Abstract: Disclosed are new fuel components for smoking articles such as cigarettes, new methods of making such fuel components, and cigarettes or other smoking articles incorporating the new fuel components. Fuel components for smoking articles are formed by continuously extruding a composition to form a preselected shape, circumscribing the continuously extruded composition with a layer of material to form a wrapped rod or composite member, preferably bonding the fuel element to the layer of material, and cutting the resulting composite member into predetermined lengths for use in assembling smoking articles.

Abstract: The invention provides machines and methods for continuously filling and closing containers supplied in random orientation. In one embodiment, apparatus in accord with the invention comprises a machine frame 10 that supports devices for continuously orienting, filling and closing containers. Device A supplies the containers in random orientation. Device B continuously orients the containers into a predetermined orientation. Device C continuously fills containers. Device D supplies powder or granular filler material to device C. Device E supplies plugs or stoppers for closing the containers. Device F continuously inserts plugs into filled containers to close the containers. The machine frame 10 contains the driving elements for the various devices of the apparatus.

Abstract: Cigarettes and methods of making them, in which an insulated fuel element is combined with a substrate assembly comprising a substrate within a tube, combining a roll of tobacco with a plug of tobacco paper, combining the fuel element/substrate assembly with the tobacco/tobacco paper assembly, and combining the resulting combination with a filter element to produce filter cigarettes. Methods of constructing the various and preferred subassemblies are also disclosed.

Abstract: A sheet cutting apparatus and a method of cutting tobacco sheet into cut filler are disclosed. The apparatus comprises a fixed ledger blade and a rotatable cutter blade coacting with the ledger blade to simultaneously cut the tobacco sheet transversely and longitudinally into cut pieces useful as cut filler in a cigarette making process. The cut pieces may have a rectangular, zigzag or scalloped shape according to different embodiments of the invention.

Abstract: A high barrier sealable packaging material and a high barrier heat sealed package for smoking articles, such as cigarettes and the like, are disclosed. The packaging material comprises a base layer of a polymeric film, such as a biaxially oriented polyethylene terephthalate (PET) film which has been metallized on one surface thereof with a layer of metal, such as aluminum. The metallized film is then imprinted with ink with a design and/or printed matter on either the metallized or unmetallized surface. Subsequently to or concurrently with the printing, a heat seal layer is applied to the printed and/or unprinted surface for forming a heat seal about which the material is wrapped. In one embodiment, the high barrier packaging material is used as an overwrap for a cigarette package having a tear tape for removing one end of the overwrap.

Abstract: Disclosed is a stabilized substrate composition for smoking articles, particularly cigarettes. In general, the stabilized substrate composition comprises an admixture of a binder and an aerosol forming material which plasticizes the binder, together with optional fillers and/or base materials. In the stabilized substrate compositions of the present invention the relative amounts of binder and aerosol former depend particularly on the situation in which the substrate composition is used. In general, the ratio of aerosol former to binder is between about 3:1 and about 40:1. When the stabilized composition is used on a base material such as tobacco cut filler, the ratio of aerosol former to binder should be at least about 15:1, and preferably is from about 25-35:1, with a maximum ratio of about 40:1. If the composition is formed into a cast sheet, the minimum ratio is about 3:1, the preferred ratio is about 8:1, and the maximum ratio is about 10:1.

Abstract: A cigarette smoking article includes a tobacco rod and a dual filter comprising a tobacco rod end segment made of cellulose acetate tow and a mouth end segment made of a gathered, perforated polymeric film blended with a whitener to produce a substantially non-staining mouth end surface. The polymeric film may also comprise a coextruded flavor film with a flavor carrier layer disposed between a pair of barrier layers for releasing a flavorant into the mainstream smoke during smoking of the cigarette. Transparent wraps may be used to construct the cigarette from the component parts so that the filtration surfaces of the filter rod are visible through the wraps.

Abstract: Disclosed is a stabilized substrate composition for smoking articles, particularly cigarettes. In general, the stabilized substrate composition comprises an admixture of a binder and an aerosol forming material which plasticizes the binder, together with optional fillers and/or base materials. In the stabilized substrate compositions of the present invention the relative amounts of binder and aerosol former depend particularly on the situation in which the substrate composition is used. In general, the ratio of aerosol former to binder is between about 3:1 and about 40:1. When the stabilized composition is used on a base material such as tobacco cut filler, the ratio of aerosol former to binder should be at least about 15:1, and preferably is from about 25-35:1, with a maximum ratio of about 40:1. If the composition is formed into a cast sheet, the minimum ratio is about 3:1, the preferred ratio is about 8:1, and the maximum ratio is about 10:1.

Abstract: A cigarette filter connected to a tobacco rod is provided with air dilution holes which extend radially into the fibrous material of the filter to a depth of about 1.0 to about 4.0 millimeters. When a smoker draws on the cigarette, air admitted into the air dilution holes flows to a central or core region of the filter and thence to the smoker's mouth. Mainstream smoke from the tobacco rod flows into the filter and is diverted to an annular region surrounding the core region.

Abstract: A cigarette includes a rod of smoking material, such as tobacco, to which is attached a mouthpiece that is substantially impervious to air and smoke except for an unfiltered axial bore or flow passage which extends through the mouthpiece. Unfiltered smoke flows from the rod to the interface between the rod and mouthpiece where it is substantially diluted with air and passes through the flow passage for delivery as unfiltered, air diluted smoke. The air dilution reduces the gas phase components of the unfiltered smoke thereby providing a smoother, better tasting cigarette.

Abstract: A fluid injection device and method of injecting and distributing a fluid, such as a gas, liquid or combination thereof, to a continuous, multifilament filter tow used in the manufacture of filters for smokable tobacco products. The injection device includes a converging tongue portion from which a nozzle block is suspended and rigidly supported. A nozzle conduit with a plurality of feed holes is formed in the nozzle block for delivering the fluid to a precise location in the advancing filter tow during its formation and consolidation into a filter rod. Additives, such as flavorants, may be injected into the tow or the tow may be further bloomed by a gas, such as air, to decrease tow usage.

Abstract: A cigarette packaging machine is provided with a mechanism for rejecting defective cigarette packs of a two pack stack of cigarette packs. A defective top pack of the stack is rejected at a first rejection station by a blast of pressurized air or a pusher bar and a defective bottom pack of the stack is rejected at a second rejection station downstream of the first rejection station by a movable arm which pivots away from a position supporting the stack and then pivots toward the stack to strike the bottom pack and eject it from the stack. A magazine filled with acceptable packs is located downstream of the second rejection station for replacing defective packs ejected from the stack.

Abstract: An enclosure is disclosed for minimizing or eliminating the effect of uncontrolled air currents and temperature gradients on a blown film bubble emerging from the die of a blown film extruder. The enclosure includes a flexible, transparent shroud supported by a support frame in a substantially cylindrical shape, tapering down to a frusto-conical shape adjacent the extruder head. The lower edge of the shroud is releasably affixed to an annular platform mounted adjacent to the extruder head in coaxial alignment therewith. Sections of the annular platform and shroud support frame are hinged to enable easier access to the die and extruder head.

Abstract: A method of making an electrochemical heat source is disclosed. The non-combustion heat source includes at least two metallic agents capable of interacting electrochemically with one another, such as magnesium and iron or nickel. The metallic agents may be provided in a variety of forms, including a frozen melt, a bimetallic foil, wire of a first metal wrapped around strands of a different metal, and a mechanical alloy. The metallic agents may be in the form of a powder filling a straw, or small particles extruded with a binder or pressed to form a rod. The powder filled straw or rod may be placed in a heat chamber surrounded by tobacco in a smoking article. An electrolyte solution contacts the metallic agents in the heat chamber to initiate the electrochemical interaction, generating heat which in turn may be used to volatilize nicotine and flavor materials in the tobacco.

Abstract: A new substrate for cigarettes includes an overwrapped rod of gathered cellulose-based paper having an outer diameter of from about 4 mm to about 8 mm; wherein the paper has a basis weight in the range of about 10 g/m.sup.2 to about 90 g/m.sup.2 ; and the paper can include up to about 50 weight percent of one or more burn retardant hydrated salts. The substrate typically comprises an overwrapped rod of a gathered web of a nonwoven cellulosic material, having a length of about 10 mm; wherein the dry unit weight of the substrate rod is from about 20 mg to about 120 mg; and wherein the web of cellulosic material is embossed or scored prior to gathering, thereby providing a substrate rod with a pressure drop of from about 2 to about 40 mm of H.sub.2 O, under FTC conditions.

Abstract: The present invention is directed to improvements in carbonaceous fuel elements wherein (a) the fuel elements are provided with a composite support member which assists in retaining the fuel element within the cigarette structure during smoking, and (b) the fuel elements burn at a lower average temperature than previously known carbonaceous fuel elements. In one preferred embodiment of the present invention, the fuel element comprises at least two different materials contiguous throughout the length thereof, and including one material which burns, and another material which preferably does not burn, or burns more slowly than the burnable material. The non-burning, or substantially non-burning material is advantageously a heat exchange material such as graphite.

Abstract: A tobacco-containing paper is provided using a reconstituted tobacco material as a component thereof. A reconstituted tobacco material, provided using papermaking techniques from a refined tobacco pulp, is refined into a pulp form and provided as a slurry in water. The slurry is combined with inorganic filler (e.g., calcium carbonate particles) and cellulosic pulp (e.g., wood pulp). The resulting slurry is then employed to provide a paper using papermaking techniques. The tobacco-containing paper has many desirable physical characteristics.

Abstract: The present invention relates to a method of providing an aromatic and flavorful precursor for use in a smoking article to alter the aroma of mainstream and sidestream smoke upon burning the cigarette during use. In particular, 2,3-pinanediol and transcinnamaldehyde are contacted together, preferably in the presence of an acid catalyst. The resulting aromatic and flavorful precursor is then collected.

Abstract: A method of and an appratus for automatically determining the moisture content of a tobacco sample and for then automatically determining the stem content of the tobacco sample are disclosed. The apparatus utilizes a dryer, such as a rotary drum dryer with internal agitating vanes, for applying heat to remove moisture and volatiles from the sample and for reducing the sample to lamina and stem portions. Electronic scales are used to weigh the sample before and after drying to determine and store the "wet" and "dry" weights of the sample. Based on the stored wet and dry weights the moisture content is determined. The stem portions are classified into two categories and weighed to determine the stem content by weight of the sample.

Abstract: The present invention relates to an improved insulating sheet material and to cigarettes and other smoking articles which employ the insulating sheet material as one or more components thereof. The improved insulating material is particularly useful in smoking articles having a fuel element and a physically separate aerosol generating means, e.g. as an insulating member for insulating the fuel element. In general, the sheet material of the present invention is formable without the use of any organic binder and comprises an inorganic fibrous material such as calcium sulfate fibers, calcium sodium phosphate fibers, or mixtures thereof, and a relatively small amount of highly refined cellulose-based fibers such as wood pulp.