III USOO5692525A
`5,692,525
`Dec. 2, 1997
`
`Patent Number:
`Date of Patent:
`
`11)
`45
`
`3,738,374
`3,744,496
`3,804,100
`3,889,690
`4,016,061
`4,068,672
`4077,784
`4,131,119
`
`6/1973
`Bennett.
`McCarty et al. .
`7/1973
`4/1974
`Fariello,
`Guarnieri.
`6/1975
`Wasa et al. .
`4/1977
`1/1978
`Guerra.
`Wayrynen .
`3/1978
`12/1978
`Blasutti.
`(List continued on next page.)
`FOREIGN PATENT DOCUMENTS
`1202378 3/1986 Canada.
`87/104.459 2/1988 China.
`0 295 122 12/1988 European Pat. Of..
`0.358 002 3/1990 European Pat. Off. .
`0.358 114 3/1990 European Pat. Off. .
`O 430566A2 6/1991 European Pat. Off. .
`0 438 862 A2 7/1991 European Pat. Off. .
`3 640917 8/1988 Germany.
`3 735 704 5/1989 Germany.
`61-68061
`4/1986 Japan.
`2 132 539 7/1984 United Kingdom.
`2 148 079 5/1985 United Kingdom.
`2 148 676 5/1985 United Kingdom.
`WO 86/02528 5/1986 WIPO
`WO95/05094 2/1995 WIPO
`Primary Examiner-Jennifer Bahr
`Attorney, Agent, or Firm-Charles E. B. Glenn; James E.
`Schardt; James T. Moore
`57)
`ABSTRACT
`A cigarette adapted for use in an electrical cigarette system
`having a tobacco rod having filled and unfilled tobacco rod
`portions and being arranged so that electrical heater ele
`ments may overlap the filled and unfilled tobacco rod
`portions. The tobacco rod includes a tobacco web rolled into
`tubular form. The tobacco web is constructed in accordance
`with a process having the steps of converting tobacco
`feedstock into a continuous sheet of tobacco web and
`converting the continuous sheet of tobacco web into one or
`more bobbins of tobacco web suitable for automated manu
`facture of cigarettes.
`
`14 Claims, 16 Drawing Sheets
`
`United States Patent (19)
`Counts et al.
`
`CGARETTE FOR ELECTRICAL SMOKING
`SYSTEM
`
`Inventors: Mary Ellen Counts; Willie G. Houck,
`Jr., both of Richmond; Michael A.
`Moore, Midlothian; Wesley G.
`Sanderson, Richmond; Michael L.
`Watkins, Chester; Susan E. Wrenn,
`Chesterfield, all of Wa.
`Assignee: Philip Morris Incorporated, New
`York, N.Y.
`
`Appl. No.: 425,166
`Fed:
`Apr. 20, 1995
`Related U.S. Application Data
`Division of Ser. No. 425,166, Apr. 20, 1995, which is a
`continuation-in-part of Ser. No. 380,718, Jan. 30, 1995,
`which is a continuation of Ser. No. 118,665, Sep. 10, 1993,
`Pat. No. 5,388,594, which is a continuation-in-part of Ser.
`No. 943,504, Sep. 11, 1992, Pat. No. 5,505,214.
`Int. Cl. ... A24F 47/00
`U.S. Cl. ..................... 131/194
`Field of Search .................................... 131/360, 194,
`131/361, 364, 331, 344
`
`54
`
`(75)
`
`73)
`
`21
`22
`
`60
`
`51)
`52
`58)
`
`56)
`
`1,771,336
`1968,509
`2,057,353
`2,104.266
`2,442004
`2,974,669
`3,200,819
`3.255,760
`3,363.633
`3,402,723
`3,482,580
`3496,336
`3.591,753
`3,608,560
`
`References Cited
`U.S. PATENT DOCUMENTS
`Wyss et al. .
`7/1930
`Tiffany.
`7/1934
`10/1936
`Whitemore, Jr. .
`McCormick.
`1/1938
`Hayward-Butt.
`5/1948
`3/1961
`Elis.
`8/1965
`Gilbert.
`6/1966
`Selke.
