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`US 20070215167Al
`
`c19) United States
`c12) Patent Application Publication
`Llewellyn Crooks et al.
`
`c10) Pub. No.: US 2007/0215167 Al
`Sep. 20, 2007
`(43) Pub. Date:
`
`(54) SMOKING ARTICLE
`
`(76)
`
`Inventors: Evon Llewellyn Crooks, Mocksville,
`NC (US); Billy Tyrone Conner,
`Clemmons, NC (US); Dempsey Bailey
`Brewer JR., East Bend, NC (US);
`Louis John Read JR., Winston-Salem,
`NC (US)
`
`Correspondence Address:
`BRINKS HOFER GILSON & LIONE
`P.O. BOX 10395
`CHICAGO, IL 60610 (US)
`
`(21) Appl. No.:
`
`111377,630
`
`(22) Filed:
`
`Mar. 16, 2006
`
`Publication Classification
`
`(51)
`
`Int. Cl.
`A24B 1100
`(2006.01)
`(52) U.S. Cl.
`........................... 131/335; 131/360; 131/361
`
`(57)
`
`ABSTRACT
`
`A smoking article, such as a cigarette, comprises a lighting
`end and a mouth end. The smoking article possesses an
`
`aerosol-generation system that includes (i) a heat generation
`segment, and (ii) an aerosol-generating region or segment. A
`mouth end piece segment can be located at the mouth end of
`the smoking article. A segment of tobacco cut filler, gathered
`tobacco paper, or other type of flavor source material, can be
`positioned between the mouth end piece segment and the
`aerosol-generation segment. Optionally, segment composed
`of tobacco cut filler can be positioned so as to provide a
`lighting end segment. The smoking article possesses an
`overwrap (e.g., a single paper overwrap) that extends over
`the longitudinally extending surface of the mouth end piece
`segment, the aerosol generation segment, at least a portion
`of the length of the heat generation segment, any segment
`located between the mouth end piece and aerosol generation
`segments, and at least a portion of the length of the optional
`lighting end segment. Alternatively, the smoking article
`possesses an overwrap (e.g., a single paper overwrap) that
`extends over the longitudinally extending surface of the
`aerosol-generating segment, at least a portion of the length
`of the heat generation segment, at least a portion of any
`segment located downstream from the aerosol-generating
`segment, and at least a portion of the length of the optional
`lighting end segment, thereby forming a cigarette rod; and
`the cigarette rod is connected or attached to a filter element
`using a tipping type of material and arrangement.
`
`Philip Morris Products, S.A.
`Exhibit 1023
`Page 001
`
`

`

`Patent Application Publication Sep. 20, 2007 Sheet 1 of 5
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`US 2007/0215167 Al
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`30
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`14;
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`30
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`65 !18
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`81
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`Fig. 1
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`70
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`130
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`64
`58
`Fig. 3
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`Philip Morris Products, S.A.
`Exhibit 1023
`Page 002
`
`

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`Patent Application Publication Sep. 20, 2007 Sheet 2 of 5
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`US 2007/0215167 Al
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`65
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`75 (
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`131
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`64
`Fig. 4
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`131
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`115
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`Fig. 5
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`134
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`131
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`64
`Fig. 6
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`Philip Morris Products, S.A.
`Exhibit 1023
`Page 003
`
`

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`Patent Application Publication Sep. 20, 2007 Sheet 3 of 5
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`US 2007/0215167 Al
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`42
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`14}
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`150
`Fig. 7
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`Fig. 8
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`f C 81
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`51
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`f
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`161
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`64
`Fig. 9
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`78
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`Philip Morris Products, S.A.
`Exhibit 1023
`Page 004
`
`

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`Patent Application Publication Sep. 20, 2007 Sheet 4 of 5
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`US 2007/0215167 Al
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`161
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`115
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`72 180
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`120
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`(35
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`(51
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`
`5
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`c81 120
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`f 155
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`115
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`Fig. 12
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`Philip Morris Products, S.A.
`Exhibit 1023
`Page 005
`
`

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`Patent Application Publication Sep. 20, 2007 Sheet 5 of 5
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`US 2007/0215167 Al
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`40 42
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`55
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`195
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`115
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`159
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`158
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`Fig. 13
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`Philip Morris Products, S.A.
