Patent Publication Number: US-7913699-B2

Title: Tobacco articles and methods

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to U.S. provisional application Ser. No. 60/764,108 filed on Jan. 31, 2006 by Strickland et al. and entitled “Tobacco Articles and Methods,” the contents of which are incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     This document relates to tobacco articles and methods of making such tobacco articles. 
     BACKGROUND 
     Smokeless tobacco products are manufactured in a variety of forms including chewing tobacco, dry snuff, and moist snuff. Generally, these types of products are made using one or more of the following steps: cutting or grinding the tobacco into a particular size; dipping or spraying the tobacco with a casing solution; partially drying the tobacco; storing the tobacco in containers for a period of time; and packaging it. 
     An adult consumer who chooses to use a smokeless tobacco product selects the product according to their individual preferences, such as flavor, cut of tobacco, form, ease of use, and packaging. 
     SUMMARY 
     Some embodiments of a tobacco article may include tobacco disposed in a porous matrix. The tobacco article may provide tobacco, tobacco constituents, or both tobacco and tobacco constituents to the adult consumer&#39;s mouth in the form of particles, liquid, or vapor so as to provide tobacco satisfaction to the adult consumer. For example, the tobacco article may comprise a substantially cylindrical body having tobacco disposed in the pores of a porous matrix so that the adult consumer may draw air and tobacco vapors through the pores and into the consumer&#39;s mouth for receiving tobacco and tobacco constituents or tobacco constituents. In another example, the tobacco article may comprise a conduit body having tobacco disposed in the pores of a porous matrix, and at least a portion of the conduit body may be configured to be wetted (e.g., temporarily exposed to water or another liquid) so that the consumer may draw liquid from the wetted portion, through the porous matrix, and to the consumer for the tobacco or tobacco constituents. In a further example, the tobacco article may comprise a body configured to be wholly received by the consumer, and at least a portion of the body may have tobacco disposed in the pores of a porous matrix so that the consumer&#39;s saliva or another liquid may pass through the pores for releasing tobacco or tobacco constituents into the consumer&#39;s mouth. In further aspect of this particular embodiment, another portion of the article may also be comprised of said pores of the porous matrix so that the consumer&#39;s saliva may be absorbed in a manner to alleviate the need for expectoration. In particular embodiments of a tobacco article, the tobacco may be integrally molded with a plastic material, said material being hydrophobic, hydrophilic or a combination thereof so that at least a portion of the tobacco is disposed in pores of the matrix. 
     In some embodiments, a tobacco article may comprise a substantially cylindrical body including a porous matrix and an outer shell surface impermeable to migration of tobacco constituents. The outer shell surface may at least partially surround the porous matrix. The article may also comprise tobacco disposed in pores of the porous matrix so that, when air is passed through the porous matrix, at least one of tobacco or a tobacco constituent is introduced into the air flowing through the article by way of vaporization. 
     In other embodiments, a tobacco article may comprise a conduit body including a porous matrix and an outer shell surface. The outer shell surface may at least partially surround the porous matrix. The article may further include tobacco disposed in pores of the porous matrix so that, when at least a portion of the porous matrix is exposed to a liquid, at least one of tobacco or a tobacco constituent is introduced into the liquid. Wetting of said article may occur through complete submersion thereof, through capillary action, or through injection. 
     In certain embodiments, a tobacco article may comprise a conduit means for receiving a liquid. The conduit means may include a porous means for retaining tobacco in a network of pores and a shell means for guiding the liquid in the porous means. The shell means may at least partially surround the porous means. The tobacco article may also comprise tobacco disposed in the pores of the porous means so that, when at least a portion of the porous means is exposed to a liquid, at least one of tobacco or a tobacco constituent is introduced into the liquid. 
     Some embodiments may include a method of introducing tobacco or tobacco constituents into liquid. The method may comprise exposing to liquid in a reservoir a first end portion or second end portion of a tobacco article. The tobacco article may include a conduit body including a porous matrix and an outer shell surface. The outer shell surface may at least partially surround the porous matrix, and tobacco may be disposed in pores of the porous matrix. The method may further comprise introducing at least one of tobacco or a tobacco constituent into the liquid by drawing the liquid through the pores of the porous matrix and over the tobacco disposed in the pores. 
     In further embodiments, a tobacco article may comprise a body that is wholly receivable in a mouth of a consumer, and the body may include a porous polymer matrix. The article may also comprise tobacco disposed in pores of the porous polymer matrix so that, when the body is exposed to saliva, at least one of tobacco or a tobacco constituent is introduced into the saliva. In further aspect of this particular embodiment, another portion of the article may include a second porous matrix so that the consumer&#39;s saliva may be absorbed in a manner to alleviate the need for expectoration. 