`1/1968
`Weber.
`9/1968
`Hu.
`Hollebaugh.
`12/1969
`Hingorany et al. .
`2/1970
`7/1971
`Gartner.
`9/1971
`Briskin.
`
`O2
`
`112
`
`
`
`
`
`
`
`7777227A722422/777-22222222
`State at AS
`as YaS
`
`rearrars
`-a assaa
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 001
`
`

`

`5,692,525
`Page 2
`
`U.S. PATENT DOCUMENTS
`2/1979 Burruss.
`8/1979 Pearlman.
`3/1980 Faris et al. .............................. 13/71
`3/1980 Nakajima et al. ..
`... 219/216
`5/1980 Nakatani et al. ...
`... 219/216
`8/1980 Bron ...................
`... 13/262
`8/1980 Tabatznik et al.
`... 131/170
`1/1981 Ogden et al. ........................... 131/171
`3/1981 Carter et al. ......................... 219/10.75
`3/1981. Ohkubo .......
`... 219/216
`4/1981 Green, Jr. .
`... 131/330
`12/1981 Burruss, Jr. ............................. 13/271
`3/1982 Keith et al. ............................. 131/359
`7/1983 Jacobs .....
`... 131/273
`2/1984 Riccio .....
`... 219/238
`3/1984 Green, Jr. ................................ 131/330
`7/1984 Lawrence et al. ...................... 219,236
`3/1985 Cogbill et al. .......................... 13/334
`4f1985 Keitsis et al. .
`12/1985 Lawrence ................................ 29/421
`2/1986 Herron .................................... 31/85
`4/1986 Green, Jr. .
`... 131/330
`11/1986 Osterrath .........
`... 131f185
`11/1986 Derbyshire et al. ...................... 48/3
`12/1986 Spector ................................... 422/124
`1/1987 Bonanno et al. ....................... 131/175
`4/1987 Derbyshire.
`7/1987 Drapeau et al..
`8/1987 Spector.
`9/1987 Spector.
`9/1987 Ruderian.
`4/1988 Gerth et al. .
`9/1988 Myer.
`
`
`
`4,141,369
`4,164,230
`4,193,411
`4,194,108
`4203,025
`4215,708
`4,219,032
`4,246,913
`4.256,945
`4,259.564
`4,259.970
`4,303,083
`4,319,591
`4,393,884
`4,431,903
`4,436,100
`4,463,247
`4505282
`4510,950
`4562,337
`4,570,646
`4,580,583
`4,621,649
`4,623.401
`4,629,604
`4,637.407
`4,659,912
`4,682,010
`4,686,353
`4,692,590
`4,694,824
`4,735,217
`4,771,796
`
`4,776.353
`4,837,421
`4,846,199
`4,848,376
`4,874,924
`4,877,989
`4,922,901
`4.945.931
`4,947.874
`4,947,875
`4,966,171
`4,981.522
`4,991,606
`4,998,541
`5,016,656
`5,040,552
`5,042,510
`5,060,671
`5,076,296
`5,093,894
`5,095,921
`5,144.962
`5,159,940
`5,179,966
`5,188,130
`5,224,498
`5,235,157
`5.249,586
`5,269,327
`5,274,214
`5,285,050
`5.388,594
`5,479,948
`
`10/1988
`6/1989
`7/1989
`7/1989
`10/1989
`Of1989
`5/1990
`8/1990
`8/1990
`8/1990
`10/990
`1/1991
`2/1991
`3/1991
`5/1991
`8/1991
`8/1991
`10/1991
`12/1991
`3/1992
`3/1992
`9/1992
`11/1992
`1/1993
`2/1993
`7/1993
`8/993
`10/1993
`12/1993
`12/1993
`2/1994
`2/1995
`1/1996
`
`Lilja et al..
`Luthy.
`Rose.
`Lilja et al. .
`Yamamoto et al. .
`Drews et al. .
`Brooks et al. .
`Gori.
`Brooks et al. .
`Brooks et al.,
`Seranno et al. .
`Nichols et al. .
`Seranno et al..
`Perfetti et al. .
`McMurtrie.
