ORAL POUCH PRODUCTS
A pouched product configured for insertion into the mouth of a user of that product is provided herein. The pouched product can include an outer water-permeable pouch defining a cavity containing a composition adapted for oral use and having a surface area, wherein the outer water-permeable pouch can include a nonwoven spunlaid web comprising a plurality of continuous filament heat sealable fibers.
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This application claims priority to U.S. provisional application No. 62/100,687, filed on Jan. 7, 2015, which is herein incorporated by reference in its entirety.
FIELD OF INVENTIONThe present disclosure relates to a pouched product adapted for oral use and a method of manufacturing thereof.
BACKGROUNDCertain types of pouches or sachets have been employed to contain compositions adapted for oral use. For example, tobacco can be enjoyed in a so-called smokeless form. Particularly popular smokeless tobacco products are employed by inserting some form of processed tobacco or tobacco-containing formulation into the mouth of the user. See for example, the types of representative smokeless tobacco products, as well as the various smokeless tobacco formulations, ingredients and processing methodologies, referenced in the background art set forth in U.S. Pat. Pub. Nos. 2011/0303511 to Brinkley et al. and 2013/0206150 to Duggins et al.; which are incorporated herein by reference. During use, those pouches or sachets are inserted into the mouth of the user, and water soluble components contained within those pouches or sachets are released as a result of interaction with saliva.
Certain commercially available smokeless tobacco products, such as products commonly referred to as “snus,” comprise ground tobacco materials incorporated within sealed pouches. Representative types of snus products have been manufactured in Europe, particularly in Sweden, by or through companies such as Swedish Match AB (e.g., for brands such as General, Ettan, Goteborgs Rape and Grovsnus); Fiedler & Lundgren AB (e.g., for brands such as Lucky Strike, Granit, Krekt and Mocca); JTI Sweden AB (e.g., for brands such as Gustavus) and Rocker Production AB (e.g., for brands such as Rocker). Other types of snus products have been commercially available in the U.S.A. through companies such as Philip Morris USA, Inc. (e.g., for brands such as Marlboro Snus); U.S. Smokeless Tobacco Company (e.g., for brands such as SKOAL Snus) and R. J. Reynolds Tobacco Company (e.g., for brands such as CAMEL Snus). See also, for example, Bryzgalov et al., 1N1800 Life Cycle Assessment, Comparative Life Cycle Assessment of General Loose and Portion Snus (2005); which is incorporated herein by reference.
Various types of snus products, as well as components for those products and methods for processing components associated with those products, have been proposed. See, for example, U.S. Pat. Nos. 8,067,046 to Schleef et al. and 7,861,728 to Holton, Jr. et al.; U.S. Pat. Pub. Nos. 2004/0118422 to Lundin et al.; 2008/0202536 to Torrence et al.; 2009/0025738 to Mua et al.; 2011/0180087 to Gee et al.; 2010/0218779 to Zhuang et al.; 2010/0294291 to Robinson et al.; 2010/0300465 to Zimmermann; 2011/0061666 to Dube et al.; 2011/0303232 to Williams et al.; 2012/0067362 to Mola et al.; 2012/0085360 to Kawata et al.; 2012/0103353 to Sebastian et al. and 2012/0247492 to Kobal et al.; and PCT Pub. Nos. WO 05/063060 to Atchley et al. and WO 08/56135 to Onno; which are incorporated herein by reference. In addition, certain quality standards associated with snus manufacture have been assembled as a so-called GothiaTek standard. Furthermore, various manners and methods useful for the production of snus types of products have been proposed. See, for example, U.S. Pat. Nos. 4,607,479 to Linden and 4,631,899 to Nielsen; and U.S. Pat. Pub. Nos. 2008/0156338 to Winterson et al.; 2010/0018539 to Brinkley et al.; 2010/0059069 to Boldrini; 2010/0071711 to Boldrini; 2010/0101189 to Boldrini; 2010/0101588 to Boldrini; 2010/0199601 to Boldrini; 2010/0200005 to Fallon; 2010/0252056 to Gruss et al.; 2011/0284016 to Gunter et al.; 2011/0239591 to Gruss et al.; 2011/0303511 to Brinkley et al.; 2012/0055493 to Novak III et al. and 2012/0103349 to Hansson et al.; and PCT Pub. Nos. WO 2008/081341 to Winterson et al. and WO 2008/146160 to Cecil et al.; which are incorporated herein by reference. Additionally, snus products can be manufactured using equipment such as that available as SB 51-1/T, SBL 50 and SB 53-2/T from Merz Verpackungmaschinen GmBH.
Certain types of products employing pouches or sachets that contain tobacco substitutes (or combinations of tobacco and tobacco substitutes) also have been proposed. See, for example, U.S. Pat. Nos. 5,167,244 to Kjerstad and 7,950,399 to Winterson et al.; and U.S. Pat. Pub. Nos. 2005/0061339 to Hansson et al.; 2011/0041860 to Essen et al. and 2011/0247640 to Beeson et al.; which are incorporated herein by reference.
Certain types of product employing pouches or sachets have been employed to contain nicotine, such as those used for nicotine replacement therapy (NRT) types of products (e.g., a pharmaceutical product distributed under the tradename ZONNIC® by Niconovum AB). See also, for example, the types of pouch materials and nicotine-containing formulations set forth in U.S. Pat. No. 4,907,605 to Ray et al.; U.S. Pat. Pub. Nos. 2009/0293895 to Axelsson et al. and 2011/0268809 to Brinkley et al.; and PCT Pub. Nos. WO 2010/031552 to Axelsson et al. and WO 2012/134380 to Nilsson; which are incorporated herein by reference.
To manufacture pouched products of the type noted above, the pouches must be sealed after being filled with the desired material. As noted in U.S. Pat. Pub. No. 2014/0026912 to Rushforth et al., such sealing is typically accomplished by application of a binder material to the fiber network, which enables the pouch to be sealed upon application of heat. However, conventional binders applied to such fibrous pouches, such as acrylic polymers, are costly to apply to pouches and inhibit biodegradability of the discarded pouch.
