Abstract: A smoking article is provided in which a replaceable tobacco flavor unit containing tobacco flavor material is electrically heated by a set of permanent reusable heaters to evolve flavors or other components in vapor or aerosol form for delivery to a smoker. Each heater heats only a portion of the available tobacco flavor material so that a plurality of individual puffs of tobacco flavor substance can be delivered sequentially to the smoker. The replaceable tobacco flavor unit can also include a filter to reduce the effect of residual aerosol which settles or condenses on the permanent portions of the article and which can result in undesirable flavor generation when reheated. A method and apparatus for manufacturing the replaceable tobacco flavor unit is also provided.

Abstract: A smoking system is provided in which a replaceable cigarette containing tobacco flavor material is electrically heated by a set of electrical heater elements contained within a lighter to evolve tobacco flavors or other components in vapor or aerosol form for delivery to a smoker. The cigarette and lighter are adapted to provide air flow patterns through the smoking system such that air flows transversely into the cigarette. Such patterns improve aerosol and flavor delivery to the smoker and reduce the condensation of residual heater-region vapor/aerosol in the smoking system.

Abstract: A novel cigarette of an electrical cigarette system and method of making same, the cigarette comprising a tubular tobacco web and a plug disposed within said tubular tobacco web which provides a structural connection that remains intact after a smoking of the cigarette. The disclosure includes a double-belled plug extending between a free end and a tipped end of a tobacco rod, or in the alternative, a column of tobacco with higher and lower density segments. The disclosure includes a method comprising the steps of producing a continuous plug, passing same through a die, overwrapping the rod with tobacco mat and overwrap, and severing the rod.

Abstract: A method of manufacturing cigarettes including the steps of establishing a succession of 2-up hollow plugs in alternating relation to 2-up tobacco plugs and wrapping same in a tobacco web and overwrap, severing the resultant continuous rod at mid points of preselected 2-up tobacco plugs and severing again to establish associated pairs of singular tobacco rod plugs, separating the members of associated pairs of tobacco rod plugs and placing 2-up filter tipping plugs therebetween, and subsequently wrapping the interposed 2-up filter tipping plug together with adjacent portions of the singular tobacco rod plugs and severing the resultant tipped structure into individual cigarettes. Also provided are cigarettes constructed in accordance with the novel method.

Abstract: A smoking system is provided in which a replaceable cigarette containing tobacco flavor material is electrically heated by a set of electrical heater elements contained within a lighter to evolve tobacco flavors or other components in vapor or aerosol form for delivery to a smoker. The cigarette and lighter are adapted to provide air flow patterns through the smoking system such that air flows transversely into the cigarette. Such patterns improve aerosol and flavor delivery to the smoker and reduce the condensation of residual heater-region vapor/aerosol in the smoking system.

Abstract: A cylindrical tube is provided of a mechanically strong and flexible electrical conductor such as a metal and has a plurality of separated regions. An electrically insulating layer such as a ceramic is applied on the outer surface except for one exposed portion. Electrically resistive heaters are then applied to the insulated regions and are electrically connected at one end to the underlying electrical conducting region. The electrical conductor is connected to the negative terminal of a power source. The other end of all the heaters are adapted to be connected to the positive terminal of the source. Accordingly, an electrically resistive heating circuit is formed wherein the tube serves as a common for all of the heating elements. The tubular heater can comprise an exposed end hub with a plurality of blades extending therefrom. Each blade can have an individual heater deposited thereon. Alternatively, every other blade can have a heater deposited thereon.

Abstract: A smoking article is provided in which a replaceable tobacco flavor unit containing tobacco flavor material is electrically heated by a set of permanent reusable heaters to evolve flavors or other components in vapor or aerosol form for delivery to a smoker. Each heater heats only a portion of the available tobacco flavor material so that a plurality of individual puffs of tobacco flavor substance can be delivered sequentially to the smoker. The replaceable tobacco flavor unit can also include a filter to reduce the effect of residual aerosol which settles or condenses on the permanent portions of the article and which can result in off-tastes when reheated. A method and apparatus for manufacturing the replaceable tobacco flavor unit is also provided.

Abstract: A smoking article is provided in which a replaceable tobacco flavor unit containing tobacco flavor material is electrically heated by a set of permanent reusable heaters to evolve flavors or other components in vapor or aerosol form for delivery to a smoker. Each heater heats only a portion of the available tobacco flavor material so that a plurality of individual puffs of tobacco flavor substance can be delivered sequentially to the smoker. The replaceable tobacco flavor unit can also include a filter to reduce the effect of residual aerosol which settles or condenses on the permanent portions of the article and which can result in undesirable flavor generation when reheated. A method and apparatus for manufacturing the replaceable tobacco flavor unit is also provided.

Abstract: A smoking article wrapper comprising a base web material having a first burn rate and one or more regions having a second burn rate is provided. The regions having a second burn rate are comprised of a composite layer structure of: said base web material, a layer is particulate material, and an adhesive layer which adheres to said base web material and to said layer of particular material. The particulate material is subsequently applied to the adhesive layer. An apparatus and method for applying the particulate material onto the base web is also provided.

Abstract: A smoking system is provided in which a replaceable cigarette containing tobacco flavor material is electrically heated by a set of electrical heater elements contained within a lighter to evolve tobacco flavors or other components in vapor or aerosol form for delivery to a smoker. The cigarette and lighter are adapted to provide air flow patterns through the smoking system such that air flows transversely into the cigarette. Such patterns improve aerosol and flavor delivery to the smoker and reduce the condensation of residual heater-region vapor/aerosol in the smoking system.

