SMOKING ARTICLE

Abstract

 A smoking article comprises in this order
a) a functional segment
b) a tobacco rod,
c) a cooling segment
d) a filter segment,
e) wherein the tobacco rod comprises a tobacco filler and an aerosol source,
f) wherein the length of the functional segment is 5 to 10 mm,
g) wherein the amount of aerosol source is 5 to 50 wt. %, preferably 10 to 30 wt. %, based on the dry weight of the tobacco filler.

Description

TECHNICAL FIELD

[0001] The present invention relates to a smoking article.

BACKGROUND ART

[0002] A smoking article, such as a cigarette, that includes a tobacco rod, a cooling segment, and a filter segment has a problem of falling tobacco shreds or the like from the leading end, in other words, the end opposite to the mouth end. To prevent this, it has been proposed to apply an adhesive on the inner side of a paper wrapper near the leading end (Patent Literature (PTL) 1).

CITATION LIST

PATENT LITERATURE

[0003] Japanese Patent No. 3202221

SUMMARY OF INVENTION

TECHNICAL PROBLEM

[0004] Since a filter for preventing such falling from the leading end is generally shorter than a tobacco rod, the handling thereof in the manufacturing process is not easy. In view of this, an object of the present invention is to provide a smoking article that can be manufactured efficiently and includes a functional segment for functionalizing the end opposite to the mouth end of a tobacco rod.

SOLUTION TO PROBLEM

[0005] The inventors resolved the above-mentioned problem by the smoking article of claim 1. Preferred embodiments are described in the further claims. In other words, the above-mentioned problem is resolved by the present invention below. In the method of manufacturing the article, this is supported by placing a functional segment in the center, followed by separating and inverting. Methods of manufacturing the smoking article are described hereinafter.

[Embodiment 1] A method of manufacturing a smoking article that has a functional segment, a tobacco rod, a cooling segment, and a filter segment, including

(A) preparing a segment A that contains a double-length functional segment, which has a double length of the functional segment, and the tobacco rods at either end of the double-length functional segment;

(C) preparing a pair of the cooling segments and placing the cooling segments in contact with either end of the segment A to prepare a segment C;

(D) cutting and separating the segment C in the central part in the longitudinal direction to prepare a pair of segments D and inverting the segments D, thereby placing the segments D via a gap to align the longitudinal axes of the segments D and allow the cooling segments to face each other;

(E) preparing a double-length filter segment, which has a double length of the filter segment, and placing the double-length filter segment in the gap such that both ends of the double-length filter segment come into contact with the end on the cooling segment side of either of the segments D, thereby preparing a segment E;

(F) integrating the segment E by wrapping in one tipping paper to produce a double-length smoking article, which has a double length of the smoking article; and

(G) cutting the double-length smoking article in the central part in the longitudinal direction to yield smoking articles.

[Embodiment 2] The method according to Embodiment 1, where the functional segment comprises a filter member.

[Embodiment 3] The method according to Embodiment 1 or 2, where the functional segment contains a flavor.

[Embodiment 4] The method according to any of Embodiments 1 to 3, where a step of A is a step of preparing a double-length functional tobacco segment by

(A1) preparing a pair of the tobacco rods and placing the tobacco rods via a gap to align the longitudinal axes of the tobacco rods; and

(A2) preparing a double-length functional segment, which has a double length of the functional segment, and placing the double-length functional segment in the gap such that both ends of the double-length functional segment come into contact with either of the tobacco rods.

[Embodiment 5] The method according to any of Embodiments 1 to 4, where a step of A is a step of preparing a double-length functional tobacco segment by

(A1') preparing a double-length tobacco rod, which has a double length of the tobacco rod, and cutting then separating the double-length tobacco rod in the central part in the longitudinal direction, thereby placing the tobacco rods via a gap to align the longitudinal axes of the tobacco rods; and

(A2') preparing a double-length functional segment, which has a double length of the functional segment, and placing the double-length functional segment in the gap such that both ends of the double-length functional segment come into contact with either of the tobacco rods.

[Embodiment 6] The method according to any of Embodiments 1 to 5, further including, between steps of A and C,
(B) integrating the segment A by wrapping in one second tipping paper.

[Embodiment 7] The method according to any of Embodiments 1 to 6, where the filter segment includes an acetate filter and a center hole filter.

[Embodiment 8] The method according to any of Embodiments 1 to 7, where the smoking article includes the functional segment, the tobacco rod, the cooling segment, and the filter segment in this order toward the downstream direction.

