Smoking articles

Abstract

The invention relates to a smoking article ( 1 ) having a high proportion of non-combustible, inorganic material and a relatively low level of visible sidestream. The smoking article comprises a substantially non-combustible, wrapper ( 5 ) which extends along the full length of the smoking material rod and enwraps a combustible fuel source ( 6 ) and aerosol generating means ( 7 ), both of which extend substantially along the length of the smoking material rod. Various suitable fuel source system and aerosol generating systems are described. The article has a visible burn line which advances along the article and produces an ash which can be removed by the smoker in the normal way.

1 . A smoking article having a smoking material rod comprising a substantially non-combustible wrapper extending substantially along the length of the smoking material rod and enwrapping smoking material, said smoking material comprising a combustible fuel source extending substantially along the length of the smoking material rod and aerosol generating means extending substantially along the length of the smoking material rod, characterised in that said wrapper is comprised of predominantly non-combustible, particulate, inorganic filler material, a binder, optionally a plasticiser, and optionally a small amount of cellulosic fibre material, and said inorganic filler material is at least 65% by weight of said wrapper.  
     
     
         2 . A smoking article having a smoking material rod comprising a substantially non-combustible wrapper extending substantially along the length of the smoking material rod and enwrapping smoking material, said smoking material comprising a combustible fuel source extending substantially along the full length of the smoking material rod, and aerosol generating means being disposed between the fuel source and the wrapper and extending substantially along the length of the smoking material rod, characterised in that said wrapper is comprised of predominantly non-combustible, particulate, inorganic filler material, a binder, optionally a plasticiser, and optionally a small amount of cellulosic fibre material, and said inorganic filler material is at least 65% by weight of said wrapper.  
     
     
         3 . A smoking article according to claims  1  or  2 , wherein the fuel source and/or the aerosol generating means comprise longitudinally extending rods, strands or filaments.  
     
     
         4 . A smoking article according to claims  1  or  2 , wherein the fuel source comprises cut filler material.  
     
     
         5 . A smoking article according to claims  1  or w, wherein the fuel source and/or the aerosol generating means comprise a rolled sheet.  
     
     
         6 . A smoking article according to any one of  claims 1  to  4  wherein the aerosol generating means is cut filler material.  
     
     
         7 . A smoking article according to any one of claims  1 - 4  or wherein the fuel source and the aerosol generating means both comprise cut filler material.  
     
     
         8 . A smoking article according to  claim 7 , wherein the cut filler materials are intimately mixed.  
     
     
         9 . A smoking material according to  claim 1  or  2 , wherein aerosol generating means and the fuel source are combined to provide an aerosol generating fuel source.  
     
     
         10 . A smoking article as claimed in any one of  claims 1  to  7 , wherein the aerosol generating means and the fuel source comprise a core and annulus arrangement.  
     
     
         11 . A smoking article according to any one of claims  1 - 10 , wherein the aerosol generating means and the duel source comprise a core and annulus arrangement of foamed components.  
     
     
         12 . A smoking article according to  claim 1  or  2 , wherein one of the fuel source or aerosol generating means is foamed.  
     
     
         13 . A smoking article according to any one of  claims 1  to  12 , wherein the smoking article further comprises a filter element.  
     
     
         14 . A smoking article according to any one of  claims 1  to  13 , wherein at least 50% by weight of the article is inorganic material.  
     
     
         15 . A smoking article according to any one of  claims 1  to  10 , wherein the wrapper has the features of any one of  claims 20  to  42 .  
     
     
         16 . A smoking article according to any one of  claims 1  to  10 , wherein the fuel source has the features of any one of  claims 43  to  58 .  
     
     
         17 . A smoking article according to any one of  claims 1  to  10 , wherein the aerosol generating means has the features of any one of  claims 59  to  72 .  
     
     
         18 . A smoking article according to  claim 9 , wherein the aerosol generating fuel source has the features of any one of  claims 73  to  85 .  
     
     
         19 . A smoking article produced according to the method of any one of  claims 86  to  95 .  
     
     
         20 . A substantially non-combustible smoking article wrapper comprised of predominantly non-combustible, particulate, inorganic filler material, a binder, optionally a plasticiser, and optionally a small amount of cellulosic fibre material, said inorganic filler material being at least 65% by weight of said wrapper.  
     
     
         21 . A substantially non-combustible smoking article wrapper according to  claim 20 , wherein said non-combustible inorganic filler material is a non-metallic material.  
     
     
         22 . A wrapper according to any one of claims  20  or  21 , herein said non-combustible inorganic filler material is one or more of perlite, vermiculite, diatomaceous earth, colloidal silica, chalk, magnesium oxide, magnesium sulphate, magnesium carbonate, or other low density, non-combustible inorganic filler materials.  
     
     
         23 . A wrapper according to  claim 20 , wherein the inorganic filler material comprises at least 90% by weight of the wrapper.  
     
     
         24 . A wrapper according to  claim 24 , wherein the inorganic filler material comprises at least 80% by weight of the wrapper.  
     
     
         25 . A wrapper according to  claim 24 , wherein the inorganic filler material comprises at least 90% by weight of the wrapper.  
     
     
         26 . A wrapper according to any one of  claims 20  to  25 , wherein the wrapper comprises less than 10% fibre material by weight of, the wrapper.  
     
     
         27 . A wrapper according to any one of  claims 20  to  26 , wherein the wrapper comprises a binder and/or a plasticiser at up to 30% by weight of the wrapper.  
     
     
         28 . A wrapper according to  claim 27 , wherein the binder is not present at more than 25% by weight of the wrapper.  
     
     
         29 . A wrapper according to  claim 27  or  28 , wherein the binder is present at about 8-10% by weight of the wrapper.  
     
     
         30 . A wrapper according to  claim 27  or  28 , wherein the binder is present at about 5% or less by weight of the wrapper.  
     
     
         31 . A wrapper according to any one of  claims 27  to  30 , wherein the binder is an organic binder selected from one or more of the classes of cellulose derivatives, cellulose ethers, alginic binders, gums, gels, pectins or starches.  
     
     
         32 . A wrapper according to  claim 31 , wherein the organic binder is one or more of sodium carboxymethyl cellulose, methyl cellulose, hydroxypropyl cellulose, hyroxyethyl cellulose, ammonium alginate, sodium alginate, sodium calcium alginate, calcium ammonium alginate, potassium alginate, magnesium alginate, triethanol-amine alginate, propyliene glycol aluminate, aliminium alginate, copper alginate, zinc alginate, silver alginate, gum arabic, gum ghatti, gum tragacanth, Karaya gum, locust bean gum, acacia gum, guar gum, quince seed gum, xanthan gum, agar, agarose, carrageenans, fucoidan or furcelleran.  
     
     
         33 . A wrapper according to any one of  claims 27  to  30 , wherein the binder is an inorganic, non-combustible binder.  
     
     
         34 . A wrapper according to  claim 33 , wherein the binder is ore or more of potassium silicate, magnesium oxide in combination with potassium silicate, or cement.  
     
     
         35 . A wrapper according to  claim 27 , wherein the plasticiser is present at up to 20% by weight or the wrapper.  
     
     
         36 . A wrapper according to  claim 35 , wherein the plasticiser is present at about 10% no less by weight of the wrapper.  
     
     
         37 . A wrapper according to  claim 36 , wherein the plasticiser is present at about 5% or less by weight of the wrapper.  
     
     
         38 . A wrapper according to any one of  claims 27  to  37 , wherein the plasticiser is one or more of glycerol, propylene glycol, low melting point fats or low melting point oils.  
     
     
         39 . A wrapper according to any one of  claims 20  to  38 , wherein the permeability of said wrapper is within the range of 1-150 Coresta Units.  
     
     
         40 . A wrapper according to any one of  claims 20  to  39 , wherein the wrapper comprises a deodoriser selected from citronellal, geraniol or vanillin.  
     
     
         41 . A smoking article fuel source of substantially the whole length of a smoking article, the fuel source comprising carbonaceous material, an inorganic non-combustible binder and optionally a burn promoter.  
     
     
         42 . A smoking article according to  claim 41 , wherein said inorganic non-combustible binder comprises one or more of potassium silicate, magnesium oxide in combination with potassium silicate or cement, such as Portland cement.  
     
     
         43 . A smoking article fuel source according to  claim 41  or  42 , wherein said inorganic non-combustible binder is present within the range of 10-65% by weight of the fuel source.  
     
     
         44 . A smoking article fuel source according to  claim 43 , wherein the binder is present at less than 40% by weight of the fuel source.  
     
     
         45 . A smoking article fuel source according to any one or  claims 41  to  44 , wherein the fuel source comprises 5-20% by weight thereof of a burn promoter.  
     
     
         46 . A smoking article fuel source according to any one of  claims 41  to  45 , wherein the fuel source comprises 25-70% carbon by weight thereof.  
     
     
         47 . A smoking article fuel source according to  claim 46 , wherein the fuel source comprises at least 55% carbon weight thereof.  
     
     
         48 . A smoking article fuel source according to  claim 41 , wherein the fuel source comprises about 30% carbon, 60% inorganic, non-combustible binder and less than about 10% burn promoter.  
     
     
         49 . A smoking article fuel source of substantially the whole length of a smoking article, the fuel source comprising 15-70% carbon, 84-5% non-combustible inorganic filler material, 0-5% plasticiser, 1-20% organic binder and 0-20% inorganic binder, the plasticiser comprising one or more of low melting point fats or low melting point oils.  
     
     
         50 . A smoking article fuel source according to  claim 49 , wherein carbon is present within the range of 25-35% by weight of the fuel source.  
     
     
         51 . A smoking article fuel source according to any one of claims  49  or  50 , wherein the non-combustible inorganic filler material comprises one or more of perlite, vermiculite, diatomaceous earth, colloidal silica, chalk, magnesium oxide, magnesium sulphate, magnesium carbonate or other low density, non-combustible inorganic filler materials.  
     
     
         52 . A smoking article fuel source according to any one of  claims 49  to  51 , wherein the organic binder is selected from one or more of the classes of cellulose derivatives, cellulose ethers, alginic binders, gums, gels, pectins or starches.  
     
     
         53 . A smoking article fuel source according to  claim 52 , wherein the organic binder is sodium carboxymethyl cellulose, methyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, ammonium alginate, sodium alginate, sodium calcium alginate, calcium ammonium alginate, potassium alginate, magnesium alginate, triethanol-amine alginate, propylene glycol alginate, aluminium alginate, copper alginate, zinc alginate, silver alginate, gum arabic, gum ghatti, gum tragacanth, Karaya gum, locust bean gum, acacia gum, guar gum, quince seed gum, xanthan gum, agar, agarose, carrageenans, fucoidan or furcelleran.  
     
     
         54 . A smoking article fuel source according to any one of  claims 49  to  51 , wherein the inorganic binder is one or more of potassium silicate, magnesium oxide in combination with potassium silicate or cement.  
     
     
         55 . A smoking article aerosol generating means comprising a non-combustible inorganic filler material, aerosol forming means, and an organic or inorganic binder.  
     
     
         56 . A smoking article aerosol generating means according to  claim 55 , wherein the aerosol generating means comprises 95-30% inorganic, non-combustible binder, 45-90% non-combustible inorganic filler material and 5-30% aerosol forming means.  
     
     
         57 . A smoking article aerosol generating means according to claim.  55 , wherein the aerosol generating means comprises 1-25% organic binder, 50-94% non-combustible inorganic filler material, and 5-30% aerosol forming means.  
     
     
         58 . A smoking article aerosol generating means comprising an organic filler material, aerosol forming means, an organic binder and optionally a non-combustible inorganic filler material.  
     
     
         59 . A smoking article aerosol generating means according to  claim 58 , wherein the aerosol generating means comprises 1-25% organic binder, 1-94% organic filler material, 0-93% inorganic filler material and 5-30% aerosol forming means.  
     
     
         60 . A smoking article aerosol generating means according to any one of  claims 55  to  59 , wherein the non-combustible inorganic filler material is one or more of perlite, vermiculite, diatomaceous earth, colloidal silica, chalk, magnesium oxide, magnesium sulphate, magnesium carbonate, dr other low density, non-combustible inorganic filler materials.  
     
     
         61 . A smoking article aerosol generating means according to any one of claims  55 - 60 , wherein the organic filler material comprises inorganic salts of organic acids, or polysaccharide material.  
     
     
         62 . A smoking article aerosol generating means according to any one of claims  55 - 61 , wherein the aerosol forming means comprises one or more of polyhydric alcohols, esters, or high boiling point hydrocarbons.  
     
     
         63 . A smoking article generating means according to  claim 62 , wherein the aerosol forming means is one or more of glycerol, propylene glycol, triethylene glycol, triethyl citrate or triacetin.  
     
     
         64 . A smoking article aerosol generating means according to any one of  claims 55  to  63 , wherein the organic binder is selected from one or more of the classes of cellulose derivatives, cellulose ethers, alginic binders, gums, gels, pectins or starches.  
     
     
         65 . A smoking article aerosol generating means according to  claim 64 , wherein the organic binder is one or more of sodium carboxymethyl cellulose, methyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, ammonium alginate, sodium alginate, sodium calcium alginate, calcium ammonium alginate, potassium alginate, magnesium alginate, triethanol-amine alginate, propylene glycol alginate, aluminium alginate, copper alginate, zinc alginate, silver alginate, gum arabic, gum ghatti, gum tragacanth, Karaya gum, locust bean gum, acacia gum, guar gum, quince seed gum, xanthan gum, agar, agarose, carrageenans, fucoidan or furcelleran.  
     
     
         66 . A smoking article aerosol generating means according to  claim 55  or  56 , wherein the inorganic binder comprises one or more of one or more of potassium silicate, magnesium oxide in combination with potassium silicate, or cement.  
     
     
         67 . A smoking article aerosol generating means according to  claim 58  or  59  wherein the aerosol generating means comprises an expansion medium  
     
     
         68 . A smoking article aerosol generating means according to any one of claims  55 - 67 , wherein the aerosol generating means comprises flavouring agents.  
     
     
         69 . A smoking article aerosol generating fuel source comprising a non-combustible inorganic filler material, aerosol forming means, an organic or inorganic binder carbon.  
     
     
         70 . A smoking article aerosol generating fuel source according to  claim 69 , wherein the aerosol generating source comprises 0-35% inorganic filler material, 5-30% aerosol forming means, 30-60% inorganic binder, 30-65% carbon and 0-10% burn promoter.  
     
     
         71 . A smoking article aerosol generating fuel source according to  claim 69 , wherein the aerosol generating fuel source comprises 86-0% inorganic filler material, 5-30% aerosol forming means, 1-25% organic binder and 8-60% carbon.  
     
     
         72 . A smoking article aerosol generating fuel source comprising organic filler material, optionally a non-combustible inorganic filler material, aerosol forming means, organic binder and carbon.  
     
     
         73 . A smoking article aerosol generating fuel source according to  claim 72 , wherein the aerosol generating fuel source comprises 93-0% organic filler material, 0-93% inorganic filler material, 5-30% aerosol forming means, 1-25% organic binder and 1-60% carbon.  
     
     
         74 . A, smoking article aerosol generating fuel source according to any one of  claims 69  to  73 , wherein non-combustible inorganic filler material comprises one or more of perlite, vermiculite, diatomaceous earth, colloidal silica, chalk, magnesium oxide, magnesium sulphate, magnesium carbonate or other low density, non-combustible inorganic filler materials.  
     
     
         75 . A smoking article aerosol generating fuel source according to any one of  claims 72  to  74 , wherein the organic filler material comprises inorganic salts of organic acids or polysaccharide material.  
     