It would be desirable to provide a pouched product, particularly one adapted for oral use, wherein the material used to form the pouched product exhibits favorable characteristics such as enhanced biodegradability and reduced cost to manufacture.
SUMMARY OF THE INVENTIONThe present invention relates to a pouched product configured for insertion into the mouth of a user of that product, wherein the pouched product can include an outer, water-permeable pouch defining a cavity that can contain a composition adapted for oral use. In certain embodiments, the composition within the cavity of the pouch can comprise at least one of a particulate tobacco material, nicotine, particulate non-tobacco material (e.g., MCC) that has been treated to contain nicotine and/or flavors, and fibrous plant material (e.g., beet root fiber) treated to contain a tobacco extract. In some embodiments, the pouched product can be configured for liquid extraction, such as in the making of tea. Accordingly, in certain embodiments, the composition within the cavity of the pouch can comprise a particulate or fibrous plant material such as would be found in various teas or tea variants. In some embodiments, the composition within the cavity can comprise a flavor component such that flavor can be added to a liquid (e.g., water).
The outer pouch can be formed from a nonwoven web that exhibits favorable taste, sensory and other beneficial characteristics in comparison to other pouched products known in the art. Specifically, outer water-permeable pouch can comprise a nonwoven spunlaid web comprising a plurality of continuous filament heat sealable fibers. The plurality of heat sealable fibers can be used in place of a binder material to heat seal the pouched product after the composition adapted for oral use has been inserted into the cavity of the pouched product. As such, the nonwoven web can be substantially free of a binder coating. In certain embodiments, the plurality of heat sealable fibers can be blended with a second plurality of dissimilar fibers.
In various embodiments of the present invention, the nonwoven web can be made in a spunlaid or spunmelt process, which includes both spunbond and meltblown processes, wherein such processes are understood to typically entail melting, extruding, collecting and bonding thermoplastic polymer materials to form a fibrous nonwoven web. Spunlaid nonwoven webs can be formed in a continuous process. Fibers can be spun and then directly dispersed into a web by deflectors or can be directed with air streams, for example. The combination of spunbond and meltblown fabrics can yield a strong, cost-effective fabric that is useful in the present invention. In various embodiments, a lightweight, fine filament web having an embossed basket weave pattern can be formed.
The spunlaid nonwoven web (e.g., spunbond and/or meltblown web) of the invention can be formed using a thermoplastic polymer. The thermoplastic polymer can exhibit a melting point in a relatively low range to facilitate heat sealing of the pouch material. For example, the thermoplastic polymer fiber (i.e., the heat sealable fiber) can have a melting point of about 200° C. or less, about 160° C. or less, about 150° C. or less, about 140° C. or less, or about 120° C. or less. Various thermoplastic polymers could be used as the heat sealable fibers in the nonwoven material, such as various polymers having a melting point within the ranges noted above. Exemplary thermoplastic polymers include various polyolefins and polyesters. In some embodiments, the heat sealable fibers can comprise a biodegradable polymer. For example, the heat sealable fibers can comprise an aliphatic polyester. In certain embodiments, the heat sealable fibers can comprise a polymer selected from the group consisting of polyglycolic acid, polylactic acid, polyhydroxyalkanoates, polycaprolactone, polybutylene succinate, polybutylene succinate adipate, and copolymers thereof. In a preferred embodiment, the nonwoven spunlaid web can be a spunbond nonwoven web comprising PLA fibers, PHA fibers, or a combination thereof.
The fibrous webs can have varying thicknesses, porosities and other parameters. The nonwoven web can be formed such that the fiber orientation and porosity of the pouched product formed therefrom can retain the composition adapted for oral use that is enclosed within the outer water-permeable pouch, but can also allow the flavors of the composition to be enjoyed by the consumer. For example, the spunlaid nonwoven web (e.g., spunbond and/or meltblown web) can have a basis weight of about 18 gsm to about 80 gsm, or about 20 gsm to about 60 gsm, or about 22 gsm to about 30 gsm, for example. In various embodiments, the spunlaid nonwoven web (e.g., spunbond and/or meltblown web) can have a thickness of about 120 microns to about 300 microns, or about 130 microns to about 200 microns. In a preferred embodiment, the fibrous web can have a thickness of about 160 microns, for example. The spunlaid nonwoven web (e.g., spunbond and/or meltblown web) can have a dry tensile (machine direction) strength of about 750 N/m to about 950 N/m, or about 825 N/m to about 875 N/m, for example. The spunlaid nonwoven web (e.g., spunbond and/or meltblown web) can have a dry tensile (cross direction) strength of about 200 N/m to about 300 N/m, or about 220 N/m to about 260 N/m, for example. The spunlaid nonwoven web (e.g., spunbond and/or meltblown web) can have a dry elongation (machine direction) of about 8% to about 20%, or about 10% to about 16%, for example. The spunlaid nonwoven web (e.g., spunbond and/or meltblown web) can have a dry elongation (cross direction) of about 10% to about 20%, or about 14% to about 18%, for example.
In various embodiments, the nonwoven web can further include an additive that can help reduce and/or dissipate static charge. The additive can be present in an amount of less than about 12% by dry weight, less than about 10% by dry weight, less than about 8% by dry weight, or less than about 5% by dry weight, for example.
Also provided herein is a pouched product configured for insertion into the mouth of a user of that product, comprising an outer water-permeable pouch defining a cavity containing a composition adapted for oral use, wherein the outer water-permeable pouch comprises a nonwoven spunlaid web comprising a plurality of continuous filament heat sealable fibers. The nonwoven spunlaid web can be a spunbond nonwoven web comprising PLA fibers, PHA fibers, or a combination thereof. Also, the composition within the cavity of the pouch can comprise at least one of a particulate tobacco material, nicotine, particulate non-tobacco material that has been treated to contain nicotine and/or flavors, and fibrous plant material treated to contain a tobacco extract.
Having thus described the invention in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
The present invention now will be described more fully hereinafter. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. As used in this specification and the claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
According to various embodiments of the invention, a pouched product configured for insertion into the mouth of a user is provided. The pouched product can comprise an outer water-permeable pouch and a composition situated within the outer water-permeable pouch. The composition positioned within the pouch can be any composition containing a water-soluble component capable of being released through the water-permeable pouch, such as tea or coffee materials (e.g., in the context of a beverage pouch adapted for brewing or steeping) or compositions adapted for oral use (e.g., tobacco-derived products such as snus or nicotine replacement therapy products). In certain embodiments, the composition within the cavity of the pouch can comprise at least one of a particulate tobacco material, nicotine, particulate non-tobacco material (e.g., MCC) that has been treated to contain nicotine and/or flavors, and fibrous plant material (e.g., beet root fiber) treated to contain a tobacco extract.
For example, as illustrated in
In various embodiments, a moisture-permeable packet or pouch can act as a container for use of the composition within. The composition/construction of such packets or pouches, such as the container pouch 20 in the embodiment illustrated in
In various embodiments of the present invention, a nonwoven web can be used to form an outer water-permeable pouch which can be used to house a composition adapted for oral use. During use, the user can place one pouched product containing the composition adapted for oral use in the mouth of the human subject/user. Saliva in the mouth of the user causes some of the components of the product to pass through the water-permeable pouch and into the mouth of the user. The pouch preferably is not chewed or swallowed. The user is provided with flavor and satisfaction, and is not required to spit out any portion of the product. After about 10 minutes to about 60 minutes, typically about 15 minutes to about 45 minutes, of use/enjoyment, substantial amounts of the product and have been ingested by the human subject, and the pouch may be removed from the mouth of the human subject for disposal.
The pouch provides a liquid-permeable container of a type that may be considered to be similar in character to the mesh-like type of material that is used for the construction of a tea bag. Components of the loosely arranged composition adapted for oral use readily diffuse through the pouch and into the mouth of the user. In certain embodiments, the pouch materials can be designed and manufactured such that under conditions of normal use, a significant amount of the tobacco formulation contents permeate through the pouch material prior to the time that the pouch undergoes loss of its physical integrity. If desired, flavoring ingredients, disintegration aids, and other desired components, may be incorporated within, or applied to, the pouch material.
Various types of pouch materials and pouch manufacturing techniques are discussed in more detail below. Generally, the products include a powdered or granular composition adapted for oral use (e.g., a tobacco-containing composition and/or a nicotine-containing pharmaceutical composition) that is disposed within a moisture-permeable container. That is, the composition adapted for oral use can be contained within a container, such as a pouch or bag, such as the type commonly used for the manufacture of snus types of products (e.g., a sealed, moisture permeable pouch that is sometimes referred to as a “portion”). A representative moisture permeable pouch can be composed of a “fleece” type of material.
In certain embodiments, the products of the disclosure will typically incorporate some form of a plant of the Nicotiana species, and most preferably, those compositions or products incorporate some form of tobacco. The selection of the plant from the Nicotiana species can vary; and in particular, the types of tobacco or tobaccos may vary. Tobaccos that can be employed include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos. Additional information on types of Nicotiana species suitable for use in the present invention can be found in U.S. Pat. Appl. Pub. No. 2012/0192880 to Dube et al., which is incorporated by reference herein.
The portion or portions of the plant of the Nicotiana species used according to the present invention can vary. For example, virtually all of the plant (e.g., the whole plant) can be harvested, and employed as such. Alternatively, various parts or pieces of the plant can be harvested or separated for further use after harvest. For example, the leaves, stem, stalk, roots, lamina, flowers, seed, and various portions and combinations thereof, can be isolated for further use or treatment. The plant material of the invention may thus comprise an entire plant or any portion of a plant of the Nicotiana species. See, for example, the portions of tobacco plants set forth in U.S. Pat. Appl. Pub. Nos. 2011/0174323 to Coleman, III et al. and 2012/0192880 to Dube et al., which are incorporated by reference herein.
The tobacco material can be subjected to various treatment processes such as, refrigeration, freezing, drying (e.g., freeze-drying or spray-drying), irradiation, yellowing, heating, cooking (e.g., roasting, frying or boiling), fermentation, bleaching, or otherwise subjected to storage or treatment for later use. Exemplary processing techniques are described, for example, in U.S. Pat. Appl. Pub. Nos. 2009/0025739 to Brinkley et al. and 2011/0174323 to Coleman, III et al., which are incorporated by reference herein.
A harvested portion or portions of the plant of the Nicotiana species can be physically processed. In certain embodiments, the tobacco material is used in a form that can be described as particulate (i.e., shredded, ground, granulated, or powder form). The manner by which the tobacco material is provided in a finely divided or powder type of form may vary. Preferably, plant parts or pieces are comminuted, ground or pulverized into a particulate form using equipment and techniques for grinding, milling, or the like. Most preferably, the plant material is relatively dry in form during grinding or milling, using equipment such as hammer mills, cutter heads, air control mills, or the like.
In certain embodiments, at least a portion of the tobacco material employed in the tobacco composition or product can have the form of an extract. Tobacco extracts can be obtained by extracting tobacco using a solvent having an aqueous character such as distilled water or tap water. As such, aqueous tobacco extracts can be provided by extracting tobacco with water, such that water insoluble pulp material is separated from the aqueous solvent and the water soluble and dispersible tobacco components dissolved and dispersed therein. Tobacco extraction techniques and tobacco extract processing techniques are described, for example, in U.S. Pat. Pub. No. 2013/0312774 to Holton, Jr., which is incorporated by reference herein.
In certain embodiments, the pouched products of the invention can include a nicotinic compound. Various nicotinic compounds, and methods for their administration, are set forth in U.S. Pat. Pub. No. 2011/0274628 to Borschke, which is incorporated herein by reference. As used herein, “nicotinic compound” or “source of nicotine” often refers to naturally-occurring or synthetic nicotinic compound unbound from a plant material, meaning the compound is at least partially purified and not contained within a plant structure, such as a tobacco leaf. Most preferably, nicotine is naturally-occurring and obtained as an extract from a Nicotiana species (e.g., tobacco). The nicotine can have the enantiomeric form S(−)-nicotine, R(+)-nicotine, or a mixture of S(−)-nicotine and R(+)-nicotine. Most preferably, the nicotine is in the form of S(−)-nicotine (e.g., in a form that is virtually all S(−)-nicotine) or a racemic mixture composed primarily or predominantly of S(−)-nicotine (e.g., a mixture composed of about 95 weight parts S(−)-nicotine and about 5 weight parts R(+)-nicotine). Most preferably, the nicotine is employed in virtually pure form or in an essentially pure form. Highly preferred nicotine that is employed has a purity of greater than about 95 percent, more preferably greater than about 98 percent, and most preferably greater than about 99 percent, on a weight basis.
Nicotinic compounds can include nicotine in free base form, salt form, as a complex, or as a solvate. See, for example, the discussion of nicotine in free base form in U.S. Pat. Pub. No. 2004/0191322 to Hansson, which is incorporated herein by reference. At least a portion of the nicotinic compound can be employed in the form of a resin complex of nicotine, where nicotine is bound in an ion exchange resin, such as nicotine polacrilex. See, for example, U.S. Pat. No. 3,901,248 to Lichtneckert et al., which is incorporated herein by reference. At least a portion of the nicotine can be employed in the form of a salt. Salts of nicotine can be provided using the types of ingredients and techniques set forth in U.S. Pat. Nos. 2,033,909 to Cox et al. and 4,830,028 to Lawson et al., and Perfetti, Beitrage Tabakforschung Int., 12: 43-54 (1983), which are incorporated herein by reference. See, also, U.S. Pub. No. 2011/0268809 to Brinkley et al., which is incorporated herein by reference. Additionally, salts of nicotine have been available from sources such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc.
Representative types of excipients or other additional ingredients that are particularly useful for the manufacture of nicotine-containing products or tobacco-containing products include fillers or carriers for active ingredients (e.g., calcium polycarbophil, microcrystalline cellulose, cornstarch, beet pulp fiber, silicon dioxide or calcium carbonate), thickeners, film formers and binders (e.g., hydroxypropyl cellulose, hydroxypropyl methylcellulose, acacia, sodium alginate, xanthan gum and gelatin), buffers and pH control agents (e.g., magnesium oxide, magnesium hydroxide, potassium carbonate, sodium carbonate, potassium bicarbonate, sodium bicarbonate, or mixtures thereof), antiadherents (e.g., talc), glidants (e.g., colloidal silica), natural or artificial sweeteners (e.g., saccharin, acesulfame K, aspartame, sucralose, isomalt, lactose, mannitol, sorbitol, xylitol and sucrose), humectants (e.g., glycerin), preservatives and antioxidants (e.g., sodium benzoate and ascorbyl palmitate), surfactants (e.g., polysorbate 80), natural or artificial flavors (e.g., mint, cinnamon, cherry or other fruit flavors), dyes or pigments (e.g., titanium dioxide or D&C Yellow No. 10), and lubricants or processing aids (e.g., calcium stearate or magnesium stearate). Certain types of nicotine-containing products or tobacco-containing products also can have outer coatings composed of ingredients capable of providing acceptable outer coatings (e.g., an outer coating can be composed of ingredients such as carnauba wax, and pharmaceutically acceptable forms of shellacs, glazing compositions and surface polish agents). Adhesives, coatings, colorants, and other ingredients used in products described herein can be generally recognized as safe, non-toxic, ingestible and otherwise suitable for oral use.
The pouches of the invention are formed from fibrous nonwoven webs. As used herein, the term “fiber” is defined as a basic element of textiles. Fibers are often in the form of a rope- or string-like element. As used herein, the term “fiber” is intended to include fibers, filaments, continuous filaments, staple fibers, and the like.
The term “nonwoven” is used herein in reference to fibrous materials, webs, mats, batts, or sheets in which fibers are aligned in an undefined or random orientation. In various embodiments of the present invention, the nonwoven web can be made in a spunlaid or spunmelt process, which includes both spunbond and meltblown processes, wherein such processes are understood to typically entail melting, extruding, collecting and bonding thermoplastic polymer materials to form a fibrous nonwoven web. Spunlaid nonwoven webs can be formed in a continuous process. Fibers can be spun and then directly dispersed into a web by deflectors or can be directed with air streams, for example.
Spunbonding typically involves melt spinning wherein a polymer is melted to a liquid state and forced through small orifices into cool air, such that the polymer strands solidify according to the shape of the orifices. The fiber bundles thus produced are then drawn, i.e., mechanically stretched (e.g., by a factor of 2-5) to orient the fibers. A nonwoven web is then formed by depositing the drawn fibers onto a moving belt. General spunbonding processes are described, for example, in U.S. Pat. Nos. 4,340,563 to Appel et al., 3,692,618 to Dorschner et al., 3,802,817 to Matsuki et al., 3,338,992 and 3,341,394 to Kinney, 3,502,763 to Hartmann, and 3,542,615 to Dobo et al., which are all incorporated herein by reference.
Meltblowing is a process wherein a polymer (or polymers) is melted to a liquid state and extruded through a linear die containing numerous (e.g., several hundred or more) small orifices. As the polymer is extruded, streams of hot air are rapidly blown at the polymer, rapidly stretching and/or attenuating the extruded polymer streams to form extremely fine filaments. The air streams typically stretch or attenuate the molten polymer by many orders of magnitude. The stretched polymer fibers are collected as a randomly entangled, self-bonded nonwoven web. The technique of meltblowing is known in the art and is discussed in various patents, for example, U.S. Pat. Nos. 3,849,241 to Butin, 3,987,185 to Buntin et al., 3,972,759 to Buntin, and 4,622,259 to McAmish et al., each of which is herein incorporated by reference in its entirety.
