Technical Field

The present invention relates to a cigarillo and a method of manufacturing a cigarillo.

Background

Cigarillos are known tobacco industry products that resemble small cigars.

Summary of the Invention

In accordance with a first aspect, a cigarillo is disclosed. The cigarillo comprises:

a rod of smokable material wrapped in a wrapper comprising reconstituted tobacco material;

a filter plug adjacent to, and in axial alignment with, the wrapped rod of smokable material; and

a band of tipping paper circumscribing the filter.

The wrapper has a porosity of 3-65 CORESTA units, and the cigarillo has a

circumference of i6-i8mm.

In accordance with a second aspect, a method of manufacturing the cigarillo of the first aspect is disclosed. The method comprises:

1) wrapping a smokable material with a wrapper to form a rod of smokable material having a circumference of i6-i8mm. The wrapper comprises reconstituted tobacco material and has a porosity of 3-65 CORESTA units;

2) axially aligning and abutting a cylindrical filter with the rod of smokable material; and

3) wrapping tipping paper around the filter and a portion of the rod of smokable material.

Brief Description of the Drawings

The invention will now be further described, by way of example only, with reference to the accompanying drawings.

FIG. 1 shows a schematic perspective view of the rod of smokable material, wrapper, filter, plug wrap, and tipping paper of a cigarillo of a first embodiment. Detailed Description

Definitions

The term‘cigarillo’ is used to describe a tobacco product that resembles a short, narrow cigar. The term“cigaritto” may also be used to refer to a tobacco product that resembles a short, narrow cigar, typically specifically in relation to a product having a

homogenized tobacco leaf wrapper. Thus, the product disclosed in the present application, which is a cigarillo having a wrapper comprising reconstituted tobacco material, may be also be referred to as a cigaritto. The term‘downstream’ is used to describe the relative positions of components of the disclosed cigarillo in relation to the direction in which smoke is drawn through the cigarillo in use. The terms‘lit end’ and‘mouth end’ are also used accordingly, such that smoke is drawn from the lit end to the mouth end of the cigarillo. The term‘length’ denotes the dimension in the longitudinal direction of the cigarillo.

The disclosed cigarillo has a length ranging from about 80 mm to about 90 mm. More preferably, the cigarillo has a length of 81-85 mm or 82-84mm, and in preferred embodiments, the cigarillo has a length of approximately 83 mm. The rod of smokable material has a length ranging from about 50 mm to about 60 mm. More preferably, the rod of smokable material has a length of 54-58 mm or 55-57mm, and in preferred embodiments, the rod of smokable material has a length of approximately 56 mm. The filter plug has a length ranging from about 25 mm to about 29 mm. More preferably, the filter plug has a length of 26-28 mm, and in preferred embodiments, the filter plug has a length of approximately 27 mm.

The tipping paper extends a distance from the mouth end of the cigarillo ranging from about 30 mm to about 34 mm. More preferably, the tipping paper extends a distance of 31-33 mm, and in preferred embodiments, the tipping paper extends a distance of approximately 32 mm.

The term‘circumference’ denotes the dimension around the edge of a circular cross- section of the cigarillo, the circular cross-section extending in a direction perpendicular to the length dimension. The cigarillo has a circumference ranging from about 16 mm to about 18 mm. More preferably, the cigarillo has a circumference ranging from about 16.5 mm to about 17.5 mm, and in preferred embodiments, the cigarillo has a circumference of approximately 17 mm. The term‘diameter’ denotes the dimension in the transverse direction of the cigarillo, perpendicular to the length. Preferably, the cigarillo has a diameter ranging from about 5.0 mm to about 5.8 mm. More preferably, the cigarillo has a diameter of 5.1-5.7, 5.2- 5.6, or 5-3-5.5 mm, and in preferred embodiments, the cigarillo has a diameter of approximately 5.4 mm.

Cigarillo Construction

The disclosed cigarillo and includes a rod of smokable material circumscribed by a wrapper and a filter adjacent to the rod of smokable material.

Cigarillos generally have a diameter of about 6-9 mm, typically about 8 mm, whereas the disclosed cigarillo has a circumference of 16-18 mm, preferably 17mm, and a diameter of 5-5.7 mm, preferably about 5.4 mm.

Cigarillos typically do not have filters, however, the disclosed cigarillo has a filter at the mouth end to filter the smoke that is in use drawn by the user. Tipping paper circumscribes the filter. Preferably, the tipping paper also circumscribes a portion of the rod of smokable material and thereby connects the filter to the rod of smokable material.

The tipping paper is preferably ventilated to provide filter ventilation at a level of about or at least 40%, such as about or at least 60%. For example, the tipping paper may be ventilated to provide filter ventilation at a level of about or at least 40, 41, 42, 44, or 46%, or at a level of about or at least 59, 60, 61, 62, or 64%, such as, for example, about

40-61%.