`Schleich et al. .
`Curtiss et al. .
`Counts et al. .
`Nystrom et al..
`Deevi.
`Losee et al. .
`Counts et al. .
`Hayward et al. .
`Losee et al. .
`Hajaligol et al. .
`Deevi et al. .
`Blackburn .
`Morgan et al. .
`Counts et al. .
`Blackburn.
`Blackburn.
`Counts et al. .
`Counts et al. .
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 002
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 1 of 16
`
`5,692,525
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 003
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 2 of 16
`
`5,692,525
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 004
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 3 of 16
`
`5,692,525
`
`
`
`28 I
`
`29
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 005
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 4 of 16
`
`5,692,525
`
`
`
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 006
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 5 of 16
`
`5,692,525
`
`
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 007
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 6 of 16
`
`5,692,525
`
`TOBACCO
`FIBER
`
`DIS PERSE
`TOBACCO FIBER
`AND
`CELLULDSIC FIBER
`
`TOBACCO
`FEED STOCK
`
`EXTRACTION
`126 Yn
`<-- 124
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`SOLUBLES
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`CELLULDSE
`
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`sity
`WEB SLURRY 1-128
`
`CAST SLURRY
`ONTO
`WEB FORMING
`MACHINE
`weB- N-- 132
`
`1 - 130
`
`
`
`ORY WEB
`
`- R -134
`
`MONITOR
`MDISTURE CONTENT
`WEIGHT
`
`CAT WEB
`WITH ALGINATE
`(OPTIONAL)
`
`
`
`MIX SLUBLES
`WTH
`e GROUND TOBACCO
`a GLY CERN
`a PECTN
`a WATER
`
`r/
`
`146
`
`SLURRIED
`TOBACCO
`MATERIA
`
`
`
`
`
`68s
`
`
`
`
`
`COAING
`OPERATION
`
`1 - 144
`
`120
`
`Topico-U-66s
`SHEET
`
`W
`
`s
`
`Fig. 5A
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 008
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 7 of 16
`
`5,692,525
`
`
`
`
`
`CDATING
`OPERATION
`
`TOBACCO
`WEB - S - 66s
`SHEET
`
`DRIED AND COOLED
`TOBACCO WEB SHEET N 66cc
`
`DECURING N - 150
`
`122
`
`
`
`
`
`
`
`
`
`MONITOR
`TEMPERATURE
`--e MDISTURE LEVEL
`TOTAL WEIGHT
`
`152-5
`
`154
`
`
`
`SPLITTER
`
`Fig. 5B
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 009
`
`

`

`5,692,525
`
`v 9 51)
`
`U.S. Patent
`
`
`
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`Dec. 2, 1997
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 010
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 9 of 16
`
`5,692,525
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 011
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 10 of 16
`
`5,692,525
`
`
`
`SMDKING
`MACHINE
`
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`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 012
`
`

`

`Philip Morris Products, S.A.
`Exhibit 1011
`Page 013
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 12 of 16
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`5,692,525
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 014
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 13 of 16
`
`5,692,525
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 015
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 14 of 16
`
`5,692,525
`
`
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`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 016
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 15 of 16
`
`5,692,525
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 017
`
`

`

`U.S. Patent
`
`Dec. 2, 1997
`
`Sheet 16 of 16
`
`5,692,525
`
`
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 018
`
`

`

`1
`CGARETTE FOR ELECTRICAL SMOKING
`SYSTEM
`
`5,692,525
`
`10
`
`15
`
`20
`
`25
`
`2
`element is communicated to the bed of tobacco-laden ele
`ments so as to cause the bed to release a tobacco aerosol.
`While this type of smoking device produces little or no
`sidestream smoke, it still generates products of combustion
`at the heat source, and once its heat source is ignited, it is not
`readily snuffed for future use in a practical sense.
`Copending and commonly assigned, U.S. patent applica
`tions Ser. No. 08/380,718, filed Jan. 30, 1995 and Ser. No.
`07/943,504, filed Sep. 11, 1992 disclose various heating
`elements and flavor generating articles which significantly
`reduce sidestream smoke while permitting the smoker to
`selectively suspend and reinitiate smoking.The parent of the
`former application issued Feb. 14, 1995, as U.S. Pat. No.
`5.388,594, and the latter application issued Apr. 9, 1996 as
`U.S. Pat No. 5,505214,
`The aforementioned, United States patent application Ser.
`No. 08/380,718 describes an electrical smoking system
`including a novel electrically powered lighter and a novel
`cigarette that cooperates with the lighter. The preferred
`embodiment of the lighter includes a plurality of metallic
`serpentine heaters disposed in a configuration that slidingly
`receives a tobacco rod portion of the cigarette.
`The preferred embodiment of the cigarette in Ser. No.
`08/380,718 comprises a tobacco-laden tubular carrier, a
`cigarette paper overwrapped about the tubular carrier, an
`arrangement of flow-through filter plugs at a mouthpiece end
`of the carrier and a filter plug at the free (distal) end of the
`carrier. The cigarette and the lighter are configured such that
`when the cigarette is inserted into the lighter and as indi
`vidual heaters are activated for each puff, localized charring
`occurs at spots about the cigarette in the locality where each
`heater was bearing against the cigarette (hereinafter referred
`to as a "heater footprint”). Once all the heaters have been
`activated, these charred spots are closely spaced from one
`another and encircle a central portion of the carrier portion
`of the cigarette.
`When we included cut filler with the hollow structure of
`the cigarette in Ser. No. 08/380,718, it was discovered that
`such cigarettes when fully filled with cut filler tobacco
`tended to operate adequately in an electrical lighter for the
`first several puffs. Thereafter, its delivery would tend to taper
`off. The same phenomenon would tend to occur when more
`traditional cigarettes were smoked in an electrical lighter
`such as the electrical lighter disclosed in U.S. Ser. No.
`08/380,718.
`When left unfilled, the hollow cigarette structures of the
`preferred embodiments of Ser. No. 08/380,718 were also
`somewhat vulnerable to collapse from extreme or rough
`handling.
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`This application is a divisional of application Ser. No.
`08/425,166 filed Apr. 20, 1995, which is a continuation-in
`part of commonly assigned, copending patent application
`Ser. No. 08/380,718, filed Jan. 30, 1995, still pending which
`is a continuation of U.S. Pat. No. 5.388,594 which issued
`from Ser. No. 08/118,665, filed Sep. 10, 1993, the latter
`being a continuation-in-part of commonly assigned patent
`application Ser. No. 07/943.504, filed Sep. 11, 1992, now
`U.S. Pat. No. 5,505,214, all which are hereby incorporated
`by reference in their entireties.
`The present application relates to commonly assigned
`patent application Ser. No. 07/943,747, filed Sep. 11, 1992
`(which issued Nov. 29, 1994, as U.S. Pat. No. 5,369,723) to
`commonly assigned U.S. Pat. No. 5,060.671, issued Oct. 29,
`1991; to commonly assigned U.S. Pat. No. 5,095,921. issued
`Mar. 17, 1992; and to commonly assigned U.S. Pat. No.
`5.224,498, issued Jul. 6, 1992; all which are hereby incor
`porated by reference in their entireties.
`The present application is also related to the commonly
`assigned, co-pending U.S. Ser. No. 08/426,165, which is
`filed concurrently herewith and entitled, "Heater For Elec
`trical Smoking System”; and the present application is
`related to the commonly assigned, co-pending U.S. Ser. No.
`08/426,006, which is filed concurrently herewith and
`entitled, "Iron Aluminide Alloys Useful as Electrical Resis
`tance Heating Elements". These related applications Ser.
`No. 08/426,165 (which issues Jan. 7, 1997, as U.S. Pat. No.
`5,591.368) and Ser. No. 08/426,006 are hereby incorporated
`by reference in their entireties.
`FIELD OF INVENTION
`The present invention relates generally to electrical smok
`ing systems, and in particular cigarettes adapted to cooperate
`with electrical lighters of electrical smoking systems.
