U.S. patent application number 13/463979 was filed with the patent office on 2013-11-07 for transparent moisture barrier coatings for containers.
This patent application is currently assigned to R.J. Reynolds Tobacco Company. The applicant listed for this patent is Bruce Bengtsson, Pankaj C. Patel, Robert J. Pound, Andries D. Sebastian. Invention is credited to Bruce Bengtsson, Pankaj C. Patel, Robert J. Pound, Andries D. Sebastian.
Application Number | 20130292279 13/463979 |
Document ID | / |
Family ID | 48485445 |
Filed Date | 2013-11-07 |
United States Patent
Application |
20130292279 |
Kind Code |
A1 |
Bengtsson; Bruce ; et
al. |
November 7, 2013 |
TRANSPARENT MOISTURE BARRIER COATINGS FOR CONTAINERS
Abstract
Containers for smokeless tobacco products and other consumer and
food products are provided. The containers include a layer of
fibrous material, wherein the layer of fibrous material includes a
moisture barrier layer imbedded within the layer of fibrous
material or carried on an outer surface of the layer of fibrous
material as a coating, the moisture barrier layer incorporating at
least one of: (i) a triazine-containing compound; (ii) a
nano-cellulose material; (iii) a nanoclay material; (iv) a polymer
composition comprising one or more of a salt of one or more of
myristic, palmitic and stearic acid, polyvinyl alcohol, and a
C.sub.9-C.sub.18 fatty acid complex of a metal ion having an
oxidation state of at least three; and (v) an inorganic oxide
material.
Inventors: |
Bengtsson; Bruce;
(Winston-Salem, NC) ; Pound; Robert J.;
(Kemersville, NC) ; Patel; Pankaj C.; (Clemmons,
NC) ; Sebastian; Andries D.; (Clemmons, NC) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Bengtsson; Bruce
Pound; Robert J.
Patel; Pankaj C.
Sebastian; Andries D. |
Winston-Salem
Kemersville
Clemmons
Clemmons |
NC
NC
NC
NC |
US
US
US
US |
|
|
Assignee: |
R.J. Reynolds Tobacco
Company
Winston-Salem
NC
|
Family ID: |
48485445 |
Appl. No.: |
13/463979 |
Filed: |
May 4, 2012 |
Current U.S.
Class: |
206/245 ;
206/524.2 |
Current CPC
Class: |
D21H 17/68 20130101;
D21H 21/52 20130101; D21H 27/10 20130101; D21H 17/36 20130101; B65D
81/24 20130101; D21H 11/18 20130101; D21H 17/14 20130101; B65D
85/10 20130101 |
Class at
Publication: |
206/245 ;
206/524.2 |
International
Class: |
A24F 23/00 20060101
A24F023/00; B65D 85/10 20060101 B65D085/10; B65D 85/00 20060101
B65D085/00 |
Claims
1. A container, comprising: a body having a bottom wall and a side
wall, the bottom wall and the side wall defining an internal
storage compartment adapted for storage of a product, and a top
configured to be engaged with the body, wherein at least one of the
bottom wall, side wall, and top comprises a layer of fibrous
material, wherein the layer of fibrous material comprises a
moisture barrier layer imbedded within the layer of fibrous
material or carried on an outer surface of the layer of fibrous
material as a coating, the moisture barrier layer comprising at
least one of: (i) a triazine-containing compound; (ii) a
nano-cellulose material; (iii) a nanoclay material; (iv) a polymer
composition comprising one or more of a salt of one or more of
myristic, palmitic and stearic acid, polyvinyl alcohol, and a
C.sub.9-C.sub.18 fatty acid complex of a metal ion having an
oxidation state of at least three; and (v) an inorganic oxide
material.
2. The container of claim 1, wherein the fibrous material is a
fiberboard, cardboard, paper, or a combination thereof.
3. The container of claim 1, further comprising a wrapping material
extending about a perimeter of the container.
4. The container of claim 3, wherein the wrapping material
comprises fiberboard, cardboard, paper, plastic, metal, or a
combination thereof.
5. The container of claim 1, wherein the polymer composition
comprises a polymer, copolymer, or a mixture of polymers and
copolymers.
6. The container of claim 5, wherein the polymer composition
comprises a polymer selected from the group consisting of styrene
butadiene copolymers, modified styrene butadiene copolymers,
styrene/acrylate copolymers, carboxylated polystyrene,
acrylic/polyacrylic polymers, polyvinyl acetate; polyvinyl alcohol,
polyvinylacetate-ethylene, polyvinyl acrylic, soy protein polymer;
corn zein (protein), starch, polyolefin dispersion, polyvinylidene
chloride, polylactic acid, polyhydroxyalkanoate polymers,
polybutylene succinate, plasticized cellulose acetate, and blends
thereof.
7. The container of claim 1, wherein the at least one
triazine-containing compound is selected from the group consisting
of melamine, ammeline, ammelide, cyanuric acid, 2-ureidomelamine,
melam, melem, melon, melamine cyanurate, melamine phosphate,
dimelamine pyrophosphate, melamine polyphosphate, hexamethoxymethyl
melamine, and acrylate-functionalized melamine.
8. The container of claim 1, wherein the nano-cellulose material is
a nano-fibrillated or nanocrystalline cellulose.
9. The container of claim 1, wherein the nanoclay material is a
platey kaolin, nanoclay, clay nanocomposite, or polymer-clay
nanocomposite.
10. The container of claim 1, wherein the inorganic oxide material
comprises AlOx, SiOx, or MgOx.
11. The container of claim 1, wherein the internal storage
compartment contains a plurality of products selected from the
group consisting of cigarettes, smokeless tobacco products, and
food products.
12. The container of claim 1, wherein the top is removable from the
body.
13. The container of claim 1, wherein the top is engaged with the
body.
14. The container of claim 1, wherein the container is a smokeless
tobacco container or a cigarette pack.
15. A container for smokeless tobacco products, comprising: a body
having a bottom wall and a side wall, the bottom wall and the side
wall defining an internal storage compartment adapted for storage
of smokeless tobacco, and a top configured to be engaged with the
body, wherein at least one of the bottom wall, side wall, and top
comprises a layer of fibrous material, wherein the layer of fibrous
material comprises a moisture barrier layer imbedded within the
layer of fibrous material or carried on an outer surface of the
layer of fibrous material as a coating, the moisture barrier layer
comprising at least one of: (i) a triazine-containing compound;
(ii) a nano-cellulose material; (iii) a nanoclay material; (iv) a
polymer composition comprising one or more of a salt of one or more
of myristic, palmitic and stearic acid, polyvinyl alcohol, and a
C.sub.9-C.sub.18 fatty acid complex of a metal ion having an
oxidation state of at least three; and (v) an inorganic oxide
material.
16. The container of claim 15, wherein the top is removable from
body.
17. The container of claim 15, wherein the bottom wall and side
wall comprise fiberboard.
18. The container of claim 17, wherein the top comprises
fiberboard.
19. The container of claim 17, wherein the top comprises a metal or
polymer.
20. The container of claim 15, wherein the polymer composition
comprises a polymer selected from the group consisting of styrene
butadiene copolymers, modified styrene butadiene copolymers,
styrene/acrylate copolymers, carboxylated polystyrene,
acrylic/polyacrylic polymers, polyvinyl acetate; polyvinyl alcohol,
polyvinylacetate-ethylene, polyvinyl acrylic, soy protein polymer;
corn zein (protein), starch, polyolefin dispersion, polyvinylidene
chloride, polylactic acid, polyhydroxyalkanoate polymers,
polybutylene succinate, plasticized cellulose acetate, and blends
thereof.
21. The container of claim 15, wherein the at least one
triazine-containing compound is selected from the group consisting
of melamine, ammeline, ammelide, cyanuric acid, 2-ureidomelamine,
melam, melem, melon, melamine cyanurate, melamine phosphate,
dimelamine pyrophosphate, melamine polyphosphate, hexamethoxymethyl
melamine, and acrylate-functionalized melamine.
22. The container of claim 15, wherein the nano-cellulose material
is a nano-fibrillated or nanocrystalline cellulose.
23. The container of claim 15, wherein the nanoclay material is a
platey kaolin, nanoclay, clay nanocomposite, or polymer-clay
nanocomposite.
24. The container of claim 15, wherein the inorganic oxide material
comprises AlOx, SiOx, or MgOx.
25. The container of claim 15, wherein the top and body are
generally cylindrical.
Description
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates to containers for packaging a
variety of consumer goods and methods of use thereof. More
particularly, the disclosure relates to packaging for products that
are derived from or that otherwise incorporate tobacco, and which
are intended for human use or consumption.
BACKGROUND OF THE DISCLOSURE
[0002] Various types of containers for dispensing solid objects,
particularly solid products intended for human consumption, are
known in the art. Such containers are often characterized by a
hand-held size that can be easily stored and transported. Exemplary
consumable products that are often packaged in such containers
include a wide variety of consumer products, including smokeless
tobacco-related products.
[0003] Tobacco may be enjoyed in a so-called "smokeless" form.
Particularly popular smokeless tobacco products are employed by
inserting some form of processed tobacco or tobacco-containing
formulation into the mouth of the user. See, for example, the types
of smokeless tobacco formulations, ingredients, and processing
methodologies set forth in U.S. Pat. Nos. 1,376,586 to Schwartz;
3,696,917 to Levi; 4,513,756 to Pittman et al.; 4,528,993 to
Sensabaugh, Jr. et al.; 4,624,269 to Story et al.; 4,991,599 to
Tibbetts; 4,987,907 to Townsend; 5,092,352 to Sprinkle, III et al.;
5,387,416 to White et al.; 6,668,839 to Williams; 6,834,654 to
Williams; 6,953,040 to Atchley et al.; 7,032,601 to Atchley et al.;
7,694,686 to Atchley et al.; 7,810,507 to Dube et al.; 7,819,124 to
Strickland et al.; and 7,861,728 to Holton, Jr. et al.; US Pat.
Pub. Nos. 2004/0020503 to Williams; 2005/0115580 to Quinter et al.;
2005/0244521 to Strickland et al.; 2006/0191548 to Strickland et
al.; 2007/0062549 to Holton, Jr. et al.; 2008/0029116 to Robinson
et al.; 2008/0029117 to Mua et al.; 2008/0173317 to Robinson et
al.; 2008/0196730 to Engstrom et al.; 2008/0209586 to Neilsen et
al.; 2008/0305216 to Crawford et al.; 2009/0065013 to Essen et al.;
2009/0293889 to Kumar et al.; and 2010/0291245 to Gao et al.; PCT
Pub. Nos. WO 04/095959 to Arnarp et al.; and WO 10/132,444 to
Atchley; each of which is incorporated herein by reference.
[0004] Representative smokeless tobacco products that have been
marketed include those referred to as CAMEL Snus, CAMEL Orbs, CAMEL
Strips and CAMEL Sticks by R. J. Reynolds Tobacco Company; GRIZZLY
moist tobacco, KODIAK moist tobacco, LEVI GARRETT loose tobacco and
TAYLOR'S PRIDE loose tobacco by American Snuff Company, LLC; KAYAK
moist snuff and CHATTANOOGA CHEW chewing tobacco by Swisher
International, Inc.; REDMAN chewing tobacco by Pinkerton Tobacco
Co. LP; COPENHAGEN moist tobacco, COPENHAGEN Pouches, SKOAL
Bandits, SKOAL Pouches, RED SEAL long cut and REVEL Mint Tobacco
Packs by U.S. Smokeless Tobacco Company; and MARLBORO Snus and
Taboka by Philip Morris USA.
[0005] Representative types of snuff products, commonly referred to
as "snus," are manufactured in Europe, particularly in Sweden, by
or through companies such as Swedish Match AB, Fiedler &
Lundgren AB, Gustavus AB, Skandinavisk Tobakskompagni A/S and
Rocker Production AB. Snus products available in the U.S.A. are
marketed under the trade names such as CAMEL Snus Frost, CAMEL Snus
Original and CAMEL Snus Spice by R. J. Reynolds Tobacco
Company.
[0006] Various types of containers for dispensing tobacco products
are known. Smokeless tobacco products are typically sold in
hand-held tins or pucks constructed of fiberboard, metal, or molded
plastic (e.g., polypropylene), and which have an outer paper or
plastic seal enclosing the container. Such containers generally
have a shallow cylindrical shape with a detachable lid. See, for
example, the containers set forth in U.S. Pat. Nos. 4,098,421 to
Foster; 4,190,170 to Boyd; and 7,798,319 to Bried et al., each of
which is incorporated herein by reference. Other tobacco products
such as cigarettes are stored or packaged in containers such as
those set forth in U.S. Pat. Nos. 5,699,903 to Focke et al.;
5,161,733 to Latif; 7,484,619 to Boriani et al; and US Pub. No.
2005/0252796, each of which is incorporated herein by
reference.
[0007] A desirable feature for certain containers is the protection
of the product from environmental effects and moisture ingress or
egress, particularly those effects that may degrade the product
stored in the container. For example, in humid environments,
moisture may invade the storage space housing the product, thereby
damaging the product or otherwise rendering the product unusable.
Alternatively, moisture within the product may escape the packaging
leaving the product prematurely dry and difficult to dispense.
Further, current fiberboard cans have poor sealing attributes
thereby posing a challenge to ensure fresh product for consumer
use. For example, moist tobacco products packaged in current
fiberboard cans have a shorter shelf life compared to tobacco
products packaged in a plastic canned product. The inside of the
current fiberboard cans are coated with a wax to control the
moisture loss. This wax coating is prone to stress cracking and
therefore is not fully effective.
[0008] It would thus be desirable to provide an improved packaging
for smokeless tobacco products and other consumer and food product
packaging, wherein the packaging provides various advantageous
features, such as protection from environmental effects and
moisture variability.
BRIEF SUMMARY OF THE DISCLOSURE
[0009] The present invention provides packaging or containers for
smokeless tobacco products and other consumer and food products.
The containers include at least one wall structure in the body or
top thereof that includes a barrier material that provides
advantageous features, such as protection against environmental
effects and moisture variability.
[0010] According to one aspect, a container is provided that
includes a body having a bottom wall and a side wall, the bottom
wall and the side wall defining an internal storage compartment
adapted for storage of a product, and a top configured to be
engaged with the body. At least one of the bottom wall, side wall,
and top includes a layer of fibrous material which, in turn,
includes a moisture barrier layer imbedded within the layer of
fibrous material or carried on an outer surface of the layer of
fibrous material as a coating. The moisture barrier layer includes
at least one of (i) a triazine-containing compound; (ii) a
nano-cellulose material; (iii) a nanoclay material; (iv) a polymer
composition comprising one or more of a salt of one or more of
myristic, palmitic and stearic acid, polyvinyl alcohol, and a
C.sub.9-C.sub.18 fatty acid complex of a metal ion having an
oxidation state of at least three; and (v) an inorganic oxide
material. According to one embodiment, the moisture barrier layer
is transparent. According to one embodiment, the moisture barrier
layer is biodegradable. According to another embodiment, the
moisture barrier layer is both transparent and biodegradable.
[0011] The polymer composition comprises a polymer, copolymer, or a
mixture of polymers and copolymers. According to one embodiment,
the polymer composition can include styrene butadiene copolymers,
modified styrene butadiene copolymers, styrene/acrylate copolymers,
carboxylated polystyrene, acrylic/polyacrylic polymers, polyvinyl
acetate; polyvinyl alcohol, polyvinylacetate-ethylene, polyvinyl
acrylic, soy protein polymer; corn zein (protein), starch,
polyolefin dispersion, polyvinylidene chloride, polylactic acid,
polyhydroxyalkanoate polymers, polybutylene succinate, plasticized
cellulose acetate, or blends thereof.
[0012] According to one embodiment, the triazine-containing
compound is melamine, ammeline, ammelide, cyanuric acid,
2-ureidomelamine, melam, melem, melon, melamine cyanurate, melamine
phosphate, dimelamine pyrophosphate, melamine polyphosphate,
hexamethoxymethyl melamine, or acrylate-functionalized melamine.
According to one embodiment, the nano-cellulose material is a
nano-fibrillated or nanocrystalline cellulose. The nanoclay
material can be platey kaolins, nanoclays, clay nanocomposite, or a
polymer-clay nanocomposite. According to one embodiment, the
inorganic oxide material comprises AlOx, SiOx, or MgOx.
[0013] The fibrous material is typically fiberboard, cardboard,
paper, or a combination thereof. The container may further include
a wrapping material made from fiberboard, cardboard, paper,
plastic, metal, or a combination thereof that extends about a
perimeter of the container. The internal storage compartment can
include a plurality of products such as cigarettes, smokeless
tobacco products, or food products. According to one embodiment,
the container is a smokeless tobacco container or a cigarette pack.
The top of the container can be either fully removable from the
body or engaged with the body, such as through hinged
engagement.
[0014] According to another embodiment, a container for smokeless
tobacco products is provided that includes a body having a bottom
wall and a side wall, the bottom wall and the side wall defining an
internal storage compartment adapted for storage of smokeless
tobacco, and a top configured to be engaged with the body. At least
one of the bottom wall, side wall, and top include a layer of
fibrous material which, in turn, includes a moisture barrier layer
imbedded within the layer of fibrous material or carried on an
outer surface of the layer of fibrous material as a coating. The
moisture barrier layer includes at least one of: (i) a
triazine-containing compound; (ii) a nano-cellulose material; (iii)
a nanoclay material; (iv) a polymer composition comprising one or
more of a salt of one or more of myristic, palmitic and stearic
acid, polyvinyl alcohol, and a C.sub.9-C.sub.18 fatty acid complex
of a metal ion having an oxidation state of at least three; and (v)
an inorganic oxide material. According to one embodiment, the
bottom wall and side wall are manufactured from fiberboard.
Optionally, the top is also manufactured from fiberboard. In an
alternative embodiment, the top is manufactured from metal or a
polymer. The top and body are generally cylindrical in one
embodiment. The smokeless tobacco product container can include any
of the specific barrier materials noted herein.
[0015] These and other features, aspects, and advantages of the
disclosure will be apparent from a reading of the following
detailed description together with the accompanying drawings, which
are briefly described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Having thus described the disclosure in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0017] FIG. 1 is a sectional view of an embodiment of a container
wall of the present disclosure;
[0018] FIG. 2 is a perspective, exploded view of a smokeless
tobacco container embodiment of the present disclosure; and
[0019] FIG. 3 is a perspective view of a cigarette container
embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0020] The present disclosure now will be described more fully
hereinafter with reference to certain preferred aspects. These
aspects are provided so that this disclosure will be thorough and
complete, and will fully convey the scope of the disclosure to
those skilled in the art. Indeed, the disclosure may be embodied in
many different forms and should not be construed as limited to the
aspects set forth herein; rather, these aspects are provided so
that this disclosure will satisfy applicable legal requirements. As
used in the specification, and in the appended claims, the singular
forms "a", "an", "the", include plural referents unless the context
clearly dictates otherwise.
[0021] The present invention provides a container exhibiting strong
moisture barrier characteristics. The containers of the invention
include at least one moisture barrier layer in the wall structure
of the container (e.g., any or all of the sidewalls, top or lid,
and bottom wall of the container). The moisture barrier layer is
advantageously characterized by one or more of good moisture and
vapor barrier properties, biodegradability, and a high degree of
transparency. The containers of the invention can include various
materials as the base structural material of the container wall, as
noted in greater detail hereinbelow, but the moisture barrier layer
of the invention is particularly well-suited for use with
fiberboard wall structures, which are inherently deficient in
moisture barrier properties.
[0022] Container wall structures manufactured from a fibrous
material have achieved consumer acceptance in certain product
areas, such as smokeless tobacco products, but suffer from
inherently low moisture and vapor barrier properties. As used
herein, the term "fiberboard" is used to refer to any solid,
supportive wall material manufactured from a fibrous or cellulosic
material such as, for example, fiberboard, cardboard, or paper
product. Conventional solutions to improve the barrier performance
of fiberboard containers suffer from drawbacks previously noted
herein. In certain embodiments, the present invention provides a
container comprising a fiberboard wall structure carrying at least
one moisture barrier layer as set forth herein. The moisture
barrier layer enhances the barrier properties of the fiberboard
container without significant reduction in biodegradability or the
aesthetic appearance of the container.
[0023] The moisture barrier layer of the invention is typically
characterized as a film-forming coating material capable of
application to a container wall surface during production thereof.
The composition of the barrier layer material can vary, but
typically includes a solvent (e.g., water) and/or a film-forming
polymer as a primary component. The barrier layer material further
includes one or more functional ingredients that provide enhanced
barrier properties, as described more fully below. In addition to
the functional components related to the barrier properties, the
barrier layer materials used in the present invention can further
include other conventional film/coating ingredients, such as
pigments or dyes, antioxidants, surfactants, fillers, defoaming
agents, slip agents, biocides, flame retardants, and the like.
[0024] According to one embodiment, the barrier layer as disclosed
herein includes one or more triazine compounds which form a durable
barrier to gases, in particular oxygen. Such a triazine-containing
coating is set forth in U.S. Pat. Nos. 6,632,519 to Shahab et al.
and 6,893,679 to Shahab et al., each of which are incorporated
herein by reference in their entirety. Suitable exemplary
triazine-containing coating products include products under the
FRESHURE.TM. technology platform available from Knowfort
Technologies BV of Geleen, The Netherlands.
[0025] A triazine-containing coating exhibits excellent sealability
and further provides scratch and crack resistance. Crack resistance
is especially favorable in that the product is further protected
from environmental pressures and moisture egress thereby aiding in
product freshness. The minimum barrier layer thickness, however,
would provide a continuous monomolecular layer of the triazine, and
more preferably, would have a thickness of typically from about 5
nanometers to about 50 microns (50,000 nanometers).
[0026] Examples of triazine compounds that can be included in a
triazine-containing coating are 1,3,5-triazines such as melamine,
ammeline, ammelide, cyanuric acid, 2-ureidomelamine, melam, melem,
melon, melamine salts such as, for example, melamine cyanurate,
melamine phosphate, dimelamine pyrophosphate or melamine
polyphosphate and functionalized melamines, such as for instance
hexamethoxymethyl melamine or acrylate-functionalized melamine.
