Patent Description:
This disclosure generally relates to a pouch material for smokeless tobacco or tobacco substitute products, methods of making pouch material, methods of pouching smokeless tobacco products, and smokeless tobacco products including the pouch material provided herein.

Smokeless tobacco is tobacco that is placed in the mouth and not combusted. There are various types of smokeless tobacco including: chewing tobacco, moist smokeless tobacco, snus, and dry snuff. Chewing tobacco is coarsely divided tobacco leaf that is typically packaged in a large pouch-like package and used in a plug or twist. Moist smokeless tobacco is a moist, more finely divided tobacco that is provided in loose form or in pouch form and is typically packaged in round cans and used as a pinch or in a pouch placed between a cheek and gum of an adult tobacco consumer. Snus is a heat treated smokeless tobacco. Dry snuff is finely ground tobacco that is placed in the mouth or used nasally.

Smokeless Tobacco can be pouched in a fabric using a pouching machine. In some cases, a method for pouching smokeless tobacco includes flavoring the smokeless tobacco, pouching the flavored smokeless tobacco into a paper or fabric, and then packaging the pouches for delivery to consumers. A conventional pouching machine may form a supply of pouching material around tube, seal the edges of the pouching material to form a tube of pouching material, form a cross-seal to form a bottom of the pouch, deliver an amount of smokeless tobacco through the tube and into the bottom-sealed pouch, move the bottom-sealed pouch off the tube, and form a second cross-seal above the smokeless tobacco to close the pouch. The second-cross-seal can also be used as the bottom seal for a subsequent pouch as the process continues. Individual pouches can be cut at the cross-seals.

<CIT> refers to a smokeless tobacco product including smokeless tobacco and a polymeric material in intimate contact with the smokeless tobacco and stabilized in conformance to a surface topography of the tobacco's fibrous structures such that the stabilized polymeric material secures the smokeless tobacco together. The smokeless tobacco product has a moisture-permeable porous surface and an overall oven volatiles content of at least <NUM> weight percent. <CIT> refers to a smokeless tobacco product configured for insertion into the mouth of a user comprising a water-permeable pouch containing a tobacco formulation that includes a granular tobacco composition, wherein the pouch comprises a fleece material configured to provide enhanced flavor. <CIT> (D7) generally describes a fiber-wrapped smokeless tobacco product and a method of making the fiber-wrapped smokeless tobacco product by directing polymeric fibers toward smokeless tobacco such that the fibers enrobe and conform to the surface topography of the tobacco fibrous structures. <CIT> (D4) refers to a high speed pouch device for making paper pouches filled with tobacco. None of these references discloses a smokeless tobacco product comprising smokeless tobacco disposed within a pouch of a fabric in the form of a side-sealed tube with first and second cross-seals formed across the side-sealed tube.

Patent documents <CIT>, <CIT>, <CIT>, and <CIT> describe fabrics and fibers made from polymers, however, they are silent as to whether fibers and/or fabrics disclosed therein are suitable for internal use. <NPL>, describes the addition of metal-oxide particles to plastics for increasing their electrical and thermal properties, and in particular the addition of magnetite (Fe2O3).

A smokeless tobacco product and a packaged smokeless tobacco product are provided herein. The smokeless tobacco product can be pouched and/or retain the smokeless tobacco material contained within the pouch, but provide an adult tobacco consumer with desirable flavor and tactile experience. In some cases, a pouched smokeless tobacco product provided herein includes a pouch material having a basis weight of between <NUM> grams per square meter (gsm) and <NUM> gsm. In some cases, a pouched smokeless tobacco product provided herein includes a pouch material having a basis weight of less than <NUM> gsm.

The smokeless tobacco can be a dry or moist smokeless tobacco. In some cases, the smokeless tobacco is moist smokeless tobacco having has an oven volatile content of about <NUM>% by weight to about <NUM> % by weight. In other embodiments, the smokeless tobacco is a dry snuff having an oven volatile content of between <NUM>% and <NUM>%. In some cases, the pouched tobacco product has an overall oven volatile content of about <NUM>% by weight to about <NUM><NUM> % by weight. In some cases, the smokeless tobacco can include an orally-disintegrable smokeless tobacco composition, such as those described in <CIT> or <CIT>. In some cases, the smokeless tobacco includes flavorants and/or other additives. Further, some systems include a container that retains a plurality of pouched smokeless tobacco products.

Example methods of preparing a pouch fabric and for preparing the pouched smokeless tobacco product are also provided. Polymeric material (e.g., polypropylene) can be melt-blown or centrifugally force spun against a support surface and a resulting fabric collected. In some cases, the polymeric fibers in the fabric are oriented in a predetermined direction to provide a predetermined tensile strength in at least one direction. In some cases, the polymeric fibers are bonded at intersection points to provide a predetermined tensile strength in at least one direction. In some cases, the surfactant is sprayed onto the polymeric material as the polymer strands exit the melt-blowing device, centrifugal force spinning device, or downstream of the fabric forming process. The surfactant can provide a hydrophilic surface. The surfactant can also quench the polymeric fibers. A fabrics provided herein can then be used in a pouching machine, where an elongated supply of the fabric is formed into a fabric tube, overlapping sides of the fabric tube are sealed to form a side-sealed tube; a first cross-seal is formed across the side-sealed tube to form a bottom seal of a pouch, a predetermined amount of smokeless tobacco (or a tobacco substitute) is delivered into the bottom-sealed pouch, and a second cross-seal is formed above the delivered smokeless tobacco (or the delivered tobacco substitute). The second-cross-seal can also be used as the bottom seal for a subsequent pouch as the process continues. Individual pouches can be cut at the cross-seals. The fabrics provided herein can also be used in an alternative pouching process where tobacco is disposed on a fabric, a layer of a second fabric is disposed over the deposits of tobacco, and the composite structure sealed and cut around each deposit of tobacco to form a pouched product.

In some cases, a system includes a container including a lid and a base that defines an interior space. A plurality of pouched smokeless tobacco products can be disposed in the interior space of the container. The plurality of pouched smokeless tobacco products can each have a substantially similar shape and/or volume.

The polymeric fibers can be polymers safe for oral use. Suitable polymers can include but are not limited to polypropylene, low density polyethylene, polyethylene terephthalate, polyurethane, polyvinyl acetate, polyvinyl alcohol, styrene, ethyl vinyl acetate, rayon, silk, cotton, polyester, cellulosic materials such as hydroxypropyl cellulose and combinations thereof. In some cases, the polymeric fibers can include pigmented or dyed polymers. In some cases, reconstituted cellulosic fibers (e.g., derived from tobacco plant tissue) can be used.

A method of using the smokeless tobacco product is also described. The method includes opening a container containing at least one pouched smokeless tobacco product, removing a pouched smokeless tobacco product, and placing the removed pouched smokeless tobacco product in a mouth of an adult tobacco consumer.

The products and methods described herein can also be applied to other orally consumable plant materials in addition to smokeless tobacco. For example, some non-tobacco or "herbal" compositions have also been developed as an alternative to smokeless tobacco compositions. Non-tobacco products may include a number of different primary ingredients, including but not limited to, tea leaves, red clover, coconut flakes, mint leaves, citrus fiber, bamboo fiber, ginseng, apple, corn silk, grape leaf, basil leaf, and other cellulosic materials. In some cases, such a non-tobacco smokeless product can further include tobacco extracts, which can result in a non-tobacco smokeless product providing a desirable mouth feel and flavor profile. In some cases, the tobacco extracts can be extracted from a cured and/or fermented tobacco by mixing the cured and/or fermented tobacco with water (or other solvents) and removing the non-soluble tobacco material. In some cases, the tobacco extracts can include nicotine. In some cases, a pouched non-tobacco product has an overall oven volatiles content of at least <NUM> weight percent. In some cases, a pouched non-tobacco product has an overall oven volatiles content of at least <NUM> weight percent.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the methods and compositions of matter belong. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the methods and compositions of matter, suitable methods and materials are described below. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

This disclosure provides a fabric for pouching smokeless tobacco and/or tobacco substitutes, a method for forming a pouching fabric provided herein, smokeless tobacco products including a pouching fabric provided herein, and non-tobacco pouched products including a pouching fabric provided herein. In some cases, the fabrics provided herein can be used in a conventional pouching machine, yet provide a smooth texture, immediate flavor/juice release, and a malleable smokeless tobacco product, such as that discussed below in reference to <FIG>. In some cases, the fabrics provided herein can be used in an alternative pouching operation, as discussed below in regards to <FIG>. In some cases, the fabric has a basis weight of less than <NUM> grams per square meter (gsm). In some cases, the fabric has a tensile integrity of at least <NUM> mJ in at least one predetermined orientation. In some cases, the fabric has oriented polymeric fibers in at least one predetermined orientation. In some cases, the polymeric fibers are bonded together at intersection points. In some cases, the polymeric fibers are contacted with a surfactant and/or water to provide a hydrophilic surface and/or to quench the polymeric fibers. In some cases, the polymeric fibers have a diameter of less than <NUM> microns, less than <NUM> microns, less than <NUM> microns, less than <NUM> microns, less than <NUM> micron, less than <NUM> microns, less than <NUM> microns, or less than <NUM> microns. In some cases, the polymeric fibers can be melt-blown polymeric fibers having a diameter of between <NUM> microns and <NUM> microns. In some case, the polymeric fibers can be centrifugal force spun fibers having a diameter of between <NUM> microns and <NUM> micron. The disclosure is based, in part, on the surprising discovery that the pouched smokeless tobacco products using the fabrics provided herein provide a unique tactile and flavor experience to an adult tobacco consumer. In particular, the polymeric strands can provide a smoother mouth texture and improved access to the smokeless tobacco as compared to a traditional pouching material, but still retain the smokeless tobacco. Furthermore, the pouching fabric provided herein can be more elastic and can permit an adult tobacco consumer to chew the pouched smokeless tobacco product and mold the pouched product into a desired shape (e.g., to comfortably conform the pouched smokeless tobacco product between the cheek and gum). For example, the melt-blown material can be an elastomer (e.g., a polymeric polyurethane such as DESMOPAN DP 9370A available from Bayer) thus forming a pouched smokeless tobacco product that can better tolerate being "worked" (e.g., chewed or squeezed) in the mouth. As compared to a typical pouch paper, the fabrics provided herein can be softer, have a lower basis weight, and act as less of a selective membrane. The methods of forming pouched smokeless tobacco products including the fabrics provided herein are also described. In some cases, combinations of mouth-stable and mouth-dissolvable polymeric materials are combined to form the fabric to produce a pouched smokeless tobacco product that becomes looser when placed in a mouth of an adult tobacco consumer, yet remains generally cohesive. Polymeric fibers in the fabric can also be a composite of multiple materials, which may include both mouth-stable and mouth-dissolvable materials.

The fabric can be made by melt-blowing polymeric fibers, centrifugal force spinning polymeric fibers, or a combination thereof. The fibers can form a non-woven fabric. Melt-blowing and centrifugal force spinning methods are discussed below.

Referring to <FIG> and <FIG>, a melt-blown fabric can be formed by depositing a plurality of melt-blow polymeric fibers <NUM> onto a support surface (e.g., rotating vacuum drum <NUM>) and collecting the melt-blown fabric <NUM>' (e.g., on a pickup roll <NUM>).

In some cases, the melt-blown polymeric fibers <NUM> have diameters of less than <NUM> microns (or less than <NUM> microns, or less than <NUM> microns, or less than <NUM> microns, or less than <NUM> microns, or less than <NUM> micron, or less than <NUM> microns. In some cases, the melt-blown polymeric fibers <NUM> have a diameter of between <NUM> and <NUM> microns.

Melt-blown polymeric fibers <NUM> can be produced using a melt-blowing device <NUM>. Melt-blowing is an extrusion process where molten polymeric resins are extruded through an extrusion die and gas is introduced to draw the filaments to produce polymeric fibers. The gas can be heated air blown at high velocity through orifices that surround each spinnerets. In some cases, layers of hot air are blown through slots between rows of spinnerets - the strands of polymeric material are attenuated by being trapped between two layers of air. Other methods of delivering the attenuating gas (e.g., heated air) are possible. The polymeric fibers can be deposited onto a support surface (e.g., moving conveyor or carrier). For example, the melt-blown polymeric fibers <NUM> are deposited onto a rotating vacuum drum <NUM> in <FIG>.

<FIG> depicts an exemplary melt-blowing device <NUM>. Other melt-blowing devices are described in <CIT>; <CIT>; <CIT>; and <CIT> and in U. Patent Applications <CIT>; <CIT>; <CIT>; <CIT>; and <CIT>.

The melt-blowing device <NUM> can include a polymer extruder that pushes molten polymer at low melt viscosities through a plurality of polymer orifices <NUM>. The melt-blowing device <NUM> includes one or more heating devices that heat the polymer as it travels through the melt-blowing device <NUM> to ensure that the polymer remains above its melting point and at a desired melt-blowing temperature. As the molten polymer material exits the polymer orifice <NUM>, the polymer material is accelerated to near sonic velocity by gas being blown in parallel flow through one or more air orifices <NUM>. The air orifices <NUM> can be adjacent to the polymer orifices <NUM>. The air orifices <NUM> may surround each polymer orifice <NUM>. Each combination of a polymer orifice <NUM> with surrounding air orifices <NUM> is called a spinneret <NUM>. For example, the melt-blowing device <NUM> can have between <NUM> and <NUM> spinnerets <NUM> per square inch. The polymer orifices <NUM> and the gas velocity through gas orifices <NUM> can be combined to form fibers of <NUM> microns or less. In some cases, the spinnerets each have a polymer orifice diameter of <NUM> microns or less. In some cases, the melt-blown polymeric fibers <NUM> have diameters of between <NUM> microns and <NUM> microns. The factors that affect fiber diameter include throughput, melt temperature, air temperature, air pressure, and distance from the drum. In some cases, the spinnerets <NUM> each have a polymer orifice diameter of less than <NUM> microns. In some cases, the spinnerets <NUM> each have a polymer orifice diameter of at least <NUM> microns. The average polymer orifice diameter can range from <NUM> microns to <NUM> microns. In particular embodiments, the average polymer orifice diameter can be between <NUM> microns and <NUM> microns. In certain cases, polymer orifice diameters of about <NUM> microns, about <NUM> microns, about <NUM> microns, or about <NUM> microns are used.

Referring back to <FIG>, rotating vacuum drum <NUM> is adapted to produce a vacuum in the area behind the spinnerets. The vacuum can pull the melt-blown polymeric fibers towards the rotating vacuum drum <NUM> and may assist in fiber bonding. In some cases, a moving conveyor (optionally passing over a vacuum chamber) can be used instead of the rotating vacuum drum <NUM>. In some cases, no vacuum is used during the melt-blowing process, which may result in a more random distribution of fibers and less fiber-to-fiber bonding during an initial melt-blowing process. The melt-blown fabric system can also include one or more spray nozzles <NUM> for directing a quenching fluid, surfactant, or other treatment solution <NUM> towards the stream of fibers as they exit the melt-blowing device <NUM>. The possible treatment fluids are discussed below in greater detail.

Centrifugal force spinning is a process where centrifugal force is used to create and orient polymeric fibers. <FIG> depict an exemplary centrifugal force spinning apparatus. As shown, a spinneret <NUM> holds polymeric material <NUM> and is rotated at high speeds with a motor <NUM> to produce polymeric fibers <NUM> that are deposited onto a fiber collector <NUM> to create a centrifugal force spun fabric <NUM>". <FIG> depicts a close-up of the spinneret <NUM> showing two orifices <NUM>. Any number of orifices <NUM> can be used. The centrifugal force spinning apparatus can also include one or more spray nozzles <NUM> for directing a quenching fluid, surfactant, or other treatment solution <NUM> towards the stream of fibers as they exit the spinneret orifices <NUM>. <FIG> depicts how the spinneret <NUM> can be equipped to also provide a treatment fluid <NUM> and a spray nozzle <NUM>. The possible treatment fluids are discussed below in greater detail.

The fiber collector <NUM> can be a continuous drum or a series of spaced collection fingers. As the spinneret <NUM> rotates, the polymeric material (in a liquid state) is pushed to the orifices <NUM> lining the outer wall of the spinneret <NUM>. As the polymeric material enters the orifice chamber, molecules disentangle and then align directionally. Centrifugal and hydrostatic forces combine to initiate a liquid material jet. The external aerodynamic environment combined with the inertial force of continued rotation further applies shear forces and promote cooling and/or solvent evaporation to further stretch the fiber. The inertia force can stretch molecular chains into the nanoscale and the air turbulence can apply a shear force.

<FIG> depicts an alternative arrangement for creating a centrifugal force spun fabric <NUM>". As shown, a spinneret <NUM> is positioned above a conveyor <NUM>. A carrier <NUM> can be used to collect a centrifugal force spun fabric <NUM>". As shown, centrifugal force spun fibers exit spinneret orifices <NUM> approximately perpendicular to the carrier <NUM>. The fibers <NUM> encounter a stream of air <NUM> (and optionally treatment fluids as discussed below) which direct the centrifugal force spun fibers towards the carrier <NUM>. A conveyor <NUM> supporting the carrier <NUM> can draw a vacuum <NUM> to facilitate the laying of a centrifugally force spun fabric <NUM>". In some cases, the carrier <NUM> is a porous carrier that facilitates the drawing of a vacuum through the carrier <NUM>. Collection fingers <NUM> can be positioned around the spinneret <NUM> to collect any stray fibers. The centrifugal force spun fabric can be collected on a pickup roll <NUM>.

The fibers of the fabric provided herein can include the full array of extrudable polymers, such as polypropylene, polyethylene, PVC, viscose, rayon, polyester, and PLA. In some cases, the fibers are mouth-stable fibers. The mouth-stable fibers can have low extractables, have FDA food contact approval, and/or be manufactured by suppliers who are GMP approved. Highly desirable are materials that are easy to process and relatively easy to approve for oral use (e.g. quality, low extractables, has FDA food contact approval, suppliers are GMP approved). In some cases, the mouth-stable structural fibers are elastomers. Elastomers can provide webs with improved elongation and toughness. Suitable elastomers include VISTAMAX (ExxonMobil) and MD-<NUM> (Kraton). In some cases, elastomers can be combined with polyolefins at ratios ranging from <NUM>:<NUM> to <NUM>:<NUM>. For example, elastomers (such as VISTAMAX or MD-<NUM>) can be combined with polypropylene.

Mouth-dissolvable fibers could be made from hydroxypropyl cellulose (HPC), methyl hydroxypropyl cellulose (HPMC), polyvinyl alcohol (PVOH), PVP, polyethylene oxide (PEO), starch and others. These fibers could contain flavors, sweeteners, milled tobacco and other functional ingredients. The fibers could be formed by extrusion or by solvent processes. In some cases, mouth dissolvable fibers can be combined with mouth-stable fibers to produce a pouching fabric <NUM>' or <NUM>" provided herein.

As discussed above, both melt-blown fibers and centrifugally force spun fibers can be treated with a treatment fluid <NUM> or <NUM> with a spray nozzle <NUM> or <NUM> as the fibers exit the melt-blowing device <NUM> or the centrifugally force spinning spinneret <NUM>. In some cases, the fibers can be treated downstream as part of a fabric <NUM>' or <NUM>".

Water vapor can be used to cool the polymeric material. For example, water vapor can be directed into the stream of molten strands of polymeric material to "quench" the polymeric strands and form the fibers. For example, as depicted in <FIG>, a mist <NUM> can be aimed towards the spinnerets <NUM> of the melt-blowing device <NUM>. As depicted in <FIG>, a centrifugally force spinning spinneret can also provide a mist <NUM> which can contact force-spun fibers as they exit orifices <NUM>. In some cases, a mist can be provide with air stream <NUM> to quench the fibers <NUM> formed in the apparatus depicted in <FIG>. A fine mist of water vapor can quickly cool the strands below the polymer glass transition temperature. In some cases, quenched fibers can have improved softness and fiber/web tensile strength.

A surfactant treatment can also be applied to the fibers of the fabric <NUM>' or <NUM>". In some cases, a surfactant is applied to the polymer fibers as they exit the spinnerets <NUM> of the melt-blowing device <NUM> or the orifices <NUM> of a centrifugally force spinning spinneret <NUM>. In some cases, surfactant can be applied as a mist <NUM> or <NUM> (either with or without water) as shown in <FIG> or <FIG>. In some cases, surfactant can be applied as a stream or a bath. In some cases, the surfactant applied as a mist <NUM> or <NUM> can quench the polymer fibers. In some cases, a mixture of water and surfactant can be atomized an applied as mist <NUM> or <NUM>. Sweeteners and/or flavorants can also be atomized and applied to the polymer fibers in mist <NUM> or <NUM>.

Quenching the polymer can modify the crystallinity of the polymer material to improve tensile strength. The surfactant can improve the hydraulic permittivity of the fabric <NUM>' or <NUM>" to improve moisture and flavor release. The hydraulic permittivity is the rate of fluid transfer through a substrate. Table <NUM> compares fabrics produced with and without surfactant treatment and water quenching. As shown in Table <NUM>, melt-blown Sample <NUM> (produced without water quenching or a surfactant treatment) had a tensile integrity of <NUM> mJ and a permittivity of <NUM> seconds. Quenching with water (Sample <NUM>) improved the tensile integrity to <NUM> mJ. Applying surfactant mixtures at different percentages also resulted in improved tensile integrity values (Samples <NUM>-<NUM>). Added surfactant in amounts of <NUM>% or greater (Samples <NUM>, <NUM>, and <NUM>) reduced the permittivity to <NUM> seconds.

The tensile integrity of the fabric <NUM>' or <NUM>" can also be improved in a machine direction by provided fiber alignment along that machine direction. For example, the fibers produced by centrifugal force spinning that are substantially aligned. As will be discussed below, improved tensile integrity in a machine direction can allow the fabric <NUM>' or <NUM>" to be pulled through a pouching machine to slit, form, and cut pouched products while still having a basis weight of less than <NUM> gsm, less than <NUM> gsm, less than <NUM> gsm, less than <NUM> gsm, or less than <NUM> gsm. In some cases, a fabric <NUM>' or <NUM>" having a basis weight of about <NUM> gsm can have a tensile integrity in a machine direction of at least <NUM> mJ, at least <NUM> mJ, or at least <NUM> mJ. Tensile integrity of the fabric <NUM>' or <NUM>" can also be improved by applying tension to the fabric <NUM>' or <NUM>" when the fabric is in a heated tunnel or zone oven. By heating the polymer fibers to the glass transition temperature while under tension, the polymer fibers can be oriented in the direction of tension.

The heating of the polymeric material to a temperature above its glass transition temperature can be accomplished by using electrically heated surfaces, ultrasonic bonding, infrared energy, radio frequency energy, and microwave energy. Stitch bonding, point bonding, and quilting are methods of applying patterns to nonwoven fabrics. These are forms of thermal bonding typically achieved with ultrasonic bonding processes although other energy sources and related equipment can be used to create particular patterns of bonding within the network of fibers. Stitch bonding, point bonding, and quilting can all be used to conform polymeric fibers to at least portions of a surface topography of at least some of the fibrous structures of the tobacco.

Bonding between the structural fibers can also be accomplished by incorporating a low melting temperature polymer into the network of structural fibers. The low melting temperature polymer could be introduced into the network in the form of fibers, beads, or random shapes. The low melting temperature polymer fibers, beads, or random shapes can be dispersed within the network of structural fibers. In some cases, the low melting temperature polymer has a melting point of between about <NUM> and <NUM>. By heating the composite of the structural fibers, the smokeless tobacco, and the low melting temperature polymeric material to a temperature between the melting points of the two different materials (thus also above the glass transition temperature of the low melting temperature polymer), the low melting temperature polymeric material can be selectively melted and thus bond to surrounding fibers and also conform to at least portions of a surface topography of at least some of the fibrous structures of the tobacco. In some cases, the structural polymeric fibers are bicomponent or multicomponent fibers made of different materials.

Chemically bonding can also be used to further secure polymer fibers in the fabric <NUM>' or <NUM>". For example, adhesive materials in the form of beads or small random shapes, solvents, and/or solutions can be intermingled with the network of polymeric fibers and activated with heat and/or pressure to bond the network. In some cases, heat is used to both activate a chemical bonding agent and to bring the polymeric material above or below its glass transition temperature to conform the polymeric material to the fibrous structures of the tobacco. In some cases, silicone or polyvinyl acetate is used as a chemical adhesive. In some cases, sodium alginate is added to the network and then a calcium salt added to make the alginate insoluble within the network and thus bond surrounding fibers. Chemical bonding can be used with any other technique described herein.

The hydraulic permittivity of the fabric can also be increased by compounding the polymeric material with a filler prior to melt-blowing the polymeric material. According to the invention the colorant can be used as the filler. For example, a brown colorant can be added to a feed hopper of the extruder along with a polymer material (e.g., polypropylene) prior to melt blowing the polymer into the fibers. In addition to improving the hydraulic permittivity, the colorant can improve the aesthetic appeal of the pouched product <NUM>. For example, a brown colorant can make a pouched moist-smokeless tobacco product appear moist. Table <NUM> below compares a melt-blown polypropylene polymer fabrics produced with and without brown colorant.

As shown, the polypropylene having the brown colorant (Techmer) had an increased tensile integrity and a permittivity. The colorant and the polymer can be compounded and pelletized prior to melt-blowing the polymer to ensure a consistent ratio of colorant to polymer.

Suitable polymeric materials 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, epoxy, cellulosics such as cellulose acetate, cellulose triacetate, cellulose nitrate, ethyl cellulose, cellulose acetate, propionate, cellulose acetate butyrate, hydroxypropyl cellulose, methyl hydroxypropyl cellulose (CMC), HPMC, carboxymethyl cellulose, cellophane and rayon, chlorinated polyether, coumarone-indene, epoxy, polybutenes, 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, (polyethylene terephthalate) PET and unsaturated polyesters such as SMC and BMC, thermoplastic polyimide, polymethyl pentene, polyolefins such as LDPE, LLDPE, HDPE, and UHMWPE, polypropylene, ionomers such as PD and poly allomers, polyphenylene oxide, polyphenylene sulfide, polyurethanes (such as DESMOPAN DP 9370A available from Bayer), 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, polymeric 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, polyvinyl pyrrolidone, and polyethylene oxide, and ethylene vinyl alcohol.

The polymeric material can include multiple materials. In some cases, fibers of a first polymeric material are interspersed or layered with fibers of a second polymeric material. For example, a lower melting polymer can function as a binder which may be a separate fiber interspersed with higher melting structural polymer fibers. In some cases, structural fibers can include multiple components made of different materials. For example, a lower melting sheath can surround a higher melting core, which can help with the conforming and/or bonding processes. The components of a multi-component fiber can also be extruded in a side-by-side configuration. For example, different polymeric materials can be co-extruded and drawn in a melt-blowing or force spun to form the multi-component structural fibers.

In some cases, the polymeric material includes one mouth-stable material and one mouth-dissolvable material such that the smokeless tobacco product will loosen but remain cohesive as the mouth-dissolvable material dissolves away. In some cases, a network of structural polymeric fibers includes mouth-dissolvable polymeric fibers and mouth-stable polymeric fibers. As used herein, "mouth-stable" means that the material remains cohesive when placed in a mouth of an adult tobacco consumer for <NUM> hour. As used herein, "mouth-dissolvable" means that the material breaks down within <NUM> hour after being exposed to saliva and other mouth fluids when placed in a mouth of an adult tobacco consumer. Mouth-dissolvable materials include hydroxypropyl cellulose (HPC), methyl hydroxypropyl cellulose (HPMC), polyvinyl alcohol (PVOH), PVP, polyethylene oxide (PEO), starch and others. Mouth-dissolvable materials could be combined with flavors, sweeteners, milled tobacco and other functional ingredients. In other embodiments, multi-component fibers include a mouth-stable material and a mouth-dissolvable material.

In some cases, the polymeric material includes reconstituted cellulosic fibers. Reconstituted cellulosic fibers can be created from various woods and annual plants by physically dissolving the wood or plant material in a suitable solvent, such as methylmorpholine oxide (MNNO) monohydrate. The concentration of cellulose in the solution can be between <NUM> weight and <NUM> weight percent. The solution can then be spun (e.g., melt-blown or centrifugally force spun) at a temperature of between <NUM> and <NUM> to create reconstituted cellulosic fibers. In some cases, the reconstituted cellulosic fibers are made using tobacco material (e.g., tobacco stems). Reconstituted tobacco cellulosic fibers can then be intermingled with smokeless tobacco having natural cellulosic fibers to create a pouched tobacco product having tobacco-derived structural fibers. The reconstituting process changes the composition of the tobacco and removes soluble tobacco components.

The polymeric material can also be combined with milled tobacco prior to contacting the tobacco with the smokeless tobacco. For example, milled tobacco could be combined into a polymeric structural fiber such that the polymeric material at least partially encapsulates the milled tobacco. For example, milled tobacco could be added to a molten polymer (e.g., polypropylene) in amounts of up to about <NUM>% and extruded in a melt-blowing or spun bond process. The milled tobacco can provide a unique texture while the polymeric material remains mouth-stable and cohesive.

The amount of polymeric material used in the pouched tobacco product <NUM> or <NUM> depends on the desired flavor profile and desired mouth feel. In some cases, the pouched tobacco product <NUM> or <NUM> includes between <NUM> and <NUM> weight percent polymeric material, which can increase the likelihood that the pouched tobacco product <NUM> or <NUM> maintains its integrity during packaging and transport.

The fabric <NUM>' or <NUM>" can be used to pouch tobacco. In some cases, the tobacco can be smokeless tobacco.

Smokeless tobacco is tobacco suitable for use in an orally used tobacco product. By "smokeless tobacco" it is meant a part, e.g., leaves, and stems, of a member of the genus Nicotiana that has been processed. Exemplary species of tobacco include N. rustica, N. tabacum, N. tomentosiformis, and N. sylvestris. Suitable tobaccos include fermented and unfermented tobaccos. In addition to fermentation, the tobacco can also be processed using other techniques. For example, tobacco can be processed by heat treatment (e.g., cooking, toasting), flavoring, enzyme treatment, expansion and/or curing. Both fermented and non-fermented tobaccos can be processed using these techniques. In other embodiments, the tobacco can be unprocessed tobacco. Specific examples of suitable processed tobaccos include, dark air-cured, dark fire-cured, burley, flue cured, and cigar filler or wrapper, as well as the products from the whole leaf stemming operation. In some cases, smokeless tobacco includes up to <NUM>% dark tobacco on a fresh weight basis.

Tobacco can be conditioned by heating, sweating and/or pasteurizing steps as described in <CIT> or <CIT>. In addition to modifying the aroma of the leaf, fermentation can change the color, texture, and other sensorial attributes (taste) of a leaf. Also during the fermentation process, evolution gases can be produced, oxygen can be taken up, the pH can change, and the amount of water retained can change. See, for example, <CIT> and <NPL>). Cured, or cured and fermented tobacco can be further processed (e.g., cut, expanded, blended, milled or comminuted) prior to incorporation into the smokeless tobacco product. The tobacco, in some cases, is long cut fermented cured moist tobacco having an oven volatiles content of between <NUM> and <NUM> weight percent prior to mixing with the polymeric material and optionally flavorants and other additives.

The tobacco can, in some cases, be prepared from plants having less than <NUM>µg of DVT per cm<NUM> of green leaf tissue. For example, the tobacco particles can be selected from the tobaccos described in <CIT>.

Tobacco compositions containing tobacco from such low-DVT varieties exhibits improved flavor characteristics in sensory panel evaluations when compared to tobacco or tobacco compositions that do not have reduced levels of DVTs.

Green leaf tobacco can be cured using conventional means, e.g., flue-cured, barn-cured, fire-cured, air-cured or sun-cured. See, for example, <NPL>) for a description of different types of curing methods. Cured tobacco is usually aged in a wooden drum (i.e., a hogshead) or cardboard cartons in compressed conditions for several years (e.g., two to five years), at a moisture content ranging from <NUM>% to about <NUM>%. See, <CIT> and <CIT>. Cured and aged tobacco then can be further processed. Further processing includes conditioning the tobacco under vacuum with or without the introduction of steam at various temperatures, pasteurization, and fermentation. Cure, aged, and fermented smokeless tobacco can be further processed (e.g., cut, shredded, expanded, or blended). See, for example, <CIT>; <CIT>; and <CIT>.

The smokeless tobacco can be processed to a desired size. For example, long cut smokeless tobacco typically is cut or shredded into widths of about <NUM> cuts/<NUM>,<NUM> up to about <NUM> cuts/<NUM>,<NUM> (<NUM> cuts/inch up to about <NUM> cuts/ inch) and lengths of about <NUM>,<NUM> (<NUM>,<NUM> inch) up to about <NUM>,<NUM> (<NUM> inch). Double cut smokeless tobacco can have a range of particle sizes such that about <NUM>% of the double cut smokeless tobacco falls between the mesh sizes of -<NUM> mesh and <NUM> mesh. Other lengths and size distributions are also contemplated.

