Process for making a carbon heat source and smoking article including the heat source and a flavor generator

A process for producing a tasteless carbon heat source from a preformed article of ligno-cellulosic material, comprising:

• pyrolyzing the article in a continuously exchanged inert atmosphere at a temperature within the range of from about 800.degree. to about 1100.degree. C. for from about 0.5 to about 3 hours,
• then cooling the pyrolyzed article in the inert atmosphere at a rate of from about 500.degree. to about 10.degree. C. per hour to a temperature within the range of from about 275.degree. C. to about 25.degree. C.,
• then adding oxygen to the pyrolyzed article, and
• then subjecting the pyrolized article to a desiccant environment.

A process for producing a tasteless carbon heat source from a preformed article of ligno-cellulosic material, comprising

• pyrolyzing the article in a continuously exchanged inert atmosphere at a temperature within the range of from about 800.degree. to about 1100.degree. C. for from about 0.5 to about 3 hours,
• then cooling the pyrolyzed article in the inert atmosphere at a rate of from about 500.degree. to about 10.degree. C. per hour to a temperature of about 25.degree. C.,
• then contacting the pyrolyzed article with a salt solution comprising a salt of a cation selected from the group consisting of K.sup.+, Fe.sup.+3, Fe.sup.+2, Mg.sup.+2, Mn.sup.+2, Ca.sup.+2 and mixtures thereof,
• then drying the article at a temperature within the range of from about 50.degree. to about 70.degree. C. in vacuum,
• then gradually heating the article up to a temperature of about 650.degree. C. in an inert atmosphere and maintaining said article at said temperature for from about 5 to about 60 minutes, and
• then cooling the article in said inert atmosphere at a rate of from about 500.degree. to about 10.degree. C. per hour to a temperature within the range of from about 275.degree. C. to about 25.degree. C.

A smoking article comprising:

• a carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source during puff induced flow, the porosity being sufficient to sustain static combustion;
• a flavor generator having a thermally releasable flavorant;
• and
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant and thereafter said distilled flavorant is delivered to the smoker by said gaseous combustion by-products generated during puff induced flow.

A smoking article comprising:

• a carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source during puff induced flow;
• a flavor generator having a thermally releasable flavorant, said flavor generator being a relatively porous combustible material disposed in the passage of the carbon heat source;
• and
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant and thereafter said distilled flavorant is delivered to the smoker by said gaseous combustion by-products during puff induced flow.

A smoking article comprising:

• a carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source, and porosity being sufficient to sustain static combustion;
• a flavor generator having a thermally releasable flavorant;
• and
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication wherein the carbon heat source and flavor generator are disposed in an abutting end to end relationship and one opening of the passage being adjacent to, abutting and in open communication with one end of the flavor generator whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant for delivery to the smoker.

A smoking article comprising:

• a carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source, the porosity being sufficient to sustain static combustion;
• a flavor generator having a thermally releasable flavorant;
• and
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication wherein the carbon heat source and flavor generator are disposed in an end to end relationship with an intervening space and an outer wrapper for enclosing said space into a chamber and one opening of the passage being in open communication with the chamber whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant for delivery to the smoker.

A smoking article comprising:

• a carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source, the porosity being sufficient to sustain static combustion;
• a flavor generator having a thermally releasable flavorant;
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant for delivery to the smoker;
• and
• a plug of porous material disposed in the passage to prevent flash jetting while the article is being ignited.

A smoking article comprising:

• a carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source, the porosity being sufficient to sustain static combustion;
• a flavor generator having a substrate impregnated with at least one thermally releasable flavorant wherein the substrate further comprises a combination of tobacco filler and at least one other material selected from among alumina, magnesium hydroxide, zeolites, glass wool, charcoal, Fuller's earth, natural clays, activated clays, and the like;
• and
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant for delivery to the smoker.

A smoking article comprising:

• a carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source, the porosity being sufficient to sustain static combustion;
• a flavor generator having a substrate inherently containing at least one thermally releasable flavorant wherein the substrate further comprises a combination of tobacco filler and at least one other material selected from among alumina, magnesium hydroxide, zeolites, glass wool, charcoal, Fuller's earth, natural clays, activated clays, and the like;
• and
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant for delivery to the smoker.

A smoking article comprising:

• a substantially cylindrical carbon heat source adapted for combustion and heat generation having a passage for the thermal and gaseous by-products of combustion to flow through the heat source, said heat source being a relatively nonporous material so that gaseous combustion by-products are substantially passed through the passage and not through the heat source, the porosity being sufficient to sustain static combustion, the heat source having a first diameter;
• a substantially cylindrical flavor generator having a thermally releasable flavorant the flavor generator having a diameter substantially equal to the first diameter;
• and
• connector means for connecting the flavor generator and heat source in thermal and gaseous communication whereby the heat and gaseous combustion by-products from the carbon heat source are passed to the thermally releasable flavorant of the flavor generator to distill said flavorant for delivery to the smoker.