HK1165231B - The method for making smokeless tobacco articles - Google Patents

Description

Method of making smokeless tobacco products

Cross Reference to Related Applications

The present application claims priority from U.S. provisional application No. 61/141,968 entitled "smokeless tobacco product" filed by Atchley et al, 31/2008, the contents of which are incorporated herein by reference.

Technical Field

The present application relates to tobacco products and methods of making smokeless tobacco products.

Background

Smokeless tobacco products are used without burning them. Such products can be manufactured in a variety of forms, including chewing tobacco, dry snuff, and moist snuff. These types of products are typically made using one or more of the following steps: cutting or grinding tobacco to a specific size, impregnating or spraying the tobacco with a packing solution (packing solution), partially drying the tobacco, storing the tobacco in a container for a period of time, and packing the tobacco.

Adult consumers who choose to use smokeless tobacco products choose the product according to their personal preferences, such as flavor, cut-off of tobacco, tobacco form, ease of use, and packaging.

Summary of The Invention

The present application is based on the discovery that tobacco (e.g., tobacco powder or sheet) can be mixed with plastic particles and reheated (e.g., by a sintering process) to produce a plastic product having tobacco dispersed therein. The product is permeable so that tobacco, tobacco flavors and other components can be released when a consumer (e.g., an adult consumer) places the product in his/her mouth. The tobacco product provided by the invention can be manufactured at lower cost and has longer shelf life than the traditional smokeless tobacco bag product. In addition, mixing tobacco with plastic particles prior to heating can provide a tobacco product that has improved properties (e.g., "roasted" or "roasted" flavor) upon heating.

In one aspect, the present application relates to a smoking article comprising a porous substrate comprising a network of pores; and tobacco disposed in the pores of the porous substrate such that when a fluid passes through the porous substrate, at least one of unburned tobacco or unburned tobacco components is introduced into the fluid, wherein the tobacco is integrally formed with the porous substrate. The tobacco may be integrally formed with the porous substrate during the plastic sintering process. The porous matrix may include particles of a thermoplastic polymer (e.g., ultra-high molecular weight polyethylene). The thermoplastic polymer particles may have an average diameter of about 10 microns to about 100 microns, or about 10 microns to about 20 microns. The tobacco product may comprise tobacco to polymer in a ratio of 30:70 to 50:50 by weight. The tobacco may include at least one of shredded tobacco (tobaccos), cut tobacco (cuttobacaccos), granulated tobacco, or powdered tobacco. The tobacco may include particulate or powdered tobacco particles having an average diameter of about 20 microns to about 100 microns, or about 40 microns to about 60 microns. The smoking article may further comprise one or more flavour components. The tobacco product may be adapted for full acceptance by adult consumers. The tobacco product may have a shelf life of at least 30 weeks. In some embodiments, the central portion of the article has a first average pore size and the peripheral portion has a second average pore size, the first average pore size being greater than the second average pore size.

In another aspect, the present application relates to a method of making a smoking article comprising mixing thermoplastic polymer particles with tobacco particles, and processing the mixture with heat such that the thermoplastic polymer forms a porous matrix comprising a network of pores, while the tobacco particles are disposed in the pores of the porous matrix. The processing may include sintering. The thermoplastic polymer may be an ultra-high molecular weight polyethylene. The thermoplastic polymer particles may have an average diameter of about 10 microns to about 100 microns, or about 10 microns to about 20 microns. The tobacco product may comprise tobacco particles and thermoplastic polymer particles in a ratio of 30:70 to 50:50 by weight. The tobacco particles may include at least one of shredded tobacco (tobaccos), cut tobacco (cuttobacaccos), granulated tobacco, or powdered tobacco. The granulated or powdered tobacco has an average diameter of about 20 to 100 microns, or about 40 to 60 microns. The method may further comprise adding one or more flavour components to the smoking article. The one or more flavor components may be added to the tobacco product after processing with heat. The tobacco product may be adapted for full acceptance by adult consumers. The tobacco product may have a shelf life of at least 30 weeks.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice of one or more embodiments disclosed herein, suitable methods and materials are described below. All publications, patent applications, patents, and other documents mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.

Drawings

Figure 1 is a cross-sectional top view of a smoking article according to some embodiments.

Figure 2 is an end view of the smoking article of figure 1.

Figure 3 is a side view of the smoking article of figure 1.

Figure 4 is a side view of the smoking article shown in figure 1, cut along axis "a".

Figure 5 is a top view of the smoking article shown in figure 1 after being cut along axis "a".

FIG. 6 is a cross-sectional view of a smoking article according to some embodiments.

FIG. 7 is a cross-sectional view of a smoking article according to some embodiments.

FIG. 8 is a cross-sectional view of a smoking article according to some embodiments.

Fig. 9A and 9B are cross-sectional views of a method of manufacturing an article according to some embodiments.

Figure 10 is a cross-sectional view of a smoking article according to some embodiments.

FIG. 11 is a cross-sectional view of a smoking article according to some embodiments.

Figure 12 is a cross-sectional view of a smoking article according to some embodiments.

Figure 13 is a cross-sectional view of a smoking article according to some embodiments.

Figure 14 is a cross-sectional view of a smoking article according to some embodiments.

Like reference symbols in the various drawings indicate like elements.