     Some of these embodiments may provide one or more of the following advantages. First, the tobacco article may provide tobacco satisfaction in the form of the experience associated with tobacco organoleptic components and added flavor components that are released in the mouth. Such organoleptic components may relate or contribute to the integrated sensory perception by the adult consumer that includes, for example, any combination of aroma, fragrance, flavor, taste, odor, mouth feel, or the like. Second, the tobacco article may provide tobacco constituents (e.g., flavors, aromas, alkaloids, or the like) to the consumer without combusting any part of the tobacco article. Third, one or more flavor agents may be added to the tobacco article to further enhance the consumer&#39;s experience. Fourth, some embodiments of the tobacco article may be manufactured in a repeatable and efficient manner. For example, in some circumstances, the tobacco may be integrally molded with the plastic granules so as to form an impermeable outer shell of polymer material that at least partially surrounds a porous interior matrix that retains the tobacco. Fifth, the tobacco article may be formed of a shape and appearance that resembles traditionally recognized shapes, such as a cigarette, a cigar, or a pouch of chewing tobacco. 
     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. 
    
    
     
       DESCRIPTION OF DRAWINGS 
         FIG. 1  is a cross-sectional view of a tobacco article in accordance with some embodiments. 
         FIG. 2  is a cross-sectional view of the tobacco article of  FIG. 1 . 
         FIG. 3  is a cross-sectional view of a tobacco article in accordance with some embodiments. 
         FIGS. 4A-B  are cross-sectional views of a process for manufacturing a tobacco article in accordance with some embodiments. 
         FIGS. 5A-B  are side views of a process for preparing tobacco for use in a tobacco article. 
         FIG. 6  is a magnified view of polymer granules mixed with the tobacco of  FIG. 5B . 
         FIG. 7  is a cross-sectional view of a tobacco article in accordance with some embodiments. 
         FIG. 8  is a cross-sectional view of a tobacco article in accordance with some embodiments. 
         FIG. 9  is a cross-sectional view of a tobacco article in accordance with some embodiments. 
         FIG. 10  is a cross-sectional view of the tobacco article of  FIG. 9 . 
         FIG. 11  is a cross-sectional view of the tobacco article of  FIG. 10  in accordance with some embodiments. 
         FIG. 12  is a cross-sectional view of a tobacco article in accordance with some embodiments. 
         FIG. 13  is a perspective view of the tobacco article of  FIG. 12  received in a consumer&#39;s mouth. 
         FIG. 14  is a cross-sectional view of the tobacco article of  FIG. 13  in accordance with some embodiments. 
     
    
    
     Like reference symbols in the various drawings indicate like elements. 
     DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS 
     Referring to  FIG. 1 , a tobacco article  100  may include an outer shell surface  110  that at least partially surrounds a porous matrix  120 . Tobacco  130  may be disposed in pores  122  of the porous matrix  120  so that the tobacco article  100  may provide tobacco, tobacco constituents, or both tobacco and tobacco constituents to a consumer&#39;s mouth in the form of particles, liquid, or vapor. As described in more detail below, providing of tobacco or tobacco constituents may provide tobacco satisfaction to the consumer. 
     The tobacco article  100  may be a noncombustible product in so far as the article  100  preferably does not require ignition during usage. In these embodiments, the tobacco article  100  may provide tobacco, tobacco constituents (e.g., flavors, aromas, alkaloids, or the like), or both tobacco and tobacco constituents to the consumer without combusting any part of the tobacco article  100  (and without igniting the tobacco  130  inside the article  100 ). Instead, the noncombusted tobacco and/or noncombusted tobacco constituents may be provided to the consumer to provide tobacco satisfaction in the form of the experience associated with tobacco constituents, organoleptic components and added flavor components that are released upon usage. Such organoleptic components may relate or contribute to the integrated sensory perception by the consumer that includes, for example, any combination of aroma, fragrance, flavor, taste, odor, mouth feel, or the like. 
     The tobacco article  100  may have a substantially cylindrical outer shape and may be configured to rest between the fingers of a consumer. At least a portion of the tobacco article  100  may comprise a moldable polymer to permit that portion to be molded into the desired shape. In some embodiments, the outer shell surface  110  and the porous matrix  120  may be integrally formed. Also, in some embodiments, the tobacco  130  and the porous matrix  120  may be integrally molded so that the tobacco  130  is disposed in the pores  122  when the porous matrix is formed. In addition or in the alternative, the tobacco article  100  may have the tobacco  130  added through addition of a tobacco slurry containing constituents, organoleptic components and added flavor components added therein after forming by way of injection, absorption or any other like method. The outer shell surface  110  and the porous matrix  120  may include the same moldable plastic material or different moldable plastic materials provided that the outer shell surface  110  is impermeable to the tobacco  130 . 