The smokeless tobacco can have a total oven volatiles content of about <NUM>% by weight or greater; about <NUM>% by weight or greater; about <NUM>% by weight or greater; about <NUM>% by weight to about <NUM>% by weight; about <NUM>% by weight to about <NUM>% by weight; about <NUM>% by weight to about <NUM>% by weight; about <NUM>% by weight to about <NUM>% by weight; or about <NUM>% by weight to about <NUM>% by weight. Those of skill in the art will appreciate that "moist" smokeless tobacco typically refers to tobacco that has an oven volatiles content of between about <NUM>% by weight and about <NUM>% by weight (e.g., about <NUM>% by weight to about <NUM>% by weight, or about <NUM>% by weight). As used herein, "oven volatiles" are determined by calculating the percentage of weight loss for a sample after drying the sample in a pre-warmed forced draft oven at <NUM> for <NUM> hours. The pouched tobacco product can have a different overall oven volatiles content than the oven volatiles content of the smokeless tobacco used to make the pouched tobacco product. The processing steps described herein can reduce or increase the oven volatiles content. The overall oven volatiles content of the pouched tobacco product is discussed below.

The pouched tobacco product <NUM> or <NUM> can include between <NUM> weight percent and <NUM> weight percent smokeless tobacco on a dry weight basis. The amount of smokeless tobacco in a pouched tobacco product <NUM> or <NUM> on a dry weight basis is calculated after drying the pouched tobacco product in a pre-warmed forced draft oven at <NUM> for <NUM> hours. The remaining non-volatile material is then separated into tobacco material and polymeric material. The percent smokeless tobacco in the pouched tobacco product is calculated as the weight smokeless tobacco divided by the total weight of the non-volatile materials. In some cases, the pouched tobacco product includes between <NUM> and <NUM> weight percent tobacco on a dry weight basis. In some cases, the pouched tobacco product includes at least <NUM> weight percent tobacco on a dry weight basis.

In some cases, a plant material other than tobacco is used as a tobacco substitute in the pouched product <NUM> or <NUM>. The tobacco substitute can be an herbal composition. Herbs and other edible plants can be categorized generally as culinary herbs (e.g., thyme, lavender, rosemary, coriander, dill, mint, peppermint) and medicinal herbs (e.g., Dahlias, Cinchona, Foxglove, Meadowsweet, Echinacea, Elderberry, Willow bark). In some cases, the tobacco is replaced with a mixture of non-tobacco plant material. Such non-tobacco compositions may have a number of different primary ingredients, including but not limited to, tea leaves, red clover, coconut flakes, mint leaves, ginseng, apple, corn silk, grape leaf, and basil leaf. The plant material typically has a total oven volatiles content of about <NUM>% by weight or greater; e.g., about <NUM>% by weight or greater; about <NUM>% by weight or greater; about <NUM>% by weight to about <NUM>% by weight; about <NUM>% by weight to about <NUM>% by weight; about <NUM>% by weight to about <NUM>% by weight; about <NUM>% by weight to about <NUM>% by weight; or about <NUM>% by weight to about <NUM>% by weight.

Flavors and other additives can be included in the compositions and arrangements described herein and can be added to the pouched tobacco product <NUM> or <NUM> at any point in the process. For example, any of the initial components, including the polymeric material, can be provided in a flavored form. In some cases, flavorants and/or other additives are included in the smokeless tobacco. In some cases, flavorants and/or other additives are absorbed into to the pouched tobacco product <NUM> or <NUM> after pouching. In some cases, flavorants and/or other additives are mixed with the polymeric material (e.g., with structural fibers) prior to melt-blowing the fibers and/or as the fibers exit the spinnerets.

Suitable flavorants include wintergreen, cherry and berry type flavorants, various liqueurs and liquors such as Drambuie, bourbon, scotch, whiskey, spearmint, peppermint, lavender, cinnamon, cardamom, apium graveolents, clove, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, Japanese mint, cassia, caraway, cognac, jasmine, chamomile, menthol, ilangilang, sage, fennel, piment, ginger, anise, coriander, coffee, liquorish, and mint oils from a species of the genus Mentha. Mint oils useful in particular embodiments of the pouched tobacco products <NUM> or <NUM> include spearmint and peppermint.

Flavorants can also be included in the form of flavor beads, which can be dispersed within the pouched tobacco product (e.g., in a nonwoven network of polymeric structural fibers). For example, the pouched tobacco product could include the beads described in <CIT>.

In some cases, the amount of flavorants in the pouched tobacco product <NUM> or <NUM> is limited to less than <NUM> weight percent in sum. In some cases, the amount of flavorants in the pouched tobacco product <NUM> or <NUM> can be limited to be less than <NUM> weight percent in sum. For example, certain flavorants can be included in the pouched tobacco product in amounts of about <NUM> weight percent.

Other optional additives can include but are not limited to fillers (e.g., starch, dicalcium phosphate, lactose, sorbitol, mannitol, and microcrystalline cellulose), soluble fiber (e.g., Fibersol from Matsushita), calcium carbonate, dicalcium phosphate, calcium sulfate, and clays), sodium chloride, lubricants (e.g., lecithin, stearic acid, hydrogenated vegetable oil, mineral oil, polyethylene glycol <NUM>-<NUM> (PEG), sodium lauryl sulfate (SLS), glyceryl palmitostearate, sodium benzoate, sodium stearyl fumarate, talc, and stearates (e.g., Mg or K), and waxes (e.g., glycerol monostearate, propylene glycol monostearate, and acetylated monoglycerides)), plasticizers (e.g., glycerine, propylene glycol, polyethylene glycol, sorbitol, mannitol, triacetin, and <NUM>,<NUM> butane diol), stabilizers (e.g., ascorbic acid and monosterol citrate, BHT, or BHA), artificial sweeteners (e.g., sucralose, saccharin, and aspartame), disintegrating agents (e.g., starch, sodium starch glycolate, cross caramellose, cross linked PVP), pH stabilizers, or other compounds (e.g., vegetable oils, surfactants, and preservatives). Some compounds display functional attributes that fall into more than one of these categories. For example, propylene glycol can act as both a plasticizer and a lubricant and sorbitol can act as both a filler and a plasticizer.