Detailed Description

Materials and methods for making smokeless tobacco products are provided wherein a mixture of tobacco particles and plastic polymer particles are mixed and heated (e.g., during sintering or the like) to form a product. Methods of making such articles are also provided. Mixing tobacco and polymer particles and heating them (e.g., by sintering) can provide a tobacco product having a pleasing flavor. Such an article may also be less expensive to make and have a longer shelf life than conventional pouch products, since it is substantially dry, rather than wet or moist. For example, the invention provides tobacco products that can have a longer shelf life (e.g., 30 weeks or more) than other smokeless tobacco products.

The tobacco articles provided by the present invention can include a porous matrix formed from particles of a plastic polymer (e.g., a thermoplastic polymer), and tobacco dispersed in the pores of the porous matrix. The smoking article may further comprise an air gap between the polymer and the tobacco. Typically, the entire article is porous such that all of the exterior surfaces have pores that are in fluid communication with the pores within the article. In some embodiments, however, only a portion of the outer surface of the article is porous. The porous matrix may be formed in a manner that controls the average pore size, pore volume, or both. For example, the porous matrix may be formed using a plastic sintering process in which the polymeric material particles are subjected to a controlled heating process under conditions of a regulated time, temperature, and number of cycles, as described further below. The size of the polymer particles can affect the size of the pores resulting from the sintering process, such that generally larger particles produce larger pores and smaller particles produce smaller pores. Larger pores can result in faster desorption of tobacco and tobacco components from the article, while smaller pores can result in slower desorption. The rate of tobacco desorption can be adjusted according to the pore size. Different polymer particle sizes may be used. For example, the smoking articles provided herein can be made from polymeric particles having an average diameter of about 10 microns to about 100 microns (e.g., about 10 microns, about 20 microns, about 30 microns, about 40 microns, about 50 microns, about 60 microns, about 70 microns, about 80 microns, about 90 microns, or about 100 microns), or any range therebetween, including but not limited to: from about 10 microns to about 20 microns, from about 15 microns to about 25 microns, from about 20 microns to about 30 microns, from about 30 microns to about 40 microns, from about 40 microns to about 50 microns, from about 50 microns to about 60 microns, from about 60 microns to about 80 microns, or from about 80 microns to about 100 microns, the resulting sintered article having an average void diameter of from about 1 to about 50 microns, or any range therebetween, including but not limited to: about 1-5 microns, about 3-15 microns, about 10-20 microns, about 20-30 microns, about 30-40 microns, or about 40-50 microns. The resulting article may also include different regions having different average pore sizes. For example, the resulting article may have a gradient of average pore sizes from a surface having a smaller average pore size to a central portion having a larger average pore size. The average pore diameter can be measured by taking a cross-section of the article, measuring the largest dimension of each observable pore between the sintered polymer particles with a microscope and taking the average of the observed largest dimensions. The resulting void volume also depends on the size of the sintered polymer particles. In some embodiments, the resulting article may also include different regions having different void volumes. For example, the resulting article may have a gradient of void volumes from a surface having a smaller void volume to a central portion having a larger void volume.

The polymer particles may include regular and irregular sized and shaped particles. In some embodiments, the polymer particles may be substantially spherical (e.g., round beads). In other embodiments, irregularly shaped polymer particles of different sizes may be used. In still other embodiments, the polymer particles may comprise flakes, cylindrical beads, films of different cut lengths, polymer flakes, chunks, and polymer fibers cut into various lengths. The shape of the polymer particles affects the average pore size, pore size distribution, and void volume.

A variety of materials are suitable for use in the porous substrate of a smoking article as described herein. For example, the porous matrix may comprise a porous, sinterable, insoluble thermoplastic, such as polyethylene. Ultra-high molecular weight polyethylene may be particularly suitable, since, for example, the particle size of the ultra-high molecular weight polyethylene beads can be easily controlled. Furthermore, the use of ultra high molecular weight polyethylene results in a particularly smooth product which is perceived as malleable in the mouth of the consumer.

The porous matrix may additionally or alternatively comprise one or more of the following polymeric materials: an acetal polymer; acrylic polymers such as polymethyl methacrylate and polyacrylonitrile; an alkyd resin; a polymer alloy; allyl polymers such as diallyl phthalate and diallyl isophthalate; amine polymers such as urea, formaldehyde and melamine formaldehyde; cellulose such as cellulose acetate, cellulose triacetate, cellulose nitrate, ethyl cellulose, cellulose acetate propionate, cellulose acetate butyrate, hydroxypropyl cellulose, cellophane and rayon; chlorinated polyether; a benzofuran-indene polymer; an epoxy polymer; fluorocarbon polymers such as PTFE, FEP, PFA, PCTFE, ECTFE, ETFE, PVDF and PVF; a furan polymer; a hydrocarbon resin; a nitrile resin; a polyaryl ether; a polyaryl sulfone; a phenol-aralkyl polymer; a phenolic polymer; polyamides (nylons); poly (amide-imide); a polyaryl ether; a polycarbonate; polyesters, such as aromatic polyesters, thermoplastic polyesters, PBT, PTMT, PET and unsaturated polyesters such as SMC and BMC; polyimides such as thermoplastic polyimides and thermosetting polyimides; polymethylpentene; polyolefins, such as LDPE, LLDPE, HDPE and UHMWPE, polypropylene; ionomers (inomers) such as PD and polytomorphs; polyphenylene ether; polyphenylene sulfide; a polyurethane; parylene (poly p-xylylene); silicones, such as silicone fluids and elastomers, rigid silicones; styrenic polymers such as PS, ADS, SAN, styrene-butadiene lattice (lattice) and styrene-based polymers; sulfone polymers such as polysulfone, polyethersulfone and polyphenylsulfone; a thermoplastic elastomer; and vinyl polymers such as PVC, polyvinyl acetate, polyvinylidene chloride, polyvinyl alcohol, polyvinyl butyrate, polyvinyl formal, propylene-vinyl chloride copolymer, ethylvinyl acetate and polyvinylcarbazole. In addition, one or more of the polymers from which the porous substrate is made can be colored to provide a colored smokeless tobacco product.