[Embodiment 9] The method according to any of Embodiments 1 to 8, where the tobacco rod has a diameter larger than a neighboring member.

[Embodiment 10] The method according to Embodiment 9, where the tobacco rod has a diameter 0.05 to 0.15 mm larger than the neighboring member.

[Embodiment 11] The method according to Embodiment 9, where the tobacco rod has a diameter 0.5 to 2.5% larger than the neighboring member.

[Embodiment 12] The method according to any of Embodiments 1 to 11, where a member neighboring the tobacco rod has stiffness higher than the tobacco rod.

[Embodiment 13] The method according to any of Embodiments 1 to 12, where the cooling segment includes a paper tube having a plurality of holes in the circumferential direction.

[Embodiment 14] The method according to Embodiment 13, where the cooling segment includes a paper tube; and the method further includes forming a plurality of holes in the circumferential direction of the paper tube by laser processing.

[Embodiment 15] The method according to any of Embodiments 1 to 14, where

a step of F is a step performed by preparing a precursor in which part of the tipping paper is attached to a circumferential surface of the segment E, placing the precursor between a rolling drum and a rolling hand that is provided facing a circumferential surface of the rolling drum, and rotating the precursor on the circumferential surface of the rolling drum; and

the rolling drum or the rolling hand has, in a portion facing a section of the tobacco rod, a depression for forming a gap from the section of the tobacco rod.

ADVANTAGEOUS EFFECTS OF INVENTION

[0006] According to the present disclosure, it is possible to provide a method of efficiently manufacturing a smoking article that includes a functional segment for functionalizing the end opposite to the mouth end of a tobacco rod.

BRIEF DESCRIPTION OF DRAWINGS

[0007] 

Fig. 1 schematically illustrates smoking articles.

Fig. 2 illustrates an embodiment of the manufacturing method of the present disclosure.

Fig. 3 illustrates an embodiment of step A in the manufacturing method of the present disclosure.

Fig. 4 is a view for illustrating a measurement method for stiffness.

Fig. 5 illustrates an embodiment of an apparatus for performing the manufacturing method of the present disclosure.

Fig. 6 illustrates an embodiment of step D.

Fig. 7 illustrates an embodiment of step F.

Fig. 8 illustrates embodiments of step F.

DESCRIPTION OF EMBODIMENTS

[0008] The present disclosure relates to a method of manufacturing a smoking article that includes a tobacco rod, a cooling segment, and a filter segment. Hereinafter, the present invention will be described in detail. In the present invention, the expression "X to Y" includes the lower and the upper limits of X and Y.

1. Smoking Article

[0009] A smoking article of the present invention includes a functional segment, a tobacco rod, a cooling segment, and a filter segment. Fig. 1 (i) illustrates an embodiment of the smoking article of the present invention. In the figure, 100 is a smoking article, 1 is a tobacco rod, 3 is a cooling segment, 5 is a filter segment, 7 is a tipping paper, and 9 is a functional segment.

(1) Tobacco Rod

[0010] A tobacco rod is an almost cylindrical member for generating smoking flavor components contained in tobacco raw materials and includes tobacco filler and a paper wrapper wrapped therearound. The tobacco filler is not limited, and tobacco shreds or tobacco sheets, for example, may be used therefor. Specifically, tobacco shreds prepared by cutting dry tobacco leaves into a width of 0.8 to 1.2 mm may be packed inside a paper wrapper. Alternatively, those prepared by uniformly pulverizing dry tobacco leaves into an average particle size of about 20 to 200 µm, forming into sheets, and cutting the sheets into a width of 0.8 to 1.2 mm may be packed inside a paper wrapper. Moreover, such sheets may be gathered, folded, or spirally rolled without cutting and packed inside a paper wrapper. Further, such sheets may be cut into strips and packed inside a paper wrapper concentrically or with the longitudinal direction of the strips aligned parallel to the longitudinal direction of a tobacco rod.

[0011] The tobacco rod 1 may generate an aerosol upon heating. To promote the generation of an aerosol, it is preferable to add an aerosol source, such as glycerol, propylene glycol, 1,3-butanediol, or other polyols, to the tobacco filler. The amount of an aerosol source to be added is preferably 5 to 50 weight% and more preferably 10 to 30 weight% based on the dry weight of the tobacco filler. In addition, the tobacco rod may contain a flavor, such as menthol. The length of the tobacco rod 1 is not limited but is preferably 15 to 25 mm The diameter is also not limited but is preferably 6.5 to 7.5 mm Meanwhile, when a neighboring member has stiffness higher than the tobacco rod, the tobacco rod preferably has a diameter larger than the neighboring member. As a result, deformation of the tobacco rod can be suppressed. In this view, the tobacco rod has a diameter preferably 0.5 to 2.5% larger and more preferably 1.0 to 2.0% larger than the neighboring member. In actual dimension, the tobacco rod preferably has a diameter about 0.05 to 0.15 mm larger than the neighboring member. Exemplary neighboring members include a cooling segment and a filter segment.

[0012] The term "stiffness" in the present invention means the resistance of a member to deformation as disclosed in paragraphs [0010] to [0014] of Japanese Unexamined Patent Application Publication (Translation of PCT Application) No. 2016-523565. Stiffness can be obtained from a change in diameter before and after applying a load F on the side surface of a tobacco rod. When the diameter of a tobacco rod before applying a load F is denoted by Ds and the diameter after applying the load is denoted by Dd as in Fig. 4, the amount depressed is d = Ds - Dd and the stiffness is defined by the following formula. The same applies to other members.

(2) Cooling Segment

[0013] A cooling segment is a member for cooling an aerosol and smoking flavor components generated in the tobacco rod 1. The cooling segment 3 may be a hollow paper tube. The paper tube is preferably made of cardboard having stiffness higher than paper wrappers and tipping papers. The paper tube may be provided with holes (ventilation holes). A plurality of holes are preferably formed along the circumference of the paper tube. In view of efficient operations, such holes are preferably formed by laser processing of a finished smoking article. Moreover, to enhance heat exchange efficiency, gathered sheets may be packed inside the cooling segment 3. Although the dimensions of the cooling segment 3 are not limited, the length is preferably 15 to 25 mm and the diameter is preferably 5.5 to 7.5 mm Meanwhile, when a member neighboring the cooling segment 3 has stiffness lower than the cooling segment 3, the cooling segment 3 has a diameter preferably 0.5 to 2.5% smaller and preferably 1.0 to 2.0% smaller than the neighboring member. When the cooling segment 3 includes a paper tube made of cardboard, the segment generally has stiffness higher than a tobacco rod.

(3) Filter Segment

[0014] A filter segment is a member including a filter. As the filter, a publicly known filter member, such as an acetate filter or a paper filter, may be used. A paper filter is a paper-filled filter prepared by creasing paper through processing with a crepe roller or the like and by rolling the paper using a plug wrapper. An acetate filter is a filter filled with cellulose acetate fibers. As illustrated in Fig. 1 (ii), a filter segment 5 is preferably composed of a plurality of members, and more preferably includes a filter 51 and a center hole filter 53. The center hole filter may be a space provided in the central part of an acetate filter, for example. The length of the filter segment 5 is not limited but is preferably 10 to 20 mm. When both a center hole filter and an acetate filter are arranged as a filter segment, the order is not limited. Moreover, individual members may be wrapped in each filter inner wrapper and joined with a filter outer wrapper. The diameter of the filter segment is not limited but is preferably almost the same as those of other segments excluding a tobacco rod. As a result, tearing and creasing of tipping paper can be suppressed.

(4) Functional Segment

[0015] A functional segment is a segment for functionalizing the smoking article 100. For example, the functional segment 9 acts to prevent falling of tobacco shreds or the like from the leading end of the tobacco rod 1 or acts to impart a unique flavor by carrying the flavor. In the former case, the functional segment 9 preferably comprises a filter, such as an acetate filter. Meanwhile, the functional segment 9 of the latter is preferably a filter or a paper tube embedded with flavor capsules. The length of the functional segment 9 is not limited but is preferably 5 to 10 mm.

(5) Tipping Paper

[0016] The term "tipping paper" refers to a paper used for joining two or more of a tobacco rod, a cooling segment, and a filter segment. Meanwhile, the term "paper wrapper" refers to a paper for wrapping individual members that constitute a tobacco rod, a cooling segment, or a filter segment. For example, when a filter segment includes a center hole filter and an acetate filter as in the foregoing, a paper for wrapping the center hole filter and a paper for wrapping the acetate filter are each paper wrapper.

[0017] Exemplary base paper for tipping papers and paper wrappers includes, but is not limited to, paper using cellulose fibers. Such cellulose fibers may be either derived from plants or chemically synthesized, or may be a mixture thereof. Exemplary plant-derived fibers include pulp of flax fibers, wood fibers, or seed fibers, for example. Such pulp may be colored unbleached pulp. However, from a viewpoint of obtaining white clean appearance, it is preferable to use bleached pulp, which is prepared using a bleaching agent, such as an oxidant or a reductant.

[0018] For a typical paper wrapper for cigarettes, a citric acid alkali metal salt or the like is used as a common burning chemical (combustion aid, for example) that can affect the spontaneous combustion rate of the paper wrapper. In the present invention, a heating-type smoking article but not a combustion-type is preferable. In this case, since the combustion of a paper wrapper is unnecessary, the paper wrapper need not contain a burning chemical.

[0019] The lower limit of the basis weight of a paper wrapper is preferably 30 g/m² or more, more preferably 35 g/m² or more, and further preferably 40 g/m² or more. The upper limit is preferably 65 g/m² or less and more preferably 50 g/m² or less. Meanwhile, the lower limit of the basis weight of a tipping paper is preferably 20 g/m² or more, more preferably 25 g/m² or more, and further preferably 30 g/m² or more. The upper limit is preferably 50 g/m² or less, more preferably 45 g/m² or less, and further preferably 40 g/m² or less. The basis weight can be measured by the method specified in JIS P 8124.

2. Manufacturing Method

[0020] The outline of the present process is illustrated in Fig. 2. In the figure, "w" indicates "double-length." For example, 5w represents a double-length filter segment.

(1) Step A

[0021] This step prepares a segment A that includes a double-length functional segment 9w, which has a double length of the functional segment 9, and the tobacco rods 1 at either end of the double-length functional segment. The double-length functional segment 9w and the tobacco rods 1 may be in mere contact with each other and need not be attached.

[0022] Step A may include the following steps as illustrated in Fig. 3:

(A1) a step of preparing a pair of tobacco rods 1 and placing via a gap to align the longitudinal axes of the tobacco rods; and

(A2) a step of preparing a double-length functional segment 9w and placing in the gap such that both ends of the double-length functional segment come into contact with either of the tobacco rods 1.

[0023] Moreover, step A may include the following steps:

(A1') a step of preparing a double-length tobacco rod 1w, which has a double length of the tobacco rod 1, and cutting then separating the double-length tobacco rod 1w in the central part in the longitudinal direction, thereby placing the tobacco rods via a gap to align the longitudinal axes of the tobacco rods; and

(A2') a step of preparing a double-length functional segment 9w, which has a double length of the functional segment 9, and placing in the gap such that both ends of the double-length functional segment come into contact with either of the tobacco rods 1, thereby preparing a double-length functional tobacco segment.

[0024] Through this step, it is possible to easily functionalize the upstream portion of a smoking article. For example, when the functional segment 9 is a filter, falling from the leading end can be prevented.

[0025] The manufacturing method of the present disclosure can be performed using any appropriate apparatus but is preferably performed using, for example, an apparatus that includes a plurality of drums and that feeds each member from above as illustrated in Fig. 5. One drum preferably has one function rather than a plurality of functions since defect generation can be suppressed in high-speed manufacture. For example, step A can be performed in the first unit 81 of Fig. 5 where 81f is a feeder for tobacco rods 1, 81p is a picking-up drum, and 81s is a separating drum. A pair of tobacco rods 1 fed from the feeder 81f are passed to a holding section provided on the circumferential surface of the picking-up drum 81p. Subsequently, the pair of the tobacco rods 1 are passed to the separating drum 81s and placed via a gap in a holding section while being transferred. Further, the pair of the tobacco rods 1 placed via a gap are passed in this state to a receiving drum 81a by a transfer drum 81t.

[0026] Here, 81'f is a feeder for a double-length functional segment 9w and 81'p is a picking-up drum A double-length functional segment 9w fed from the feeder 81'f is passed to a holding section provided on the circumferential surface of the picking-up drum 81'p. Meanwhile, the pair of the tobacco rods 1 are placed via a gap on the receiving drum 81a. The double-length functional segment 9w is placed in the gap to come into contact with the tobacco rods 1. In each unit of the apparatus, one or a plurality of drums may have a feeding, receiving, transferring, or separating function.

(2) Step B

[0027] The manufacturing method of the present disclosure preferably includes, between steps A and C, step B of integrating the segment A by wrapping in one second tipping paper 71. For convenience, the integrated segment A is also referred to as segment B. As the second tipping paper 71, paper common in the field concerned can be used. The second tipping paper 71 may be coated with a publicly known adhesive. As a result, the functional segment and the tobacco rods in the separable state are integrated into the inseparable state.

[0028] By adjusting the length of the second tipping paper used in this step, it is possible to functionalize a smoking article. For example, when the second tipping paper has a length that can cover the entire tobacco rods 1, it is possible to maintain satisfactory appearance since stains, even if formed on the tobacco rods 1, can be hidden. Alternatively, it is also possible to set a region covered with the second tipping paper 71 to a region, when the length of the tobacco rod 1 is denoted by X, from the bonding face between the tobacco rod 1 and the functional segment 9 to the position of 0.1X to 0.3X in the longitudinal direction of the tobacco rod 1. By setting the wrapped region within this range, lowering in thermal conductivity can be avoided during heating of the tobacco rod 1.

[0029] This step can be performed in the second unit 82 of Fig. 5 where 82f is a feeder for a second tipping paper 71, 82t is a transfer drum, 82r is a rolling drum, and 82h is a rolling hand. Since this step is the same as step F, the details will be described in step F.

(3) Step C

[0030] In this step, a pair of cooling segments 3 are prepared and placed in contact with either end of the segment B to prepare a segment C.

[0031] This step can be performed in the third unit 83 of Fig. 5 where 83f is a feeder for cooling segments 3, 83ps is a picking-up and separating drum, and 83a is a receiving drum A pair of cooling segments 3 fed from the feeder 83f are passed to a holding section provided on the circumferential surface of the picking-up and separating drum 83ps while being placed via a gap. Meanwhile, the segment B prepared in the preceding step is passed to the receiving drum 83a via a transfer drum 83t. The pair of the cooling segments 3 are passed to the receiving drum 83a and placed at either end of the segment B to come into contact with the end face of either of the tobacco rods 1.

(4) Step D

[0032] In this step, the segment C is cut and separated in the central part in the longitudinal direction to prepare a pair of segments D. Subsequently, the segments D are inverted to be placed via a gap to align the longitudinal axes of the segments D and allow the cooling segments 3 to face each other.

[0033] This step can be performed in the fourth unit 84 of Fig. 5 where 84c is a cutter drum and 84c' is a cutter. The segment B is passed to the cutter drum 84c and cut with the cutter 84c' in the central part in the longitudinal direction. Subsequently, the cut segments are passed to two inverting drums 84i and inverted. With reference to Fig. 6, the mechanism of inversion will be described. A guide G on the inverting drum 84i is a holding section for a segment D, which is either of the segment C divided into two, and is provided in a rotatable manner around one corner on the drum The segment D held in the guide G illustrated with a dotted line is moved to the solid-line position through the rotation of the guide G as the inverting drum 84i rotates. Subsequently, the segment D is passed to a guide G' illustrated with a dotted line on the inverting drum 84i'. The guide G' slides on the inverting drum 84i' to the solid-line position where the distance between a pair of the segments D is a desirable value. The pair of the divided segments C are thus inverted.

(5) Step E

[0034] In this step, a double-length filter segment 5w, which has a double length of the filter segment 5, is prepared and placed in the gap such that both ends of the double-length filter segment come into contact with the end on the cooling segment side of either of the segments D, thereby preparing a segment E.

[0035] This step can be performed in the fifth unit 85 of Fig. 5 where 85f is a feeder for a double-length filter segment 5w, 85p is a picking-up drum, and 85a is a receiving drum. A double-length filter segment 5w fed from the feeder 85f is passed to a holding section provided on the circumferential surface of the picking-up drum 85p. Meanwhile, the pair of the segments D placed via a gap are passed in this state to the receiving drum 85a. The double-length filter segment 5w from the picking-up drum 85p is placed in the gap between the pair of the segments D on the receiving drum 85a.

(6) Step F

[0036] In this step, the segment E is integrated by wrapping in one tipping paper 7 to prepare a double-length smoking article 100w, which has a double length of the smoking article 100. As the tipping paper 7, the same as the second tipping paper 71 may be used. As a result, the segment E in the separable state is integrated into the inseparable state. On this occasion, the tipping paper 7 need not cover the entire range of the tobacco rods 1. When the length of the tobacco rod 1 is denoted by X, a region covered with the tipping paper 7 is preferably a region extending from the bonding face between the tobacco rod 1 and the cooling segment 3 to the position of 0.2X to 0.4X in the longitudinal direction of the tobacco rod 1. By setting the wrapped region within this range, lowering in thermal conductivity can be avoided during heating of the tobacco rod 1.

[0037] This step can be performed in the sixth unit 86 of Fig. 5 where 86f is a feeder for a tipping paper, 86t is a transfer drum, 86r is a rolling drum, and 86h is a rolling hand. A rolling drum is a drum having a holding section that is for holding a member on the circumferential surface and that enables a segment or another member to rotate on its central axis in the longitudinal direction. A rolling hand is a means that is disposed facing the circumferential surface of the rolling drum and that is for forming a gap of a constant distance from the circumferential surface. The segment E is passed to the transfer drum 86t and then passed to the rolling drum 86r. Meanwhile, part of the tipping paper 7 fed from the feeder 86f is attached to the circumferential surface of the segment E on the rolling drum 86r, thereby forming a precursor 92 (see Fig. 7). The precursor 92 includes the tipping paper 7 attached, like a flag, to the segment denoted by 90. In other words, part of the tipping paper 7 is attached to the circumferential surface of the segment E while leaving the remainder free. The precursor 92 is fixed to the holding section on the circumferential surface of the rolling drum 86r through suction or the like and transferred to the gap formed between the rolling drum 86r and the rolling hand 86h. While passing through this gap, the entire circumferential surface of the precursor 92 is wrapped in the tipping paper 7 to form a double-length smoking article 100w (see Fig. 7).

[0038] As in the foregoing, the tobacco rod 1 preferably has a diameter larger than the neighboring cooling segment 3 in the present invention. In this case, if the surfaces of the rolling drum 86r and the rolling hand 86h are flat, excessive contact arises between these surfaces and the tobacco rod 1 (Fig. 8 (1)). This results in a problem of falling fillings from the leading end under the impact on the tobacco rod 1. In addition, the difference in circumference causes twisting, thereby developing defects, such as creases, in a product. For these reasons, it is preferable in the present invention to form a gap from the tobacco rod 1 by providing a depression on the rolling drum 86r or rolling hand 86h surface that faces the tobacco rod 1 as illustrated in Figs. 8 (2) and (3). Although Figs. 8 (2) and (3) illustrate embodiments in which a depression is provided on the rolling hand 86h, a depression may be provided on the rolling drum 86r or both the rolling drum and the rolling hand. The depth of the depression (T in Figs. 8 (2) and (3)) is appropriately adjusted and is preferably 0.05 to 0.15 mm Such a depression need not be provided on the entire surface that faces the tobacco rod 1. As illustrated in Fig. 8, a depression may be provided on part of the surface that faces the tobacco rod 1. Meanwhile, to reliably attach a tobacco rod to another member by using a tipping paper, a depression is preferably absent near the boundary between these two members.

[0039] In the present invention, the segment E is wrapped in one tipping paper in the final stage. Accordingly, it is possible to avoid steps formed on a product due to the use of many tipping papers and consequently reduce the occurrence of defects in manufacture.

(7) Step G

[0040] In this step, the double-length smoking article 100w is cut in the central part in the longitudinal direction to yield smoking articles 100. This step may further include aligning two smoking articles 100 in the same direction by inverting either of the smoking articles 100.

[0041] This step can be performed in the seventh unit 87 of Fig. 5 where 87c is a cutter drum, 87c' is a cutter, and 87a is a receiving drum The cutting is performed as described in step D.

[0042] In the present disclosure, the double-length functional segment 9w is placed in the center, cut and separated in the central part, and inverted. As a result, efficient operations are possible when the leading end of a smoking article is functionalized.

[Example 1]

[0043] The following members were prepared.

Tobacco rod of 7.0 mm in diameter and 20.0 mm in length (from Japan Tobacco Inc.)

Acetate filter of 6.9 mm in diameter and 16 mm in length as a double-length functional segment

Paper tube of 6.9 mm in diameter and 20.0 mm in length as a cooling segment

Double-length filter segment of 6.9 mm in diameter consisting of a center hole filter (8.0 mm)/a double-length acetate filter (14.0 mm)/a center hole filter (8.0 mm)

Second tipping paper of 24 mm × 26 mm

First tipping paper of 24.0 mm × 80.0 mm

[0044] A double-length tobacco rod was prepared and cut then separated in the central part in the longitudinal direction, thereby placing tobacco rods via a gap to align the longitudinal axes of the tobacco rods. Subsequently, a double-length functional segment was placed in the gap to prepare a segment A that includes the double-length functional segment and the tobacco rods at either end of the double-length functional segment (step A).

[0045] The segment A was integrated by wrapping in one second tipping paper to prepare a segment B (step B). A pair of paper tubes were prepared and placed in contact with either end of the segment B to prepare a segment C (step C). The segment C was cut and separated in the central part in the longitudinal direction to prepare a pair of segments D, and the segments D were inverted to be placed via a gap to align the longitudinal axes of the segments D and allow the paper tubes to face each other (step D). A double-length filter segment, which has a double length of a filter segment, was prepared and placed in the gap such that both ends of the double-length filter segment come into contact with the end on the paper tube side of either of the segments D to prepare a segment E (step E). The segment E was integrated by wrapping in one tipping paper to produce a double-length smoking article, which has a double length of a smoking article (step F). The double-length smoking article was cut in the central part in the longitudinal direction to manufacture smoking articles (step G).

REFERENCE SIGNS LIST

[0046] 

1

Tobacco rod

1w

Double-length tobacco rod

3

Cooling segment

5

Filter segment

5w

Double-length filter segment
51 Acetate filter
53 Center hole filter

7

Tipping paper

71

Second tipping paper

9

Functional segment

9w

Double-length functional segment

10

Tobacco segment

80

Manufacturing apparatus

81

First unit
81f, 81'f Feeder
81p, 81'p Picking-up drum
81s Separating drum
81t Transfer drum
81a Receiving drum

82

Second unit
82f Tipping paper feeder
82t Transfer drum
82h Rolling hand
82r Rolling drum

83

Third unit
83f Feeder
83ps Picking-up and separating drum
83t Transfer drum
83a Receiving drum

84

Fourth unit
84c Cutter drum
84c' Cutter
84i Inverting drum
84'i Inverting drum

85

Fifth unit
85f Feeder
85p Picking-up drum
85a Receiving drum

86

Sixth unit
86f Tipping paper feeder
86t Transfer drum
86r Rolling drum
86h Rolling hand

87

Seventh unit
87c Cutter drum
87c' Cutter
87a Receiving drum

90

Segment E

92

Precursor

100

Smoking article

100w

Double-length smoking article

The following numbered paragraphs describe embodiments of the method of manufacturing a smoking article in accordance with the present invention and part of the present disclosure.

1. A method of manufacturing a smoking article that includes a functional segment, a tobacco rod, a cooling segment, and a filter segment, comprising

(A) preparing a segment A that includes a double-length functional segment, which has a double length of the functional segment, and the tobacco rods at either end of the double-length functional segment;

(C) preparing a pair of the cooling segments and placing the cooling segments in contact with either end of the segment A to prepare a segment C;

(D) cutting and separating the segment C in the central part in the longitudinal direction to prepare a pair of segments D and inverting the segments D, thereby placing the segments D via a gap to align the longitudinal axes of the segments D and allow the cooling segments to face each other;

(E) preparing a double-length filter segment, which has a double length of the filter segment, and placing the double-length filter segment in the gap such that both ends of the double-length filter segment come into contact with the end on the cooling segment side of either of the segments D, thereby preparing a segment E;

(F) integrating the segment E by wrapping in one tipping paper to produce a double-length smoking article, which has a double length of the smoking article; and

(G) cutting the double-length smoking article in the central part in the longitudinal direction to yield smoking articles.

2. The method according to 1, wherein the functional segment comprises a filter member.

3. The method according to 1 or 2, wherein the functional segment contains a flavor.

4. The method according to any of 1 to 3, wherein a step of A is a step of preparing a double-length functional tobacco segment by

(A1) preparing a pair of the tobacco rods and placing the tobacco rods via a gap to align the longitudinal axes of the tobacco rods; and

(A2) preparing a double-length functional segment, which has a double length of the functional segment, and placing the double-length functional segment in the gap such that both ends of the double-length functional segment come into contact with either of the tobacco rods.