`Exhibit 1023
`Page 006
`
`

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`US 2007/0215167 Al
`
`Sep.20,2007
`
`1
`
`SMOKING ARTICLE
`
`FIELD OF THE INVENTION
`
`[0001] The present invention relates to tobacco products,
`such as smoking articles (e.g., cigarettes).
`
`BACKGROUND OF THE INVENTION
`
`[0002] Popular smoking articles, such as cigarettes, have a
`substantially cylindrical rod-shaped structure and include a
`charge, roll or colunm of smokable material, such as shred(cid:173)
`ded tobacco (e.g., in cut filler form), surrounded by a paper
`wrapper, thereby forming a so-called "smokable rod,""to(cid:173)
`bacco rod" or "cigarette rod." Normally, a cigarette has a
`cylindrical filter element aligned in an end-to-end relation(cid:173)
`ship with the tobacco rod. Preferably, a filter element com(cid:173)
`prises plasticized cellulose acetate tow circumscribed by a
`paper material known as "plug wrap." Certain filter elements
`can incorporate polyhydric alcohols. See, for example, UK
`Pat. Spec. 755,475. Certain cigarettes incorporate a filter
`element having multiple segments, and one of those seg(cid:173)
`ments can comprise activated charcoal particles. See, for
`example, U.S. Pat. No. 5,360,023 to Blakley et al. and U.S.
`Pat. No. 6,537,186 to Veluz. Preferably, the filter element is
`attached to one end of the tobacco rod using a circumscrib(cid:173)
`ing wrapping material known as "tipping paper." It also has
`become desirable to perforate the tipping material and plug
`wrap, in order to provide dilution of drawn mainstream
`smoke with ambient air. Descriptions of cigarettes and the
`various components thereof are set forth in Tobacco Pro(cid:173)
`duction, Chemistry and Technology, Davis et al. (Eds.)
`(1999). A cigarette is employed by a smoker by lighting one
`end thereof and burning the tobacco rod. The smoker then
`receives mainstream smoke into his/her mouth by drawing
`on the opposite end (e.g., the filter end) of the cigarette.
`
`[0003] Through the years, there have been proposed vari(cid:173)
`ous methods for altering the composition of mainstream
`tobacco smoke. In PCT Application Pub. No. WO 02/37990
`to Bereman, it has been suggested that metallic particles
`and/or carbonaceous particles can be incorporated into the
`smokable material of a cigarette in an attempt to reduce the
`amounts of certain compounds in the smoke produced by
`that cigarette. In U.S. Patent Application Pub. No. 2005/
`0066986 to Nestor et al., it has been suggested that a tobacco
`rod can incorporate tobacco filler combined with an aerosol(cid:173)
`forming material, such as glycerin. U.S. Pat. No. 6,874,508
`to Shafer et al. proposes a cigarette having a paper wrapped
`tobacco rod having a tip portion that is treated with an
`additive, such as potassium bicarbonate, sodium chloride or
`potassium phosphate.
`
`[0004] Various tobacco substitute materials have been
`proposed, and substantial listings of various types of those
`materials can be found in U.S. Pat. No. 4,079,742 to Rainer
`et al. and U.S. Pat. No. 4,771,795 to White et al. Certain
`cigarette-type products that employ non-tobacco materials
`(e.g., dried vegetable leaves, such as lettuce leaves) as filler
`that is burned to produce smoke that resembles tobacco
`smoke have been marketed under the trade names "Cubebs,
`""Triumph,""Jazz," and "Bravo." See, for example, the
`types of materials described in U.S. Pat. No. 4,700,727 to
`Torigian. Furthermore, tobacco substitute materials having
`the trade names "Cytrel" and "NSM" were introduced in
`Europe during the 1970s. Representative types of proposed
`
`synthetic tobacco substitute materials, smokable materials
`incorporating tobacco and other components, and cigarettes
`incorporating those materials, are described in British Pat.
`No. 1,431,045; and U.S. Pat. No. 3,738,374 to Bennett; U.S.
`Pat. No. 3,844,294 to Webster; U.S. Pat. No. 3,878,850 to
`Gibson et al.; U.S. Pat. No. 3,931,824 to Miano et al.; U.S.
