U.S. patent application number 15/974012 was filed with the patent office on 2018-09-13 for method for making particle of a hydrophobic additive and a polysaccharide coating and tobacco products containing particle of a hydrophobic additive and a polysaccharide coating.
This patent application is currently assigned to Philip Morris USA Inc.. The applicant listed for this patent is Philip Morris USA Inc.. Invention is credited to Georgios Karles, Yi Zeng, Shuzhong Zhuang.
Application Number | 20180255828 15/974012 |
Document ID | / |
Family ID | 44344065 |
Filed Date | 2018-09-13 |
United States Patent
Application |
20180255828 |
Kind Code |
A1 |
Zeng; Yi ; et al. |
September 13, 2018 |
Method for Making Particle of a Hydrophobic Additive and a
Polysaccharide Coating and Tobacco Products Containing Particle of
a Hydrophobic Additive and a Polysaccharide Coating
Abstract
A method for providing particles of encapsulated flavorants or
chemesthetic agents comprises forming an emulsion comprising: (i) a
first aqueous solution, comprising one or more polysaccharides; and
(ii) a hydrophobic additive; atomizing said emulsion in an atomizer
into droplets; introducing said droplets into a second aqueous
solution, comprising one or more metal cations, to form particles
comprising one or more cross-linked polysaccharides and said
additive encapsulated therein; and removing said particles from
said second aqueous solution and drying said particles.
Inventors: |
Zeng; Yi; (Richmond, VA)
; Zhuang; Shuzhong; (Richmond, VA) ; Karles;
Georgios; (Richmond, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Philip Morris USA Inc. |
Richmond |
VA |
US |
|
|
Assignee: |
Philip Morris USA Inc.
Richmond
VA
|
Family ID: |
44344065 |
Appl. No.: |
15/974012 |
Filed: |
May 8, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12748227 |
Mar 26, 2010 |
9993019 |
|
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15974012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24B 13/00 20130101;
A24D 3/048 20130101; A24D 1/002 20130101; A23L 27/72 20160801; A24B
15/283 20130101 |
International
Class: |
A24B 15/28 20060101
A24B015/28; A23L 27/00 20060101 A23L027/00; A24D 3/04 20060101
A24D003/04; A24B 13/00 20060101 A24B013/00; A24D 1/00 20060101
A24D001/00 |
Claims
1. