Abstract: A flavor source to be used as a thermally releasable flavorant for smoking articles that do not combust tobacco. The flavor source includes tobacco particles, an aerosol precursor that forms an aerosol upon exposure to heat, and a gelling agent that imparts sufficient structural framework for rigidity to the flavor source. The material is mixed, extruded through a die, and cut into the shape of a one-piece flavor source. The flavor source is loaded into a chamber for inclusion in a smoking article as a flavor generator.

Abstract: A filter cigarette comprising a tobacco rod and filter portion comprising a fluted tubular extrusion. The flutes are blocked intermediate the rod end and mouth end of the extrusion. The tobacco rod is circumferentially wrapped with a porous wrapper comprising a longitudinal band of perforations. The fluted tubular extrusion is attached with tipping paper to the tobacco rod. A mouthband and a rodband of perforations circumscribes the tipping paper. A rod of charcoal-impregnated filter material may abut the tubular extrusion.

Abstract: A polyolefin material having improved fibrillation properties, allowing one to achieve higher yield in cigarette filters made from the fibrillated material is provided. The material includes between about 70% and about 99% of at least one polypropylene homopolymer with a melt index of between about 1.2 to about 3.0 (measured according to ISO standard 1133 at 230.degree. C., 2.16 kgf) and a density of about 0.905 g/cc, and between about 1% and about 30% of at least one low density polyethylene homopolymer with a melt index of between about 0.9 and 3.0 (measured according to ISO standard 1133 at 190.degree. C., 2.16 kgf) and a density of about 0.921 g/cc.

Abstract: An improved stuffer box used for crimping textile fibers, particularly fibrillated polyolefin films. The width of the stuffer box is related to the linear density of the fiber bundles to be crimped whereby there is one millimeter of width for each fiber bunder size in the range of from about 200 to about 750 denier. Pressure controlled hinged lid or fixed lid exit orifices may be employed. Also employed may be a distributing device for applying additive material to the textile fibers prior to crimping to enhance the crimping operation or to enhance the end use of the crimped fiber or both. Fibrillated polyolefin materials that are crimped in accordance with the invention are adapted for use as filter materials in smoking articles.

Abstract: A cigarette filter has a substantially cylindrical inner member of filter material surrounded by an outer member of filter material and a plugwrap. The density of the inner and outer members are typically different, and a flavorant is added to at least one of the members. Methods and apparatus for making the filter are also disclosed.

Abstract: An apparatus and a method for processing extruded tobacco-containing materials as they are continuously extruded by applying a powdery material to the surface of the extrudate, optionally wiping the coated extruded material in order to smear or embed the powdery materials along and into the surface of the extruded material. The powdery material may be a flavorant or other additive materials modifying the characteristics of the extruded material. The invention is useful particularly for use in processing foamed, extruded materials into smoking articles which can be used with conventional cigarette maker equipment to produce large quantities of foamed, extruded tobacco-containing smoking articles having properties substantially equivalent to those of a conventional cigarette.

Abstract: A flavor source to be used as a thermally releasable flavorant for smoking articles that do not combust tobacco. The material includes tobacco particles, an aerosol precursor that forms an aerosol upon exposure to heat, and a filler material that absorbs and radiates heat to minimize the likelihood that the flavor material will ignite. The material is mixed in an extruder, extruded through a die, and cut into pellets having a substantially uniform shape. The pellets are loaded into a chamber for inclusion in a smoking article as a flavor generator.

Abstract: A method is provided for heating fibrillated polyolefin film prior to crimping, to improve the crimping, and thus the yield and variability as a filter, of the tow. The fibrillated tow is crimped while still hot from the heating step. The resulting fibers have more uniform crimping at higher levels than those not subject to heating.

Abstract: Apparatus and a method for processing hot, moist extruded tobacco-containing materials as they are continuously extruded by drying the extruded material rapidly with microwave energy, and then cooling the extruded material rapidly so that the surface temperature of the extruded material is decreased below the bulk temperature to provide the extruded material with an adequately rigid and stable dimensionally structure that can be formed into a smoking article. Microwave drying provides substantially uniform drying without case hardening the material. Cooling may occur by passing air at high velocity, refrigerated air or presenting a partial vacuum across the advancing extruded material, or contacting the material with cold contacting members or a cryogenic bath. Conventional maker devices can be used for forming smoking articles from the dried and cooled extruded material.

Abstract: A filter cigarette is provided in which the smoker can select different flavorants or filter media for interposition in the smoke stream. A filter segment having two flow paths, each containing different flavoring or filtering media, cooperates with one or two rotatable end caps having openings for selective registration with the flow paths, are used to select the desired flow path. A method of delivering "air-swept flavor" is also provided.

Abstract: A method for applying additives to a cigarette filter rod during its formation is disclosed. The additives are applied in the form of a liquid foam, allowing low application rates with uniform distribution. According to the method, it is not necessary to use large amounts of solvents to apply the additives, thereby avoiding overwetting of the filter material.

Abstract: A variable dilution cigarette is provided having two-layer laminated tipping. Dilution patterns and break lines are formed in the layers before they are laminated. The laminate is applied to a segmented filter such that the dilution pattern of one layer moves relative to that of the other, changing their degree of registry and varying the dilution value of the cigarette, as the filter segments are rotated relative to one another. Because the two dilution patterns can be formed separately, non-linear dilution variation is possible, as well as more nearly constant resistance-to-draw. A method of manufacturing the cigarette is also provided.

Abstract: A cigarette is provided having a variable length. A filter or mouthpiece slides within a sleeve attached to the cigarette, or a sleeve attached to the filter or mouthpiece slides over the cigarette. A single band is adhered to one element and a pair of bands is adhered to the other element. The single band is captive between the pair of bands so that the cigarette can be lengthened or shortened within the range allowed by the pair of bands, but the filter or mouthpiece cannot be removed from the cigarette. The variable length mechanism can be made to additionally provide variable dilution or variable flavorant.

Abstract: A filter cigarette is provided which is adjustable to provide a wide range of air dilution and/or RTD values and which comprises a tobacco rod, a wrapped, substantially cylindrical filter plug, and tipping paper. The filter plug comprises a first, mouth-end segment and a second, axially aligned, rod-end segment spaced apart from the first segment. The wrapping circumscribes the first and second segments defining a substantially cylindrical void therebetween which may include means of releasing varying amounts of a flavorant. The first segment is movable towards the second segment thereby compressing the plug wrap between the segments which decreases the volume of the void and increases the RTD value of the cigarette.

Abstract: A variable dilution cigarette, of the type having a filter with two relatively rotatable segments having slits in the plug wrapping and the tipping paper which rotate in and out of rotational registry to vary the dilution level, is provided which is insensitive to slight longitudinal misalignment of the slits. An array of longitudinal depressions is formed in one segment of the filter plug centered on the slit in the plug wrapping and ending short of both ends of the filter segment containing the slit. The depressions act as a plenum allowing the longitudinal flow of air between the slit in the tipping paper and the slit in the plug wrapping in case of longitudinal misalignment arising during use, but do not allow circumferential air flow when the slits are intentionally deregistered by relative rotation of the filter segments. Because the depressions do not reach the ends of the filter segment containing the slit, they do not allow any unwanted air into the filter.

Abstract: A variable dilution filter cigarette is provided which includes a substantially cylindrical tobacco rod, an axially aligned, substantially cylindrical wrapped filter plug, and tipping paper which circumscribes the filter plug and joins the filter plug to the tobacco rod. The filter plug has first and second ends, which are open to permit the passage of air and smoke. The plug wrap is substantially air-impermeable and is divided into a mouth-end band, a central band, and a rod-end band having a first opening. The first and third bands are attached to the filter. The tipping paper is also substantially air-impermeable, circumscribes the filter plug, and extends from the mouth end of the filter plug to a position on the tobacco rod adjacent the rod end of the filter plug. The tipping paper is divided into first and second bands, the first band extending from the mouth end of the filter plug to a position overlying the rod-end band.

Abstract: A substantially cylindrical foamed, extruded, tobacco-containing smoking article and a method of making the article. The article has properties substantially equivalent to a conventional cigarette. It contains from about 5 to about 98 wt. % of particulate tobacco, from 0 to about 60 wt. % of particulate filler, from about 2 to about 40 wt. % of a cellulosic binder selected from among hydroxypropyl cellulose, carboxymethyl cellulose, and its sodium, potassium and ammonium salts, cross-linked carboxymethyl cellulose, and its sodium, potassium and ammonium salts, hydroxyethyl cellulose, ethyl hydroxyethyl cellulose, hydroxypropyl methyl cellulose, methyl cellulose, ethyl cellulose, and mixtures thereof, and from about 5 to about 20 wt. % of water. The article has a density within the range of from about 0.05 to about 1.5 g/cc. The method of making such articles comprises the step of (a) dry blending the tobacco particles having an OV value of from about 3 to about 20% with from 0 to about 60 wt.

Abstract: A filter cigarette is provided which comprises a tobacco rod which includes a charge of tobacco wrapped in cigarette paper, an integral, axially aligned wrapped cylindrical filter plug, and tipping paper. The filter plug is divided into first and second segments with the first segment being rotatable with respect to the second segment. Rotation of the first segment with respect to the second segment causes axial movement of the first segment which serves to vary the air dilution value of the cigarette by uncovering a permeable region in the plug wrapping.

Abstract: A cigarette is provided which comprises a substantially cylindrical tobacco rod, and an integral, axially aligned, substantially cylindrical assembly at the mouth end of the cigarette which preferably includes a wrapped substantially cylindrical filter plug and tipping paper, and which is provided with a mechanism to adjust the air dilution value of the cigarette. The assembly has first and second ends, which are open to permit the passage of air and smoke, and at least two openings in addition to the open ends. Structure is provided for rotating one opening relative to the other so that the openings are in varying degrees of registry to permit varying amounts of air to combine with and dilute the smoke. A method of making the cigarette is also disclosed.

Abstract: A variable dilution filter cigarette is provided which includes a substantially cylindrical tobacco rod, an axially aligned, substantially cylindrical wrapped filter plug, and tipping paper which circumscribes the filter plug and joins the filter plug to the tobacco rod. The filter plug has first and second ends, which are open to permit the passage of air and smoke. The plug wrap is substantially air-impermeable and is divided into a mouth-end band, a central band, and a rod-end band having a first opening. The first and third bands are attached to the filter. The tipping paper is also substantially air-impermeable, circumscribes the filter plug, and extends from the mouth end of the filter plug to a position on the tobacco rod adjacent the rod end of the filter plug. The tipping paper is divided into first and second bands, the first band extending from the mouth end of the filter plug to a position overlying the rod-end band.