`Pat. No. 3,943,941 to Boyd et al.; U.S. Pat. No. 4,044,777
`to Boyd et al.; U.S. Pat. No. 4,233,993 to Miano et al.; U.S.
`Pat. No. 4,286,604 to Ehretsmann et al.; U.S. Pat. No.
`4,326,544 to Hardwick et al.; U.S. Pat. No. 4,920,990 to
`Lawrence et al.; U.S. Pat. No. 5,046,514 to Bolt; U.S. Pat.
`No. 5,074,321 to Gentry et al.; U.S. Pat. No. 5,092,353 to
`Montoya et al.; U.S. Pat. No. 5,778,899 to Saito et al.; U.S.
`Pat. No. 6,397,852 to McAdam; and U.S. Pat. No. 6,408,856
`to McAdam. Furthermore, various types of highly processed
`smokable materials incorporating tobacco and other ingre(cid:173)
`dients are set forth in U.S. Pat. No. 4,823,817 to Luke; U.S.
`Pat. No. 4,874,000 to Tamai et al.; U.S. Pat. No. 4,977,908
`to Luke; U.S. Pat. No. 5,072,744 to Luke et al.; U.S. Pat. No.
`5,829,453 to White et al. and U.S. Pat. No. 6,182,670 to
`White et al.
`[0005] Certain types of coaxial or concentric-type smok(cid:173)
`ing articles have been proposed. There have been proposed
`cigarette-type smoking articles which have included tobacco
`smokable materials surrounding longitudinally extending
`cores of other materials. UK Pat. Application 2,070,409
`proposes a smoking article having a rod of smoking material
`having at least one filament extending over at least a major
`portion of the length of the rod. U.S. Pat. No. 3,614,956 to
`Thornton proposes a smoking article having an annular outer
`portion made of tobacco smoking material and a central
`cylindrical core of absorbent material. U.S. Pat. No. 4,219,
`031 to Rainer et al. proposes a smoking article having a
`central core of carbonized fibers circumscribed by tobacco.
`U.S. Pat. No. 6,823,873 to Nichols et al. proposes a cigarette
`including an ignition element surrounded by tobacco, which
`is in tum surrounded by a composite outer wrapper. One
`type of cigarette-type smoking article has included a rod of
`tobacco smokable material surrounded by a longitudinally
`extending annulus of some other material. For example, U.S.
`Pat. No. 5,105,838 to White et al. proposes a rod of
`smokable material, normally circumscribed by a layer of
`wrapping material, which is in tum circumscribed by an
`insulating material (e.g., glass filaments or fibers). PCT
`Application Pub. No. WO 98/16125 to Snaidr et al. proposes
`a smoking device constructed from a very thin cigarette
`designed to fit into a tubular ceramic cartridge.
`[0006] Numerous references have proposed various smok(cid:173)
`ing articles of a type that generate flavored vapor, visible
`aerosol, or a mixture of flavored vapor and visible aerosol.
`Some of those proposed types of smoking articles include
`tubular sections or longitudinally extending air passage(cid:173)
`ways. See, for example, those types of smoking articles
`described in U.S. Pat. No. 3,258,015 to Ellis et al.; U.S. Pat.
`No. 3,356,094 to Ellis et al.; U.S. Pat. No. 3,516,417 to
`Moses; U.S. Pat. No. 4,347,855 to Lanzellotti et al.; U.S.
`Pat. No. 4,340,072 to Bolt et al.; U.S. Pat. No. 4,391,285 to
`Burnett et al.; U.S. Pat. No. 4,917,121 to Riehl et al.; U.S.
`Pat. No. 4,924,886 to Litzinger; and U.S. Pat. No. 5,060,676
`to Hearn et al. Many of those types of smoking articles have
`employed a combustible fuel source that is burned to pro(cid:173)
`vide an aerosol and/or to heat an aerosol-forming material.
`See, for example, the background art cited in U.S. Pat. No.
`4,714,082 to Banerjee et al. and U.S. Pat. No. 4,771,795 to
`
`Philip Morris Products, S.A.
`Exhibit 1023
`Page 007
`
`

`

`US 2007/0215167 Al
`
`Sep.20,2007
`
`2
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`White et al.; which are incorporated herein by reference in
`their entireties. See, also, for example, those types of smok(cid:173)
`ing articles described in U.S. Pat. No. 4,756,318 to Clear(cid:173)
`man et al.; U.S. Pat. No. 4,714,082 to Banerjee et al.; U.S.
`Pat. No. 4,771,795 to White et al.; U.S. Pat. No. 4,793,365
`to Sensabaugh et al.; U.S. Pat. No. 4,917,128 to Clearman et
`al.; U.S. Pat. No. 4,961,438 to Korte; U.S. Pat. No. 4,966,
`171 to Serrano et al.; U.S. Pat. No. 4,969,476 to Bale et al.;
`U.S. Pat. No. 4,991,606 to Serrano et al.; U.S. Pat. No.
`5,020,548 to Farrier et al.; U.S. Pat. No. 5,033,483 to
`Clearman et al.; U.S. Pat. No. 5,040,551 to Schlatter et al.;
`U.S. Pat. No. 5,050,621 to Creighton et al.; U.S. Pat. No.
`5,065,776 to Lawson; U.S. Pat. No. 5,076,296 to Nystrom et
`al.; U.S. Pat. No. 5,076,297 to Farrier et al.; U.S. Pat. No.
`5,099,861 to Clearman et al.; U.S. Pat. No. 5,105,835 to
`Drewett et al.; U.S. Pat. No. 5,105,837 to Barnes et al.; U.S.
`Pat. No. 5,115,820 to Hauser et al.; U.S. Pat. No. 5,148,821
`to Best et al.; U.S. Pat. No. 5,159,940 to Hayward et al.; U.S.
`Pat. No. 5,178,167 to Riggs et al.; U.S. Pat. No. 5,183,062
`to Clearman et al.; U.S. Pat. No. 5,211,684 to Shannon et al.;
`U.S. Pat. No. 5,240,014 to Deevi et al.; U.S. Pat. No.
`5,240,016 to Nichols et al.; U.S. Pat. No. 5,345,955 to
`Clearman et al.; U.S. Pat. No. 5,551,451 to Riggs et al.; U.S.
`Pat. No. 5,595,577 to Bensalem et al.; U.S. Pat. No. 5,819,
`751 to Barnes et al.; U.S. Pat. No. 6,089,857 to Matsuura et
`al.; U.S. Pat. No. 6,095,152 to Beven et al; U.S. Pat. No.
`to
`6,578,584 Beven; and U.S. Pat. No. 6,730,832
`Dominguez. Furthermore, certain types of cigarettes that
`employ carbonaceous fuel elements have been commer(cid:173)
`cially marketed under the brand names "Premier" and
`"Eclipse" by R. J. Reynolds Tobacco Company. See, for
`example, those types of cigarettes described in Chemical
`and Biological Studies on New Cigarette Prototypes that
`Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco
`Company Monograph (1988) and Inhalation Toxicology,
`12:5, p. 1-58 (2000). More recently, it has been suggested
`that the carbonaceous fuel elements of those types of ciga(cid:173)
`rettes can incorporate ultrafine particles of metals and metal
`oxides. See, for example, US Pat. Application Pub. No.
`2005/0274390 to Banerjee et al., which is incorporated by
`reference herein.
`[0007] Yet other types of smoking articles, such as those
`types of smoking articles that generate flavored vapors by
`subjecting tobacco or processed tobaccos to heat produced
`from chemical or electrical heat sources are described in
`U.S. Pat. No. 4,848,374 to Chard et al.; U.S. Pat. No.
`4,947,874 to Brooks et al.; U.S. Pat. No. 5,146,934 to Deevi
`et al.; U.S. Pat. No. 5,224,498 to Deevi; U.S. Pat. No.
`5,285,798 to Banerjee et al.; U.S. Pat. No. 5,357,984 to
`Farrier et al.; U.S. Pat. No. 5,593,792 to Farrier et al.; U.S.
`Pat. No. 5,369,723 to Counts; U.S. Pat. No. 5,865,185 to
`Collins et al.; U.S. Pat. No. 5,878,752 to Adams et al.; U.S.
`Pat. No. 5,880,439 to Deevi et al.; U.S. Pat. No. 5,915,387
`to Baggett et al.; U.S. Pat. No. 5,934,289 to Watkins et al.;
`and U.S. Pat. No. 6,164,287 to White; and US Pat. Publi(cid:173)
`cation No. 2005/0016549 to Banerjee et al. One type of
`smoking article that has employed electrical energy to
`produce heat has been commercially marketed by Philip
`Morris Inc. under the brand name "Accord."
`[0008] Smoking articles that employ tobacco substitute
`materials and smoking articles that employ sources of heat
`other than tobacco cut filler to produce tobacco-flavored
`vapors or tobacco-flavored visible aerosols have not
`received widespread commercial success. However,
`it
`
`would be highly desirable to provide aesthetically pleasing
`smoking articles that demonstrate the ability to provide to a
`smoker many of the benefits and advantages of conventional
`cigarette smoking, without delivering considerable quanti(cid:173)
`ties of incomplete combustion and pyrolysis products.
`
`SUMMARY OF THE INVENTION
`[0009] The present invention relates to smoking articles,
`and in particular, to rod-shaped smoking articles, such as
`cigarettes. A smoking article comprises a lighting end (i.e.,
`an upstream end) and a mouth end (i.e., a downstream end).
`The smoking article further comprises an aerosol-generation
`system that includes (i) a heat generation segment, and (ii)
`an aerosol-generating region or segment located down(cid:173)
`stream from the heat generation segment. Most preferably,
`the heat generation segment possesses a short heat source
`comprising a combustible, carbonaceous fuel element. The
`aerosol-generating region incorporates an aerosol-forming
`material (e.g., glycerin and flavors). A mouth end piece or
`segment can be located at the mouth end of the smoking
`article, allowing the smoking article to be placed in the
`mouth of the smoker, and to be drawn upon by the smoker.
`Preferably, the mouth end piece has the form of a filter
`element. If desired, at least one segment of a material such
`as tobacco cut filler, gathered tobacco paper, or other type of
`flavor source material, can be positioned between the mouth
`end piece and the aerosol-generating region. In one embodi(cid:173)
`ment, the smoking article possesses an overwrap (e.g., a
`single paper outer overwrap) that extends over the longitu(cid:173)
`dinally extending surface of the mouth end piece, the
`aerosol-generating region, at least a portion of the length of
`the heat source segment, and any segment located between
`the filter and aerosol generation segments. In another
`embodiment, the smoking article possesses an overwrap
`(e.g., a single paper outer overwrap) that extends over the
`longitudinally extending surface of the aerosol-generating
`region, at least a portion of the length of the heat source
`segment, and at least a portion of any segment located
`downstream from the aerosol generation region, thereby
`forming a cigarette rod; and the cigarette rod is connected or
`attached to a filter element using a tipping type of material
`and arrangement.
`
`[0010] Optionally, upstream from the heat generation seg(cid:173)
`ment (e.g., at the extreme lighting end of the smoking
`article), there can be positioned a longitudinally extending
`segment comprising smokable material that is intended to be
`lit and burned. The aerosol that is generated by the burning
`of that smokable material is drawn into the mouth of the
`smoker through the mouth end of that smoking article. An
`aerosol-generation system is located between that lighting
`end segment and the mouth end piece. The heat generation
`segment of the aerosol-generation system is located down(cid:173)
`stream from, and adjacent to, the lighting end segment. The
`lighting end segment is in a heat exchange relationship with
`the heat generation segment such that during use of smoking
`article, burning smokable material within the lighting end
`segment or smokable segment can ignite the combustible
`fuel element of the heat generation segment. An aerosol(cid:173)
`generating region or segment located downstream from, and
`in a heat exchange relationship with, the heat generation
`segment. If desired, at least one segment of a material, such
`as tobacco cut filler, gathered tobacco paper, or other type of
`flavor source material, can be positioned between the mouth
`end piece and the aerosol-generating region. In one embodi-
`
`Philip Morris Products, S.A.