     Still referring to  FIG. 1 , the outer shell surface  110  may fully or partially surround the porous matrix  120  and the tobacco  130  disposed therein. In this embodiment, the outer shell surface  110  is formed to fully surround the porous matrix  120  within a longitudinally extending surface  112  and first and second cap surfaces  114  and  116 . The outer shell surface  110  may comprise a generally continuous layer of material that is impermeable to the migration of tobacco constituents inside the article  100 . Alternatively, the article  100  may be constructed in such a way that the first and second cap surfaces  114  and  116  are not created during formation. Either configuration may inhibit the tobacco  130  or tobacco constituents (e.g., flavors, aromas, alkaloids, or the like) from migrating away from the porous matrix  120  before the ordinary use of the article  100  has commenced. In some embodiments, the outer shell surface  110  may comprise a polymer material that can be formed to provide the substantially continuous layer. Formation of the article  100  or any parts thereof excluding the tobacco particles  130 , may be made using any material suitable therefore or combination thereof. For example, the article  100  may comprise a copolymer of acrylonitrile and methyl acrylate (or an equivalent resin) known to provide barrier characteristics that inhibit the migration of the tobacco constituents, including volatile tobacco constituents. Such a copolymer of acrylonitrile and methyl acrylate is available under the trade name BAREX™ from Innovene LLC of Chicago, Ill. Some other polymer materials, such as polyethylene naphthalate (PEN), polytrimethylene naphthalate (PTN), or some polyester-based liquid crystal polymers (LCP), may alternatively be employed to provide barrier characteristics that inhibit the migration of the tobacco constituents. Furthermore, glass wool, cellulose fibers, a tobacco matrix such as reconstituted sheet or tobacco leaf, shreds and the like or any other type inert material may be used to form the porous matrix  120 . 
     The porous matrix  120  may comprise a plurality of pores  122  that are arranged to permit the passage of air from a first portion  124  to a second portion  126 . In some embodiments, the pores  122  may be randomly oriented to form a network of miniature passages through which air may pass over the tobacco  130  disposed in the porous matrix  120 . In other embodiments, the pores  122  may be manufactured to have a generally predetermined pore orientation, such as a plurality of pores that extend in a generally axial direction within the porous matrix  120 . The porous matrix  120  may be formed in a manner to control the average pore size, pore volume, or both. For example, as described in more detail below, the porous matrix  120  may be formed using a plastic sintering process in which granules of a polymer material are subjected to a controlled heating process for a regulated period of time. Furthermore, the article  100  may be colored or wrapped in paper or reconstituted tobacco sheet after formation thereof as desired. 
     It should be understood that, in some embodiments, the tobacco article  100  may comprise one or more polymer materials other than the previously described BAREX™ material. For example, the porous matrix  120  or other portions of the article  100  may include one or more of the following polymer materials: acetals, acrylics such as polymethylmethacrylate and polyacrylonitrile, alkyds, polymer alloys, allyls such as diallyl phthalate and diallyl isophthalate, amines such as urea, formaldehyde, and melamine formaldehyde, cellulosics such as cellulose acetate, cellulaose triacetate, cellulose nitrate, ethyl cellulose, cellulose acetate propionate, cellulose acetate butyrate, hydroxypropyl cellulose, cellophane and rayon, chlorinated polyether, coumarone-indene, epoxy, fluorocarbons such as PTFE, FEP, PFA, PCTFE, ECTFE, ETFE, PVDF, and PVF, furan, hydrocarbon resins, nitrile resins, polyaryl ether, polyaryl sulfone, phenol-aralkyl, phenolic, polyamide (nylon), poly (amide-imide), polyaryl ether, polycarbonate, polyesters such as aromatic polyesters, thermoplastic polyester, PBT, PTMT, PET and unsaturated polyesters such as SMC and BMC, polyimides such as thermoplastic polyimide and thermoset polyimide, polymethyl pentene, polyolefins such as LDPE, LLDPE, HDPE, and UHMWPE, polypropylene, inomers such as PD and poly allomers, polyphenylene oxide, polyphenylene sulfide, polyurethanes, poly p-xylylene, silicones such as silicone fluids and elastomers, rigid silicones, styrenes such as PS, ADS, SAN, styrene butadiene latricies, and styrene based polymers, suflones such as polysulfone, polyether sulfone and polyphenyl sulfones, thermoplastic elastomers, and vinyls such as PVC, polyvinyl acetate, polyvinylidene chloride, polyvinyl alcohol, polyvinyl butyrate, polyvinyl formal, propylene-vinyl chloride copolymer, ethylvinyl acetate, and polyvinyl carbazole. 
     Still referring to  FIG. 1 , the tobacco  130  may be whole, shredded, cut, cured, aged, fermented, granulated or powdered, encapsulated, or otherwise processed. For example, as shown in  FIG. 1 , the tobacco  130  may be in a granulated or powdered form so that the tobacco  130  is sized to fit within the pores  122  of the porous matrix  120 . Further, it should be understood that the tobacco  130  may include an extract of tobacco that provides tobacco constituents (e.g., flavors, aromas, alkaloids, or the like), as described in more detail below. In some circumstances, some or all of the tobacco  130  in the article  100  may be processed from reconstituted tobacco. 