In certain embodiments, spunbond webs can be combined with meltblown nonwovens in a layered spunmelt product. The combination of spunbond and meltblown fabrics can yield a strong, cost-effective fabric that is useful in the present invention. In various embodiments, a lightweight, fine filament web having an embossed basket weave pattern (or any other desired pattern) can be formed.
In various embodiments of the present invention, the nonwoven web can be subjected to some type of bonding process, as is known in the art. For example, the nonwoven web can be subjected to thermal fusion or bonding, mechanical entanglement, chemical adhesives, or a combination thereof. In certain embodiments, the nonwoven web can be thermally bonded using a calendar roll or a thru-air oven. If a calendar process is used to thermally bond a nonwoven web, various patterns can be used (e.g., point bonding, a basket weave, etc.).
In the present invention, the need for a heat sealable binder coating on the pouch material is reduced or eliminated. Accordingly, in certain embodiments of the invention, the pouched product can be described as substantially free of a heat sealable binder coating. For example, the nonwoven web used to form the pouched product can comprise no more than about 0.5% by weight, no more than about 0.25% by weight, or no more than about 0.1% by weight (based on total weight of the nonwoven web) of a heat sealable binder coating. In some embodiments, the nonwoven web will be completely free of heat sealable binder coatings. As used herein, “heat sealable binder coatings” refers to liquid coating materials, such as acrylic polymer compositions, applied to a nonwoven web and which are capable of sealing seams of individual pouches upon heating. The absence of such heat sealable binder coatings can enhance biodegradability of the pouches and reduce cost of manufacturing by removing the need for a wet chemistry step. In addition, a heat sealable binder coating can produce an undesirable slimy mouth feel when wetted by saliva. There is also a potential for retardation of flavor transfer due to the presence of a binder layer. These shortcomings can be avoided in the present invention.
The spunlaid nonwoven web (e.g., spunbond or meltblown web) of the invention can be formed using a thermoplastic polymer. The thermoplastic polymer can exhibit a melting point in a relatively low range to facilitate heat sealing of the pouch material. For example, the thermoplastic polymer fiber can typically have a melting point of about 200° C. or less, about 160° C. or less, about 150° C. or less, about 140° C. or less, or about 120° C. or less. In one embodiment, the melting point of the thermoplastic polymer fiber can be about 175° C. to about 200° C. Exemplary thermoplastic polymers include various polyolefin and polyester materials. Advantageously, the thermoplastic polymer of the heat sealable fibers can be a biodegradable polymer, such as an aliphatic polyester. Exemplary aliphatic polyesters include polyglycolic acid (PGA), polylactic acid (PLA) (e.g., poly(L-lactic acid) or poly(DL-lactic acid)), polyhydroxyalkanoates (PHAs) such as polyhydroxypropionate, polyhydroxyvalerate, polyhydroxybutyrate, polyhydroxyhexanoate, and polyhydroxyoctanoate, polycaprolactone (PCL), polybutylene succinate, polybutylene succinate adipate, and copolymers thereof (e.g., polyhydroxybutyrate-co-hydroxyvalerate (PHBV)). Specific examples of commercially available PLA fibers include Ecodear® from Toray of Japan; Ingeo™ based PLA fibers from Fiber Innovations Technology, USA; and PLA fibers from Trevira GmbH. PLA and PHA materials can be sourced from a variety of plant materials, including tobacco. In certain embodiments, the thermoplastic polymer can comprise plasticized cellulose acetate and/or calcium alginate.
Biodegradability can be measured, for example, by placing a sample in environmental conditions expected to lead to decomposition, such as placing a sample in water, a microbe-containing solution, a compost material, or soil. The degree of degradation can be characterized by weight loss of the sample over a given period of exposure to the environmental conditions. U.S. Pat. No. 5,970,988 to Buchanan et al. and U.S. Pat. No. 6,571,802 to Yamashita provide exemplary test conditions for degradation testing. The degradability of a plastic material also may be determined using one or more of the following ASTM test methods: D5338, D5526, D5988, and D6400.
In certain embodiments, the nonwoven web of the invention may include additional fiber types blended with the above-noted thermoplastic polymer fibers. Exemplary fibers include those made of wool, cotton, fibers made of cellulosic material, such as regenerated cellulose, cellulose acetate, cellulose triacetate, cellulose nitrate, ethyl cellulose, cellulose acetate propionate, cellulose acetate butyrate, hydroxypropyl cellulose, methyl hydroxypropyl cellulose, protein fibers, and the like. See also, the fiber types set forth in U.S. Pat. Appl. Pub. No. 2014/0083438 to Sebastian et al., which is incorporated by reference herein.
Regenerated cellulose fibers are particularly advantageous, and are typically prepared by extracting non-cellulosic compounds from wood, contacting the extracted wood with caustic soda, followed by carbon disulfide and then by sodium hydroxide, giving a viscous solution. The solution is subsequently forced through spinneret heads to create viscous threads of regenerated fibers. Exemplary methods for the preparation of regenerated cellulose are provided in U.S. Pat. No. 4,237,274 to Leoni et al; U.S. Pat. No. 4,268,666 to Baldini et al; U.S. Pat. No. 4,252,766 to Baldini et al.; U.S. Pat. No. 4,388,256 to Ishida et al.; U.S. Pat. No. 4,535,028 to Yokogi et al.; U.S. Pat. No. 5,441,689 to Laity; U.S. Pat. No. 5,997,790 to Vos et al.; and U.S. Pat. No. 8,177,938 to Sumnicht, which are incorporated herein by reference. The manner in which the regenerated cellulose is made is not limiting, and can include, for example, both the rayon and the TENCEL processes. Various suppliers of regenerated cellulose are known, including Lenzing (Austria), Cordenka (Germany), Aditya Birla (India), and Daicel (Japan).
The heat sealable nonwoven webs of the invention can be found commercially or manufactured using known melt-spinning techniques. For example, see the PLA spunmelt grade CD50009O or CD50082M nonwoven fabrics produced by Ahlstrom Chirnside Limited of Scotland. See further, the entire line of PLA-based webs marketed under the BIOWEB® tradename by Ahlstrom Corporation headquartered in Finland.
The fibers used in the nonwoven web according to the present invention can vary, and include fibers having any type of cross-section including, but not limited to, circular, rectangular, square, oval, triangular, and multilobal. In certain embodiments, the fibers can have one or more void spaces, wherein the void spaces can have, for example, circular, rectangular, square, oval, triangular, or multilobal cross-sections.
The physical parameters of the fibers present in the nonwoven web of the invention can vary. For example the fibers used in the nonwoven web can have varying size (e.g., length, dpf) and crimp characteristics. In some embodiments, fibers used in the nonwoven web can be nano fibers, sub-micron fibers, and/or micron-sized fibers. In certain embodiments, fibers useful herein can measure about 1.5 dpf to about 2.0 dpf, or about 1.6 dpf to about 1.90 dpf. In various embodiments, each fiber can measure about 4-10 crimps per cm, or about 5-8 crimps per cm. The fibers can be in staple form in certain embodiments, but advantageously, the fibers of the nonwoven web are in the form of continuous filaments.
The means of producing the nonwoven web can vary. Web formation can be accomplished by any means known in the art. As mentioned above, in various embodiments of the present invention, the nonwoven web can be produced by a spunbond process and or a meltblown process.
The fibrous webs can have varying thicknesses, porosities and other parameters. The nonwoven web can be formed such that the fiber orientation and porosity of the pouched product formed therefrom can retain the composition adapted for oral use that is enclosed within the outer water-permeable pouch, but can also allow the flavors of the composition to be enjoyed by the consumer. For example, the spunmelt nonwoven fabric can have a basis weight of about 18 gsm to about 80 gsm, or about 20 gsm to about 60 gsm, or about 22 gsm to about 30 gsm, for example. Basis weight of a fabric can be measured using ASTM D3776/D3776M-09a(2013) (Standard Test Methods for Mass Per Unit Area (Weight) of Fabric), for example. In various embodiments, the spunmelt nonwoven fabric can have a thickness of about 120 microns to about 300 microns, or about 130 microns to about 200 microns. In a preferred embodiment, the spunmelt nonwoven fabric can have a thickness of about 160 microns, for example. The spunmelt nonwoven fabric can have a dry tensile (machine direction) strength of about 750 N/m to about 950 N/m, or about 825 N/m to about 875 N/m, for example. The spunmelt nonwoven fabric can have a dry tensile (cross direction) strength of about 200 N/m to about 300 N/m, or about 220 N/m to about 260 N/m, for example. Dry tensile strength can be measured by, for example, ISO 1924-2:2008 (Paper and board—Determination of tensile properties—Part 2: Constant rate of elongation method (20 mm/min)). The spunmelt nonwoven fabric can have a dry elongation (machine direction) of about 8% to about 20%, or about 10% to about 16%, for example. The spunmelt nonwoven fabric can have a dry elongation (cross direction) of about 10% to about 20%, or about 14% to about 18%, for example. Elongation and breaking strength of textile fabrics can be measured using ASTM D5034-09(2013) (Standard Test Method for Breaking Strength and Elongation of Textile Fabrics (Grab Test)), for example.
In various embodiments of the pouched product described herein, the outer water-permeable pouch is made from a nonwoven web as described above. In some embodiments, pouch is constructed of a single layer of the nonwoven web. In various embodiments, the pouch material comprises a multilayer composite made up of two or more nonwoven layers. Each nonwoven layer can be formed by any process known in the art, as discussed above. In a multilayer structure, as illustrated in
In certain embodiments, an outer hydrophilic layer can comprise a flavor component (such as any of the flavor components noted herein), which can be applied to the nonwoven layer in any conventional manner such as by coating, printing, and the like. In some embodiments, the flavor within an outer hydrophilic layer can differ from a flavor contained within the internal composition adapted for oral use. By having a hydrophobic layer between the inner composition and the outer hydrophilic layer, the different flavors can be prevented from blending because the hydrophobic layer can prevent moisture from leaving the inner composition until enough moisture from the mouth of the user overwhelms the hydrophobic layer and thereby allows moisture to enter and leave the inner area of the pouched product where the composition is housed. By the time this takes place, the flavor component of the outer hydrophilic layer can have dissipated. In this manner, the product can be designed to provide multiple, different sensory experiences, a first sensory experience where the flavor in the outer layer transitions into the mouth of the user and a second sensory experience, typically occurring later in time, where the flavor of the internal composition transitions into the mouth of the user.
The hydrophilic and hydrophobic layers are typically formed from similar nonwoven web compositions, but wherein one of the nonwoven webs is treated to enhance either hydrophobicity or hydrophilicity. For example, a layer of the nonwoven web can be treated with a wet chemical solution to confer hydrophilicity thereupon. In one such process, a nonwoven web layer is treated with an aqueous alcohol solution containing a food-grade surfactant. The surfactant may include, for example one or more of sorbitan aliphatic acid ester, polyglycerin aliphatic acid ester, or sucrose aliphatic acid ester (see, e.g., U.S. Pat. No. 7,498,281 to Iwasaki et al., which is incorporated herein by reference). In some embodiments, the fleece fabric layers can be made hydrophilic or hydrophobic by changing the cellulose fiber chosen. For example, predominantly hydrophobic cellulose fibers are commercially available as Tencel® Biosoft from Lenzing of Austria and Olea Fiber from Kelheim of Germany. In various embodiments, the hydrophilic layer can incorporate cationic or anionic cellulose fibers that are also available from Kelheim of Germany, for example. The hydrophilic layer can contain additives such as polyethylene glycols, methyl cellulose, hydroxypropylmethyl cellulose, hydroxypropyl cellulose, hydroxypropylmethyl cellulose phthalate, polyvinyl pyrrolidone, polyvinyl alcohol, polyacrylic acids, gelatins, alginates, sulfosuccinates, and combinations thereof.
Various manufacturing apparatuses and methods can be used to create a pouched product described herein. For example, U.S. Publication No. 2012/0055493 to Novak, III et al., previously incorporated by reference in its entirety, relates to an apparatus and process for providing pouch material formed into a tube for use in the manufacture of smokeless tobacco products. Similar apparatuses that incorporate equipment for supplying a continuous supply of a pouch material (e.g., a pouch processing unit adapted to supply a pouch material to a continuous tube forming unit for forming a continuous tubular member from the pouch material) can be used to create a pouched product described herein. Representative equipment for forming such a continuous tube of pouch material is disclosed, for example, in U.S. Patent Application Publication No. U.S. 2010/0101588 to Boldrini et al., which is incorporated herein by reference in its entirety. The apparatus further includes equipment for supplying pouched material to the continuous tubular member such that, when the continuous tubular member is subdivided and sealed into discrete pouch portions, each pouch portion includes a charge of a composition adapted for oral use. Representative equipment for supplying the filler material is disclosed, for example, in U.S. Patent Application Publication No. U.S. 2010/0018539 to Brinkley, which is incorporated herein by reference in its entirety. In some instances, the apparatus may include a subdividing unit for subdividing the continuous tubular member into individual pouch portions and, once subdivided into the individual pouch portions, may also include a sealing unit for sealing at least one of the ends of each pouch portion. In other instances, the continuous tubular member may be sealed into individual pouch portions with a sealing unit and then, once the individual pouch portions are sealed, the continuous tubular member may be subdivided into discrete individual pouch portions by a subdividing unit subdividing the continuous tubular member between the sealed ends of serially-disposed pouch portions. Still in other instances, sealing (closing) of the individual pouch portions of the continuous tubular member may occur substantially concurrently with the subdivision thereof, using a closing and dividing unit.
An exemplary apparatus for manufacturing an oral pouch product is illustrated in FIGS. 1-5 of U.S. Publication No. 2012/0055493 to Novak, III et al.; however, this apparatus is used in a generic and descriptive sense only and not for purposes of limitation. It should also be appreciated that the following manufacturing process and related equipment is not limited to the process order described below. In various embodiments of the present invention, an apparatus similar to that described in U.S. Publication No. 2012/0055493 can be configured to removably receive a first bobbin on an unwind spindle assembly, the first bobbin having a continuous length of a material, such as a pouch material, wound thereon. When the first bobbin is engaged with the apparatus, the pouch material can be routed from the first bobbin to a forming unit configured to form a continuous supply of the pouch material into a continuous tubular member defining a longitudinal axis.
As such, as the pouch material is unwound from the first bobbin, the pouch material can be directed around an arrangement of roller members, otherwise referred to herein as a dancer assembly. A forming unit can be configured to cooperate with the first bobbin and the dancer assembly to take up slack in the pouch material and to maintain a certain amount of longitudinal tension on the pouch material as the pouch material is unwound from the first bobbin and fed to the forming unit, for example, by a drive system. One of ordinary skill in the art will appreciate that, between the first bobbin and the forming unit, the pouch material can be supported, routed, and/or guided by a suitably aligned series of any number of, for example, idler rollers, guideposts, air bars, turning bars, guides, tracks, tunnels, or the like, for directing the pouch material along the desired path. Typical bobbins used by conventional automated pouch making apparatuses often contain a continuous strip of pouch material of which the length may vary. As such, the apparatus described herein can be configured so as to handle bobbins of that type and size.
The forming unit can include one or more roller members configured to direct the pouch material about a hollow shaft such that the continuous supply of the pouch material can be formed into a continuous tubular member. The forming unit can include a sealing device configured to seal, fix, or otherwise engage lateral edges of the pouch material to form a longitudinally-extending seam, thereby forming a longitudinally-extending continuous tubular member. In various embodiments, an insertion unit can be configured to introduce charges of the composition adapted for oral use into the continuous tubular member through the hollow shaft. The insertion unit may be directly or indirectly engaged with the hollow shaft.
A leading edge or end (also referred to as a laterally-extending seam) of the continuous tubular member can be closed/sealed such that a charge of composition adapted for oral use inserted by the insertion unit, is contained within the continuous tubular member proximate to the leading end. The leading end can be closed/sealed via a closing and dividing unit configured to close/seal a first portion of the continuous tubular member to form the closed leading end of a pouch member portion. The closing and dividing unit can also be configured to form a closed trailing edge or end of a previous pouch member portion. In this regard, the closing and dividing unit can also be configured to close a second portion of the continuous tubular member to form the closed trailing end of the pouch member portion. In this regard, the closing and dividing unit can close the ends, by heat-sealing, or other suitable sealing mechanism.
As discussed above, a binder coating is not necessary for embodiments of the present invention. Instead, the heat sealable fibers incorporated into the nonwoven web of the pouch material can act as a heat sealable binder to seal the pouch once the composition adapted for oral use is inserted within the outer water-permeable pouch.
As illustrated in FIGS. 20-22 of U.S. Publication No. 2012/0055493 to Novak, III et al., the closing and dividing unit can be configured to divide the continuous tubular member, between the closed trailing end and the closed leading end of serially-disposed pouch member portions, along the longitudinal axis of the continuous tubular member, and into a plurality of discrete pouch member portions such that each discrete pouch member portion includes a portion of the oral composition from the insertion unit. In this regard, the closing and dividing unit can include a blade, heated wire, or other cutting arrangement for severing the continuous tubular member into discrete pouch member portions. For example, the closing and dividing unit can include first and second arm members configured to interact to close and divide the continuous tubular member.
In operation, a charge of the composition adapted for oral use (i.e., an amount suitable for an individual pouch member portion) can be supplied to the pouch member portion by an insertion unit after a leading end has been closed, but prior to the closing of a trailing end. In various embodiments, after receiving the charge of the oral composition, the discrete individual pouch member portion can be formed by closing the trailing end and severing the closed pouch member portion from the continuous tubular member such that an individual pouched product is formed.