`Exhibit 1023
`Page 008
`
`

`

`US 2007/0215167 Al
`
`Sep.20,2007
`
`3
`
`ment, the smoking article possesses an overwrap (e.g., a
`single paper outer overwrap) that extends over the longitu(cid:173)
`dinally extending surface of the mouth end piece, the aerosol
`generation region, the heat source segment, any segment
`located between the filter and aerosol-generating segments,
`and at least a portion of the length of the lighting end
`segment. In another embodiment, the smoking article pos(cid:173)
`sesses an overwrap (e.g., a single paper outer overwrap) that
`extends over longitudinally extending surface of the aerosol(cid:173)
`generating region, the heat source segment, at least a portion
`of the length of the lighting end segment, and at least a
`portion of any segment located downstream from the aero(cid:173)
`sol-generating region, thereby forming a cigarette rod; and
`the cigarette rod is connected or attached to a filter element
`using a tipping type of material and arrangement.
`
`[0011] A preferred cigarette of the present invention pos(cid:173)
`sesses a cigarette rod portion that, except for a short region
`at the extreme lighting end thereof, possesses a single layer
`of outermost overwrap material. As such, a cigarette having
`an aesthetically pleasing cigarette rod portion is provided.
`That is, for a preferred cigarette, except for a short region at
`its extreme lighting end, the cigarette possesses what
`appears to be a single outer layer of cigarette rod wrapping
`material.
`
`[0012] The present invention also relates to manners and
`methods for manufacturing, or otherwise producing or
`assembling, smoking articles of the type set forth in accor(cid:173)
`dance with the present invention. As such, there are provided
`manners and methods for producing aesthetically pleasing
`smoking articles.
`
`[0013] Further features and advantages of the present
`invention are set forth in the following more detailed
`description.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0014] FIG. 1 through FIG. 13 provide longitudinal cross(cid:173)
`sectional views of smoking articles representative of the
`present invention.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`
`[0015] Aspects and embodiments of the present invention
`relating to various smoking articles, the arrangement of
`various components thereof, and the manner that those
`smoking articles incorporate overwrap components, are
`illustrated with reference to FIGS. 1 through 13. Like
`components are given like numeric designations throughout
`the figures. For the various figures, the thicknesses of the
`various wrapping materials and overwraps of the various
`smoking articles and smoking article components are exag(cid:173)
`gerated. Most preferably, wrapping materials and overwrap
`components are tightly wrapped around the smoking articles
`and smoking article components to provide a tight fit, and
`provide an aesthetically pleasing appearance.
`
`[0016] Referring to FIG. 1, a representative smoking
`article 10 in the form of a cigarette is shown. The smoking
`article 10 has a rod-like shape, and includes a lighting end
`14 and a mouth end 18.
`
`[0017] At the lighting end 14 is positioned a longitudinally
`extending, generally cylindrical smokable lighting end seg(cid:173)
`ment 22, incorporating smokable material 26. A represen-
`
`tative smokable material 26 can be a plant-derived material
`(e.g., tobacco material in cut filler form). An exemplary
`cylindrical smokable lighting end segment 22 includes a
`charge or roll of the smokable material 26 (e.g., tobacco cut
`filler) wrapped or disposed within, and circumscribed by, a
`paper wrapping material 30. As such, the longitudinally
`extending outer surface of that cylindrical smokable lighting
`end segment 22 is provided by the wrapping material 30.
`Preferably, both ends of the segment 22 are open to expose
`the smokable material 26. The smokable lighting end seg(cid:173)
`ment 22 can be configured so that smokable material 26 and
`wrapping material 30 each extend along the entire length
`thereof.
`
`[0018] Located downstream from the smokable lighting
`end segment 22 is a longitudinally extending, generally
`cylindrical heat generation segment 35. The heat generation
`segment 35 incorporates a heat source 40 circumscribed by
`insulation 42, which is coaxially encircled by wrapping
`material 45.
