Method of preparing a rod for use in the preparation of a smoking article   

Abstract: A method of preparing a rod for use in the preparation of a smoking article is described. The rod has a first end and a second end. The rod has located therein a solid support. The solid support extends in a linear fashion from the first end of said rod to the second end of said rod. At least a portion of said solid support is coated and/or impregnated with an additive. The rod is prepared using rod forming means, wherein said rod forming means comprises a channel ending in an open exit, wherein material may pass through at least part of the channel and leave via the open exit in the form of a rod.

The present invention relates to a method and to an apparatus for use in same. The present invention also relates to articles made by said method.

In particular, the present invention relates to a method of forming a rod for use in the preparation of a smoking article.

Rods with threads therein for use as filter rods are known. Examples of such rods are taught in U.S. Pat. No. 4,281,671 and US 2005/0255978. There are a number of problems associated with the methods disclosed therein for preparing the rod articles. For example, the methodology taught in U.S. Pat. No. 4,281,671 does not reliably allow manufacturers to accurately place the threads inside the rods. If—for example—it was desirous to have the thread running along the central axis of the rod then the method taught in U.S. Pat. No. 4,281,671 does not allow workers to create with some degree of accuracy such embodiments, meaning that the threads are prone to being off-centre. This can result in uneven migration of the menthol—which in some cases can result in spotting or similar spoilage of the casings or coverings or wrappers wrapped around filters etc. A problem with the methodology taught in US 2005/0255978 is that it is not best suited for the application of volatile flavourants, such as menthol, since the flavourants are coated onto the solid support at a location quite remote from the rod forming means.

The present invention seeks to overcome these problems. In this respect, the present invention provides a method of preparing a rod having therein a solid support wherein the solid support may be more accurately located inside of the rod and wherein the support comprises and/or has coated thereon an additive.

GB-A-2 070 409 discloses a method of producing a smoking material rod wherein smoking material, a filament comprising a smoke-modifying agent and a wrapper web are fed to a rod-forming device of a rod making machine in order to produce a wrapped rod incorporating the filament. However, the smoke-modifying agent is coated onto the filament prior to entry of the filament into the garniture of the rod making machine.

WO 2005/096851 discloses a method for preparing smoking articles wherein an extrudate is formed and applied to scattered tobacco. The extrudate contains a base constituent to which an additive has been discontinuously supplied. The additive is, therefore, applied remote from the tobacco rolling or rod forming means.

Features and aspects of the present invention will now be described under different sections. It is to be noted that the teachings in each section are applicable to all of the other sections.

The smoking article of the present invention comprises smokable material (sometimes referred to as “smoking material”) wrapped in a wrapper.

The term ‘smokable material’ means any material which can be used in a smoking article. It does not necessarily mean that the material itself will necessarily sustain combustion. The smokable material may be tobacco material or may, alternatively be a tobacco substitute material. A tobacco, substitute material is usually produced as a sheet, and then cut to resemble cut tobacco. The smokable material may then_be blended with other materials to produce a smokable filler material.

The smokable material is typically retained in the form of a rod, commonly known as a smokable material rod or a smoking material rod. These terms are merely intended to mean that part of the smoking article which is contained within the wrapper (which may be a paper or other wrapper, which other wrapper may or may not be combustible) and should not have imported therein any association as to the combustibility or otherwise of individual components of the rod of the smoking material.

The smoking article of the present invention may take any form. For example the smoking article may be one in which the tobacco is smoked by igniting the smoking material and inhaling the products of combustion, as for example in a cigarette, cigar or cigarillo. Alternatively the smoking article may be one in which the smoking material is heated to a temperature at which decomposition in to pyrolysis products occurs without combustion. Such articles are well known and incorporate electrical or other heating means such as a charcoal element.

The preferred smoking article of the present invention is a cigarette comprising a rod of tobacco, a wrapper, and a smoke filter wherein the filter comprises the rod of the present invention.

In particular the smoking article of the present invention may comprise a rod of smoking material optionally in a casing, with or without a filter. The casing may be a wrapper of paper, tobacco leaf or reconstituted tobacco. Alternatively, where, for example, the smoking article is intended to produce low emissions of sidestream smoke, or lower levels of pyrolysis products in the mainstream smoke, the casing may be composed of non-combustible inorganic material such as a ceramic material. The filter may be of any suitable material, for example fibrous cellulose acetate, polypropylene or polyethylene, or paper.

The rod of the present invention has a first end and a second end. Located in the rod is a solid support. The solid support extends in a linear fashion from the first end of said rod to the second end of said rod.

Examples of solid supports for use in the present invention include textile materials and other suitable materials. The solid supports may be in the form of threads or tapes. The solid supports may be coated or impregnated with flavourants, in particular menthol if the smoking article is a cigarette.

In a broad aspect, the present invention provides a method of preparing a rod for use in the preparation of a smoking article. The rod has a first end and a second end. The rod has located therein a solid support. The solid support extends in a linear fashion from the first end of said rod to the second end of said rod. At least a portion of said solid support is coated and/or impregnated with an additive. The rod is prepared using rod forming means, wherein said rod forming means comprises a channel ending in an open exit, wherein material may pass through at least part of the channel and leave via the open exit in the form of a rod. The rod is prepared by: (i) providing starting material for forming said rod; (ii) providing the solid support for location within said formed rod; (iii) providing an additive for coating and/or impregnating at least a portion of said solid support; wherein the initial contact of the solid support with the additive occurs in said rod forming means. The method includes contacting a section of said starting material with a section of said solid support; wherein the initial contact of said section of starting material with said section of said solid support occurs in said rod forming means.

In accordance with the present invention, the rod is prepared by: (i) providing starting material for forming said rod; (ii) providing the solid support for location within said formed rod; (iii) providing an additive for coating and/or impregnating at least a portion of said solid support; wherein the initial contact of the solid support with the additive occurs in said rod forming means. The method includes contacting a section of said starting material with a section of said solid support; wherein the initial contact of said section of starting material with said section of said solid support occurs in said rod forming means.

Thus, in this broad aspect, the present invention provides a method of preparing a rod for use in the preparation of a smoking article; wherein the rod has a first end and a second end; wherein the rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein the rod is prepared using rod forming means, wherein said rod forming means comprises a channel ending in an open exit, wherein material may pass through at least part of the channel and leave via the open exit in the form of a rod; wherein the rod is prepared by: (i) providing starting material for forming said rod; (ii) providing the solid support for location within said formed rod; (iii) providing an additive for coating and/or impregnating at least a portion of said solid support; wherein the initial contact of the solid support with the additive occurs in said rod forming means; and (iv) contacting a section of said starting material with a section of said solid support; wherein the initial contact of said section of starting material with said section of said solid support occurs in said rod forming means.

In another broad aspect, the present invention provides an apparatus for use in such a method. In this respect, the present invention provides an apparatus for preparing a rod suitable for use in the preparation of a smoking article; wherein said rod has a first end and a second end; wherein said rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein said apparatus comprises a rod forming means; wherein said rod forming means comprises: means for providing starting material for forming said rod; means for providing the solid support for location within said formed rod; means for providing an additive for coating and/or impregnating at least a portion of said solid support; means for coating and/or impregnating at least a portion of said solid support with said additive within said channel, wherein the initial contact of the solid support with the additive occurs in said rod forming means; means for allowing a section of said starting material to contact a section of said solid support coated and/or impregnated with said additive within said channel, wherein the initial contact of said section of starting material with said section of said solid support occurs in said rod forming means.

The means may be separate means. Alternatively, two or more of the means may be the same.

As used herein in connection with the present invention, the term “rod forming means” refers to that part of a rod making apparatus in which the rod of starting material is formed.

According to a first aspect of the present invention there is provided a method of preparing a rod for use in the preparation of a smoking article; wherein said rod has a first end and a second end; wherein said rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein said rod is prepared using rod forming means, wherein said rod forming means comprises a channel ending in an open exit, wherein material may pass through at least part of the channel and leave via the open exit in the form of a rod; wherein said rod is prepared by: (i) providing starting material for forming said rod; (ii) providing the solid support for location within said formed rod; (iii) providing an additive for coating and/or impregnating at least a portion of said solid support; (iv) allowing said starting material to travel through at least part of said channel of said rod forming means; (v) coating and/or impregnating at least a portion of said solid support with said additive within said channel; (vi) allowing said solid support coated and/or impregnated with said additive to travel through at least part of channel of said rod forming means; wherein said method comprises: (a) contacting a section of said starting material with a section of said solid support; wherein the initial contact of said section of starting material with said section of said solid support occurs in said rod forming means; (b) allowing the contacted sections of starting material and solid support to travel through at least part of said channel of said rod forming means in the direction of said open exit; (c) allowing the remainder of the starting material and the remainder of the solid support to contact in the rod forming means; (d) allowing the contacted remainder of the starting material and the solid support to travel through at least part of said channel of said rod forming means; (e) forming said rod by said rod forming means, such that on forming said rod said solid support extends within said rod from the first end of said rod to the second end of said rod; and (f) allowing said formed rod to exit from said open exit.

