Smoking article with tobacco beads

Abstract

A component of a smoking article having tobacco beads. The tobacco beads can be located in a filter and/or a tobacco rod. The filter can be a multi-component filter, wherein an sorbent (preferably upstream) removes at least one constituent from mainstream tobacco smoke passing through the filter and downstream tobacco beads compensates for taste lost to the sorbent. The tobacco beads optionally include flavorants in addition to tobacco particulates. The tobacco beads can be located within a cavity in the filter or within the tow. This component can comprise additional flavors, which are released into the mainstream smoke under ambient conditions. The tobacco beads optionally include binders such as microcrystalline cellulose or other cellulosic material, which can be formed into a paste with tobacco powder and optionally with additional flavors. The paste can be extruded and spheronized to form the tobacco beads.

1 . A smoking article comprising a tobacco rod and a multi-component filter comprising a sorbent and ventilation along the filter, the sorbent and ventilation constructed and arranged to substantially remove of at least one smoke constituent from mainstream tobacco smoke as mainstream smoke is drawn through the filter, and tobacco beads, wherein the tobacco beads comprise tobacco particles.  
   
   
       2 . The smoking article of  claim 1 , wherein: (a) the tobacco beads further comprise a binder; (b) the tobacco beads further comprise a binder, wherein the binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose; (c) the tobacco beads further comprise a binder, wherein the binder is a powdered dry binder and is a water swellable polymer or a polymer binder; (d) the tobacco beads further comprise a binder, wherein the binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose, and wherein the microcrystalline cellulose is AVICEL® PH101, AVICEL® PH102, AVICEL® PH105, AVICEL® PH112, AVICEL® PH113, AVICEL® PH200, AVICEL® PH301, AVICEL® PH302, AVICEL® RC591, Prosolv SMCC50, or Ceolus KG 801; (e) the tobacco beads are in the amount of about 20 mg to about 300 mg; (f) the tobacco beads further comprise a controlled release coating; (g) the tobacco beads are located downstream of the sorbent in a direction of mainstream smoke drawn through the filter; (h) the tobacco beads are located in the tobacco rod upstream of the sorbent; (i) the tobacco beads are located in a cavity downstream of the tobacco rod and upstream of a cellulose acetate filter; (j) the tobacco beads are formed from tobacco powder, a cellulosic material, water, a flavorant, a diluent, an aerosol forming agent, or a combination thereof; (k) the tobacco beads are formed from tobacco powder, a cellulosic material, water, a flavorant, a diluent, an aerosol forming agent, or a combination thereof, wherein the aerosol forming agent is glycerin, propylene glycol, triacetin, or propylene carbonate; (l) the tobacco beads further comprise a cellulosic component selected from the group consisting of powdered cellulose and microcrystalline cellulose; (m) the tobacco beads further comprise microcrystalline cellulose; (n) the tobacco beads include a coating effective to minimize migration of volatile flavorant constituents during storage of the smoking article; (o) the tobacco beads are contained in filter material forming a component of the filter; (p) the tobacco beads have a particle size of about 0.2 to about 1.0 mm; (q) the tobacco particles comprise about 10 weight % to about 90 weight % or about 90 to 100 weight % of the solids content of the tobacco beads; (r) the tobacco particles comprise about 30 weight % to about 60 weight % or about 60 weight % to about 90 weight % of the tobacco beads; and/or (s) the tobacco particles are a blend of tobaccos.  
   
   
       3 . The smoking article of  claim 2 , wherein: (a) tobacco beads further comprise a water swellable polymer selected from the group consisting of hydroxypropyl methylcellulose, low substituted hydroxypropyl cellulose, and hydroxypropyl cellulose; and/or (b) tobacco beads further comprise a polymer binder selected from the group consisting of polyvinyl pyrolidone, EUDRAGIT®, and a cellulose ether.  
   