[0027] According to one embodiment, an adhesive or adhesive layer
is utilized for attaching the triazine-containing coating to a
container wall. The triazine compound itself may act as the
adhesive or may serve as a major component of the adhesive. The
triazine-containing coating may be applied to a substrate using
known vapor deposition techniques and equipment. Vapor deposition
of the triazine-containing coating on the substrate may take place
under elevated pressure or atmospheric pressure, but reduced
pressures are preferred (e.g., less than 1000 Pa). The temperature
necessary to vaporize the triazine compound depends on both the
type of triazine compound selected and the pressure at which the
deposition is conducted. The rate at which the selected triazine
compound is vaporized is temperature and pressure dependent, with
higher temperatures and lower pressures providing increased
vaporization. Through selection of appropriate temperature and
pressure combinations, the vaporization rate, or sublimation rate,
of the triazine-containing coating can be adjusted to control the
rate at which the resulting barrier is formed on the substrate.
[0028] According to another embodiment, the barrier layer as
disclosed herein includes at least one polymer composition that is
capable of being deposited on a solid surface such as fiberboard,
cardboard, or other paper-based product. An exemplary polymer
composition is available from Retec F3 Technologies, Inc. of
Granby, Quebec, Canada and is disclosed in WO2009/070895 and
WO2010/139070, both to Dandenault et al., each of which is
incorporated herein by reference. According to one embodiment, the
polymer composition forms a water-based coating that is resistant
to water vapor, moisture, gases, oil, and grease.
[0029] When applied, the resulting fiberboard, fiberboard, or paper
container is repulpable, compostable and recyclable. According to a
preferred embodiment, the polymer composition contains: i) 5% to
30% of a salt of one or more of myristic, palmitic and stearic
acid; ii) 0.5% to 3% of at least one of: a) polyvinyl alcohol and
b) a C.sub.9-C.sub.18 fatty acid complex of a metal ion that has an
oxidation state of at least three; and iii) 25% to 80% of a
polymeric composition comprising a polymer, copolymer, or a mixture
of polymers and copolymers. Suitable salts include calcium stearate
and zinc stearate. The metal ion is suitably chromium, such as in
chromium pentahydroxy(tetradecanoato) di-, tetradecanoato chromic
chloride hydroxide, and octadecanoato chromic acid hydroxide.
Chromium metal complexes of fatty acids are available under the
trade name QUILON.RTM. from Zaclon LLC. Suitable polymers and
copolymers include styrene butadiene copolymers, modified styrene
butadiene copolymers, styrene/acrylate copolymers, carboxylated
polystyrene, acrylic/polyacrylic polymers, polyvinyl acetate;
polyvinyl alcohol, polyvinylacetate-ethylene, polyvinyl acrylic,
soy protein polymer; corn zein (protein), starch, polyolefin
dispersion (e.g., modified propylene-based dispersion),
polyvinylidene chloride, polylactic acid, polyhydroxyalkanoate
polymers, polybutylene succinate, plasticized cellulose acetate,
and blends thereof.
[0030] According to one embodiment, the barrier layer as disclosed
herein includes at least one nano-cellulose material such as, for
example, nano-fibrillated or nanocrystalline cellulose (NCC). The
barrier layer can include nanocrystalline cellulose which is a
uniform, redispersible natural nanoparticle obtained from the
crystalline regions of cellulose fibers. The cellulose can be
derived from natural cellulose such as wood or wheat straw.
Alternatively, the cellulose can be derived from a regenerated
source such as rayon or viscose. Exemplary nanocrystalline
cellulose is available from CELLUFORCE.TM. of Montreal, Quebec,
Canada.
[0031] Nanocrystalline cellulose is typically about 100 nm to 200
nm long and is typically about 5 nm to 10 nm in diameter. During
manufacture, cellulose is milled and hydrolyzed to remove amorphous
regions. The resulting nanocrystalline cellulose is then separated
and concentrated before being modified for coating applications.
Nanocrystalline cellulose can form stable suspensions or slurries
with a latex or polymer solution that self-assemble into oriented
films or coatings upon drying. Nanocrystalline cellulose provides
structural reinforcement, reduced wear, and gas impermeability.
Nanocrystalline cellulose is light weight, biodegradable,
non-toxic, cost-efficient, and recyclable. Nano-fibrillated
cellulose can be prepared according to known methods (see e.g.,
Zhu, J. Y. et al. Integrated production of nano-fibrillated
cellulose and cellulosic biofuel by enzymatic fractionation of wood
fibers. Green Chem., 2011, 13, 1339--incorporated herein by
reference in its entirety).
[0032] According to yet another embodiment, the barrier layer as
disclosed herein includes at least one layer of a nanoclay
material. Suitable nanoclay materials include platey kaolins,
nanoclays, clay nanocomposite, and polymer-clay nanocomposite
structures including hyper-platey, nano-dimensional thickness
crystals. Nanoclay materials as described herein can be dispersed
within a polymer-based or water-based matrix. According to one
embodiment, the nanoclay material is present (e.g., loading) in an
amount of typically from about 50% to about 65% weight. According
to one embodiment, platey kaolin is utilized and creates a tortuous
path that reduces the penetration rate of a permeating material
and, thus, provides effective barrier performance against liquid,
moisture, vapor, and gas penetration. Such materials are marketed
under the BARRISURF.TM. trademark and available from Imerys of
Paris, France. Nanoclay materials can be prepared by surface
treating clay via cation exchange, mixing the resulting clay with a
suspension of polymer latex and associated additives, and
subjecting the resulting nanoclay material to ultrasonification.
Other methods of preparation are provided by Sun Q., et al.
Water-based polymer/clay nanocomposite suspension for improving
water and moisture barrier in coating. Composites Science and
Technology 67 (2007) 1823-1829, the contents of which are
incorporated herein by reference in its entirety.
[0033] According to yet another embodiment, the barrier layer as
disclosed herein includes at least one layer of a plasma-based
inorganic oxide material. Suitable inorganic oxide materials that
perform as a barrier layer or coating include aluminum oxide
(AlOx), silicon oxide (SiOx), and magnesium oxide (MgOx). In the
aforementioned oxide materials, "x" is a suitable number or
fraction for the stoichiometric amount of oxygen (e.g.,
Al.sub.2O.sub.3, SiO.sub.2, MgO). Such oxide coatings may be
prepared using plasma-assisted deposition on a substrate according
to various methods (Transparent barrier coatings update: flexible
substrates. 36.sup.th Annual Technical Conference Proceedings:
Society of Vacuum Coaters. (1993) 1-878068-12-1; 0. S. Kolluri, S.
L. Kaplan, D. A. Frazier. Plasma Assisted Coatings for the Plastics
Industry. Presented at the Fourth International Conference on
Surface Modification Technologies. November, 1990, Paris,
France--the contents of each are incorporated herein by reference
in their entirety). According to one embodiment, at least one
plasma-based oxide material is applied to a fiberboard wall of a
container to improve both gas and moisture barrier performance.
According to one embodiment, a lacquer coating is first applied or
deposited directly on the fiberboard to enhance the smoothness of
the surface. The plasma-based oxide coating is then deposited
directly on the lacquer.
[0034] FIG. 1 is a sectional view of an embodiment of a container
wall 100 of the present disclosure. The wall 100 may be
incorporated into any portion of the container embodiments
disclosed herein. In one embodiment, the wall 100 serves as a top,
bottom, side wall, or all of the above. As shown, the wall 100 is
typically multi-layer, with any or all of the layers carrying or
containing a barrier layer material as described herein. According
to the embodiment shown in FIG. 1, the wall includes three layers.
Each of the first layer 102, second layer 104, and third layer 106
includes a solid, supportive material with at least one layer or
coating of a barrier layer material 101 as disclosed herein.
According to one embodiment, each of the layers is manufactured
from a fibrous material such as, for example, fiberboard,
cardboard, or other paper product. According to one embodiment, the
third layer 106 optionally includes a label or wrapper (not shown).
The label material is selected based on aesthetics, branding or
advertising, and desired barrier properties.
[0035] As illustrated, the barrier layer material 101 (e.g.,
particulate materials such as the nanocellulose materials or clay
materials described herein) can optionally be dispersed in a random
fashion within one or more of each of the layers 102, 104, and 106
upon manufacture. Alternatively, the barrier layer material 101 can
be present as a layer adjacent to one or more of the structural
layers 102, 104, 106. Note that FIG. 1 illustrates a barrier layer
material 101 applied between layers 106 and 104, between layers 104
and 102, and also on the exterior surface of layer 102. The
presence of these barrier layer materials 101 is merely to show the
various places where such materials can be used. The invention is
not limited to container walls containing a barrier layer material
in every location set forth in FIG. 1. Instead, the invention
includes container walls containing only a single barrier layer
material 101 in a single location or any combination of barrier
layer materials shown in the figure.
[0036] The containers of the present disclosure can be prepared by
any known manufacturing process, such as the spiral bound
manufacturing processes set forth in U.S. Pat. Nos. 5,556,365 to
Drummond et al.; 5,829,669 to Drummond et al.; and 6,036,629 to Rea
et al., each of which are herein incorporated by reference in their
entirety. In a spiral bound process, a first innermost fiberboard
or paperboard layer is wound onto a stationary mandrel while
simultaneously winding one or more exterior fiberboard or
paperboard plies successively radially outwardly from the exterior
of the first ply. In one embodiment, the container can be
manufactured in a manner to produce a single ply paperboard
container according to the process forth in U.S. Pat. No. 5,586,963
to Lennon et al., which is incorporated herein by reference in its
entirety. In another embodiment, the container can be manufactured
in a manner to produce a multi-ply paperboard container according
to the process as set forth in U.S. Pat. No. 6,558,306 to Lowry et
al., which is incorporated herein by reference in its entirety.
[0037] According to one embodiment of the invention, at least one
barrier layer is applied to an exterior face or surface of the
paperboard ply and/or to the interior face of the adjacent exterior
paperboard ply via mist, spray, vapor deposition, or other
acceptable deposition techniques. The at least one barrier layer is
applied during manufacture of the side wall, bottom wall, and cover
(i.e., simultaneously) or after each component is prepared such
that the resulting container's interior receives at least one
barrier layer. As a result, radially adjacent plies forming
separate layers adhere strongly to each other so that the container
exhibits considerable strength. Although each of the spirally wound
layers includes a continuous helical seam, the walls or casing
material formed from several layers does not readily unravel
because the seams in adjacent paperboard layers are offset radially
from each other and because of the substantial surface bonding
between adjacent tube layers. In another embodiment, the at least
one barrier layer is applied to a separate fiber or paper substrate
which is, in turn, applied to the fiberboard or paperboard middle
layer that was manufactured via one of the aforementioned
processes. The steps of coating the substrate and applying the
substrate may be carried out in sequential or simultaneous
manner.
[0038] The container embodiments described in the present
application can be used to store any solid products, but are
particularly well-suited for products designed for human use or
oral consumption. Exemplary consumable products that are often
packaged in such containers include a wide variety of consumer
products, food products, and tobacco products. The number of solid
product units stored in the containers of the disclosure can also
vary, depending on the size of the container and the size of the
product units. Consumer products and food products include any
product that is susceptible to environmental pressures and exhibit
moisture sensitivity. Exemplary consumer products include, but are
not limited to, baby powder, beverages, potato chips, nuts, juice,
baby formula, powdered cleansers or detergents, cereal, pizza,
hamburgers, chicken, french fries, cookies, crackers, danishes, and
cookie dough.
