifices of