Cigarette for electrical smoking system

A cigarette comprising a tobacco rod, said tobacco rod comprising a tubular tobacco web and a plug disposed within said tubular tobacco web, said tobacco rod having a free end and an opposite end, said tubular tobacco web comprising a base web and a layer of tobacco material disposed along an inside surface of said base web, said tobacco material including ground tobacco, said base web adapted to transfer heat from an electrical heating element to said tobacco material, said tobacco rod adapted to operatively receive an electrical heating element at an intermediate location between said free end and said opposite end, said plug providing structural connection of said free end with said opposite end, said structural connection of said free end with said opposite end intact after a smoking of said cigarette;

• said plug including a stem portion concentrically disposed within said tubular tobacco web;
• said plug including a first portion which extends across said free end;
• said plug including a second portion which extends across said opposite end, said second portion including a passage, said passage configured to facilitate withdrawal of aerosol released from said tubular tobacco web through said opposite end;
• said plug passage at said opposite end communicating with a space enclosed by said tobacco web;
• said plug including belled plug portions adjacent said free end and said opposite end;
• and
• wherein said passage is defined by a flute in said belled portion adjacent said opposite end.

A cigarette comprising a tobacco rod, said tobacco rod comprising a tubular tobacco web and a plug disposed within said tubular tobacco web, said tobacco rod having a free end and an opposite end, said tubular tobacco web comprising a base web and a layer of tobacco material disposed along an inside surface of said base web, said tobacco material including ground tobacco, said base web adapted to transfer heat from an electrical heating element to said tobacco material, said tobacco rod adapted to operatively receive an electrical heating element at an intermediate location between said free end and said opposite end, said plug providing structural connection of said free end with said opposite end, said structural connection of said free end with said opposite end intact after a smoking of said cigarette;

• said plug including a stem portion concentrically disposed within said tubular tobacco web;
• said plug including a first portion which extends across said free end;
• said plug including a second portion which extends across said opposite end, said second portion including a passage, said passage configured to facilitate withdrawal of aerosol released from said tubular tobacco web through said opposite end;
• said plug passage at said opposite end communicating with a space enclosed by said tobacco web;
• said tobacco rod further comprising an overwrap about the tubular tobacco web;
• said cigarette further comprising filter tipping at said opposite end;
• and
• wherein said passage through said plug portion adjacent said opposite end communicates the space within said tubular tobacco web with a space defined within said free flow filter.

A cigarette comprising a tobacco rod, said tobacco rod comprising a tubular tobacco web and a plug disposed within said tubular tobacco web, said tobacco rod having a free end and an opposite end, said tubular tobacco web comprising a base web and a layer of tobacco disposed along an inside surface of said base web, said tobacco material including ground tobacco, said base web adapted to transfer heat from an electrical heating element to said tobacco material, said tobacco rod adapted to operatively receive an electrical heating element at an intermediate location between said free end and said opposite end, said plug providing structural connection of said free end with said opposite end, said structural connection of said free end with said opposite end intact after a smoking of said cigarette;

• said plug including a stem portion concentrically disposed within said tubular tobacco web;
• said plug including a first portion which extends across said free end;
• said plug including a second portion which extends across said opposite end, said second portion including a passage, said passage configured to facilitate withdrawal of aerosol released from said tubular tobacco web through said opposite end;
• said plug passage at said opposite end communicating with a space enclosed by said tobacco web;
• said plug being constructed from a molded material;
• and
• said plug including cylindrical end portions connected by a stem portion, said cylindrical portions in substantial surface-to-surface contact with said tobacco web at locations adjacent said free end and said opposite end;
• said cigarette further comprising filter tipping at said opposite end.

A cigarette comprising a tobacco rod, said tobacco rod comprising a tubular tobacco web and a plug disposed within said tubular tobacco web, said tobacco rod having a free end and an opposite end, said tubular tobacco web comprising a base web and a layer of tobacco material disposed along an inside surface of said base web, said tobacco material including ground tobacco, said base web adapted to transfer heat from an electrical heating element to said tobacco material, said tobacco rod adapted to operatively receive an electrical heating element at an intermediate location between said free end and said opposite end, said plug providing structural connection of said free end with said opposite end, said structural connection of said free end with said opposite end intact after a smoking of said cigarette;

• wherein said plug comprises a column of cut filler tobacco;
• wherein said tobacco column includes first and second segments, said first segment having a density greater than said second segment, said first segment at an intermediate location along said tobacco rod;
• and
• wherein said second segment extends to said free end.

A method of producing cigarettes, said cigarette comprising a tubular tobacco web and a plug disposed within said tubular tobacco web, said tubular tobacco web having a free end and a opposite end, said plug structurally connecting said free end with said opposite end, said process comprising the steps of:

• (a) producing a continuous plug rod from a supply of fibrous tow material;
• (b) passing said continuous plug rod through a die forming station so as to form a die-formed plug rod having narrowed stem portions at spaced locations along said die-formed plug rod, said die forming step further including the step of alternately forming at locations along said die-formed plug rod between said formed stem portions a smooth belled portion and a fluted belled portion;
• (c) overwrapping said die formed plug rod with a tobacco web and overwrap, together with the application of an adhesive so as to produce a continuous tobacco rod;
• (d) transversely severing said continuous tobacco rod at spaced locations, said spaced locations being intermediate of at least one of said smooth belled portion and said fluted belled portion within said continuous tobacco rod.