   
       4 . The smoking article of  claim 1 , wherein: (a) the sorbent comprises activated carbon in the form of beads located in a cavity in the filter and/or activated carbon particles incorporated in a plug of filter material; (b) the sorbent comprises granules in an upstream cavity, and the tobacco beads are located in a downstream cavity of the filter; (c) the sorbent is disposed in a cavity defined between a tobacco end filter component and a central filter component, the cavity in a condition of being at least 85% filled; (d) the sorbent comprises at least 90 mg of activated carbon granules; (e) the sorbent comprises a high surface area activated carbon of at least about 90 mg to about 240 mg of the activated carbon in an 85% filled condition or greater; (f) the sorbent comprises a high surface area activated carbon of at least about 45 mg to about 180 mg in fully filled condition; (g) the tobacco end filter end component is located adjacent the tobacco rod, the central filter component having an end portion adjacent the sorbent; (h) the ventilation is in the range of about 5% to about 55%, and wherein the multi-component filter further comprises a mouth end filter component downstream of the tobacco beads; (i) the ventilation comprises a circumferential row of perforations through a tipping paper, the tipping paper attaching the multi-component filter to the tobacco filter rod; (j) the multi-component filter includes a component in the form of a plug defining a flow path configured to produce an increased pressure drop and increased dwell time of mainstream tobacco smoke in the filter; and/or (k) the multi-component filter includes a component in the form of a plug providing a flow constriction downstream of the sorbent.  
   
   
       5 . The smoking article of  claim 4 , wherein: (a) the plug providing the flow constriction downstream of the sorbent defines an annular flow path; (b) the plug providing the flow constriction downstream of the sorbent defines a central flow path; and/or (c) the plug providing the flow constriction downstream of the sorbent comprises a concentric filter.  
   
   
       6 . The smoking article of  claim 1 , wherein the smoking article is a cigarette, and the ventilation is located at least 12 mm from a buccal end of the cigarette.  
   
   
       7 . The smoking article of  claim 1 , wherein the smoking article is a cigarette, wherein: 
 (i) the tobacco beads are located downstream of the sorbent, the sorbent comprising high surface area, activated carbon so that as mainstream smoke is drawn through the upstream portion of the filter, gas phase smoke constituents are removed and flavor is optionally released from sorbent, and thereafter additional flavor is released into the mainstream smoke as it passes through the tobacco beads; and    (ii) filter ventilation arranged at a location spaced downstream from the sorbent so as to lower mainstream smoke velocity through the sorbent; and    (iii) the activated carbon comprising at least about 45 mg to about 180 mg of the activated carbon in a fully filled condition, or at least about 90 mg to about 240 mg of the activated carbon in an 85% filled condition; and    wherein the cigarette achieves a significant reduction in a gas phase constituent of the mainstream smoke; and wherein the tobacco beads comprise tobacco particles.    
   
   
       8 . The cigarette of  claim 7 , wherein: (a) the tobacco beads further comprise a binder selected from the group consisting of microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose, and wherein the tobacco beads further comprise a liquid binder; and/or (b) the tobacco beads further comprise a binder selected from the group consisting of microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose, and wherein the microcrystalline cellulose is AVICEL 200  PH101, AVICEL® PH102, AVICEL® PH105, AVICEL® PH112, AVICEL® PH113, AVICEL® PH200, AVICEL® PH301, AVICEL® PH302, AVICEL® RC591, Prosolv SMCC50, or Ceolus KG 801.  
   
   
       9 . The cigarette of  claim 7 , wherein: (a) the cigarette achieves significant reductions in gas phase constituents of the mainstream smoke, including reductions in 1,3-butadiene, acrolein, isoprene, propionaldehyde, acrylonitrile, benzene, toluene, and/or styrene; and/or (b) the cigarette achieves significant reductions in gas phase constituents of the mainstream smoke, including reductions in acetaldehyde and/or hydrogen cyanide.  
   
   
       10 . The smoking article of  claim 1 , wherein the smoking article is a cigarette, and wherein the filter comprises: 
 (i) a downstream flavor segment and an upstream sorbent segment, the flavor segment comprising the tobacco beads and the sorbent comprising a high surface area, activated carbon, the activated carbon being present such that as mainstream smoke is drawn through the upstream portion of the filter, gas phase smoke constituents are removed, and wherein the tobacco beads comprise tobacco particles;    (ii) filter ventilation arranged at a location spaced downstream from the sorbent so as to lower mainstream smoke velocity through the sorbent;    (iii) the activated carbon comprising at least about 45 mg to about 180 mg of the activated carbon in a fully filled condition, or at least about 90 mg to about 240 mg of the activated carbon in an 85% filled condition;    (iv) the filter ventilation being spaced from a mouth end of the cigarette by at least approximately 12 mm; and    wherein the cigarette achieves a significant reduction in a gas phase constituent of the mainstream smoke.    
   
   
       11 . A multi-component filter of a smoking article comprising at least one sorbent constructed and arranged to remove at least one smoke constituent from mainstream tobacco smoke, and at least one flavor-releasing segment constructed and arranged to release flavor to mainstream smoke, the flavor-releasing segment comprising tobacco beads located downstream of the sorbent, wherein the tobacco beads comprise tobacco particles.  
   
   
       12 . The filter of  claim 11 , wherein: (a) the tobacco beads further comprise a powdered binder, a liquid binder, and a flavorant; (b) the tobacco beads further comprise a powdered binder, a liquid binder, and a flavorant, wherein the powdered binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose; (c) the tobacco beads further comprise a powdered binder, a liquid binder, and a flavorant, wherein the powdered binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose, and wherein the microcrystalline cellulose is AVICEL® PH101, AVICEL® PH102, AVICEL® PH105, AVICEL® PH112, AVICEL® PH113, AVICEL® PH200, AVICEL® PH301, AVICEL® PH302, AVICEL® RC591, Prosolv SMCC50, or Ceolus KG 801; (d) the tobacco beads further comprise a controlled release coating; (e) tobacco beads further comprise a controlled release coating, wherein the controlled-release coating further comprises a flavorant; (f) the tobacco beads are present in the amount of about 20 mg to about 300 mg; (g) the flavor-releasing segment includes a plug of filter material having the tobacco beads therein; (h) the sorbent includes activated carbon with flavorant on the activated carbon; (i) the sorbent includes three filter components including activated carbon with flavorant on the activated carbon and cellulose acetate tow components on opposite sides of the activated carbon; (j) the flavor-releasing segment includes a cellulose acetate plug with flavorant thereon; (k) the flavor-releasing segment includes a cellulose acetate plug surrounded by plug wrap with flavorant on the plug wrap; (l) the sorbent includes activated carbon granules with flavorant on the granules; and/or (m) the sorbent includes at least about 45 mg to about 180 mg of activated carbon in a fully filled condition, or at least about 90 mg to about 240 mg of activated carbon in an 85% filled condition or greater.  
   
   
       13 . The multi-component filter of  claim 11 , comprising: 
 (i) an absorbent bearing segment adjacent an upstream end portion of the filter, the absorbent bearing segment having a particulate efficiency in the range of about 10% to about 20% and a lesser RTD;    (ii) an RTD-inducing segment including a flow constriction and ventilation and wherein the RTD-inducing segment is located at an intermediate location along the filter, and wherein the RTD-inducing segment has a particulate efficiency in the range of about 10% to about 20%; and    (iii) the tobacco beads located downstream along the filter have a particulate efficiency in the range of about 10% to about 20% and a lesser RTD, and wherein the lesser RTD being less than an RTD of the RTD inducing segment.    
   
   
       14 . The multi-component filter of  claim 13 , wherein the ventilation is adjacent an upstream end portion of the RTD-inducing segment.  
   
   
       15 . A filtered cigarette, wherein the filter comprises tobacco beads, wherein the tobacco beads comprise tobacco particulates and at least one volatile flavorant.  
   
   
       16 . The filtered cigarette of  claim 15 , wherein: (a) the tobacco beads comprise a binder; (b) the tobacco beads comprise a binder, wherein the binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose; (c) the tobacco beads comprise a binder, wherein the binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose, and wherein the microcrystalline cellulose is AVICEL® PH101, AVICEL® PH102, AVICEL® PH105, AVICEL® PH112, AVICEL® PH113, AVICEL® PH200, AVICEL® PH301, AVICEL® PH302, AVICEL® RC591, Prosolv SMCC50, or Ceolus KG 801; (d) the tobacco beads have a barrier coating thereon; (e) the tobacco beads have a barrier coating thereon, wherein the barrier coating is a controlled release coating; (f) the cigarette is a traditional lit-end cigarette or a cigarette useful in an electrical smoking system; (g) the filter does not include a sorbent therein; (h) the cigarette comprises a tobacco rod with a hollow core; (i) the cigarette comprises a tobacco rod with a hollow core, wherein the filter comprises a cavity between the tobacco rod with the hollow core and a cellulose acetate filter, and wherein the cavity has therein the tobacco beads; (j) the filter includes a sorbent upstream of the tobacco beads; (k) the tobacco beads are contained in a cavity in the filter, or the tobacco beads are contained in a plug of filter tow material; and/or (l) the tobacco beads comprise microcrystalline cellulose and the tobacco beads have diameters of about 0.2 mm to about 1.0 mm.  
   
   
       17 . The cigarette of  claim 15 , wherein the cigarette comprises a tobacco rod and a multi-component filter comprising at least one sorbent-bearing segment constructed and arranged to remove at least one smoke constituent from mainstream tobacco smoke as mainstream smoke is drawn through the filter, and at least one flavor-releasing segment constructed and arranged to release flavor to mainstream smoke, the flavor-releasing segment being located downstream of the sorbent-bearing segment in a direction of mainstream smoke drawn through the filter, and the flavor-releasing segment comprising the tobacco beads.  
   
   
       18 . The cigarette of  claim 17 , wherein: (a) the flavor-releasing segment includes a plug of filter material having the tobacco beads therein; (b) the sorbent-bearing segment includes beads of activated carbon located in a cavity in the filter; (c) the sorbent-bearing segment comprises a plug of filter material having activated carbon particles therein; (d) the cigarette includes tipping paper surrounding the multi-component filter, and perforations in the tipping paper downstream from the sorbent-bearing segment for introducing ambient air into mainstream tobacco smoke drawn through the filter; (e) the flavor-releasing segment includes a cellulose acetate plug with tobacco beads therein; (f) the tobacco beads further comprise a binder, wherein said binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose; (g) the tobacco beads further comprise a binder, wherein said binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose, wherein the microcrystalline cellulose is AVICEL® PH101, AVICEL® PH102, AVICEL® PH105, AVICEL® PH112, AVICEL® PH113, AVICEL® PH200, AVICEL® PH301, AVICEL® PH302, AVICEL® RC591, Prosolv SMCC50, or Ceolus KG 801; (h) the tobacco beads are present in the amount of 20 mg to about 300 mg; (i) the tobacco beads comprise tobacco particles in the amount of about 10 weight % to about 90 weight % or about 90 to about 99 weight %; (j) the filter includes plug wrap with flavorant on the plug wrap; (k) the sorbent-bearing segment includes activated carbon granules with flavorant on the granules, and wherein the granules are contained in a cavity of the filter; and/or (l) the sorbent-bearing segment includes activated carbon granules with flavorant on the granules, wherein the granules are contained in a cavity of the filter, and wherein the sorbent-bearing segment includes at least about 45 mg to about 180 mg of said activated carbon in a fully filled condition, or at least about 90 mg to about 240 mg of said activated carbon in an 85% filled condition  
   
   
       19 . A method of treating mainstream tobacco smoke produced by a traditional or non-traditional cigarette having a cigarette filter at a downstream end thereof, comprising passing mainstream tobacco smoke through the cigarette filter such that the mainstream smoke contacts tobacco beads, wherein the tobacco beads comprise tobacco particles.  
   
   
       20 . The method of  claim 19 , wherein: (a) tobacco beads further comprise a binder; (b) tobacco beads further comprise a binder, and wherein the binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose; (c) tobacco beads further comprise a binder, wherein the binder is microcrystalline cellulose, pectinic acid, lactose, glyceryl monostearate, or powdered cellulose, and wherein the microcrystalline cellulose is AVICEL® PH101, AVICEL® PH102, AVICEL® PH105, AVICEL® PH200, AVICEL® PH301, AVICEL® PH302, AVICEL® RC591, Prosolv SMCC50, or Ceolus KG 801; (d) tobacco beads further comprise a binder and a volatile flavorant, which releases into the mainstream tobacco smoke; (e) the method further comprises contacting the mainstream tobacco smoke with a constituent reducing agent; and/or (f) the method further comprises contacting the mainstream tobacco smoke with a constituent reducing agent, wherein the mainstream tobacco smoke first contacts a constituent reducing agent and then contacts the tobacco beads.  
   
   
       21 . A method of producing tobacco beads comprising: 
 (a) mixing tobacco particles and water to form a mixture;    (b) extruding the mixture to form an extrudate;    (c) forming tobacco beads by rounding portions of the extrudate, wherein the tobacco beads have a first moisture content; and    (d) drying the tobacco beads to a second moisture content to obtain the tobacco beads.    
   
   
       22 . The method of  claim 21 , wherein the drying comprises vacuum drying and the second moisture content is about 8% to about 25%.  
   
   
       23 . The method of  claim 21 , wherein (a) the ratio of the tobacco particles and water is about 4:1 and about 1:4 or about 2:1; (b) the first moisture content is about 20% to about 40% or about 40% to about 60% of a total weight of the tobacco beads; (c) the second moisture content is about 0.5% to about 25% of a total weight of the tobacco beads; (d) the second moisture content is about 0.5% to about 8%, about 8% to about 10%, about 10% to about 15%, about 15% to about 20%, or about  20 % to about 25% of a total weight of the tobacco beads; (e) the tobacco particles have a maximum size of about 0.5 mm; (f) the tobacco beads are in the form of spheroids, wherein the spheroids are substantially round or substantially oval in shape; (g) the tobacco beads are in the form of spheroids, wherein each spheroid has a diameter of about 0.1 to about 2.5 mm; (h) the tobacco beads are in the form of spheroids, wherein each spheroid has a diameter of about 0.2 to about 1.2 mm; (i) the tobacco beads are in the form of spheroids, wherein each spheroid has a diameter of about 0.3 to about 0.7 mm; (j) the ground tobacco has been sieved to pass through a mesh size no larger than 35 mesh; (k) the tobacco particles are obtained from lamina of tobacco plants; (I) the tobacco particles are obtained from lamina of tobacco plants or combined lamina and stems of tobacco plants, wherein the tobacco is selected from the group consisting of Burley, Bright, and Oriental; (m) the tobacco particles include up to 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% by weight of Burley; up to 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% by weight of Bright; and/or up to 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% by weight of Oriental; (n) the forming of the tobacco beads from the extrudate is by using a spinning friction plate at a rotation speed of up to about 1200 RPM for up to about 30 minutes; (o) the tobacco beads further comprise optional flavorant, wherein the flavorant is selected from the group consisting of liquid flavorant, solid and/or gel flavorant; (p) the tobacco beads further comprise flavorant, wherein the flavorant comprises menthol; (q) the tobacco beads further comprise flavorant, wherein the flavorant is present in the tobacco beads in an amount of up to 50% by weight; (r) the drying of the tobacco beads is carried out under vacuum to the second moisture content wherein the second moisture content is about 8% to about 25% of a total weight of the tobacco beads; and/or (s) the second moisture content is about 10% to about 20% of a total weight of the tobacco beads.  
   
   
       24 . A tobacco bead consisting essentially of: 
 (a) tobacco lamina particles;    (b) water; and    (c) optionally one or more flavorants,    wherein the tobacco bead has a moisture content of about 8% to about 25% of a total weight of the tobacco bead.    
   
   
       25 . The tobacco bead of  claim 24 , wherein the tobacco bead is in a condition of having been extruded, rounded and vacuum dried to said moisture content.  
   
   
       26 . The tobacco bead of  claim 24 , wherein the tobacco bead includes tobacco stem particles and/or tobacco dust particles.  
   
   
       27 . The tobacco bead of  claim 24 , wherein the tobacco bead consists of ground tobacco lamina particles and water.  
   
   
       28 . The tobacco bead of  claim 24 , wherein the tobacco bead is in the form of a spheroid having a diameter of about 0.3 mm to about 0.7 mm.  
   
   
       29 . The tobacco bead of  claim 24 , wherein the tobacco bead includes up to about 50% by weight of said one or more flavorants.  
   
   
       30 . The tobacco bead of  claim 24 , wherein the tobacco bead includes a moisture content of about 10% to about 20%.  
   
   
       31 . The tobacco bead of  claim 24 , wherein the tobacco bead further comprises a flavorant, a diluent, an aerosol forming agent, or a combination thereof.  
   
   
       32 . The tobacco bead of  claim 24 , wherein: (a) the tobacco particles have an average particle diameter of less than about 0.5 mm; (b) the tobacco bead is in the form of a spheroid, wherein the spheroid is substantially round or substantially oval in shape; (c) the tobacco bead is in the form of a spheroid, wherein the spheroid has a diameter of about 0.1 to about 2.5 mm; (d) the tobacco bead is in the form of a spheroid, wherein the spheroid has a diameter of about 0.2 to about 1.2 mm; (e) the tobacco bead is in the form of a spheroid, wherein the spheroid has a diameter of about 0.3 to about 0.7 mm; (f) the tobacco particles have a maximum size of about 0.5 mm; (g) the tobacco particles comprise ground tobacco selected from the group consisting of Burley, Bright, and Oriental; (h) the tobacco bead comprises one or more flavorants, wherein the one or more flavorants is selected from the group consisting of liquid, solid and/or gel flavorant; (i) the tobacco bead comprises one or more flavorants, wherein the one or more flavorants is present in the tobacco bead in an amount of up to 50% by weight; and/or (j50 parts of ) the moisture content is about 8% to about 10%, about 10% to about 15%, about 15% to about 20%, or about 20% to about 25% of the total weight of the tobacco bead.  
   
   
       33 . A smoking article comprising the tobacco bead of  claim 24 .  
   
   
       34 . The smoking article of  claim 33 , wherein said smoking article further comprises a filter and a tobacco rod, said filter including a sorbent at an upstream location along said filter and the tobacco bead at a downstream location along the filter.