The tobacco contained in the articles provided herein can be granular, powdered, flaked, shredded, cut (e.g., long cut tobacco), cured, aged, fermented, heat-treated, pasteurized, encapsulated, or otherwise processed. Powdered, granulated or flaked tobacco may be particularly suitable. For example, the tobacco may be in granular or powdered form, such that its size is set within the pores of the porous substrate. In some embodiments, some or all of the tobacco of the smoking article can be processed with reconstituted tobacco. In other embodiments, the tobacco may be long cut tobacco having a length of about 0.25 inches to 1 inch and a width of 0.005 inches to 0.05 inches. For example, the tobacco may include a middle 35 cuts per inch. In some embodiments, the long cut tobacco may remain in a central portion of the article while a peripheral portion of the article is substantially free of long cut tobacco. In some embodiments, the article may include different combinations of different shaped tobaccos, optionally located in different portions of the article. For example, an article having a central portion comprising long cut tobacco may also comprise powdered tobacco in other portions of the article (e.g., in peripheral portions of the article having a smaller average pore size than the central portion). Smaller average pore sizes in the outer portions of the article also prevent larger tobacco sheets in the central portion of the article from moving into the mouth of the user.

The tobacco particles can be separated into different size ranges using methods known in the art (e.g., mesh screening). In addition, a variety of tobacco particle sizes can be used in the articles provided herein. For example, the tobacco product can comprise tobacco particles, tobacco powder, or tobacco sheets having a tobacco particle average diameter or width of about 20 microns to 100 microns (e.g., about 20 microns, about 30 microns, about 40 microns, about 50 microns, about 60 microns, about 70 microns, about 80 microns, about 90 microns, or about 100 microns), or any range therebetween (e.g., about 20 microns to about 40 microns, about 40 microns to about 60 microns, or about 60 microns to about 100 microns). Tobacco particles having an average diameter or width of about 40 microns to about 60 microns can be particularly useful because such particles are readily available and result in a tobacco product that is smooth in texture and free of gritty feel. Where a more gritty texture is desired, particles having an average diameter of about 60 microns to 100 microns can be used. The size of the tobacco particles can be adjusted according to the grinding method (e.g., hammer milling).

Tobacco includes a portion (e.g., leaf, flower, and/or stem) of a member of the genus Nicotiana (Nicotiana). Exemplary species include yellow tobacco (n.rustica), American tobacco (n.sylvestris), hairy tobacco (n.tominosiformis) and common tobacco (n.tabacum) (e.g., varieties and/or cultivars known as LA B21, LN KY171, TI1406, Basma, Galpao, pereque, Beinhart1000-1 and pelico). Other species include stemless tobacco (n.acaulis), pointy tobacco (n.acuminata), floret tobacco (n.acuminata var. multiflora), african tobacco (n.africana), floret tobacco (n.alata), stemmed tobacco (n.amplexicaulis), allent tobacco (n.arentsii), attenuated tobacco (n.attentus), bennard tobacco (n.bennavidesii), benseram tobacco (n.benthamiana), indian tobacco (n.biogelovii), endonexine tobacco (n.bonariensis), cave tobacco (n.cavicola), cleveland tobacco (n.clevelandi), heart leaf tobacco (n.cordifolia), umbelliform tobacco (n.coermboy), di (n.berg), tobacco (n.e. kuchen), cross-cut tobacco (n.kuchen), cross-kuchen tobacco (n.g. tobacco), cross-cut tobacco (n.kuchen.e.g. tobacco) Examples of the tobacco source include, but are not limited to, narrow leaf tobacco (n.linearis), long flower tobacco (n.longiflora), seashore tobacco (n.maritima), ultramarine tobacco (n.megalosiphon), morsella tobacco (n.miersii), nocturnal tobacco (n.noctiflora), nude stem tobacco (n.nudicaulis), obustifolia tobacco (n.obtusifolia), western tobacco (n.occidentalis), western mustard tobacco (n.occidentalis), cornua tobacco (n.otophoora), paniculata, pauciflora, petunia, n.paradisiaria, petunia, n.curainia, setaria, n.dreuifolia, n.quarriella, n.rosepalatinia, n.solanum, n.solanaceous cut, n.sylvestris, n.rosepalatinia, n.sylvestris, n.n.n.sylvestris, n.n.sylvestris, n.n.n.n.n.solanaceous tobacco (n., Hairy tobacco (n.tominosa), tabacum triangularis (n.trigonophylia), germinated tobacco (n.particulate), tabacum undulatum (n.undulata), tabacum tinguis (n.velutina), tabacum apium (n.wilgandiides) and tabacum carthami (N.x sanderade).

In some cases, the tobacco can be prepared from plants having less than 20 micrograms/cm 2 of 4,8, 13-duratriene 1, 3-diol (DVT; also known as 4,8, 13-cematriene 1, 3-diol) in green leaf tissue. For example, tobacco particles can be prepared from low DVT tobacco as described in U.S. patent publication No. 2008/0209586, which is incorporated herein by reference. Such low DVT tobacco varieties can exhibit improved flavor characteristics (e.g., sensory taster evaluation) as compared to tobacco with no reduction in DVT content.

In some embodiments, the tobacco can comprise one or more components, such as flavor extracts, flavor masking agents, bitter taste sensory site blockers, sensory site enhancers, sweeteners, and additives such as chlorophyll, minerals, botanicals, or breath freshening agents. Some of these components are described, for example, in U.S. patent applications 10/982,248 and 10/979,266, which are incorporated herein by reference in their entirety. These components may be present in the tobacco as a powder, oil, powder in fine particle form, or powder in encapsulated form.

In some embodiments, the tobacco may be processed to include flavor components prior to making the molded article. Such "primary" flavor components can be added, for example, by spraying the tobacco with a flavor extract prior to mixing the tobacco with the thermoplastic polymer and forming a tobacco product. In another example, tobacco flavor can be imparted by mixing solid or liquid flavors with the tobacco material and incubating under suitable conditions, for example, as described in the aforementioned application No. 10/982,248. Additionally or alternatively, the smoking article may be further processed by capillary action, infusion or other introduction methods to add one or more "secondary" flavor components, such that the flavor components may be added after the article is made. In these embodiments, the tobacco product may be flavoured according to a customer order, with the result, for example, of improved inventory control. In other embodiments, the flavor can be added by placing the article in a vacuum after forming the article, and then placing the flavor in a vacuum chamber to fill the article with the flavor.

The flavor can be provided with synthetic flavors, flavor extracts, plant matter, or combinations thereof. Suitable flavoring agents and flavor extracts include, but are not limited to: menthol, cinnamon, wintergreen, cherry, berry, peach, apple, spearmint, peppermint, bergamot, vanilla, coffee, peppermint oil from a species of the mint (Mentha) genus, or other desirable flavors. Flavor can also be provided by plant matter (e.g., mint leaves) which typically contains 10% flavor oils and 90% insoluble fiber. Suitable plant matter may be obtained from plants such as species of the genera clove, cinnamon, herb (herb), berry, peach, apple, lavender, rose, vanilla, lemon, orange, coffee or mint (Mentha). As further described herein, flavor can also be provided by imitation, synthetic or artificial flavor ingredients and blends containing such ingredients. For example, suitable sweeteners include, for example, sucralose, acesulfame potassium (Ace-K), aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, and mannitol. Liquid smoke or other heat activated flavorants may also be added to provide additional flavor.

Tobacco (e.g., granular, powdered, flaked tobacco particles, or long cut tobacco) may be mixed with the polymeric material in a selected ratio, and the mixture may then be used in an integral molding process (e.g., as described in connection with fig. 9A and 9B). Typically, the products provided herein comprise from about 30% to about 60% by weight tobacco, such that the ratio of tobacco to polymer is about 30:70 to 60: 40 (e.g., about 40: 60, about 45: 55, or about 50: 50). In another aspect, the tobacco products provided herein can comprise from about 20% to about 80% by weight tobacco, such that the ratio of tobacco to polymer is about 20: 80 to 70: 30 (e.g., about 20: 80, about 45: 55, about 50:50, about 60: 40, or about 70: 30). A relatively low ratio of tobacco and polymer may result in a perceived product being hard, while a relatively high ratio may result in a loss of structural integrity and may result in a perceived product being soft.

The tobacco particles and the polymer particles may be different sizes from one another. However, where larger tobacco particles are typically used (e.g., 60 to 100 microns in average diameter), larger polymer particles must also be used so that the resulting product has sufficient structural integrity. Smaller tobacco particles (e.g., 40 to 60 microns in average diameter) can be used, as can smaller polymer particles (e.g., 10 to 20 microns in average diameter). The size of the tobacco particles and the polymer particles can affect the texture of the resulting tobacco product. For example, smaller particles can result in a smoother product, while larger particles can result in a rougher or more gritty product. Thus, the tobacco products provided herein can be manufactured in a variety of texture profiles.

The smoking articles provided herein can have a variety of shapes (e.g., rectangular, square, spherical, cylindrical, rod-shaped, or sheet-shaped suitable for placement in the mouth). In some embodiments, the tobacco product may be suitable for full acceptance by adult consumers. These tobacco products can be configured in a nearly unlimited number of forms. For example, the tobacco product may be configured to resemble a pouch, may be generally oval, but other embodiments may be pillow-shaped, boat-like shaped, circular, flat rectangular, and the like. Further, the smoking articles described herein can be formed or molded on an inseparable substrate.