     In some embodiments, the tobacco  130  may include portions of leaves, flowers, roots, stems, or extracts thereof of any member of the genus  Nicotiana . Exemplary species include  N. rustica  and  N. tabacum  (e.g., varieties and/or cultivars designated LA B21, LN KY171, TI 1406, Basma, Galpao, Perique, Beinhart 1000-1, and Petico). Other species include  N. acaulis, N. acuminata, N. acuminata  var.  multiflora, N. africana, N. alata, N. amplexicaulis, N. arentsii, N. attenuata, N. benavidesii, N. benthamiana, N. bigelovii, N. bonariensis, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. debneyi, N. excelsior, N. forgetiana, N. fragrans, N. glauca, N. glutinosa, N. goodspeedii, N. gossei, N. hybrid, N. ingulba, N. kawakamii, N. knightiana, N. langsdorffii, N. linearis, N. longiflora, N. maritima, N. megalosiphon, N. miersii, N. noctiflora, N. nudicaulis, N. obtusifolia, N. occidentalis, N. occidentalis  subsp.  hesperis, N. otophora, N. paniculata, N. pauciflora, N. petunioides, N. plumbaginifolia, N. quadrivalvis, N. raimondii, N. repanda, N. rosulata, N. rosulata  subsp.  ingulba, N. rotundifolia, N. setchellii, N. simulans, N. solanifolia, N. spegazzinii, N. stocktonii, N. suaveolens, N. sylvestris, N. thyrsiflora, N. tomentosa, N. tomentosiformis, N. trigonophylla, N. umbratica, N. undulata, N. velutina, N. wigandioides , and  N. x sanderae.    
     In some embodiments described herein, the tobacco  130  may include one or more components such as flavor extracts, flavor masking agents, bitterness receptor site blockers, receptor 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 application Ser. Nos. 10/982,248 and 10/979,266, both of which are incorporated herein by reference. Such components may be present in the tobacco  130  as a powder, an oil, a powder in fine particulate form, or in encapsulated form. 
     In some embodiments, the tobacco  130  may be processed to include these flavor components prior to construction of the article  100 . For example, some components can be added by spraying a flavor extract. In another example, flavor can be imparted to tobacco  130  by combining solid or liquid flavor agents with a tobacco material and incubating under suitable conditions, as described, for example, in previously incorporated application Ser. No. 10/982,248. In addition, the tobacco  130  may be processed to include these flavor components after construction of the article  100  via capillary action, injection, or other introduction means. 
     Suitable flavors and flavor extracts include menthol, cinnamon, wintergreen, cherry, berry, peach, apple, spearmint, peppermint, bergamot, vanilla, coffee, a mint oil from species of the genus  Mentha  or other desired flavors. Flavors may also be provided by plant matter, e.g., mint leaves, which are typically 10% flavor oils and 90% insoluble fiber. Suitable plant matter may be obtained from plants such as clove, cinnamon, herb, cherry, peach, apple, lavender, rose, vanilla, lemon, orange, coffee, or species of the genus  Mentha . Flavor may be provided by synthesized flavors, flavor extracts, plant matter, or a combination thereof. As further provided herein, flavor may also be provided by imitation, synthetic, or artificial flavor ingredients and blends containing such ingredients. Suitable sweeteners include sucralose, acesulfame potassium (Ace-K), aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, and mannitol. 
     Referring now to  FIG. 2 , some embodiments of the tobacco article  100  may be configured to expose the first and second portions  124  and  126  of the porous matrix  120 . For example, in the embodiments in which the outer shell surface  110  includes first and second cap surfaces  114  and  116 , at least a portion of each cap surface  114  or  116  may be cut, punctured, or otherwise removed to expose the first and second ends  124  and  126  of the porous matrix  120 . This removal process may be performed during the manufacturing or packaging of the tobacco article  100  (e.g., cutting the cap surfaces  114  and  116  to provide a uniform length of the article and then wrapping one or more articles  100  in an impermeable package) or may be performed by the consumer immediately before using the tobacco article  100 . In some embodiments, the tobacco article  100  may be supplied to the consumer in a package that includes a cutter mechanism or a puncture mechanism to facilitate the use of the tobacco article. When the cap surfaces  114  and  16  are removed, the longitudinally extending surface  112  of the outer shell surface  110  may remain intact so as to substantially surround the outer radial area of the porous matrix  120 . The first and second portions  124  and  126  of the porous matrix  120  may be exposed to the atmosphere so that air may be passed through the network of pores  122  and over the tobacco  130  disposed therein. As further provided herein, some embodiments of the tobacco article  100  may be configured to expose the first and second portions  124  and  126  of the porous matrix  120  during manufacturing thus eliminating the need to cut the cap surfaces  114  and  116 . 
     Referring to  FIG. 3 , some embodiments of the tobacco article  100  may be adapted to provide tobacco or tobacco constituents to a consumer in the form of a liquid, vapor or, in particular circumstances, a combination of vapor and fine particles or a combination of vapor and fine particles. In this embodiment, the first and second portions  124  and  126  of the porous matrix  120  may be exposed to the atmosphere, and a consumer may force air from the first portion  124 , through the network of pores  122  and over the tobacco  130  disposed therein, and out from the second portion  126 . For example, the consumer may create a negative pressure on the tobacco article  100  proximal to the second portion  126  so that the air is drawn through the porous matrix  120  and into the consumer. As the air passes through the porous matrix  120 , tobacco constituents  132  may be introduced into the air and are provided to the consumer. The tobacco constituents (e.g., flavors, aromas, alkaloids, or the like) may be in the form of vapor that transfers from the tobacco  130  to the air that is passed through the porous matrix  120 . As previously described, the tobacco  130  may be supplemented with extract of tobacco that provides additional tobacco constituents to the tobacco  130  in the porous matrix  120 , thereby further increasing the level of tobacco constituents  132  that may be experienced by the consumer. Accordingly, the tobacco article  100  may provide tobacco satisfaction in the form of the experience associated with tobacco organoleptic components and added flavor components that are released upon usage. Such organoleptic components may relate or contribute to the integrated sensory perception by the consumer that includes, for example, any combination of aroma, fragrance, flavor, taste, odor, mouth feel, or the like. Further, the tobacco article  100  may provide the tobacco constituents  132  to the consumer without combusting the tobacco article  100  or the tobacco  130  disposed therein. As previously described, tobacco  130  may include one or more flavor agents, or flavor agent particles may be disposed in the pores  122  of the porous matrix  120 . In these circumstances, the flavor agents may be introduced into the air so that a combination of flavor agents and tobacco constituents  132  are provided to the consumer. 
     In particular embodiments, the tobacco  130  may be arranged in a manner that permits the tobacco article  100  to provide tobacco and tobacco constituents to a consumer in the form of vapor and fine particles. For example, the tobacco  130  in the porous matrix  120  may be finely granulated so that fine tobacco particles are capable of passing through the network of pores  122  in the porous matrix  120 . In such circumstances, the consumer may suck on the tobacco article  100  proximal to the second portion  126  so that the air is drawn through the porous matrix  120  by the consumer. As the air passes through the porous matrix  120 , the fine tobacco particles and tobacco constituents  132  may be provided to the consumer as a combination of vapor and fine particles. Again, the tobacco article  100  may provide tobacco satisfaction to the consumer without combusting the tobacco article  100  or the tobacco  130  disposed therein. 
       FIGS. 4A-B  describe an example of a plastic sintering process to form the porous matrix  120  or the entire article  100 . Such a plastic sintering process may include controlled application of heat using one of a variety of heating techniques, some of which are described, for example, in U.S. Pat. No. 4,375,441 to Adams et al. (which is incorporated herein by reference). It should be understood that plastic sintering is only one process of several possible processes that may be used to form the porous matrix of the tobacco articles described herein. 
     Referring now to  FIGS. 4A-B , some embodiments of the tobacco article  100  may be integrally formed in a molding process. In this embodiment, the outer shell surface  110  and the porous matrix  120  may be integrally formed using a plastic sintering process. In some circumstances, the tobacco  130  may be mixed with the polymer granules  128  during the molding process so that the tobacco  130  is integrally molded with the porous matrix  120 . It should be understood that, in other embodiments, the tobacco  130  may be integrally molded with the porous matrix  120  without necessarily forming the outer shell surface  110 . Also, it should be understood that the tobacco  130  can be pressure injected into the porous matrix  120  after the formation of the porous matrix  120  (e.g., the tobacco  130  may not be integrally molded with the porous matrix  120 ). 
     As shown in  FIG. 4A , the formation process may include first and second mold pieces  170  and  180  that may fit together to define and internal cavity  175 . The internal cavity may include machined surfaces that at least partially define the desired outer shape of the tobacco article  100 . The tobacco  130  and the polymer resins that are combined to form the tobacco article  100  may be placed in the internal cavity  175 . As previously described, the outer shell surface  110  may be formed to have a generally continuous layer of material that is impermeable to the migration of tobacco constituents, such as BAREX material. Accordingly, granules  118  of this copolymer may be arranged along the outer portions of the internal cavity  175  so that these granules  118  can be merged to form at least a portion of the outer shell surface  110  during the plastic sintering process. The granules  128  of polymer material that form at least a portion of the porous matrix  120  may be arranged in a central portion of the internal cavity  175 . As described in more detail below, these granules  128  may comprise a different polymer material and may have a larger average size that the outer granules  118  so as to provide a network of pores  122  after the molding process. Further, the tobacco  130  may be mixed with the central granules  128  before or during insertion into the cavity  175 . Accordingly, the tobacco  130  may be intermixed with the granules  128  during the plastic sintering process so that at least a portion of the tobacco  130  is disposed in the pores  122  after the granules  128  have formed the porous matrix  120 . (It should be understood that the granules  118  and  128  and the tobacco  130  are not necessarily drawn to scale, and the sizes may be exaggerated for purposes of illustration.) 