According to a second aspect of the present invention there is provided an apparatus for preparing a rod suitable for use in the preparation of a smoking article; wherein said rod has a first end and a second end; wherein said rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein said rod forming means comprises: (i) a channel ending in an open exit (ii) means for allowing material to pass through at least part of the channel and leave via the open exit in the form of a rod; (iii) means for providing starting material for forming said rod; (iv) means for providing the solid support for location within said formed rod; (v) means for providing an additive for coating and/or impregnating at least a portion of said solid support; (vi) means for coating and/or impregnating at least a portion of said solid support with said additive within said channel; (vii) means for allowing a section of said starting material to contact a section of said solid support coated and/or impregnated with said additive within said channel; (viii) means for allowing said solid support coated and/or impregnated with said additive to travel through at least part of said channel of said rod forming means; (ix) means for allowing said formed rod to exit from said open exit.

The means may be separate means. Alternatively, two or more of the means may be the same.

According to a third aspect of the present invention there is provided an apparatus for preparing a rod suitable for use in the preparation of a smoking article; wherein said rod has a first end and a second end; wherein said rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein said rod forming means comprises: (i) a channel ending in an open exit (ii) means for allowing material to pass through at least part of the channel and leave via the open exit in the form of a rod; (iii) means for providing starting material for forming said rod; (iv) means for providing the solid support for location within said formed rod; (v) means for providing an additive for coating and/or impregnating at least a portion of said solid support; (vi) means for coating and/or impregnating at least a portion of said solid support with said additive within said channel; (vii) means for allowing a section of said starting material to contact a section of said solid support coated and/or impregnated with said additive within said channel; (viii) means for allowing said solid support coated and/or impregnated with said additive to travel through at least part of said channel of said rod forming means; (ix) means for allowing said formed rod to exit from said open exit; wherein said rod forming means comprises a garniture having a channel; wherein the initial coating or impregnation of said portion of said solid support with an additive occurs whilst the solid support is located in the garniture; and wherein the initial contact of the solid support with said starting material occurs whilst the starting material is located in the garniture.

The means may be separate means. Alternatively, two or more of the means may be the same.

According to a third aspect of the present invention there is provided a rod obtained by the method according to the present invention.

According to a fourth aspect of the present invention there is provided a method of forming a smoking article comprising using the method of the present invention or a rod according to the present invention.

In a highly preferred aspect there is provided a method of preparing a rod for use in the preparation of a smoking article; wherein said rod has a first end and a second end; wherein said rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein said rod is prepared using rod forming means, wherein said rod forming means comprises a channel ending in an open exit, wherein material may pass through at least part of the channel and leave via the open exit in the form of a rod; wherein said rod is prepared by: (i) providing starting material for forming said rod; (ii) providing the solid support for location within said formed rod; (iii) providing an additive for coating and/or impregnating at least a portion of said solid support; (iv) allowing said starting material to travel through at least part of said channel of said rod forming means; (v) coating and/or impregnating at least a portion of said solid support with said additive within said channel; (vi) allowing said solid support coated and/or impregnated with said additive to travel through at least part of said channel of said rod forming means; wherein said method comprises: (a) contacting a section of said starting material with a section of said solid support; wherein the initial contact of said section of starting material with said section of said solid support occurs in said rod forming means; (b) allowing the contacted sections of starting material and solid support to travel through at least part of said channel of said rod forming means in the direction of said open exit; (c) allowing the remainder of the starting material and the remainder of the solid support to contact in the rod forming means; (d) allowing the contacted remainder of the starting material and the solid support to travel through at least part of said channel of said rod forming means; (e) forming said rod by said rod forming means, such that on forming said rod said solid support extends within said rod from the first end of said rod to the second end of said rod; and (f) allowing said formed rod to exit from said open exit; wherein said rod forming means comprises a garniture defining said channel; wherein the initial coating or impregnation of said portion of said solid support with an additive occurs whilst the solid support is located in said garniture; and wherein the initial contact of the solid support with said starting material occurs whilst the starting material is located in said garniture.

