Reconstituted tobacco sheet and smoking article therefrom

Abstract

A smoking article having one or more reconstituted tobacco split inner wrap strips is described. One or more split inner wrap strips extend coaxially along the tobacco column between the inner surface of an outer wrap of cigarette paper and the tobacco column. The tobacco blend includes burley and a second tobacco, such as flue-cured, oriental, Maryland, or rare and exotic tobaccos, and combinations thereof. This blend improves burley smoke character without increasing Hoffman analyte levels, especially tobacco-specific nitrosamines (i.e., TNSAs). A cigarette with an improved burley smoke character without increasing Hoffman analyte levels is also described.

1 . A process for making a bandcast tobacco sheet comprising the steps of: 
 preparing a slurry containing an aqueous solution and a solid mixture, said solid mixture having from about 30% to about 80% by weight of a tobacco blend, from about 5% to about 40% by weight wood pulp, from about 8% to about 40% by weight binder, wherein said tobacco blend is comprised of a first tobacco and a second tobacco, said first tobacco being burley which is at least about 30% by weight of said solid mixture, and said second tobacco being up to about 30% by weight of said solid mixture, said solid mixture being about 2% to about 10% by weight of said slurry;    casting said slurry onto a casting surface; and    drying said slurry to form a sheet of bandcast tobacco.    
     
     
         2 . The process of  claim 1 , wherein said second tobacco is selected from the group consisting of flue-cured tobacco, oriental tobacco, Maryland tobacco, exotic tobacco, and combinations thereof.  
     
     
         3 . The process of  claim 2 , wherein said exotic tobacco is selected from the group consisting of Izmar tobacco, Samsun tobacco, Yaka tobacco, Latakia tobacco, Perique tobacco, Cavendish tobacco, Rustica tobacco, Fire-cure tobacco, Dark or Sun-cure tobacco, and combinations thereof.  
     
     
         4 . The process of  claim 1 , said drying being at about 180° F. to about 220° F.  
     
     
         5 . The process of  claim 1 , said tobacco blend being added to said slurry firstly, said wood pulp being added to said slurry secondly, and said binder being added to said slurry thirdly, each of said tobacco blend, wood pulp, and binder being dissolved or dispersed before adding a next of said tobacco blend, wood pulp, and binder.  
     
     
         6 . The process of  claim 1 , including the addition of up to 30% by weight of menthol in said solid mixture.  
     
     
         7 . The process of  claim 1 , wherein said binder is selected from the group consisting of an alginate, guar, xanthum, acacia, pectin, other gums, modified cellulose compounds, and hydrocolloid compounds.  
     
     
         8 . The process of  claim 7 , said alginate being sodium alginate.  
     
     
         9 . The process of  claim 1 , including the addition of a humectant.  
     
     
         10 . The process of  claim 9 , said humectant being selected from the group consisting of glycerin and propylene glycol.  
     
     
         11 . The process of  claim 10 , said glycerin being up to 30% by weight of said solid mixture.  
     
     
         12 . The process of  claim 1 , further comprising: 
 cutting said sheet of bandcast tobacco into longitudinal strips; and    inserting a plurality of said longitudinal strips of said bandcast tobacco into a cigarette adjacent a tobacco column.    
     
     
         13 . A process for making a bandcast tobacco sheet comprising the steps of: 
 preparing a slurry including a solid mixture of wood pulp, binder, a humectant, a tobacco blend, and a flavoring, in an aqueous solution, said tobacco blend including a first tobacco and a second tobacco, said tobacco blend being from about 30% to about 80% by weight of said mixture and dispersed firstly into said aqueous solution, said wood pulp being from about 5% to about 40% by weight of said mixture and dispersed secondly into said aqueous solution, said binder being about 8% to about 40% by weight of said mixture and dispersed thirdly into said aqueous solution, said humectant being up to about 30% by weight of said mixture and dispersed fourthly into said aqueous solution, and then up to about 30% by weight of menthol being dispersed lastly into said aqueous solution, said mixture being about 2% to 10% by weight of said slurry, wherein said first tobacco is burley which is at least about 30% by weight of said solid mixture and said second tobacco is up to about 30% by weight of said solid mixture;    casting said slurry onto a casting band, said casting band being maintained at from about 180° F. to about 220° F.; and,    drying said slurry to form a sheet of bandcast tobacco.    
     
     
         14 . The process of  claim 13 , wherein said second tobacco is selected from the group consisting of flue-cured tobacco, oriental tobacco, Maryland tobacco, exotic tobacco, and combinations thereof.  
     
     
         15 . The process of  claim 14 , wherein said exotic is selected from the group consisting of Izmar tobacco, Samsun tobacco, Yaka tobacco, Latakia tobacco, Perique tobacco, Cavendish tobacco, Rustica tobacco, Fire-cure tobacco, Dark or Sun-cure tobacco, and combinations thereof.  
     
     
         16 . A process for making a paper tobacco sheet comprising the steps of: 
 extracting one part of solid mixture with from about 11 to about 20 parts of an aqueous solvent at from about 160° F. to about 190° F. for about 30 minutes, wherein said solid mixture is comprised of from about 30% by weight to about 80% by weight of a tobacco blend, said tobacco blend comprised of burley and a second tobacco, said second tobacco selected from the group consisting of flue-cured tobacco, oriental tobacco, Maryland tobacco, exotic tobacco, and combinations thereof, said burley being at least about 30% by weight of said solid mixture, and said second tobacco being up to about 30% by weight of said solid mixture;    separating a soluble extract from said solid mixture;    concentrating said soluble extract via vacuum evaporation;    refining said solid mixture;    mixing said solid mixture with greater than 10% pre-refined wood fibers;    forming a sheet over a wire with said solid mixture and drying; and    reapplying said soluble extract to said sheet.    
     
     
         17 . The process of  claim 16 , wherein said soluble extract is separated from said solid mixture via a process selected from the group consisting of centrifugation, filtration, and pressing.  
     
     
         18 . The process of  claim 16 , further including treating said soluble extract with adsorbents prior to concentrating said soluble extract.  
     
     
         19 . The process of  claim 16 , wherein a binder being from about 8% to about 40% by weight of said solid mixture is added to said soluble extract after concentrating said soluble extract and prior to reapplying said soluble extract to said sheet.  
     
     
         20 . The process of  claim 19 , wherein said binder is selected from the group consisting of alginate, guar, xanthum, acacia, pectin, other gums, modified cellulose compounds, and hydrocolloid compounds.  
     
     
         21 . The process of  claim 20 , wherein said alginate is sodium alginate  
     
     
         22 . The process of  claim 16 , said drying being at about 180° F. to about 220° F.  
     
     
         23 . The process of  claim 16 , including the addition of up to about 20% by weight of a humectant.  
     
     
         24 . The process of  claim 23 , wherein said humectant is selected from the group consisting of glycerin and propylene glycol.  
     
     
         25 . The process of  claim 16 , wherein said exotic tobacco is selected from the group consisting of Izmar tobacco, Samsun tobacco, Yaka tobacco, Latakia tobacco, Perique tobacco, Cavendish tobacco, Rustica tobacco, Fire-cure tobacco, Dark or Sun-cure tobacco, and combinations thereof.  
     
     
         26 . A bandcast tobacco sheet, comprised of from about 5% to 40% by weight of wood pulp, from about 8% to 40% by weight of binder, and from about 30% to 80% by weight of a tobacco blend, wherein said tobacco blend is comprised of burley and a second tobacco, said burley being at least about 30% by weight of said bandcast tobacco sheet, said second tobacco being up to about 30% by weight of said bandcast tobacco sheet, and said second tobacco being selected from the group consisting of flue-cured tobacco, oriental tobacco, Maryland tobacco, exotic tobacco, and combinations thereof.  
     
     
         27 . The sheet of  claim 26 , wherein menthol is about 20% by weight of said bandcast tobacco sheet.  
     
     
         28 . The sheet of  claim 26 , wherein a humectant is up to about 30% by weight of said bandcast tobacco sheet.  
     
     
         29 . The sheet of  claim 28 , said humectant selected from the group consisting of glycerin and propylene glycol.  
     
     
         30 . The sheet of  claim 29 , said glycerin being approximately 13.5% by weight.  
     
     
         31 . The sheet of  claim 26 , said binder selected from the group consisting of alginate, guar, xanthum, acacia, pectin, other gums, modified cellulose compounds, and hydrocolloid compounds.  
     
     
         32 . The sheet of  claim 31 , said alginate being sodium alginate.  
     
     
         33 . The sheet of  claim 32 , said sodium alginate being about 27% by weight.  
     
     
         34 . The sheet of  claim 26 , said tobacco blend and said binder being in a ratio of from about 4.0:1.0 to about 1.0:1.0.  
     
     
         35 . The sheet of  claim 26 , said bandcast tobacco sheet formed in a plurality of longitudinal bandcast split inner wrap strips, said strips inserted into a cigarette adjacent a column of tobacco.  
     
     
         36 . The sheet of  claim 35 , wherein said plurality of longitudinal bandcast split inner wrap strips are a first and a second strip positioned equidistant from each other.  
     
     
         37 . The sheet of  claim 26 , wherein said exotic tobacco is selected from the group consisting of Izmar tobacco, Samsun tobacco, Yaka tobacco, Latakia tobacco, Perique tobacco, Cavendish tobacco, Rustica tobacco, Fire-cure tobacco, Dark or Sun-cure tobacco, and combinations thereof.  
     
     
         38 . A cigarette comprising: 
 a tobacco column surrounded by an outer wrap paper; and,    a partial inner wrap material extending longitudinally of said tobacco column and disposed between said outer wrap, said partial inner wrap material being one or more strips of a bandcast tobacco sheet which is comprised of from about 5% to about 40% by weight of wood pulp, from about 8% to about 40% by weight of binder, and from about 30% to about 80% by weight of tobacco blend, wherein said tobacco blend is further comprised of burley and a second tobacco, said burley being at least about 30% by weight of said partial inner wrap material, and said second tobacco being up to about 30% by weight of said partial inner wrap material.    
     
     
         39 . The cigarette of  claim 38 , wherein said second tobacco is selected from the group consisting of flue-cured tobacco, oriental tobacco, Maryland tobacco, exotic tobacco, and combinations thereof.  
     
     
         40 . The cigarette of  claim 39 , wherein said exotic tobacco is selected from the group consisting of Izmar tobacco, Samsun tobacco, Yaka tobacco, Latakia tobacco, Perique tobacco, Cavendish tobacco, Rustica tobacco, Fire-cure tobacco, Dark or Sun-cure tobacco, and combinations thereof.  
     
     
         41 . The cigarette of  claim 38 , including up to about 30% by weight of menthol in said inner wrap.  
     
     
         42 . The cigarette of  claim 41 , wherein said menthol is approximately 20% by weight of said inner wrap.  
     
     
         43 . The cigarette of  claim 38 , including up to about 30% by weight of a humectant in said inner wrap.  
     
     
         44 . The cigarette of  claim 43 , said humectant selected from the group consisting of glycerin and propylene glycol.  
     
     
         45 . The cigarette of  claim 44 , said glycerin being approximately 13.5% by weight.  
     
     
         46 . The cigarette of  claim 38 , said binder selected from the group consisting of alginate, guar, xanthum, acacia, pectin, other gums, modified cellulose compounds, and hydrocolloid compounds.  
     
     
         47 . The cigarette of  claim 46 , said alginate being sodium alginate.  
     
     
         48 . The cigarette of  claim 47 , said sodium alginate being about 27% by weight.  
     
     
         49 . The cigarette of  claim 38 , said tobacco blend and said binder being in a ratio of from about 4.0 to 1.0 to about 1.0 to 1.0.  
     
     
         50 . A cigarette with a burn rate modification, comprising: 
 a tobacco column surrounded by an outer wrap paper;    a tobacco inner wrap material coaxial to said tobacco column, said tobacco inner wrap material being less than about 15 mm in width and including a tobacco blend, said tobacco blend comprised of burley and a second tobacco, said burley being at least about 30% by weight of said tobacco inner wrap material, and said second tobacco being up to about 30% by weight of said tobacco inner wrap material.    
     
     
         51 . The cigarette of  claim 50 , wherein said outer wrap paper has a porosity of greater than about 15 CORESTA Units and said tobacco inner wrap material has a porosity of less than 10 CORESTA Units.  
     
     
         52 . The cigarette of  claim 51 , wherein said tobacco inner wrap material has a porosity of less than 7 CORESTA Units.  
     
     
         53 . The cigarette of  claim 50 , wherein said tobacco inner wrap material has a first tobacco inner wrap strip and a second tobacco inner wrap strip.  
     
     
         54 . The cigarette of  claim 53 , wherein said first tobacco inner wrap strip and said second tobacco inner wrap strip are each about 5 mm wide.  
     
     
         55 . The cigarette of  claim 53 , wherein said first tobacco inner wrap strip and said second tobacco inner wrap strip are each about 4 mm or less in linear width.  
     
     
         56 . The cigarette of  claim 50 , wherein said tobacco inner wrap material is a bandcast based tobacco material.  
     
     
         57 . The cigarette of  claim 50 , wherein said tobacco inner wrap material is between about 2 mm and 15 mm in width and has a porosity of less than 1 CORESTA Unit.  
     
     
         58 . The cigarette of  claim 50 , wherein said tobacco inner wrap material comprises a plurality of tobacco inner wrap strips coaxial to said tobacco column.  
     
     
         59 . The cigarette of  claim 50 , wherein said tobacco inner wrap material is a reconstituted tobacco material.  
     
     
         60 . The cigarette of  claim 50 , wherein said tobacco inner wrap material is a polymer based material.  
     
     
         61 . The cigarette of  claim 50 , wherein said tobacco inner wrap material is positioned away from an overwrap seam of said outer wrap paper.  
     
     
         62 . The cigarette of  claim 50 , wherein said second tobacco is selected from the group consisting of flue-cured tobacco, oriental tobacco, Maryland tobacco, exotic tobacco, and combinations thereof.  
     
     
         63 . The cigarette of  claim 62 , wherein said exotic tobacco is selected from the group consisting of Izmar tobacco, Samsun tobacco, Yaka tobacco, Latakia tobacco, Perique tobacco, Cavendish tobacco, Rustica tobacco, Fire-cure tobacco, Dark or Sun-cure tobacco, and combinations thereof.