The article may also comprise agglomerated particles of tobacco powder, sugar, starch and/or flavorants. The agglomerated particles comprising tobacco may be included in the article as tobacco or with other tobacco. For example, U.S. patent application No. 12/641,915 entitled "tobacco particles and methods of making tobacco particles" filed on 12/18/2009 (hereby incorporated by reference) describes agglomerated particles comprising tobacco particles. The pellet may comprise a core and one or more layers surrounding the core comprising the tobacco particles and the binder. In some embodiments, the agglomerate grains may be polymer particles coated with a polymer and used in the article as a sintering process, without using additional solid polymer particles or using additional solid polymer particles to make a polymer matrix. In some embodiments, the aggregate particles may be completely encapsulated with a polymer. In other embodiments, the agglomerate grains may include an incomplete coating to facilitate migration of tobacco, flavors, and/or other components through the porous network in the article. During use, the flavor and/or tobacco components of the agglomerate can flow out through the porous network of the article and be released into the mouth of the user. In some embodiments, the flavor is released from the encapsulated agglomerate grains in the sintered article as a result of chewing the article. Agglomerated particles, such as tobacco particles described in U.S. patent application No. 12/641,915, can be coated with a polymer according to techniques known in the art, including coating, spraying, and roller coating methods.

Turning now to the drawings, the smoking article 100 shown in FIG. 1 can include a porous substrate 110, and tobacco 120 disposed in the pores 112 of the porous substrate 110, such that the smoking article 110 can provide tobacco to the mouth of an adult consumer, for example, in particulate, liquid, or vapor form. As described herein, providing tobacco can provide tobacco satisfaction to a consumer.

The smoking article 100 may be a non-combustible product in that the article 100 does not need to be ignited during use. The tobacco product 100 can provide tobacco to a consumer without burning any portion of the tobacco product 100 and without igniting the tobacco 120 in the product 100. But rather can provide the consumer with non-combustible tobacco to provide tobacco satisfaction in the form of sensations associated with the tobacco components released upon use, sensory components, and added flavor components. Such sensory components may be associated with or have an effect on a consumer's integrated sensory experience, including, for example, aroma, fragrance, flavor, taste, odor, or oral experience.

The tobacco product 100 can include a moldable polymer that can be molded into a desired shape. The tobacco 120 and the porous substrate 110 can be integrally molded such that the tobacco 120 is disposed within the pores 112 when the porous substrate 110 is formed. For example, the polymer particles may be mixed with tobacco particles, and the mixture may be subjected to a process such as sintering to provide the smoking article 100.

The porous matrix 110 may include a plurality of pores 112 capable of allowing air and/or liquid (e.g., water or saliva) to pass from the first portion 114 to the second portion 116. In some embodiments, the pores 112 may be randomly oriented to form a network of microchannels through which air or liquid can pass over the tobacco 120 disposed in the porous substrate 110. In other embodiments, the pores 112 may be fabricated to have a generally predetermined pore orientation, e.g., a plurality of pores in the porous matrix 110 extend generally in an axial direction.

As shown in figures 1-3, the smoking article 100 is substantially rectangular in shape with pillow-shaped corners and sides that are curved to provide a smooth outer surface. The thickness of the smoking article may be the same or different. For example, figures 2 and 3 show end and side views, respectively, of a smoking article 100, which may have a thicker thickness in the center of the article than at the periphery of the article. In some embodiments, the tobacco product can be molded (e.g., sintered) as described herein and further processed into the desired shape of the final product. For example, the smoking articles shown in fig. 1-3 can be cut along line "a" to provide substantially "boat-shaped" smoking articles 100a and 100b, as shown in fig. 4 and 5. Different regions of the article 100 may have different porosities depending on the size of the polymer particles from which the article 100 is made. For example, if the average diameter of the polymer particles in the central region of the article 100 is larger than the particles around the periphery of the article 100, the pores on the cut surfaces 140 of the articles 100a and 100b may be larger than the pores on the other surfaces of the articles 100a and 100 b.

Figure 6 shows another embodiment of a smoking article adapted for full acceptance by consumers. The smoking article 200 can have a first porous matrix 210, tobacco particles 220, and a second porous matrix 250, the second porous matrix 250 can in some cases act as a reservoir for saliva. The saliva reservoir 250 may be a porous matrix integrally formed with the first porous matrix 210 comprising tobacco 220. The saliva reservoir 250 may include pores 252 having a pore size and pore volume that is significantly larger than the first porous matrix 210. For example, the saliva reservoir 250 may be formed from polymer particles that are much larger in size than the particles used to form the first porous matrix 210. Thus, during the plastic sintering process, the saliva reservoir 250 may become a porous matrix having pores 252, the pores 252 being larger in size than the pores 212 of the first porous matrix 210.

The tobacco products 100 and 200 may be placed between the gums and lips of a consumer and may be contacted with the saliva of the consumer. For example, referring to fig. 7, when the first porous matrix 210 is in contact with consumer saliva 240, a portion of the saliva will be forced into the pores 212. Saliva 240 may pass through the network of pores 212 such that tobacco components 232 (and in some cases fine tobacco particles) are introduced into the consumer's saliva. Thus, the tobacco component 232 can be mixed with saliva 240. When tobacco is provided to a consumer, the saliva reservoir 250 can absorb a portion of the consumer's saliva, reducing the amount of spitting often associated with the use of smokeless tobacco products (e.g., chewing tobacco or snuff). Thus, the tobacco product 200 can provide tobacco satisfaction to the consumer without burning the tobacco product 200 or the tobacco 220 disposed therein. Optionally, the tobacco 220 can contain one or more flavors or other components (as previously described), or flavor particles can be disposed in the pores 212 of the porous matrix 210. In these cases, the flavoring can be incorporated into the saliva liquid, which can provide the consumer with a combination of the flavoring and the tobacco component 232.