`BACKGROUND OF THE INVENTON
`Traditional cigarettes deliver flavor and aroma to the
`smoker as a result of combustion, during which a mass of
`tobacco is combusted at temperatures which often exceeds
`800° C. during a puff. The heat of combustion releases
`various gaseous combustion products and distillates from
`the tobacco. As these gaseous products are drawn through
`the cigarette, they cool and condense to form an aerosol
`50
`which provides the tastes and aromas associated with smok
`Ing.
`Traditional cigarettes produce sidestream smoke during
`smoldering between puffs. Once lit, they must be fully
`consumed or be discarded. Re-lighting a traditional cigarette
`is possible but is usually an unattractive proposition to a
`discerning smoker for subjective reasons (flavor, taste,
`odor).
`An alternative to the more traditional cigarettes includes
`those in which the combustible material itself does not itself
`release the tobacco aerosol. Such smoking articles may
`comprise a combustible, carbonaceous heating element (heat
`source) located at or about one end of the smoking article
`and a bed of tobacco-laden elements located adjacent the
`aforementioned heating element. The heating element is
`ignited with a match or cigarette lighter, and when a smoker
`draws upon the cigarette, heat generated by the heating
`
`60
`
`35
`
`45
`
`SUMMARY OF THE INVENTION
`Accordingly, a primary object of the present invention is
`to provide a novel cigarette which contains cut filler and yet
`is operable with consistency when smoked as part of an
`electrical smoking system.
`Another object of the present invention is to provide a
`cigarette containing cut filler, which cigarette is adapted to
`cooperate with an electrical lighter and render satisfying
`levels of taste and delivery.
`Yet another object of the present invention is to provide a
`cigarette for an electrical smoking system which includes
`cut filler, yet provides improved consistency in delivery
`from puff to puff.
`Still another object of the present invention is to provide
`a smoking article which is readily manufactured and packed
`into attractive packaging.
`
`55
`
`65
`
`Philip Morris Products, S.A.
`Exhibit 1011
`Page 019
`
`

`

`5,692,525
`
`O
`
`15
`
`25
`
`30
`
`35
`
`3
`It is a still further object of the present invention to
`provide a cigarette which is physically robust and minimizes
`condensation and/or filtration of aerosol within the cigarette
`and/or the lighter.
`Another object of the present invention is to provide a
`cigarette adapted for use in electrical smoking systems,
`which cigarette is resistive to breakage during the with
`drawal of the cigarette from the lighter thereof.
`It is another object of the present invention to provide a
`cigarette suited for consumption with a lighter of an elec
`trical smoking system, wherein the cigarette itself is less
`vulnerable to collapse or breakage during rough handling by
`the consumer.
`It is another object of the present invention to provide a
`cigarette suited for consumption with a lighter of an elec
`trical smoking system wherein the cigarette itself is not
`prone to collapse or breakage during the manufacture or
`packing of the cigarette.
`It is still a further object of this invention to provide a
`novel cigarette that is operative with an electrical lighter and
`conducive to cost-effective methods of manufacture, even at
`production speeds.
`These objects and other advantages are provided by the
`present invention which provide a smoking system for
`delivering a flavored tobacco response to a smoker. The
`system includes a cigarette and an electrically operated
`lighter, which lighter includes a plurality of electrical
`heaters, with each of the heaters being adapted to, either
`singularly or in concert, to thermally release a predetermined
`quantity of tobacco aerosol from the cigarette upon its/their
`activation.
`In accordance with one aspect of the present invention,
`the cigarette comprises a tubular tobacco web, wherein a
`first portion of the tubular tobacco web is filled with a
`column of tobacco, preferably in the form of cut filler, and
`a second portion of the tubular tobacco web is left unfilled
`or hollow so as to define a void in the tobacco column.
`More particularly, the aforementioned cigarette prefer
`ably comprises a tobacco rod formed from a tubular tobacco
`web and a plug of tobacco located within the tubular tobacco
`web. The tobacco rod is adapted to be slidingly received by
`an electrical heater fixture such that the heater elements
`locate alongside the tobacco rod at a location between the
`free end and an opposite end of the tobacco rod. Preferably
`the plug (or column) of tobacco extends from the free end of
`the tobacco rod to a location that is spaced from the opposite
`end of the tobacco rod so as to define a void (or hollow
`portion) adjacent the opposite end.