     Referring to  FIG. 4B , when the granules  118  and  128  and the tobacco  130  are arranged in the mold cavity  175 , the mold pieces  170  and  180  may apply pressure while the granules  118  and  128  are heated in for a controlled period of time. Such pressure and heat causes the outer shell surface  110  to form into its desired shape while the central granules  128  are controllably melted for a limited period of time. While it is not intended that the present invention be limited by any theory by which it achieves its advantageous result, it is believed that, during this plastic sintering process, the outer granules  118  may melt at a faster rate to form a substantially continuous layer along the outer shells surface  110 , while the central granules  128  melt at a slower rate (e.g., the granule surfaces may partially heat to bond with adjacent granules even though some of the granules  128  may not completely melt). Such a process may form a porous matrix  120  that is at least partially surrounded by the outer shell surface  110 . It should be understood that some portion of the central granules  128  may melt and merge with outer granules along a transition zone near the outer shell surface  110 . In some circumstances, the central granules  128  may comprise a different polymer material, may have a larger average size, or both compared to the outer granules  118  so as facilitate the slower melting rate of the granules  128  along the interior of the tobacco article  100 . Because the tobacco  130  was mixed with the central granules  128 , at least a portion of the tobacco  130  may be disposed in the pores  122  after the granules  128  have formed the porous matrix  120 . It should be understood that some characteristics of the pores  122  (e.g., average pore size, average pore volume, or the like) may be selected by varying, for example, the size of granule materials used to form the porous matrix  120 , the temperature level at which the granules  128  are heated, the amount of time at which the granules  128  are heated, and the pressure used in a molding process. 
     In this embodiment, the central granules  128  comprise the same copolymer material (e.g., BAREX™) as the outer granules  118 , and the central granules may have a larger average size than the outer granules. It should be understood that, in some circumstances, the central granules  128  and the outer granules  118  may have similar average sizes. In some embodiments, the central granules  128  may comprise a material other than the outer granules  118  so that the porous matrix  120  generally comprises a different material that the outer shell surface  110 . For example, the central granules may comprise a plastic polymer material, such as polyethylene or polypropylene. Further, the porous matrix  120  may generally comprise a polymer material that is water soluble or water insoluble. It should be understood that a variety of material specifications (e.g., granule size and molecular weight, granule size distribution, material type, tobacco particle size, tobacco particle distribution, and the ratio of polymer granules to tobacco particle) and also a variety of process parameters (e.g., temperature, heat exposure time, and pressure) may be used in accordance with the invention to provide a porous matrix  120  having advantageous characteristics. 
     Referring now to  FIGS. 5A-B , the tobacco  130  that is disposed in the tobacco article  100  may include extracts of tobacco that provide additional tobacco constituents (e.g., flavors, aromas, alkaloids, or the like). As previously described, these additional tobacco constituents may increase the amount of tobacco constituents that are experienced by the consumer during ordinary use of the tobacco article  100 . As shown in  FIG. 5A , a plurality of tobacco leaves  190  (or flowers or roots or stems) may be subjected to an extraction process that provides a solid or liquid extract  192  having tobacco constituents therein. For example, an aqueous extraction process may be used. As shown in  FIG. 5B , the tobacco liquid extract  192  may be applied to tobacco  194  that is whole, shredded, cut, cured, aged, granulated or powdered, or otherwise processed. In some embodiments, a portion of the extracted tobacco  190  ( FIG. 5A ) may be discarded and the tobacco liquid extract  192  may be applied a lesser amount of the tobacco  194  ( FIG. 5B ). As such, the tobacco  194  ( FIG. 5B ) may include tobacco constituents in an amount equal to or greater than that which was originally extracted. These additional tobacco constituents may increase the amount of constituents that are experienced by the consumer during ordinary use of the tobacco article  100 . While it is not intended that the present invention be limited by any theory by which it achieves its result, it is believed that, a substantial portion of the tobacco extract  192  may remain on the outer surface of the tobacco  194 , thereby facilitating the transfer of the tobacco constituents from the tobacco in the article  100  to the air or liquid that is passed through the porous matrix  120 . Tobacco constituents can include carotenoids such as beta-damascenone and megastigmatrienones, alkaloids such as nicotine, and terpenoids such as limonene. The tobacco that includes the tobacco extract  192  may be granulated or powdered to facilitate the placement of the tobacco within the porous matrix  120 . As shown in  FIG. 6 , the granulated or powdered tobacco  130  may be mixed with granules  128  of polymer material at a selected ratio, and the mixture may then be used in an integral molding process (as described, for example, in connection with  FIGS. 4A-B ). 
     Referring now to  FIG. 7 , some embodiments of a tobacco article  200  may include porous matrix  220  that is formed separately from an outer shell  210 . The porous matrix  220  may be formed using a plastic sintering process (as described in connection with  FIGS. 4A-B ). Alternatively, the porous matrix  220  may be formed using a different process in which the porous matrix  220  comprises a porous glass or ceramic material having tobacco disposed in the pores  222  or in which the porous matrix  220  comprises a fibrous material having a network of pores to receive the tobacco  130  therein. Depending on the formation process of the porous matrix  220 , the tobacco  130  may be integrally molded with the porous matrix  220  or may be pressure injected into the porous matrix  220  so that the tobacco  130  is disposed in the pores  222 . The porous matrix  220  may be formed or otherwise configured to mate with a separate shell  210 . In this embodiment, the separate shell  210  comprises a tubular configuration having an open end  216  to receive the porous matrix  220 . As such, the porous matrix  220  may be slid into and engage the separate shell  210 . 
     As previously described, the outer shell  210  may comprise a continuous layer of material that is impermeable to migration of the tobacco and tobacco constituents, such as BAREX™ material. In those embodiments in which the porous matrix  220  should be sealed until being used by a consumer, the separate shell  210  may comprise a tube of BAREX™ that is sealed at the open ends thereof after the porous matrix  220  is inserted into the shell  210 . For example, the open ends of the tubular shell  210  may be heat sealed using BAREX™ cap walls. In another example, the open ends of the tubular shell  210  may be heat sealed using a heat pinching process. 
     Referring to  FIG. 8 , some embodiments of a tobacco article  300  may include a porous matrix  320  that is formed separately from an outer shell  310  and from the tobacco  130 . For example, a first porous matrix  320  and a second porous matrix  325  may be form using a plastic sintering process (as described in connection with  FIGS. 4A-B ) or using an alternative forming process. The tobacco  130  may be whole, shredded, cut, cured, aged, granulated or powdered, or otherwise processed, and may be disposed in the outer shell  310  between the first porous matrix  320  and the second porous matrix  325 . The first porous matrix  320  and the second porous matrix  325  may comprise networks of pores  322  through which air and tobacco constituents may pass, yet the pores may be sized to permit the passage of only fine tobacco particles. The first porous matrix  320  and the second porous matrix  325  may be formed or otherwise configured to mate with the separate shell  310 . In this embodiment, the separate shell  310  comprises a tubular configuration having an open end  316  to receive the first porous matrix  320 , the tobacco  130 , and the second porous matrix  325 . As previously described, the separate shell  310  may comprise a tube of BAREX™ that is sealed at the open ends thereof after the first porous matrix  320 , the tobacco  130 , and the second porous matrix  330  are inserted into the shell  310 . For example, the open ends of the tubular shell  310  may be heat sealed using BAREX™ cap walls. In another example, the open ends of the tubular shell  310  may be heat sealed using a heat pinching process. 
     Optionally, at least one of the first porous matrix  320  and the second porous matrix  330  may include a frusto-conical channel formed therein to provide a jet stream of air toward the tobacco  130  disposed in the tobacco article  300 . In such embodiments, air may be forced into the opening of the frusto-conical channel by the consumer drawing air from the opposite end of the tobacco article  300 . The flow of air through the channel  329  may increase the air velocity that passes over the tobacco  130 , thereby facilitating the transfer of tobacco particles, tobacco constituents, or both tobacco particles and tobacco constituents from the tobacco  130  to the air. It should be understood that such a frusto-conical channel may be formed in the porous matrix of other tobacco articles, such as those described in connection with  FIGS. 1-3  and  7 . 
     Referring now to  FIGS. 9-11 , some embodiments of a tobacco article  400  may be adapted to provide tobacco and/or tobacco constituents to a consumer in the form of a liquid. Such embodiments of the tobacco article  400  may include tobacco  130  disposed in a porous matrix  420 , as described, for example, in connection with  FIGS. 1-7 . The porous matrix  420  may be form using a plastic sintering process (as described in connection with  FIGS. 4A-B ). Alternatively, the porous matrix  420  may be formed using a different process in which the porous matrix  420  comprises a porous glass or ceramic material having tobacco disposed in the pores  422  or in which the porous matrix  420  comprises a fibrous material having a network of pores to receive the tobacco  130  therein. Depending on the formation process of the porous matrix  420 , the tobacco  130  may be integrally molded with the porous matrix  420  or may be pressure injected into the porous matrix  420  so that the tobacco  130  is disposed in the pores  422 . Also, the tobacco article  400  may include a conduit  410  that surrounds at least a portion of the porous matrix  420 . The conduit  410  may be integrally formed with the porous matrix  420  (as described, for example, in connection with  FIGS. 4A-B ), or the conduit  410  may be formed separately from the porous matrix  420  (as described, for example, in connection with  FIGS. 7 and 8 ). In this embodiment, the conduit  410  is illustrated having a cylindrical shape, but the conduit  410  may have a different shape. The conduit  410  may comprise a material that prevents the migration of liquid from the outer radial area of the porous matrix  420 . As such, any liquid disposed in the porous matrix  420  is forced to pass through an exposed portion  424  or  426  of the porous matrix  420 . 
     As shown in  FIG. 10 , at least a portion of the porous matrix  420  may be temporarily exposed to a liquid  440  so that the liquid  440  is introduced into the pores  422 . For example, the liquid  440  may progress into the pores  422  of the porous matrix  420  through capillary action  445  so that some portion of the liquid remains in the porous matrix  420  even after the tobacco article  400  is removed from the liquid container  442 . In some embodiments, the liquid  440  can include water. 