[0039] Exemplary tobacco products include cigarettes, cigars,
pelletized tobacco products (e.g., compressed or molded pellets
produced from powdered or processed tobacco, such as those formed
into the general shape of a coin, cylinder, bean, pellet, sphere,
orb, strip, obloid, cube, bead, or the like), extruded or cast
pieces of tobacco (e.g., as strips, films or sheets, including
multilayered films formed into a desired shape), products
incorporating tobacco carried by a solid substrate (e.g., where
substrate materials range from edible grains to inedible cellulosic
sticks), extruded or formed tobacco-containing rods or sticks,
tobacco-containing capsule-like materials having an outer shell
region and an inner core region, straw-like (e.g., hollow formed)
tobacco-containing shapes, sachets or packets containing tobacco
(e.g., snus-like products), pieces of tobacco-containing gum, and
the like. Further, exemplary tobacco products include tobacco
formulations in a loose form such as, for example, a moist snuff
product. Exemplary loose form tobacco used with the containers of
the present disclosure may include tobacco formulations associated
with, for example, commercially available GRIZZLY moist tobacco
products and KODIAK moist tobacco products that are marketed by
American Snuff Company, LLC.
[0040] Exemplary smokeless tobacco compositions that can be
packaged in the containers of the present disclosure are set forth
in, for example, U.S. Pat. Nos. 1,376,586 to Schwartz; 3,368,567 to
Speer; 4,513,756 to Pittman et al.; 4,606,357 to Dusek et al;
4,821,749 to Toft et al.; 5,167,244 to Kjerstad; 5,387,416 to
White; 6,668,839 to Williams; 7,810,507 to Dube et al.; 7,819,124
to Strickland et al.; U.S. Patent Pub. Nos. 2005/0244521 to
Strickland et al.; 2006/0191548 to Strickland et al.; and
2008/0029116 to Robinson et al. Examples of tobacco-containing gum
are set forth in U.S. Pat. Nos. 4,624,269 to Story et al.;
4,975,270 to Kehoe; and 4,802,498 to Ogren. Various manners or
methods for packaging smokeless tobacco products are set forth in
US Patent Pub. Nos. 2004/0217024 and 2006/0118589 to Arnarp et al.;
and 2009/0014450 to Bjorkholm; and PCT Pub. Nos. WO 2006/034450 to
Budd; WO 2007/017761 to Kutsch et al.; and WO 2007/067953 to
Sheveley et al. All of the above-cited references are incorporated
by reference herein in their entirety.
[0041] Smokeless tobacco compositions utilized as the product
contained in the containers of the disclosure will often include
such ingredients as tobacco (typically in particulate form),
sweeteners, binders, colorants, pH adjusters, fillers, flavoring
agents, disintegration aids, antioxidants, oral care additives, and
preservatives. See, for example, U.S. Pat. No. 7,861,728 to Holton
et al., which is incorporated by reference herein in its
entirety.
[0042] Individual tobacco product units can be contained within a
pouch or bag, such as the type commonly used for the manufacture of
snus types of products (e.g., a sealed, moisture permeable pouch
that is sometimes referred to as a "portion"). A representative
moisture permeable pouch can be composed of a "fleece" type of
material. The tobacco formulation is in turn contained within a
package, such as the containers of the present disclosure described
more fully hereinbelow. The package is sealed tightly, and is
composed of a suitable material, such that the atmospheric
conditions within that sealed package are modified and/or
controlled. That is, the sealed package can provide a good barrier
that inhibits the passage of compositions such as moisture and
oxygen therethrough. In addition, the atmosphere within the sealed
package can be further modified by introducing a selected gaseous
species (e.g., nitrogen, argon, or a mixture thereof) into the
package prior to sealing or by drawing a vacuum therein (vacuum
sealing). As such, the atmospheric conditions to which the tobacco
composition is exposed are controlled during conditions of
preparation, packing, storage and handling. Descriptions of various
components of snus products and components thereof also are set
forth in US Pat. Pub. No. 2004/0118422 to Lundin et al., which is
incorporated herein by reference. See, also, for example, U.S. Pat.
Nos. 4,607,479 to Linden; 4,631,899 to Nielsen; 5,346,734 to Wydick
et al.; and 6,162,516 to Derr, and US Pat. Pub. No. 2005/0061339 to
Hansson et al.; each of which is incorporated herein by reference.
See, also, the representative types of pouches, and pouch material
or fleece, set forth in U.S. Pat. No. 5,167,244 to Kjerstad, which
is incorporated herein by reference. Snus products can be
manufactured using equipment such as that available as SB 51-1/T,
SBL 50 and SB 53-2/T from Merz Verpackungmaschinen GmBH. G.D SpA
out of Italy also supplies tobacco pouching equipment. Snus pouches
can be provided as individual pouches, or a plurality of pouches
and can be connected or linked together (e.g., in an end-to-end
manner) such that a single pouch or individual portion can be
readily removed for use from a one-piece strand or matrix of
pouches.
[0043] The shape of the outer surface of the containers of the
disclosure can vary. Although the container embodiments illustrated
in the drawings have certain contours, containers with other
exterior surface designs could also be used. For example, the sides
or edges of the containers of the disclosure could be flattened,
rounded, or beveled, and the various surfaces or edges of the
container exterior could be concave or convex. Further, the
opposing sides, ends, or edges of the container can be parallel or
non-parallel such that the container becomes narrower in one or
more dimensions.
[0044] The dimensions of smokeless tobacco container embodiments
described herein can vary without departing from the disclosure.
However, in preferred embodiments, the containers of the disclosure
can be described as having a cylindrical size suitable for handheld
manipulation and operation. Exemplary dimensions for such handheld
cylindrical embodiments include diameters in the range of about 50
mm to about 100 mm, and more typically about 60 mm to about 80 mm.
Exemplary wall thicknesses include the range of about 0.5 mm to
about 1.5 mm, and more typically about 0.8 mm to about 1.4 mm.
Exemplary depths for handheld container embodiments of the present
disclosure range from about 5 mm to about 50 mm, more typically
about 8 mm to about 30 mm, and most often about 15 mm to about 25
mm. An exemplary general outward appearance of the container is
that used for commercially available GRIZZLY and KODIAK products
that are marketed by American Snuff Company, LLC.