When the tobacco 220 in the porous substrate 210 is exhausted or the consumer decides to remove the tobacco product 200, the tobacco product may be discarded. Thus, the smoking article 220 may be separated for disposal, while a portion of the consumer's saliva remains in the saliva reservoir 250.

In some embodiments, the smoking article may be substantially cylindrical or rod-like in shape and may be configured to be placed between the fingers of a consumer. For example, the smoking article 300 shown in FIG. 8 is an elongated cylindrical shape. Articles such as the smoking article 300 may be adapted to provide tobacco or tobacco components to a consumer in the form of a liquid, a vapor, or, in particular instances, a combination of a vapor and fine particles. In such an embodiment, the first and second portions 314 and 316 of the porous substrate 310 may be exposed to the atmosphere, and the consumer may force air from the first portion 314, through the network of pores 312, over the tobacco 320 disposed therein, and out of the second portion 316. For example, the consumer may create a negative pressure on the smoking article 300 proximate the second portion 316 such that air is drawn through the porous substrate 310 and proximate the consumer. As the air passes through the porous matrix 310, the tobacco component may be introduced into the air and provided to the consumer. Tobacco components (e.g., flavors or aromas, etc.) can be transferred from the tobacco 320 in the form of a vapor to the air passing through the porous substrate 310. Thus, the tobacco product 300 can provide tobacco satisfaction in a sensory format associated with the released tobacco sensory components and the added flavor components. Such sensory components may be associated with or have an effect on a consumer's integrated sensory experience, including, for example, aroma, fragrance, flavor, taste, odor, or oral experience. Also as described above, the tobacco 320 can contain one or more flavorants or flavor particles can be disposed in the pores 312 of the porous matrix 310. In these cases, the flavoring can be introduced into the air, which can provide the consumer with a combination of flavoring and tobacco.

In some embodiments, the tobacco 320 is disposed in a manner that allows the tobacco product 300 to provide tobacco to the consumer in the form of vapor and fine particles. For example, the tobacco 320 in the porous matrix 310 may be formed into granules such that fine tobacco particles can pass through the network of pores 312 in the porous matrix 310. In these instances, the consumer may apply a negative pressure on the smoking article 300 proximate the second portion 316, such that air is drawn through the porous substrate 310 by the consumer. As the air passes through the porous matrix 310, the fine tobacco particles and tobacco flavor may be provided to the consumer in the form of a combination of vapor and fine particles. In addition, the tobacco product 300 can provide tobacco satisfaction to the consumer without burning the tobacco product 300 or the tobacco 320 disposed therein.

Fig. 9A and 9B illustrate an exemplary plastic sintering process that may be used to form a smoking article provided herein. Such plastic sintering methods may include controlled heating using one of a variety of heating techniques, some of which are described, for example, in U.S. patent No. 4,375,441, which is incorporated herein by reference in its entirety. It will be appreciated that plastic sintering is only one of several possible methods that may be used to form the porous substrate of the smoking articles described herein.

Referring now to fig. 9A and 9B, some embodiments of tobacco articles may be integrally formed in a molding process. The tobacco 120 can be mixed with the polymeric particles 118 during the molding process, such that the tobacco 120 is integrally molded with the porous substrate 110. As shown in fig. 9A, the molding process may use first and second molding members 170 and 180 that can be mated together to define an interior cavity 175. The interior cavity 175 can include a working surface that at least partially defines a desired exterior shape of the smoking article. Tobacco 120 and polymeric particles 118 may be disposed in the interior cavity 175. In some embodiments, different sized polymer particles 118 may be placed in the interior cavity 175 to result in tobacco products having different pore sizes. For example, the polymer particles may be arranged such that the average diameter of the particles along the outer portion of the cavity 175 is smaller than the polymer particles in the central portion of the cavity 175. After the sintering process, the resulting smoking article may have a network of pores in the central portion that is larger than the peripheral portion. In some embodiments, different types of polymer particles may be placed in the cavity 175 such that, for example, the particles along the outer portion of the cavity 175 are of a different type of material than the particles within the central portion of the cavity 175. For example, the central particle may comprise a plastics polymer material, such as polyethylene or polypropylene. In addition, the porous matrix 100 may generally comprise a water-soluble or water-insoluble polymeric material. It is understood that the specifications of a variety of materials (e.g., particle size and molecular weight, particle size distribution, material type, tobacco particle size distribution, and ratio of polymer particles to tobacco particles) and a variety of process parameters (e.g., temperature, thermal contact time, and pressure) can be used to provide the porous substrate 110 with beneficial characteristics (fig. 9B). It is understood that a portion of the center particle may melt and fuse with the outer particle along a transition zone proximate the outer particle.

The tobacco 120 may be mixed with the particles 118 during the plastic sintering process such that at least a portion of the tobacco 120 is disposed in the pores 112 after the particles 118 form the porous matrix 110. It should be understood that the particles 118 and tobacco 120 are not necessarily drawn to scale, and that the size of the polymer and tobacco particles may be exaggerated to illustrate in any of the figures provided herein.

Referring to fig. 9B, as the pellets 118 and tobacco 120 are disposed in the mold cavity 175, the molding members 170 and 180 may be pressurized while the pellets 118 are heated for a controlled period of time. This pressure and heat can cause the smoking article to form its desired shape while the central particle controllably melts for a limited period of time. It is intended that this embodiment not be limited by any theory of achieving beneficial results, and it is believed that during the plastic sintering process, the outer particles can melt at a faster rate to form a substantially continuous layer along the outer surface of the smoking article, while the central particles melt at a slower rate (e.g., the surface portions of the particles are heated to bond with adjoining particles, even if some of the particles are not completely melted). The number of cycles, cycle times and temperatures of the plastic sintering process can be varied as desired to obtain specific flavor characteristics of the tobacco product (e.g., the tobacco flavor of the roast and/or roast).

After sintering, the tobacco product may be further processed, for example, by adding one or more flavors or colors. These agents can be added using a variety of methods (e.g., capillary action, injection, spray coating, or under vacuum). The outer surface of the article can also be coated with colorants and/or flavors by "high coater" techniques, resulting in an outer coating similar to that on "gel capsule" pellets. When placed in the mouth of a consumer, the coating dissolves away, after which the tobacco can be provided to the consumer. In some embodiments, a smoking article can be manufactured with a central polymeric particle and outer polymeric particles, wherein the central polymeric particle can comprise a different polymeric material than the outer polymeric particles, or can have a larger average size, or both. Such that the particles within the smoking article can readily attain a slower melting rate. As the tobacco is mixed with the central particles, at least a portion of the tobacco may be disposed in the pores after the particles form the porous matrix. It will be appreciated that certain characteristics of the pores (e.g., average pore diameter or average pore volume, etc.) may be selected by varying, for example, the size of the particulate material used to form the porous matrix, the temperature at which the particles are heated, the time for which the particles are heated, and the pressure used during molding.

In some embodiments, the center particle may comprise the same copolymer material as the outer particle (e.g., BAREX of Innovene LLC of Chicago, Ill.)^TM) And the center particle may have a larger average size than the outer particles. It is understood that in some cases, the center particle and the outer particle may have similar average sizes.

In some embodiments, the tobacco product may be packaged with paper or reconstituted tobacco sheets after it is formed. In some examples, the smoking article may have a plastic polymer outer layer. For example, as shown in fig. 10, a smoking article 400 can include a porous substrate 410, tobacco 420, and an outer layer 430. Outer layer 430 and porous matrix 410 may comprise the same moldable plastic material or different moldable plastic materials. The outer layer 430 may wholly or partially surround the porous matrix 410 and the tobacco 420 disposed therein. In some cases, the outer layer 430 may include a generally continuous layer of material that is impermeable to migrating tobacco components in the article 400. In some embodiments, the outer layer 430 may comprise a polymeric material that can be shaped to provide a substantially continuous layer.

A variety of materials are suitable for outer layer 430. For example, the outer layer 430 may comprise a copolymer (or equivalent resin) of acrylonitrile and methyl acrylate, which is known to provide barrier properties that inhibit migration of tobacco components, including volatile tobacco components. Such copolymers of acrylonitrile and methyl acrylate are available under the trade name BAREX^TMAnd (4) obtaining the product. Other polymeric materials, such as polyethylene naphthalate (PEN), polypropylene naphthalate (PTN) or polyester based Liquid Crystal Polymers (LCP), may be selected to provide barrier properties that inhibit migration of tobacco components.

In some embodiments, the outer layer 430 can be formed to completely surround the porous matrix 410 in the longitudinally extending surface 432 and the first and second cap end surfaces 434 and 436. In another aspect, the article 400 may be constructed in such a way: the first and second cap end surfaces 434 and 436 are not formed during the molding process. Each configuration can inhibit migration of tobacco 420 or tobacco components (e.g., flavors, aromas, alkaloids, etc.) from the porous matrix 410 prior to initiation of normal use of the article 400. The tobacco product 400 may be manufactured using a sintering process, as described above. This method can form a porous matrix 410 at least partially surrounded by an outer layer 430.

Referring now to fig. 11, a smoking article 400 in some embodiments can be configured to expose first and second portions 414 and 416 of a porous substrate 410. For example, in embodiments where outer layer 430 includes first and second cap end surfaces 434 and 436, at least a portion of each cap end surface 434 or 436 may be cut, pierced, or otherwise removed to expose first and second portions 414 and 416 of porous matrix 410. Such removal may occur during manufacture or packaging of the smoking article 400 (e.g., cutting the lid end surfaces 434 and 436 to provide a consistent length of the article and then packaging one or more of the articles 400 with the impermeable wrapper), or may occur by the consumer immediately prior to use of the smoking article 400. In some embodiments, the smoking articles 400 may be supplied to the consumer in a package that includes a cutting structure or a piercing structure to facilitate use of the smoking articles. Upon removal of cap end surfaces 434 and 436, longitudinally extending surface 432 of outer layer 430 can remain intact, thereby substantially surrounding the outer radial region (radial area) of porous matrix 410. The first and second portions 414 and 416 of the porous substrate 410 may be exposed to the atmosphere such that air can pass through the network of pores 412 and over the tobacco 420 disposed therein. As further described herein, the smoking article 400 of some embodiments can be configured during manufacture to expose the first and second portions 414 and 416 of the porous substrate 410, thereby eliminating the need to cut the cap end surfaces 434 and 436.