`The relative dimensions of the cigarette and the heater
`fixture of the lighter are determined such that upon insertion
`of the cigarette into the lighter, each heater will locate
`alongside the tobacco rod at a predetermined location along
`the tobacco rod and, preferably, such that the longitudinal
`extent of contact between the heater and the cigarette
`(hereinafter "heater footprint") superposes at least a portion
`of the aforementioned void and at least a portion of the plug
`of tobacco. In so doing, consistent and satisfactory delivery
`is obtained when the cigarette is electrically smoked, and
`condensation of tobacco aerosol at or about the heater
`elements is reduced.
`In the alternative, the relative dimensions of the cigarette
`and the heater fixture of the lighter are determined such that
`upon insertion of the cigarette into the lighter, each heater
`will locate alongside the tobaccorod such that at least some,
`if not all of the heater footprints superpose only the filled
`portion of the tobacco rod (over the tobacco plug). In such
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`configurations, the void may still be employed to facilitate
`aerosol formation and to help cool the smoke.
`Preferably, a cigarette paper is wrapped about the tubular
`tobacco web so as to provide the appearance and feel of the
`more traditional cigarette during handling by the smoker.
`The tobacco web preferably comprises a nonwoven
`tobacco base web and a layer of tobacco material located
`along at least one side of the tobacco base web.
`The cigarette preferably also includes filter tipping at the
`aforementioned opposite end of the tobacco rod, which
`comprises a flow-through filter plug (also known in the art
`as "whistle-through" plugs), a mouthpiece filter plug and
`tipping paper attaching the plugs to the tobacco rod.
`When a cigarette of the present invention is inserted into
`a lighter of an electrical smoking system, the cigarette
`registers against a stop located within the heater fixture of
`the lighter (or at some equivalent registration) so that the
`electrical heating elements of the lighter locate consistently
`alongside the cigarette at generally the same location for
`each cigarette. As a puff is initiated, at least one of the
`heaters of the lighter is responsively activated to heat the
`cigarette at the aforementioned location along the tobacco
`rod. As a puff progresses, the tobacco rod is heated and
`aerosol is driven off the tobacco web and the filler. Where
`the heater footprint superposes the void in the tobacco rod,
`tobacco aerosol is almost immediately released into the
`space defined within the unfilled portion of the tobacco rod
`and drawn out of the cigarette. The tobacco web contributes
`most of this fraction of the total aerosol delivered by the
`cigarette and its immediacy is believed to favorably affect
`the nature and extent of the smoker's draw on the cigarette.
`Because of the greater mass of tobacco at the filled portion
`of the tobacco rod, there is a slight delay in the release of
`aerosol from where the heater footprint superposes the filled
`portion of the rod. The aerosol which is driven off the filled
`portion of the tobacco rod contributes an additional, domi
`nating flavor and character to the smoke.
`A further aspect of the present invention is the capacity to
`adjust delivery of a cigarette of an electrical smoking
`system, wherein the proportional amount of overlap between
`the filled and unfilled portions of the tobacco rod by the
`heater footprint effects desired adjustments in delivery from
`one brand of cigarette to another or within line extensions of
`the same brand.
`Yet another aspect of the present invention is a method of
`improving levels and consistency of delivery of aerosol from
`a cigarette operated with an electronic heater device,
`wherein the cigarette has a free end and an opposite end. The
`method comprises the steps of superposing a heater footprint
`over both a tobacco-filled portion of the cigarette adjacent
`the free end and an unfilled portion of the cigarette adjacent
`the opposite end, while simultaneously resistively heating
`along the heater footprint and drawing on the cigarette
`through the opposite end thereof.
`Still another aspect of the present invention is to provide
`a filler containing cigarette that is operative with an electri
`cal lighter, which cigarette includes a tobacco rod having a
`free-flow filter and a filler-free rod portion adjacent the free
`flow filter so as to promote consistent aerosol production.
