Method for preparing fuel element for smoking article

1. A method for making a fuel element for a smoking article, comprising:

mixing a metal-containing catalyst precursor with a filler material or graphite or a combination thereof to form a pre-treated fuel element component;

calcining the pre-treated fuel element component in order to convert the catalyst precursor to a catalytic metal compound;

after the calcining step, combining the pre-treated fuel element component with a carbonaceous material and a binder to produce a fuel element composition; and

forming the fuel element composition into a fuel element adapted for use in a smoking article.

2. The method of claim 1 , wherein the mixing step comprises mixing the metal-containing catalyst precursor with a particulate material selected from the group consisting of graphite particles, calcium carbonate particles, clay particles, and alumina particles.

3. The method of claim 1 , wherein the calcining step comprises heating or irradiating the pre-treated fuel element component, under an inert atmosphere, at a temperature and for a time sufficient to convert the catalyst precursor to a catalytic metal compound.

4. The method of claim 3 , wherein the calcining step comprises heating the pre-treated fuel element component at a temperature of between about 100° C. and about 600° C. for about 0.25 hour to about 8 hours.

5. The method of claim 1 , further comprising incorporating a Group VIIIB catalytic metal into the fuel element or onto the surface thereof.

6. The method of claim 5 , wherein said incorporating step comprises pre-treating the pre-treated fuel element component with the Group VIIIB catalytic metal.

7. The method of claim 5 , wherein the Group VIIIB catalytic metal is selected from the group consisting of palladium, platinum, rhodium, halides thereof, and nitrates thereof.

8. The method of claim 1 , wherein the binder is selected from the group consisting of guar gum, ammonium alginate, and sodium alginate.

9. The method of claim 1 , wherein the forming step comprises extruding the fuel element mixture into a rod shape.

10. The method of claim 1 , wherein the metal-containing catalyst precursor is in the form of a metal salt or an organic metal compound capable of thermal decomposition to a catalytic metal compound.

11. The method of claim 10 , wherein the metal-containing catalyst precursor is in the form of a metal salt selected from the group consisting of citrates, nitrates, ammonium nitrates, sulfates, cyanates, hydrides, amides, thiolates, carbonates, and halides.

12. The method of claim 10 , wherein the metal is selected from the group consisting of alkali metals, alkaline earth metals, transition metals in Groups IIIB, IVB, VB, VIB VIIB, VIIIB, IB, and IIB, Group IIIA elements, Group IVA elements, lanthanides, and actinides.

13. The method of claim 10 , wherein the metal-containing catalyst precursor is selected from the group consisting of iron nitrate, copper nitrate, cerium nitrate, cerium ammonium nitrate, manganese nitrate, magnesium nitrate, zinc nitrate, and combinations thereof.

14. A method for making a fuel element for a smoking article, comprising:

mixing an aqueous solution of a metal-containing catalyst precursor with a particulate filler material or particulate graphite or a combination thereof to form a pre-treated fuel element component;

calcining the pre-treated fuel element component in order to convert the catalyst precursor to a catalytic metal compound;

after said calcining step, combining the pre-treated fuel element component with a carbonaceous material and a binder to produce a fuel element composition; and

forming the fuel element composition into a fuel element adapted for use in smoking article.

15. The method of claim 14 , wherein the mixing step comprises mixing the aqueous solution of the metal-containing catalyst precursor with a particulate material selected from the group consisting of graphite particles, calcium carbonate particles, clay particles, and alumina particles.

16. The method of claim 14 , wherein the calcining step comprises heating or irradiating the pre-treated fuel element component, under an inert atmosphere, at a temperature and for a time sufficient to convert the catalyst precursor to a catalytic metal compound.

17. The method of claim 16 , wherein the calcining step comprises heating the pretreated fuel element component at a temperature of between about 100° C. and about 600° C. for about 0.25 hour to about 8 hours.

18. The method of claim 14 , further comprising pre-treating the pre-treated fuel element component with a Group VIIIB metal.

19. The method of claim 18 , wherein the Group VIIIB catalytic metal is selected from the group consisting of palladium, platinum, rhodium, halides thereof, and nitrates thereof.

20. The method of claim 14 , wherein the binder is selected from the group consisting of guar gum, ammonium alginate, and sodium alginate.

21. The method of claim 14 , wherein the forming step comprises extruding the fuel element mixture into a rod shape.

22. The method of claim 14 , wherein the metal-containing catalyst precursor is in the form of a metal salt or an organic metal compound capable of thermal decomposition to a catalytic metal compound.

23. The method of claim 22 , wherein the metal-containing catalyst precursor is in the form of a metal salt selected from the group consisting of citrates, nitrates, ammonium nitrates, sulfates, cyanates, hydrides, amides, thiolates, carbonates, and halides.

24. The method of claim 14 , wherein the metal-containing catalyst precursor is selected from the group consisting of iron nitrate, copper nitrate, cerium nitrate, cerium ammonium nitrate, manganese nitrate, magnesium nitrate, zinc nitrate, and combinations thereof.