In some embodiments, the porous substrate of the smoking article can be formed separately from the outer shell. Referring to fig. 12, for example, a smoking article 500 can include a porous substrate 510, the porous substrate 510 being formed separately from an outer shell 530. The porous matrix 510 may be formed using a plastic sintering process (e.g., as described in connection with fig. 9A and 9B). Alternatively, the porous substrate 510 may be formed using a different method, wherein the porous substrate 510 comprises a porous glass or ceramic material having tobacco 520 disposed within the pores 512. The tobacco 520 can be integrally molded with the porous substrate 510 such that the tobacco 520 is disposed within the pores 512, depending on the method of forming the porous substrate 510. The porous matrix 510 may be formed or otherwise configured to mate with the separation shell 530. In such an embodiment, the separation shell 530 may include a tubular configuration with an open end 536 to receive the porous matrix 510. In this way, the porous matrix 510 may slide into and engage the separation shell 530.

As described above, the outer shell 530 may include a material that is impermeable to migrating tobacco or tobacco components (e.g., BAREX)^TM) A continuous layer of (a). At the most untilIn embodiments where the porous matrix 510 should be sealed until use by the consumer, the separation shell 530 may include BAREX with its open end sealed after the porous matrix 510 is inserted into the shell 530^TMA tube. For example, the open end of the tubular shell 530 may be used with BAREX^TMThe lid wall is heat sealed. In another example, the open end of the tubular shell 530 may be heat sealed using a heat clamping (heat clamping) method.

As shown in fig. 13, at least a portion of the porous matrix 510 may be temporarily contacted with the liquid 540 to introduce the liquid 540 into the pores 512. For example, the liquid 540 may wick into the pores 512 of the porous substrate 510 such that a portion of the liquid remains in the porous substrate 510 even after the smoking article 500 is removed from the liquid reservoir 542. In some embodiments, the liquid 540 may comprise water.

As shown in fig. 14, the first and second portions 514 and 516 of the porous matrix 510 may be exposed to the atmosphere and a consumer may force air from the first portion 514 into the network of pores 512. The vacuum action of the consumer can cause the liquid 540 previously introduced into the first portion 514 of the porous substrate 510 to flow over the tobacco 520 disposed in the pores. In this way, liquid 540 may be drawn through porous matrix 510 and into proximity with the consumer. As the liquid 540 passes through the porous matrix 510, the tobacco 520 may be introduced into the liquid 540 so that the consumer can experience tobacco satisfaction. The tobacco 520 may be mixed with a liquid 540. Thus, the tobacco product 500 can provide tobacco satisfaction to the consumer without burning the tobacco product 500 or the tobacco 520 disposed therein. Optionally, the tobacco 520 can comprise one or more flavors or other components (as described herein), or flavor particles can be disposed in the pores 512 of the porous matrix 510. In these cases, the flavoring can be incorporated into the liquid 540 so that the consumer can experience the combination of the flavoring and the tobacco 520.

Other embodiments

It is to be understood that while the invention has been described in conjunction with the detailed description thereof, the foregoing detailed description is intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims. Other aspects, benefits and modifications are within the scope of the following claims.

Claims (13)

1. A method of making a smoking article comprising mixing thermoplastic polymer particles with tobacco particles, and processing the mixture with heat such that the thermoplastic polymer forms a porous matrix comprising a network of pores while the tobacco particles are disposed in the pores of the porous matrix, the thermoplastic polymer particles having an average diameter of from 10 microns to 100 microns.

2. The method of claim 1, wherein the article has a central portion and a peripheral portion, the central portion having a first average pore size and the peripheral portion having a second average pore size, the first average pore size being greater than the second average pore size.

3. The method of claim 1, wherein the processing comprises sintering.

4. The method of claim 1, wherein the thermoplastic polymer is ultra-high molecular weight polyethylene.

5. The method of claim 1, wherein the thermoplastic polymer particles have an average diameter of 10 to 20 microns.

6. The method of claim 1, wherein the tobacco product comprises tobacco to polymer in a ratio of 30:70 to 50:50 by weight.

7. The method of claim 1, wherein the tobacco comprises at least one of shredded tobacco, cut tobacco, granulated tobacco, or powdered tobacco.

8. The method of claim 1, wherein the tobacco particles comprise granulated or powdered tobacco having an average diameter of 20 microns to 100 microns.

9. The method of claim 1, wherein the tobacco particles comprise granulated or powdered tobacco having an average diameter of 40 to 60 microns.

10. The method of claim 1, further comprising adding one or more flavor components to the smoking article.

11. The method of claim 10, wherein said one or more flavor components are added to said smoking article after said processing with heat.

12. The method of claim 1, wherein the tobacco product is adapted for complete acceptance by an adult consumer.

13. The method of claim 1, wherein the tobacco product has a shelf life of at least 30 weeks.