`Another aspect of the present invention is a reinforced
`tubular tobacco web having flax or wood cellulosic fiber
`added to its base web so as to provide additional strength. In
`the alternative, cellulosic fiber from tobacco stem feedstock
`may be included in the composition of the base web as a
`reinforcing agent.
`Robustness of the cigarette is improved by the inclusion
`of cut filler within the confines of its tubular tobacco web so
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`Exhibit 1011
`Page 020
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`5
`as to provide a cigarette which can better withstand
`handling, including handling by cigarette manufacturing
`machines and by consumers.
`BRIEF DESCRIPTION OF THE DRAWING
`Other objects, advantages and novel features of the
`present invention will become apparent from the following
`detailed description of the preferred embodiments when
`considered in conjunction with the accompanying drawings,
`wherein:
`FIGS. 1 and 2 are perspective views of an electronic
`smoking system in accordance with a preferred embodiment
`of the present invention;
`FIG. 3 is a breakaway perspective view of a cigarette
`engaged within the heater fixture of the Smoking system
`shown in FIG. 1;
`FIG. 4A is a sectional side view of a cigarette constructed
`in accordance with a preferred embodiment of the present
`invention;
`FIG. 4B is a detailed perspective view of the cigarette
`shown in FIG. 4A, with certain components of the cigarette
`being partially unravelled;
`FIGS.5A and 5B are flow diagrams of steps in a preferred
`process of making bobbins of the tobacco web of the
`cigarette shown in FIGS. 4A and 4B, wherein FIG. 5A show
`the steps of converting tobacco feedstock into a sheet of
`tobacco web, and FIG. 5B shows the steps of converting the
`tobacco web sheet into bobbins of tobacco web;
`FIG. 6A is a cross-sectional side view of a cigarette
`constructed in accordance with a substantially hollow
`embodiment of the present invention;
`FIG. 6B is a graphical representation of aerosol produc
`tion versus time during each puff as generated by a cigarette
`constructed in accordance with the substantially hollow
`embodiment of the present invention of FIG. 6A;
`FIG. 6C is a layout of a smoke measuring device that was
`used to establish data that is represented in FIGS. 6B, 7B and
`8;
`FIG. 7A is a cross-sectional side view of a cigarette
`constructed in accordance with a fully-filled embodiment of
`the present invention;
`FIG. 7B is a graphical representation of aerosol produc
`tion versus time during each puff as generated by a cigarette
`constructed in accordance with the fully-filled embodiment
`of FIG. 7A;
`FIG. 8 is a graphical comparison of aerosol volume at
`each sequential puff as delivered by each cigarette of those
`described in reference to FIGS. 4A 6A and 7A,
`FIG. 9 is a graphical presentation of the relationship
`between the delivery of total particulate matter (TPM) and
`the amount of heater overlap over the filled portion of the
`partially filled cigarette constructed in accordance with the
`preferred embodiment (FIG. 4A) of the present invention;
`FIG. 10 is a cross-sectional side view of a cigarette
`constructed in accordance with a second preferred embodi
`ment of the present invention; and
`FIG. 11 is a cross-sectional side view of a cigarette
`constructed in accordance with a third preferred embodi
`ment of the present invention.
`DETALED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`Referring to FIGS. 1 and 2, a preferred embodiment of the
`present invention provides a smoking system 21 which
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`includes a partially-filled, filler cigarette 23 and a reusable
`lighter 25. The cigarette 23 is adapted to be inserted into and
`removed from a receptacle 27 at afront end portion 29 of the
`lighter 25. Once the cigarette 23 is inserted, the smoking
`system 21 is used in much the same fashion as a more
`traditional cigarette, but without lighting or smoldering the
`cigarette 23. The cigarette 23 is discarded after one or more
`puff cycles. Preferably, each cigarette 23 provides a total of
`eight puffs (puff cycles) or more per smoke; however it is a
`matter design expedient to adjust to a lesser or greater total
`number of available puffs.