The disclosed cigarillo includes a wrapper comprising reconstituted tobacco material. The wrapper is preferably single layered.

Cigarillo wrappers are typically non-porous. However, the disclosed cigarillo has a porosity of 3-65 CORESTA units.

The terms“filter ventilation” and“wrapper porosity” and similar terms are

conventional terms in the art and would be well-known to the skilled person. A wrapper having this specific level of porosity of 3-65 CORESTA units has been found to provide a number of advantages in a cigarillo having a circumference of i6-i8mm.

For example, cigarillos with a circumference of i6-i8mm have been found to have a limited burn duration. A wrapper having a porosity of 3-65 CORESTA units has been found to provide a cigarillo which is slower burning between puffs than corresponding cigarillos having wrappers with higher porosities.

A level of filter ventilation of at least 40%, such as about 40-61%, about 40-46%, or about 60-61%, also results in a consumer-acceptable open pressure drop across the product. The combination of wrapper porosity and filter ventilation has also been found to have particular advantages for flavour delivery in embodiments in which the filter comprises a flavourant. For example, a level of filter ventilation of about 40-46% has been found to be particularly effective in the delivery of flavourant in embodiments in which the filter comprises about 2mg of menthol flavourant. Such embodiments generally have an open pressure drop across the product of about i40-i6ommWG. Likewise, a level of filter ventilation of about 60-61% has been found to be particularly effective in the delivery of flavourant in embodiments in which the filter comprises about 4mg of menthol flavourant. Such embodiments generally have an open pressure drop across the product of about i25-i3ommWG. Wrapper

The wrapper of the disclosed cigarillo comprises reconstituted tobacco material.

Preferably the cigarillo includes a single layered wrapper.

The wrapper preferably has a machine direction (MD) tensile strength of at least 1635 g/in. Preferably, the wrapper has a MD tensile strength of 1900-2200 g/in, such as 2000, 2025, 2050, 2075, or 2100 g/in. Most preferably, the wrapper has a MD tensile strength of about 2050 g/in.

The use of a wrapper having a MD tensile strength of 1900-2200 g/in and a porosity of 3-65 CORESTA units has been found to provide a number of surprising advantages in a cigarillo having a circumference of i6-i8mm. For example, this combination of MD tensile strength and porosity has surprisingly been found to overcome specific manufacturing challenges that have been found to exist in relation to producing and rolling a cigarillo having a circumference of i6-i8mm, which is a smaller circumference than that typically found in cigarillos.

The wrapper may have a porosity of 25-60 CORESTA units. Preferably, the wrapper has a porosity of 30-55, 35-50 or 37-47 CORESTA units, such as 38, 39, 40, 41, 42, 43, 44, 45, or 46 CORESTA units. Most preferably, the wrapper has a porosity of 40 or 45 CORESTA units. The use of a reconstituted tobacco wrapper having this level of porosity has been found to provide various advantages, particularly in terms of filtration, flavour delivery, and manufacturing, when used in the production of a cigarillo with a circumference of i6-i8mm, as discussed above. Further manufacturing advantages have been surprisingly found to be provided when the wrapper has a moisture content of 9-12%. Preferably, the wrapper has a moisture content of 9.5-11.5%, such as 10, 10.3, 10.5, 10.7, or 11%. Most preferably, the wrapper has a moisture content of 10.5%.

The wrapper may have a dry basis weight of 42-45 g/ m ² . Preferably, the wrapper has a dry basis weight of 42.6-44 g/m ² , such as 43.0, 43.2, 43.3, 43.4, or 43.5 g/m ² . Most preferably, the wrapper has a dry basis weight of 43.3 g/m ² .

The wrapper may include at least 50% tobacco. Preferably, the wrapper comprises 50- 70% tobacco. Preferably, the tobacco is dark air-cured.

The wrapper may include inorganic filler material in an amount of 11.5-15.5%.

Preferably, the wrapper comprises inorganic filler material in an amount of 12-15%, such as 13, 13.3, 13.5, 13.7, or 14%. Most preferably, the wrapper comprises inorganic filler material in an amount of 13.5%. These amounts are inclusive of the amount naturally occurring in tobacco.

Any suitable inorganic filler maybe used. Preferably, the inorganic filler is calcium carbonate. The reconstituted tobacco wrapper maybe prepared by methods which are known to those skilled in the art for preparing reconstituted tobacco sheets.

Filter

The disclosed cigarillos may include filters including a single filter segment.

Alternatively, the cigarillos may include multi-component filters including two or more filter segments. The one or more filter segments may include any suitable known filtration materials including, but not limited to, cellulose acetate, paper and combinations thereof.

Preferably the filter includes at least one segment including fibrous filtration material, such as cellulosic filtration material, preferably cellulose acetate tow. Where the filter includes a plug of cellulose acetate tow, the denier per filament and total denier of the tow may be selected in order to achieve a desired overall resistance to draw for the filter. The denier per filament maybe in the range 5.0-9.0, such as 6.5-S.5, and in preferred embodiments, the denier per filament is 6.0 or 8.0. The total denier of the tow may be in the range 14,000-18,000, such as 14,500-17,500, and in preferred embodiments, the total denier of the tow is 15,000 or 17,000. Preferably, the cellulose acetate tow is 6.0/17,000 or 8.0/15,000 (denier per filament/total denier).

The filter may include a plug of cellulose acetate tow wrapped in a high porosity plug wrap.

The filter may have a hardness of at least 82%, and preferably the filter hardness is 84%.

Filters maybe prepared in multiple filter lengths, such as for example, quadruple filter lengths, and then subsequently divided during the cigarillo manufacturing process. The length of a quadruple filter maybe 100-116, 104- 112mm, and is preferably about 108mm. Preferably, for a quadruple filter of 108mm in length, the resistance to draw (RTD) of the filter length maybe 300-6oommH20, such as for example, 400 or 500mmH20. The filter may include one or more sorbents capable of removing at least one gas phase constituent from mainstream smoke drawn through the filter. Suitable sorbents include, but are not limited to, carbon, activated alumina, zeolites, molecular sieves, silica gel and combinations thereof. The sorbent maybe included in the filter or a filter segment in any known manner, such as for example, by inclusion in a filter cavity, or in the form of a Dalmatian filter or filter segment.

Tipping Paper

The disclosed cigarillo includes a band of tipping paper circumscribing the filter.

In general, cigarillos have a low level of filter ventilation or are unventilated. In the disclosed cigarillos, however, the tipping paper is preferably ventilated to provide filter ventilation at a level of 40-61%, such as about 40% or about 60%. This high level of filter ventilation has been found to provide various advantages to the disclosed cigarillo, particularly in terms of filtration improvements, and also flavour delivery.

The tipping paper may circumscribe the filter and an adjacent portion of the rod of smokable material. Preferably, the portion of the tobacco rod circumscribed by the band of tipping paper ranges from about 2 mm to about 12 mm in length, such as 3- 10mm or 4- 12mm.

Filter ventilation may be provided in the form of perforations, provided at a location along the filter in order to ventilate mainstream smoke drawn through the filter from the tobacco rod.

Generally, the ventilation may include between one and four circumferential rows of perforations through the visible mouth-end portion of the tipping paper. The ventilation preferably includes one circumferential row of perforations through the tipping paper.

The ventilation may include 12-20 perforation holes per row, such as 14-17 holes. Preferably the ventilation includes about 15 perforation holes per row.

The at least one circumferential row of perforations maybe positioned at least 11mm, such as 11-16, 12-15, or 13-14mm and preferably 13mm, from the mouth end of the cigarillo. In embodiments having two or more rows of perforation holes, the rows of perforations are preferably spaced by o.5-i.5mm.

Methods for forming perforation holes are known and any suitable method or apparatus may be used. For example, a laser may be used to perforate the tipping paper of a partially or fully assembled cigarillo.

Smokable Material

The disclosed cigarillos may include any type of smokable material, for example, including smokable material based on tobacco material. The term“tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may comprise one or more of ground tobacco, tobacco fibre, cut tobacco, extruded tobacco, tobacco stem, tobacco lamina, reconstituted tobacco and/or tobacco extract.

The smokable material may be tobacco cut filler material comprising natural tobacco. The term“natural tobacco” denotes a section of a tobacco leaf. For example, the natural tobacco may be an elongate strip of tobacco leaf or a substantially rectangular portion of tobacco leaf.

The cigarillo may include varieties of tobacco such as Virginia, Burley, Oriental and Semi Oriental. The tobacco cut filler may include a single type of tobacco or a blend of two or more different types of tobacco, such as, for example, a blend of two or more of the different types of tobacco mentioned above, such as an American blend.

The tobacco cut filler may include tobaccos that are, for example, air, sun or flue-cured. Alternatively or in addition, the tobacco cut filler may have been treated or processed, for example, to reduce tobacco-specific nitrosamines (TSNA).

In addition, or as an alternative, to tobacco leaf, the smokable material may include other ingredients typically found in tobacco cut filler such as, for example, expanded tobacco, homogenized tobacco (for example reconstituted tobacco, cast tobacco or extruded tobacco), tobacco stem (for example expanded or improved stem), tobacco fines, and/or combinations of these ingredients. The tobacco cut filler may be cut with a cut width of between about 0.4 mm and about 2.0 mm, more preferably with a cut width of between about 0.5 mm and about 0.8 mm.