5. The method according to any of 1 to 4, wherein a step of A is a step of preparing a double-length functional tobacco segment by

(A1') preparing a double-length tobacco rod, which has a double length of the tobacco rod, and cutting then separating the double-length tobacco rod in the central part in the longitudinal direction, thereby placing the tobacco rods via a gap to align the longitudinal axes of the tobacco rods; and

(A2') preparing a double-length functional segment, which has a double length of the functional segment, and placing the double-length functional segment in the gap such that both ends of the double-length functional segment come into contact with either of the tobacco rods.

6. The method according to any of 1 to 5, further comprising, between steps of A and C,
(B) integrating the segment A by wrapping in one second tipping paper.

7. The method according to any of 1 to 6, wherein the filter segment includes an acetate filter and a center hole filter.

8. The method according to any of 1 to 7, wherein the smoking article includes the functional segment, the tobacco rod, the cooling segment, and the filter segment in this order toward the downstream direction.

9. The method according to any of 1 to 8, wherein the tobacco rod has a diameter larger than a neighboring member.

10. The method according to 9, wherein the tobacco rod has a diameter 0.05 to 0.15 mm larger than the neighboring member.

11. The method according to 9, wherein the tobacco rod has a diameter 0.5 to 2.5% larger than the neighboring member.

12. The method according to any of 1 to 11, wherein a member neighboring the tobacco rod has stiffness higher than the tobacco rod.

13. The method according to any of 1 to 12, wherein the cooling segment includes a paper tube having a plurality of holes in the circumferential direction.

14. The method according to 13, wherein the cooling segment includes a paper tube; and the method further comprises forming a plurality of holes in the circumferential direction of the paper tube by laser processing.

15. The method according to any of 1 to 14, wherein

a step of F is a step performed by preparing a precursor in which part of the tipping paper is attached to a circumferential surface of the segment E, placing the precursor between a rolling drum and a rolling hand that is provided facing a circumferential surface of the rolling drum, and rotating the precursor on the circumferential surface of the rolling drum; and

the rolling drum or the rolling hand has, in a portion facing a section of the tobacco rod, a depression for forming a gap from the section of the tobacco rod.

Claims

1. A smoking article comprising in this order

a) a functional segment

b) a tobacco rod,

c) a cooling segment

d) a filter segment,

e) wherein the tobacco rod comprises a tobacco filler and an aerosol source,

f) wherein the length of the functional segment is 5 to 10 mm,

g) wherein the amount of aerosol source is 5 to 50 wt. %, preferably 10 to 30 wt. %, based on the dry weight of the tobacco filler.

2. Smoking article according to claim 1, a first segment being integrated by a first tipping paper wrapped around the filter segment and the cooling segment.

3. Smoking article according to claim 1 or 2, a second segment being integrated by a second tipping paper wrapped around the functional segment and the tobacco rod.

4. Smoking article according to claims 1-3, wherein the length of the tobacco rod is 15 to 25 mm

5. Smoking article according to claims 1-4, wherein the cooling segment is a hollow paper tube , wherein the paper tube is preferably provided with ventilation holes.

6. Smoking article according to claims 1-5, wherein the tobacco filler comprises tobacco sheets, preferably:
wherein the tobacco sheets are cut into strips and packed inside a paper wrapper concentrically or with the longitudinal direction of the strips aligned parallel to the longitudinal direction of a tobacco rod.

7. Smoking article according to claim 1-6, wherein the tobacco filler comprises tobacco shreds, preferably:
wherein the tobacco shreds are prepared by cutting dry tobacco leaves into a width of 0.8 to 1.2 mm and packed inside a wrapper.

8. Smoking article according to claims 1-7, wherein the filter segment includes a filter and center hole filter.

9. Smoking article according to claims 1-8, wherein the length of the filter segment is 10 to 20 mm

10. Smoking article according to any of claims 1-9, wherein the tobacco rod has a diameter larger than a neighboring member, preferably 0.05 to 0.15 mm larger than the neighboring member, most preferred 0.5 to 2.5% larger than the neighboring member.

11. Smoking article according to any of claims 1-10, wherein a member neighboring the tobacco rod has stiffness higher than the tobacco rod.

12. Smoking article according to any of claims 1-11, wherein the cooling segment is in contact with the tobacco rod and/or the filter segment is in contact with the cooling segment.

13. Smoking article according to any of claims 1-12, wherein the functional segment comprises a filter.

14. Smoking article according to any of claims 1-13, wherein the filter segment comprises an acetate filter.

15. Smoking article according to any of claims 1 -14, wherein the diameter of the filter segment is substantially the same as those of the other segments excluding the tobacco rod.

Drawing