Abstract: A bladed tubular array for use as a heating element in an electrical smoking article, and a tobacco flavor element for such an article based thereon, are provided. The integral carbon heater preferably provides eight thermally and electrically discrete heating zones to provide an optimized heating zone when each blade is individually powered. Each blade has a desired resistance, to provide temperature preferably in the range of from about 300.degree. C. to about 900.degree. C., or higher. The relatively brittle carbon composite conductive blades are supported by a reinforcing tube of spiral-wound paperboard. A common ring of the same conductive material serves as a common electrical terminal for the blades, while the free end of each blade serves as the other electrical terminal of that blade.

Abstract: A method and apparatus for orienting elongated components, where the components are initially oriented in a random manner with respect to the ends of the components. Improperly oriented components are separated from properly oriented ones and are transferred to a turnaround device; this device rotates the improperly oriented components 180.degree. about a transverse axis running from one end of the component to the other end of the component. The stream of rotated elongated components is then reintegrated with the stream of elongated components which were initially properly oriented. All of the elongated components are then removed from the orienting apparatus. The output stream of properly oriented elongated components coincides with the input stream of randomly oriented elongated components.

Abstract: This invention relates to a method for delivering free-flowing material into discrete receiving spaces separating filter plugs in partially constructed cigarette filter assemblies. The method entails rapidly feeding a free flowing material such as charcoal into partially constructed cigarette filter assemblies. The free flowing material is dispensed to a first conveyance means and is subsequently transferred to a second conveyance means that is positioned parallel and above the first conveyance means. Vacuum is used to hold the free flowing particulate material onto the first conveyance means and is used to transfer the free flowing material to the second conveyance means and to hold it there. The free flowing material is next transferred into receiving spaces formed between articles such as cigarette filter plugs that are disposed on a third conveyance means. The transfer of the free flowing material to the receiving spaces may also be accomplished by use of vacuum or gravity.

Abstract: Apparatus and a method for laminating patches to a base web accurately, and as efficiently as possible, are provided. Two webs are fed at speeds which are related as the ratio of the width of each patch to the separation distance between patches, the patch web moving more slowly. Patches are cut from the patch web and transferred to the other web while being accelerated to the higher speed.

Abstract: This invention relates to a device for delivering free-flowing material into discrete receiving spaces separating filter plugs in partially constructed cigarette filter assemblies. The device has a metering drum for dispensing free-flowing material onto an air permeable transport tape. A vacuum source beneath the transport tape retains the free-flowing material on the transport tape which conveys the free-flowing material beneath a set of pockets mounted on or within a moving belt. Each pocket is divided by a screen permeable to air but not to the free-flowing material. As the transport tape moves beneath the pockets, vacuum applied beneath the tape ceases, and vacuum applied to the pockets draws the free-flowing material up into the pockets, and retains the free-flowing material in the pockets. When the belt transfers the pockets out from under the vacuum hood, and the vacuum is no longer applied, the free-flowing material is released from the pockets.

Abstract: Apparatus and a method for laminating patches to a base web accurately, and as efficiently as possible, are provided. Two webs are fed at speeds which are related as the ratio of the width of each patch to the separation distance between patches, the patch web moving more slowly. Patches are cut from the patch web and transferred to the other web while being accelerated to the higher speed.

Abstract: A method and apparatus is provided for cutting a disk of material from a continuously advancing strip of material, forming the disk into a cup, and inserting the cup into the end of a tube. The apparatus comprises a first rotating member having a plurality of workstations positioned around its periphery, a second rotating member into which tubes without cups are loaded and from which tubes containing cups are unloaded, and a set of stationary cams which control the operation of the workstations. The strip of material passes around a section of the periphery of the first member, advances at the same rate as the circumferential velocity of the first member, and comes into relative stationary contact with a number of the workstations. The rotation of the first member relative to the stationary cams provides motion to a cutting mandrel, a forming mandrel, a cutting and forming die, and an insertion mandrel associated with each workstation to perform the tasks of cutting, forming, and inserting.

Abstract: Methods and apparatus are provided for sorting and transporting cylindrical articles from a jumbled mass into a continuous stream of uniformly spaced articles aligned end-to-end. The methods include the steps of sorting, spacing and incorporating the spaced apart articles into component assemblies. The invention apparatus comprises a bowl feeder, a series of frictional, suction and lugged belt conveyors and a plurality of vacuum transfer and assembly drums. The apparatus includes a plurality of sensors, a control system and transmission systems for regulating the sorting and transfer of the articles, for synchronizing transfer of the articles between apparatus subsystems, and for incorporating the articles into component assemblies.

Abstract: An apparatus for cutting and forming tubular members useful for positioning heat sources inside a smoking article is disclosed. The tubular members are carried by a plurality of fluted drums from one operation to the next. The tubular members are cut to the desired size by a plurality of rotating circular knives. The ends of the tubular members are then formed by one or more dies that are caused to move into contact with the ends of the tubular members.

Abstract: Relatively fragile components for cigarette-like smoking articles are wrapped with an overwrap by bringing an exposed axial surface portion of the component into resilient contact with the overwrap, and by then rolling the component about its longidudinal axis, again by resiliently contacting the component. Smoking articles including the foregoing components as the distal component and at least one other proximal component are made by supplying a pair of distal components with their distal ends facing one another and pushed up against an interposed stop. The overwrap is slit parallel to the stop just prior to application to the distal components. After overwrapping, the distal components are reoriented so that their distal ends face away from one another. A pair of proximal components is then placed between the distal components, and each proximal component is joined to the adjacent distal component by a tipping overwrap.