`
`[0019] The heat source 40 typically possesses a combus(cid:173)
`tible fuel element that has a generally cylindrical shape and
`incorporates a combustible carbonaceous material. Carbon(cid:173)
`aceous materials generally have high carbon contents. Pre(cid:173)
`ferred carbonaceous materials are composed predominantly
`of carbon, typically have carbon contents of greater than
`about 60 percent, generally greater than about 70 percent,
`often greater than about 80 percent, and frequently greater
`than about 90 percent, on a dry weight basis. Fuel elements
`can incorporate components other than combustible carbon(cid:173)
`aceous materials (e.g., tobacco components, such as pow(cid:173)
`dered tobaccos or tobacco extracts; flavoring agents; salts,
`such as sodium chloride, potassium chloride and sodium
`carbonate; heat stable graphite fibers; iron oxide powder;
`glass filaments; powdered calcium carbonate; alumina gran(cid:173)
`ules; ammonia sources, such as ammonia salts; and/or
`binding agents, such as guar gum, ammonium alginate and
`sodium alginate). A representative fuel element has a length
`of about 12 mm and an overall outside diameter of about 4.2
`mm. A representative fuel element can be extruded or
`compounded using a ground or powdered carbonaceous
`material, and has a density that is greater than about 0.5
`g/cm3
`, often greater than about 0.7 g/cm3
`, and frequently
`greater than about 1 g/cm3
`, on a dry weight basis. See, for
`example, the types of fuel element components, formula(cid:173)
`tions and designs set forth in U.S. Pat. No. 5,551,451 to
`Riggs et al.
`
`[0020] A representative layer of insulation 42 can com(cid:173)
`prise glass filaments or fibers. The insulation 42 can act as
`a jacket that assists in maintaining the heat source 40 firmly
`in place within the smoking article 10. The insulation 42 can
`be provided as a multi-layer component including an inner
`layer or mat 47 of non-woven glass filaments, an interme(cid:173)
`diate layer of reconstituted tobacco paper 48, and an outer
`layer of non-woven glass filaments 49. Preferably, both ends
`of the heat generation segment 35 are open to expose the
`heat source 40 and insulation 42 to the adjacent segments.
`The heat source 40 and the insulation 42 around it can be
`configured so that the length of both materials is co-exten(cid:173)
`sive (i.e., the ends of the insulating jacket 42 are flush with
`the respective ends of the heat source 40, and particularly at
`the downstream end of the heat generation segment).
`Optionally, though not necessarily preferably, the insulation
`42 may extend slightly beyond (e.g., from about 0.5 mm to
`
`Philip Morris Products, S.A.
`Exhibit 1023
`Page 009
`
`

`

`US 2007/0215167 Al
`
`Sep.20,2007
`
`4
`
`about 2 mm beyond) either or both ends of the heat source
`40. Moreover, smoke produced when the smokable lighting
`end segment 22 is burned during use of the smoking article
`10 can readily pass through the heat generation segment 35
`during draw by the smoker on the mouth end 18.
`
`[0021] The heat generation segment 35 is positioned adja(cid:173)
`cent to the downstream end of the smokable lighting end
`segment 22 such that those segments are axially aligned in
`an end-to-end relationship, preferably abutting one another.
`The close proximity of the heat generation segment 35 and
`the smokable lighting end segment 22 provides for an
`appropriate heat exchange relationship (e.g., such that the
`action of burning smokable material within the smokable
`lighting end segment 22 acts to ignite the heat source of the
`heat generation segment 35). The outer cross-sectional
`shapes and dimensions of the smokable and heat generation
`segments 22, 35, when viewed transversely to the longitu(cid:173)
`dinal axis of the smoking article, can be essentially identical
`to one another (e.g., both appear to have a cylindrical shape,
`each having essentially identical diameters).
`
`[0022] The cross-sectional shape and dimensions of the
`heat generation segment 35, prior to burning, can vary.
`Preferably, the cross-sectional area of the heat source 40
`makes up about 10 percent to about 35 percent, often about
`15 percent to about 25 percent of the total cross-sectional
`area of that segment 35; while the cross-sectional area of the
`outer or circumscribing region (comprising the insulation 42
`and relevant outer wrapping materials) makes up about 65
`percent to about 90 percent, often about 75 percent to about
`85 percent of the total cross-sectional area of that segment
`35. For example, for a cylindrical cigarette having a cir(cid:173)
`cumference of about 24 mm to about 26 mm, a representa(cid:173)
`tive heat source 40 has a generally circular cross-sectional
`shape with an outer diameter of about 2.5 mm to about 5
`mm, often about 3 mm to about 4.5 mm.
`
`[0023] Located downstream from the heat generation seg(cid:173)
`ment 35 is a longitudinally extending, cylindrical aerosol(cid:173)
`generating segment 51. The aerosol-generating segment 51
`incorporates a substrate material 55 that, in turn, acts as a
`carrier for an aerosol-forming agent or material (not shown).