Oven volatiles, such as water, may also be added to the pouched tobacco product <NUM> or <NUM> to bring the oven volatiles content of the pouched tobacco product into a desired range. In some cases, flavorants and other additives are included in a hydrating liquid.

The pouched tobacco product <NUM> or <NUM> can have a total oven volatiles content of between <NUM> and <NUM> weight percent. In some cases, the total oven volatiles content is at least <NUM> weight percent. The oven volatiles include water and other volatile compounds, which can be a part of the tobacco, the polymeric material, the flavorants, and/or other additives. As used herein, the "oven volatiles" are determined by calculating the percentage of weight loss for a sample after drying the sample in a pre-warmed forced draft oven at <NUM> for <NUM> hours. Some of the processes may reduce the oven volatiles content (e.g., heating the composite or contacting the smokeless tobacco with a heated polymeric material), but the processes can be controlled to have an overall oven volatiles content in a desired range. For example, water and/or other volatiles can be added back to the pouched tobacco product to bring the oven volatiles content into a desired range. In some cases, the oven volatiles content of the composite pouched tobacco product <NUM> is between <NUM> and <NUM> weight percent. For example, the oven volatiles content of smokeless tobacco used in the various processed described herein can be about <NUM> weight percent. In other embodiments, the oven volatiles content can be between <NUM> and <NUM> weight percent.

Tobacco or a tobacco substitute can be pouched in a fabric provided herein as shown in <FIG>. As shown, fabric <NUM>' or <NUM>" is formed around tube <NUM> to form a tube of pouching fabric <NUM>. The overlapping edge portions of the fabric <NUM>' or <NUM>" can be heat sealed together against tube <NUM> or between pinch rollers to form the fabric tube <NUM>. A seal <NUM> can be made along the fabric tube <NUM> to form a bottom of a pouch. Tobacco or a tobacco substitute <NUM> can be deposited into the partially formed pouch <NUM> through tube <NUM>. The fabric can continue to be advanced and a second seal <NUM> can be made to fully seal the pouch <NUM> and provide a bottom seal for a subsequent pouch <NUM>. The pouches <NUM> can be separated along the seal <NUM> and deposited into a bottom portion <NUM> of a container. The lid <NUM> of the container can be connected to the bottom portion <NUM> to enclose the pouches <NUM>.

The bottom container <NUM> and lid <NUM> can releasably mate at a connection rim so as to maintain freshness and other product qualities of pouched tobacco products <NUM> contained therein. Such qualities may relate to, without limitation, texture, flavor, color, aroma, mouth feel, taste, ease of use, and combinations thereof. In particular, the container may have a generally cylindrical shape and include a base and a cylindrical side wall that at least partially defines the interior space. In some cases, the container is moisture-tight. Certain containers can be air-tight. The connection rim formed on the container can provide a snap-fit engagement with the lid. It will be understood from the description herein that, in addition to the container, many other packaging options are available to hold one or more of the pouched tobacco products <NUM>.

Tobacco or a tobacco substitute T can also be pouched in a fabric provided herein in a method such as that shown in <FIG>. As shown in <FIG>, discrete deposits of smokeless tobacco <NUM> or a tobacco substitute can be deposited on a fabric <NUM>' or <NUM>" and one or more additional layers of polymeric fibers <NUM> can be deposited thereon bonded to the fabric <NUM>' or <NUM>" around the periphery of each discrete deposit of smokeless tobacco. For example, discrete deposits of the smokeless tobacco <NUM> can be deposited onto fabric <NUM>' or <NUM>". In some cases, the discrete deposits includes a smokeless tobacco having an aspect ratio greater than <NUM> (e.g., long-cut smokeless tobacco). In some cases, the smokeless tobacco has a moisture content of at least <NUM> weight percent OV. In some cases, one or more conveyor parts <NUM> and/or <NUM> are shaped to size, compact, and/or position each discrete deposit. In some cases, the smokeless tobacco is deposited in a loose form. In some cases, loose deposits of smokeless tobacco can include a binder to help with the binding properties. For example, in some embodiments, conveyor <NUM> may include bumps, cavities, and/or ridges that correspond to predetermined discrete deposit sizes and shapes. Each discrete deposit can correspond approximately to an amount of smokeless tobacco generally found in a pouched smokeless tobacco product (e.g., between about <NUM> to <NUM> grams). For example, the smokeless tobacco product can include about <NUM> grams of smokeless tobacco. Melt-blown or centrifugally force spun polymeric fiber <NUM> or <NUM> can then be deposited over the fabric <NUM>' or <NUM>" and the discrete deposits <NUM> as a continuous layer <NUM>. The polymeric fibers <NUM> or <NUM> can be bond with fabric <NUM>' or <NUM>" and conform to the surface topography of some of the tobacco fibrous structures. In some cases, heat can be used to seal the edges around each deposit <NUM>. The composite can then be die cut to separate the pouches <NUM>. <FIG> depict various views of a pouched tobacco product <NUM> after being sealed and cut. As shown, the pouched tobacco product <NUM> can have a relatively flat surface and a curved surface.

Claim 1:
A smokeless tobacco product comprising:
a pouch consisting of a fabric in the form of a side-sealed tube,
smokeless tobacco disposed within the pouch,
a first cross-seal across the side-sealed tube forming a bottom seal of the pouch, and
a second cross-seal across the side-sealed tube enclosing the smokeless tobacco within the pouch,
wherein the fabric comprises melt-blown polypropylene polymer fibers comprising a surfactant added as a mist with water to provide to the polymer fibers a hydrophilic surface,
wherein the fabric has a basis weight of less than <NUM> gsm, and
wherein the polymer fibers comprise a brown colorant.