In another highly preferred aspect there is provided a method of preparing a rod for use in the preparation of a smoking article; wherein said rod has a first end and a second end; wherein said rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein said rod is prepared using a rod forming means, wherein said rod forming means comprises a garniture defining a channel ending in an open exit, wherein material may pass through at least part of the channel and leave via the open exit in the form of a rod; wherein said rod is prepared by: (i) providing starting material for forming said rod; (ii) providing the solid support for location within said formed rod; (iii) providing an additive for coating and/or impregnating at least a portion of said solid support; (iv) allowing said starting material to travel through at least part of said channel of said rod forming means; (v) coating and/or impregnating at least a portion of said solid support with said additive within said channel; (vi) allowing said solid support coated and/or impregnated with said additive to travel through at least part of said channel of said rod forming means; wherein said method comprises: (a) contacting a section of said starting material with a section of said solid support; wherein the initial contact of said section of starting material with said section of said solid support occurs when the starting material is located in the garniture; (b) allowing the contacted sections of starting material and solid support to travel through at least part of said channel of said rod forming means in the direction of said open exit; (c) allowing the remainder of the starting material and the remainder of the solid support to contact in the rod forming means; (d) allowing the contacted remainder of the starting material and the solid support to travel through at least part of said channel of said rod forming means; (e) forming said rod by said rod forming means, such that on forming said rod said solid support extends within said rod from the first end of said rod to the second end of said rod; and (f) allowing said formed rod to exit from said open exit; wherein the initial coating or impregnation of said portion of said solid support with an additive occurs whilst the solid support is located in the garniture; and wherein the initial contact of the solid support with said starting material occurs whilst the starting material is located in the garniture.

In another highly preferred aspect there is provided an apparatus for preparing a rod suitable for use in the preparation of a smoking article; wherein said rod has a first end and a second end; wherein said rod has located therein a solid support; wherein the solid support extends in a linear fashion from the first end of said rod to the second end of said rod; wherein at least a portion of said solid support is coated and/or impregnated with an additive; wherein said rod forming means comprises: (i) a channel ending in an open exit (ii) means for allowing material to pass through at least part of the channel and leave via the open exit in the form of a rod; (iii) means for providing starting material for forming said rod; (iv) means for providing the solid support for location within said formed rod; (v) means for providing an additive for coating and/or impregnating at least a portion of said solid support; (vi) means for coating and/or impregnating at least a portion of said solid support with said additive within said channel; (vii) means for allowing a section of said starting material to contact a section of said solid support coated and/or impregnated with said additive within said channel; (viii) means for allowing said solid support coated and/or impregnated with said additive to travel through at least part of said channel of said rod forming means; (ix) means for allowing said formed rod to exit from said open exit wherein said rod forming means comprises a garniture defining a channel; wherein the initial coating or impregnation of said portion of said solid support with an additive occurs whilst the solid support is located in the garniture; and wherein the initial contact of the solid support with said starting material occurs whilst the starting material is located in the garniture.

The means may be separate means. Alternatively, two or more of the means may be the same.

One of the key differences between the method (and apparatus) of the present invention and method (and apparatus) of U.S. Pat. No. 4,281,671 and US 2005/0255978 lies in the initial contact between the starting material and the solid support material. In the case of U.S. Pat. No. 4,281,671, that initial contact occurs remote from the rod forming means. In the present invention, the initial contact takes place in the rod forming means. This has many advantages. For example, after contact the ability for the solid support material to move for example laterally is minimised—which means that workers can more accurately place the support material inside the rod. In the case of U.S. Pat. No. 4,281,671, the solid support material can move easily in a lateral direction, making the alignment prone to error etc. In addition, if the support material is impregnated with volatile flavourants—such as menthol—then with the present invention one can achieve higher dosing of the flavourant in the rod. This is because the flavourant does not have to travel very far—relative to the distances of the methodology taught in U.S. Pat. No. 4,281,671 and US 2005/0255978—to be encapsulated in the rod. In addition, with the present invention it is possible to use pure flavourants—such as pure menthol for the method; thereby minimising the use of carrier solvents etc. for the flavourant. In some instances, it may be possible to load the support material with sufficient flavourant thereby reducing or even eliminating the need to also load the tobacco with flavourant. Other advantages will be apparent to those skilled in the art in the light of the following commentary.

Preferred features are defined in the accompanying claims and in the following commentary.

Preferably all of said solid support is coated with an additive.

Preferably at least a part of the external surface of said rod is covered with a cover.

Preferably said cover is paper.

Preferably the edges of said cover are fixed to each other by means of an adhesive.

Preferably said adhesive is a hot melt adhesive.

Preferably said rod is subsequently cut into a smaller rod for use in the preparation of a smoking article.

Preferably said rod or smaller rod is a filter rod.

Preferably said smoking article is a cigarette.

Preferably said support material enters the rod forming means via a port that is operably linked to the channel.

Preferably said solid support is positioned along the central longitudinal axis of the rod.

Preferably the additive is a smoke-modifying agent.

Preferably the additive is a flavourant.

Preferably the additive is a flavourant in substantially pure form.

Preferably said additive is menthol.

Preferably at least one end of the solid material is at one end of the rod.

Preferably the ends of the solid material are at opposite ends of the rod.

Preferably said section of said starting material is an end of said starting material.

Preferably said section of said solid support is an end of said solid support.

Preferably said starting material enters the channel at an open entrance opposite the open exit.

Preferably said channel is conical.