`For example, the aerosol-generating segment 51 can possess
`a reconstituted tobacco material that incorporates processing
`aids, flavoring agents and glycerin.
`
`[0024] A representative wrapping material 58 for the sub(cid:173)
`strate material 55 can possess heat conductive properties,
`and can have the form of a metal or metal foil (e.g.,
`aluminum) tube, or a laminated material having an outer
`surface comprised of paper and an inner surface comprised
`of metal foil. For example, the metal foil can conduct heat
`from the heat generation segment 35 to the aerosol-gener(cid:173)
`ating segment 51, in order to provide for the volatilization of
`the aerosol forming components contained therein.
`
`[0025] The substrate material 55 can be provided from a
`blend of flavorful and aromatic tobaccos in cut filler form.
`Those tobaccos, in turn, can be treated with aerosol-forming
`material and/or at least one flavoring agent. The substrate
`material can be provided from a processed tobacco (e.g., a
`reconstituted tobacco manufactured using cast sheet or
`papermaking types of processes) in cut filler form. That
`tobacco, in turn, can be treated with, or processed to
`incorporate, aerosol-forming material and/or at least one
`flavoring agent. The inner metal surface of the wrapping
`
`material of the aerosol-generating segment can act as a
`carrier for aerosol-forming material and/or at least one
`flavoring agent. For example, aerosol-forming material and/
`or at least one flavoring agent can be incorporated within a
`film formed on the inner metallic surface of a laminate of
`paper and aluminum foil using a polymeric film forming
`agent, such as ammonium alginate, sodium alginate, guar
`gum, ethyl cellulose, starch, or the like. In addition, aerosol(cid:173)
`forming material and/or at least one flavoring agent can be
`carried by a plurality of metal pieces that can be dispersed
`throughout tobacco filler within the aerosol-generating seg(cid:173)
`ment. For example, aerosol-forming material can be carried
`on the surface of about 10 to about 20 strips of heat
`conductive material (e.g., thin aluminum foil), each strip
`being about 1 mm to about 2 mm wide, and about 10 mm to
`about 20 mm long. Furthermore, components of the aerosol(cid:173)
`generating segment can include aerosol-forming material
`and/or at least one flavoring agent carried by a gathered or
`shredded paper-type material, such as a paper incorporating
`particles of absorbent carbon, alumina, or the like.
`
`[0026] The foregoing components of the aerosol-generat(cid:173)
`ing segment 51 can be disposed within, and circumscribed
`by, a wrapping material 58. A wrapping material 58 can be
`adapted to facilitate the transfer of heat from the upstream
`end 14 of the smoking article 10 (e.g., from the heat
`generation segment 35) to components of the aerosol-gen(cid:173)
`erating segment 51. That is, the aerosol-generating segment
`51 and the heat generation segment 35 can be configured in
`a heat exchange relationship with one another. The heat
`exchange relationship is such that sufficient heat from the
`heat source is supplied to the aerosol-formation region to
`volatilize aerosol-forming material for aerosol-formation. In
`some embodiments, the heat exchange relationship is
`achieved by positioning those segments in close proximity
`to one another. A heat exchange relationship also can be
`achieved by extending a heat conductive material from the
`vicinity of the heat source 40 into or around the region
`occupied by the aerosol-generating segment 51.
`
`[0027] For preferred smoking articles, both ends of the
`aerosol-generating segment 51 are open to expose the sub(cid:173)
`strate material 55 thereof. Components of the aerosol pro(cid:173)
`duced by burning the smokable lighting end segment 22
`during use of the smoking article can readily pass through
`the aerosol-generating segment 51 during draw on the mouth
`end 18.
`
`[0028] Together, the heat generating segment 35 and the
`aerosol-generating segment 51 form an aerosol-generation
`system 60. The aerosol-generating segment 51 is positioned
`adjacent to the downstream end of the heat generation
`segment 35 such that those segments 51, 35 are axially
`aligned in an end-to-end relationship. That is, those seg(cid:173)
`ments are physically separate relative to one another. Those
`segments can abut one another, or be positioned in a slightly
`spaced apart relationship. The outer cross-sectional shapes
`and dimensions of t