`The lighter 25 includes a housing 31 having front and rear
`housing portions 33 and 35. One or more batteries 35a are
`removably located within the rear housing portion 35 and
`supply energy to a plurality of electrically resistive, heating
`elements 37 which are arranged within the front housing
`portion 33 adjacent the receptacle 27. A control circuit 41 in
`the front housing portion 33 establishes electrical commu
`nication between the batteries 35a and the heater elements
`37. Preferably, the rear portion 35 is adapted to be readily
`opened and closed, such as with screws or snap-fit
`components, to facilitate replacement of the batteries. If
`desired, an electrical socket or contacts may be provided for
`recharging the batteries with house current or the like.
`Preferably, the front housing portion 33 is removably
`joined to the rear housing portion 35, such as with a dovetail
`joint or a socketfit. The housing 31 is preferably made from
`a hard, heat-resistant material. Preferred materials include
`metallic or, more preferably, polymeric materials.
`Preferably, the housing 31 has overall dimensions of about
`10.7 cm by 3.8 cm by 1.5 cm. so that it may fit comfortably
`in the hand of a smoker.
`The batteries 35a are sized to provide sufficient power for
`the heaters 37 to function as intended and preferably com
`prise a replaceable and rechargeable type. Alternate sources
`of power are suitable, such as capacitors. In the preferred
`embodiment, the power source comprises four nickel
`cadmium battery cells connected in series with a total.
`non-loaded voltage of approximately 4.8 to 5.6 volts. The
`characteristics required of the power source are, however,
`selected in view of the characteristics of other components
`in the smoking system 21, particularly the characteristics of
`the heating elements 37. U.S. Pat. No. 5,144.962, hereby
`incorporated by reference, describes several types of power
`sources useful in connection with the smoking system of the
`present invention, such as rechargeable battery sources and
`power arrangements which comprise a capacitor which is
`recharged by a battery.
`Referring now to FIG. 3, the front housing portion 33 of
`the lighter 25 supports a substantially cylindrical heater
`fixture 39 which slidingly receives the cigarette 23. The
`heater fixture 39 houses the heater elements 37 and is
`adapted to support an inserted cigarette 23 in a fixed relation
`to the heater elements 37 such that the heater elements 37 are
`positioned alongside the cigarette at approximately the same
`location along each cigarette. Where each heater element 37
`bears against (or is in thermal contact with) a fully inserted
`cigarette 23 is referred to herein as the heater footprint.
`To assure consistent placement of the heating elements 37
`relative to each cigarette 23 from cigarette to cigarette, the
`heater fixture 39 is provided with a stop 182 against which
`the cigarette is urged during its placement into the lighter 25.
`Other expedients for registering the cigarette 23 relative to
`the lighter 25 could be used instead.
`The front housing portion 33 of the lighter 25 also
`includes an electrical control circuitry 41 which delivers a
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`Philip Morris Products, S.A.
`Exhibit 1011
`Page 021
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`predetermined amount of energy from the power source 35a
`to the heating elements 37. In the preferred embodiment, the
`heater fixture 39 includes eight circumferentially spaced
`apart heating elements 37 which are concentrically aligned
`with the receptacle 27 and of serpentine form. Details of the
`heaters 37 are illustrated and described in commonly
`assigned U.S. Pat No. 5,505.214, copending herewith and in
`commonly assigned, U.S. Pat. No. 5.388,594, both of which
`documents are incorporated herein by reference in their
`entireties. Additional heater fixtures 37 that are operable as
`part of the lighter 25 include those disclosed in commonly
`assigned, copending U.S. patent application Ser. No. 08/370,
`125 filed Jan. 6, 1995 in commonly assigned, U.S. Pat. No.
`5,591.368 and commonly assigned, U.S. Pat. No. 5,498,855,
`all which documents are incorporated herein by reference in
`their entireties. Preferably, the heaters 37 are individually
`energized by the power source 35a under the control of the
`circuitry 41 to heat the cigarette 23 preferably eight times at
`spaced locations about the periphery of the cigarette 23. The
`heating renders eight puffs from the cigarette 23, as is
`commonly achieved with the smoking of a more traditional
`cigarette. It may be preferred to fire more than one heater
`simultaneously for one or more of the puffs.
`Another preferred heater arrangement is set forth in
`co-pending, commonly assigned, U.S. patent application
`Ser. No.