Each of the disclosed cigarillos may have a smokable material content of 200-350mg (net weight), such as 220-300 or 240-28omg. Preferably, each of the disclosed cigarillos has a smokable material content of about 260 mg.

The moisture content of the tobacco cut filler maybe 10-18%, such as 12-16 or 13-15%. Preferably the moisture content of the tobacco cut filler is 14%

Rod ofSmokable Material

To produce the disclosed cigarillos, rods of smokable material circumscribed by a wrapper are advantageously manufactured on standard high-speed cigarette making machinery.

In the high speed manufacture of cigarillos having a circumference of i6-i8mm, the use of a wrapper having a porosity of 3-65 CORESTA units, and preferably also a MD tensile strength of 1900-2200 g/in, and has been surprisingly found to be highly advantageous.

The wrapper may be wrapped around the rod of smokable material and joined to form a seam. The seam is preferably a longitudinal seam extending in a direction substantially parallel to the longitudinal axis of the cigarillo. The rod of smokable material may be combined with the filter and overwrapped with tipping paper.

The smokeable material may or may not be enclosed with a binder. The rod of smokable material may have a firmness of 55-70%, such as 56-65%, 58-64%, or 60-63%. Preferably, the rod of smokable material has a firmness of about 61%.

Flavourant

The use of a wrapper with a porosity of 3-65 CORESTA units, particularly in

combination with a level of filter ventilation of at least 40%, such as about 40-61%, about 40-46%, or about 60-61%, has been found to provide surprising advantages in terms of flavour delivery when the disclosed cigarillo is provided with a flavourant in the filter material.

As used herein, the terms“flavour” and“flavourant” refer to materials which, where local regulations permit, may be used to create a desired taste or aroma in a product for adult consumers.

They may include extracts (e.g., licorice, hydrangea, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, menthol, Japanese mint, aniseed, cinnamon, herb, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, piment, ginger, anise, coriander, coffee, or a mint oil from any species of the genus Mentha), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, oil, liquid, or powder.

Preferably the flavourant is a menthol flavourant.

The flavourant may be included in the filter in various ways. For example, the plug of cellulose acetate tow may be impregnated with a liquid flavourant. The liquid flavourant maybe applied directly into a stream of cellulose acetate tow during manufacture of the filter, either by spraying the liquid flavourant under pressure onto the tow or by injecting the liquid flavourant into the tow. The amount of liquid flavourant included in the filter tow may be 1-5mg, and preferably the amount of flavourant included in the filter tow is 2-4 mg. The menthol flavourant may be provided by natural menthol crystal.

In preferred embodiments, the cigarillo, and in particular, the filter of the cigarillo, does not include a capsule. Examples

An example of the disclosed cigarillo is shown in Figure 1. The cigarillo 1 includes an elongate cylindrical tobacco rod 2 including a tobacco cut filler. The tobacco rod 2 is circumscribed by a wrapper 3 comprising reconstituted tobacco.

A cylindrical filter 4 including a plug of cellulose acetate tow 5 circumscribed by a high porosity plug wrap 6 is axially aligned with the tobacco rod 2. The filter 4 and tobacco rod 2 are attached to one another in abutting end-to-end relationship by means of a tipping paper 7, which circumscribes the filter 4 and an adjacent portion of the tobacco rod 2.

A single row of perforations 8 are provided in the tipping paper 7, located

approximately 13mm from the mouth end of the filter 4.

Various example cigarillos according to embodiments of the invention were produced and the specifications of specific example cigarillos are set out below in Tables 1 and 2. The cigarillos were produced using known processes and apparatus employed in the production of filter cigarettes and cigarillos.

Table 1

Table 2

When compared with existing cigarillos, the example cigarillos were found to provide the advantages described above. In particular, relative to cigarillos having a larger or smaller diameter, the wrapper of the example cigarillos (which is the same in both examples) was found to provide significant manufacturing advantages. Tests on similar example cigarillos revealed that these advantages resulted from the use of wrappers having a porosity of 3-65 CORESTA units. In particular, manufacturing advantages were observed with the use of wrappers having a porosity of 3-65 CORESTA units and MD tensile strength of 1900-2200 g/in.

In addition, when compared to existing cigarillos having larger or smaller diameters, the combination of wrapper porosity of 3-65 CORESTA units and filter ventilation of about or at least 40% or 60% (such as 40-61%, 40-46%, or 60-61%) of the example cigarillos was found to provide significant improvements in filtration and flavour delivery.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) may be practiced and provide for superior cigarillos. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/ or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and

modifications maybe made without departing from the scope and/or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which maybe claimed in future.