     
         76 . A smoking article aerosol generating fuel source according to any one of  claims 69  to  75 , wherein the aerosol forming means comprises one or more of polyhydric alcohols, esters, or high boiling point hydrocarbons.  
     
     
         77 . A smoking article aerosol generating fuel source according to  claim 76 , wherein the aerosol forming means is one or more of glycerol, propylene glycol, triethylene glycol, triethyl citrate or triacetin.  
     
     
         78 . A smoking article aerosol generating fuel source according to  claim 69  or  70  wherein the inorganic binder comprises one or more of potassium silicate, magnesium oxide in combination with potassium silicate or cement.  
     
     
         79 . A smoking article aerosol generating fuel source according to any one of claims  69  and  71  to  78 , wherein the organic binder is selected from one or more of the classes of cellulose derivatives, cellulose ethers, alginic binders, gums, gels, pectins or starches.  
     
     
         80 . A smoking article aerosol generating fuel source according to  claim 79 , wherein the organic binder is one or more of sodium carboxymethyl cellulose, methyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, ammonium alginate, sodium alginate, sodium calcium alginate, calcium ammonium alginate, potassium alginate, magnesium alginate, triethanol-amine alginate, propylene glycol alginate, aluminium alginate, copper alginate, zinc alginate, silver alginate, gum arabic, gum ghatti, gum tragacanth, Karaya gum, locust bean gum, acacia gum, guar gum, quince seed gum, xanthan gum, agar, agarose, carrageenans, fucoidan or furcelleran.  
     
     
         81 . A smoking article aerosol generating fuel source according to any one of claims  72  or  73 , wherein the aerosol generating fuel source comprises an expansion medium.  
     
     
         82 . A method of producing a substantially non-combustible smoking article wrapper comprising predominantly non-combustible inorganic filler material and a binder, the method comprising producing a mixture of the non-combustible inorganic filler material and a binder, extruding the mixture to provide a hollow tube, and contacting the hallow tube with a material which causes the hollow tube to set rapidly.  
     
     
         83 . A method according to  claim 82 , wherein said material which causes said hollow tube to set is either a water scavenging substance which removes water contained in said tube, a solution which renders a soluble binder in said mixture of said tube insoluble, or a hydrophilic substance which removes water from an aqueous-containing mixture of said tube.  
     
     
         84 . A method according to  claim 82  or  83 , wherein the extrusion process occurs at not more than 3-4 bar (300-400 kPa) at the extruder die of a ram extruder.  
     
     
         85 . A method according to  claim 82  or  83 , wherein the extrusion process occurs at not more than 9 bar (900 kPa) when using a screw extruder.  
     
     
         86 . A method according to  claim 83 , wherein the water scavenging substance is light magnesium oxide.  
     
     
         87 . A method according to  claim 83 , wherein a soluble alginate is rendered insoluble by the addition of solubilising agents, such as ammonium hydroxide or calcium chloride.  
     
     
         88 . A method according to  claim 83 , wherein the hydrophilic substance is ethanol.  
     
     
         89 . A method according to any one of claims  82 - 88 , wherein pre-extrusion a sub-critical level of precipitating agent is present in the extruder barrel and post extrusion the level of precipitating agent is increased to a critical level to cause complete precipitation.  
     
     
         90 . A method according to  claim 82 , wherein the method comprises sequential application of said processes.  
     
     
         91 . A method according to any one of  claims 82  to  83 , wherein the wrapper mixture comprises sacrificial molecules which can be removed after the formation of said wrapper by application of heat or chemical reaction.  
     
     
         92 . A smoking article having a smoking material rod comprising a substantially non-combustible wrapper extending substantially along the length of the smoking material rod and enwrapping a combustible fuel source extending substantially along the length of the smoking material rod and aerosol generating means extending substantially along the length of the smoking material rod.  
     
     
         93 . A smoking article having a smoking material rod comprising a substantially non-combustible wrapper extending substantially along the length of the smoking material rod and enwrapping a combustible fuel source extending substantially along the full length of the smoking material rod, and aerosol generating means being disposed between the fuel source and the wrapper and extending substantially along the length of the smoking material rod.