     As shown in  FIG. 11 , the first and second portions  424  and  426  of the porous matrix  420  may be exposed to the atmosphere, and a consumer may force air from the first portion  424  and into the network of pores  422 . The consumer&#39;s vacuum action may cause the liquid  440  that was previously introduced into the first portion  424  of the porous matrix  420  to pass over the tobacco  130  disposed in the pores. As such, the liquid  440  is drawn through the porous matrix  420  and to the consumer. As the liquid  440  passes through the porous matrix  420 , tobacco and/or tobacco constituents  132  may be introduced into the liquid  440  so that the tobacco and/or tobacco constituents are experienced by the consumer. The tobacco and/or tobacco constituents  132  may be mixed with the liquid  440 . 
     As previously described, the tobacco  130  may include extract of tobacco that provides additional tobacco constituents to the tobacco  130  in the porous matrix  420 , thereby further increasing the level of tobacco constituents  132  that may be introduced in the liquid  440  for providing to the consumer. Accordingly, the tobacco article  400  may provide tobacco satisfaction to the consumer without combusting the tobacco article  400  or the tobacco  130  disposed therein. Optionally, the tobacco  130  may include one or more flavor agents or other components (as previously described), or flavor agent particles may be disposed in the pores  422  of the porous matrix  420 . In such circumstances, the flavor agents may be introduced into the liquid  440  so that a combination of flavor agents, tobacco and tobacco constituents  132  are experienced by the consumer. 
     Referring now to  FIGS. 12-14 , some embodiments of a tobacco article  500  may be adapted to be wholly received by the consumer and to introduce tobacco and/or tobacco constituents into the consumer&#39;s saliva. The tobacco article  500  may be configured to resemble a tobacco pouch. In this embodiments, the tobacco article has generally elliptical shape, but other embodiments may have a pillow shape, a circular shape, a flat rectangular shape, or the like. Such embodiments of the tobacco article  500  may include tobacco  130  disposed in a first porous matrix  520 , as described, for example, in connection with  FIGS. 1-7 . The porous matrix  520  may be formed using a plastic sintering process (as described in connection with  FIGS. 4A-B ) or using an alternate process. Depending on the formation process of the porous matrix  520 , the tobacco  130  may be integrally molded with the porous matrix  520  or may be pressure injected into the porous matrix  520  so that the tobacco  130  is disposed in the pores  522 . 
     Optionally, the tobacco article  500  may include a second porous matrix  550  that, in some circumstances, can serve as a saliva reservoir. The saliva reservoir  550  may be a porous matrix that is integrally formed with the first porous matrix  520  that contains the tobacco  130 . The saliva reservoir  550  may include pores  552  having a substantially greater pore size and pore volume than the first porous matrix  520 . For example, the saliva reservoir may be formed from polymer granules having a much larger size than the granules used to form the first porous matrix  520 . Thus, during a plastic sintering process, the saliva reservoir  550  may become a porous matrix having pores  552  that are greater in size than the pores  522  of the first porous matrix  520 . 
     As shown in  FIG. 13 , the tobacco article  500  may be wholly received by the consumer. For example, the tobacco article  500  may be placed between the gums and the lip of the consumer. In such circumstances, the tobacco article  500  may be exposed to the consumer&#39;s saliva. 
     Referring to  FIG. 14 , when the first porous matrix  520  is be exposed to the consumer&#39;s saliva  540 , a portion of the consumer&#39;s saliva  540  will be forced into the pores  522 . The saliva  540  may pass through the network of pores  522  so that tobacco constituents  132  (and, in some cases, fine tobacco particles) are introduced into the consumer&#39;s saliva. Accordingly, the tobacco constituents  132  may mix with the saliva  540  and subsequently be ingested by the consumer. While the tobacco, tobacco constituents, or both tobacco and tobacco constituents are provided to the consumer, the saliva reservoir  550  may absorb some portion of the saliva of the consumer, which may reduce the amount of spitting normally associated with chewing tobacco or snuff. As previously described, the tobacco  130  may be supplemented with extract of tobacco that provides additional tobacco constituents to the tobacco  130  in the first porous matrix  520 , thereby increasing the level of tobacco constituents  132  that may be introduced in the saliva  540  for providing to the consumer. Accordingly, the tobacco article  500  may provide tobacco satisfaction to the consumer without combusting the tobacco article  500  or the tobacco  130  disposed therein. Optionally, the tobacco  130  may include one or more flavor agents or other components (as previously described), or flavor agent particles may be disposed in the pores  522  of the porous matrix  520 . In such circumstances, the flavor agents may be introduced into the liquid saliva so that a combination of flavor agents and tobacco constituents  132  are provided to the consumer. 
     When the tobacco  130  in the porous reservoir  550  is exhausted or the consumer decides to remove the tobacco article  500 , the tobacco article may be discarded. Thus, the tobacco article  500  may be discretely discarded with some portion of the consumer&#39;s saliva retained in the saliva reservoir  550 . 
     A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.