The amount of material contained within each pouch may vary. In smaller embodiments, the dry weight of the material within each pouch is at least about 50 mg to about 150 mg. For a larger embodiment, the dry weight of the material within each pouch preferably does not exceed about 300 mg to about 500 mg. In some embodiments, each pouch/container may have disposed therein a flavor agent member, as described in greater detail in U.S. Pat. No. 7,861,728 to Holton, Jr. et al., which is incorporated herein by reference. For example, at least one flavored strip, piece or sheet of flavored water dispersible or water soluble material (e.g., a breath-freshening edible film type of material) may be disposed within each pouch along with or without at least one capsule. Such strips or sheets may be folded or crumpled in order to be readily incorporated within the pouch. See, for example, the types of materials and technologies set forth in U.S. Pat. Nos. 6,887,307 to Scott et al. and 6,923,981 to Leung et al.; and The EFSA Journal (2004) 85, 1-32; which are incorporated herein by reference.
In various embodiments, the nonwoven web can be sufficiently tacky so as to create issues with high-speed pouching equipment. Therefore, in certain embodiments, a TEFLON® coating, or similar material, can be applied to one or more surfaces of the pouching equipment that touch the nonwoven web such as, for example, rollers, cutting instruments, and heat sealing devices in order to reduce and/or alleviate the problem of the pouch material sticking to the pouching equipment during processing.
As illustrated in
The pouched products can further include product identifying information printed or dyed on the outer water-permeable pouch or imprinted (e.g., embossed, debossed, or otherwise pressed) on the outer water-permeable pouch, such as described in U.S. Pat. Appl. No. 13/792,926 to Reddick et al., filed Mar. 11, 2013, which is incorporated by reference herein. Flavorants, hydrophilic materials, or other fiber finishes can also be incorporated into the nonwoven web to introduces flavor enhancing agents to the nonwoven web or to further enhance flavor transfer into the mouth, such as by coating or printing an edible flavorant ink onto the nonwoven web. See, e.g., U.S. Pat. Appl. Pub. Nos. 2012/0085360 to Kawata et al. and 2012/0103353 to Sebastian et al., each of which is herein incorporated by reference.
EXPERIMENTALAspects of the present invention are more fully illustrated by the following examples, which are set forth to illustrate certain aspects of the present invention and is not to be construed as limiting thereof.
The following non-limiting example describes how a nonwoven web and pouch can be made with polylactic acid fibers as the heat sealable fiber.
Polylactic acid spunmelt nonwoven fabric grade CD50009O is provided by Ahlstrom Chirnside Limited of Scotland. The nonwoven material is formed into a pouch suitable for oral use. A tobacco composition is inserted inside the pouch before sealing the material. The fabric is heat sealed along the long seam of the pouch under the following conditions: 200 N pressure, 150° C., 5 mm×50 mm area of seal, and 0.3 s dwell time. The fabric is heat sealed along the short seam of the pouch (i.e., the ends of the pouch) under the following conditions: 200 N pressure, 140° C., 5 mm×50 mm area of seal, and 0.3 s dwell time. The heat seal is measured in the machine direction using a peel test. The RDM tensile tester is used to peel the heat seal apart and results are reported in N/50 mm. The strength of the heat seal is within the acceptable range of values for a pouched product.
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing description. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
Claims
1. A pouched product configured for insertion into the mouth of a user of that product, comprising:
- an outer water-permeable pouch defining a cavity containing a composition adapted for oral use, wherein the outer water-permeable pouch comprises a nonwoven spunlaid web comprising a plurality of continuous filament heat sealable fibers.
2. The pouched product of claim 1, wherein the heat sealable fibers have a melting point of less than about 200° C.
3. The pouched product of claim 2, wherein the heat sealable fibers have a melting point of less than about 140° C.
4. The pouched product of claim 1, wherein the heat sealable fibers comprise a biodegradable polymer.
5. The pouched product of claim 1, wherein the heat sealable fibers comprise an aliphatic polyester.
6. The pouched product of claim 1, wherein the heat sealable fibers comprise a polymer selected from the group consisting of polyglycolic acid, polylactic acid, polyhydroxyalkanoates, polycaprolactone, polybutylene succinate, polybutylene succinate adipate, and copolymers thereof.
7. The pouched product of claim 1, wherein the nonwoven spunlaid web is a spunbond nonwoven web comprising PLA fibers, PHA fibers, or a combination thereof.
8. The pouched product of claim 1, wherein the nonwoven web is substantially free of a binder coating.
9. The pouched product of claim 1, wherein the composition within the cavity of the pouch comprises at least one of a particulate tobacco material, nicotine, particulate non-tobacco material that has been treated to contain nicotine and/or flavors, and fibrous plant material treated to contain a tobacco extract.
10. A pouched product configured for insertion into the mouth of a user of that product, comprising:
- an outer water-permeable pouch defining a cavity containing a composition adapted for oral use and comprising a tobacco material, wherein the outer water-permeable pouch comprises a nonwoven spunlaid web comprising a plurality of continuous filament heat sealable fibers.
11. The pouched product of claim 10, wherein the nonwoven spunlaid web is a spunbond nonwoven web comprising PLA fibers, PHA fibers, or a combination thereof.
12. The pouched product of claim 10, wherein the composition within the cavity of the pouch comprises at least one of a particulate tobacco material, nicotine, particulate non-tobacco material that has been treated to contain nicotine and/or flavors, and fibrous plant material treated to contain a tobacco extract.
13. The pouched product of claim 10, wherein the heat sealable fibers have a melting point of less than about 200° C.
14. The pouched product of claim 13, wherein the heat sealable fibers have a melting point of less than about 140° C.
15. The pouched product of claim 10, wherein the nonwoven web is substantially free of a binder coating.
Type: Application
Filed: Jan 6, 2016
Publication Date: Jul 7, 2016
Applicant:
Inventors: Andries Don Sebastian (Clemmons, NC), Alton Busbee (Lexington, NC)
Application Number: 14/989,489