[0045] FIG. 2 illustrates one embodiment of a container in
accordance with the present disclosure. In this embodiment, a
smokeless tobacco container 10 is illustrated. The container 10 may
be formed by an open-ended body 20 and a cover 40. The body 20 has
a bottom wall which, in some instances, may be substantially
circular, and a side wall 24 having an inner surface 25 facing the
tobacco product. The side wall 24 depends from a bottom wall 22
which has an inner surface 23 and, in some instances, may be
cylindrical as shown. The side wall 24 defines a peripheral portion
of the container 10 such that the side wall 24 includes an outer
peripheral surface 28. The bottom wall 22 and the side wall 24
cooperate to define an internal storage compartment 26 for storage
of a plurality of units of a product. In some instances, an upper
portion 30 of the side wall 24 may define a lip 32 in such a manner
that the upper portion 30 the side wall 24 has a reduced diameter
(as compared to the diameter of the remainder of the outer surface
of the side wall).
[0046] The cover 40 may be provided for enclosing the units of
product within the internal storage compartment 26. In this regard,
the cover 40 is typically removably secured to the body 20 by a
snap-fit or an interference fit. As shown in FIG. 2, the cover 40
has a top wall 42 having an inner surface 43, which, in some
instances, may be substantially planar, and a peripheral flange 44
depending from the top wall 42 which, in some instances, may be
cylindrical. The peripheral flange 44 of the cover 40 is received
over the side wall 24 of the body 20 so as to form an enclosure
therebetween. In an alternative embodiment, protrusions,
projections, or ribs (not shown) may interact with the outer
peripheral surface 28 of the side wall 24 of the body 20.
[0047] The cover 40 will typically have the same approximate size
or diameter as the side wall 24 of the body 20 such that the cover
40 and body 20 form a smooth exterior surface when the cover is
placed over the of the lip 32 and fully seated upon the body.
Hence, the container 10 may be compact and flat so as to be
suitable for storage and transportation by a user.
[0048] The material of construction of the container 10 can vary.
Exemplary materials include metal, wood, fiberboard or cardboard,
polymeric, and synthetic plastic materials. Polymeric materials
that can be extruded and/or molded into desired shapes include
polyethylene, polystyrene, polyamide, polylactic acid,
polyhydroxyalkanoate polymers, polybutylene succinate, plasticized
cellulose acetate, and blends or copolymers thereof. In a preferred
embodiment, the body 20 and cover 40 are each formed from a
fiberboard material. Such a configuration is advantageous in that
it provides an aesthetically appealing appearance, while also
allowing the body to be produced by an economical and
environmentally-friendly process. Alternatively, the body 20 is a
formed of a fiberboard material and the cover 40 is metal.
[0049] FIG. 3 is a perspective view of another container embodiment
of the present disclosure. In this embodiment, a cigarette
container or "carton" 60 is illustrated. The container 60 has an
outer casing 62 and an inner frame 64 having an inner frame surface
66. The inner frame 64 protrudes from the upper end of the outer
casing 62 and forms an opening 68 in cooperation with the outer
casing 62. In this illustrated, exemplary embodiment, the container
60 further includes a lid 70 having an inner lid surface 72, which
is integrally jointed to a rear edge of the opening end 68 of the
inner frame 62 with a self hinge. The lid 70 is therefore rotatable
around an axis of the self hinge. In an alternative embodiment (not
shown), the lid is completely removable and replaceable.
[0050] The outer casing 62 and inner frame 64 may be manufactured
from fiberboard, cardboard, or thin foil or metal. The outer casing
62 may optionally include a label or wrapper on an outer face.
Typically, the selection of the packaging outer layer, label or
wrapper is dependent upon factors such as aesthetics, branding or
advertising, and desired barrier properties so as to provide
additional protection from exposure to the atmosphere and ingress
or regress of moisture. The outer casing 62 and inner frame 64 may
be prepared by known processes from a "blank" as described in U.S.
Pat. Nos. 5,699,903 to Focke et al.; 5,161,733 to Latif; 7,484,619
to Boriani et al; and US Pub. No. 2005/0252796, each of which is
incorporated by reference herein. In one embodiment, the outer
casing 62 is manufactured separately and subsequently superimposed
and adhered to the inner frame 62. Alternatively, the outer casing
62 and inner frame 64 are manufactured simultaneously as one
blank.
[0051] According to one embodiment, the inner frame surface 66 and
inner lid surface 72 each include at least one barrier layer as
described herein. According to one embodiment, a barrier layer
composition as described herein may be randomly disbursed within
the outer casing and inner frame during manufacture of the outer
casing 62 and inner frame 64 which is present either in addition to
the barrier layer of the inner frame surface 66 and inner lid
surface 72 or dispersed alone. In any of the aforementioned
embodiments, a barrier layer composition as described herein can be
applied to an inner surface of the outer casing 62.
[0052] According to one embodiment, the resulting containers can
then be sealed via application of a circumferential outer layer.
The outer layer may optionally include a label or wrapper on an
outer face. Typically, the selection of the packaging outer layer,
label or wrapper is dependent upon factors such as aesthetics,
branding or advertising, and desired barrier properties so as to
provide additional protection from exposure to oxygen and ingress
or regress of moisture. In an alternative embodiment, the outer
layer is directly applied to the middle layer during manufacture of
the middle layer.
[0053] Many modifications and other aspects of the disclosure set
forth herein will come to mind to one skilled in the art to which
the disclosure pertains having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the disclosure is
not to be limited to the specific aspects disclosed and that
modifications and other aspects are intended to be included within
the scope of the appended claims. Although specific terms are
employed herein, they are used in a generic and descriptive sense
only and not for purposes of limitation.
* * * * *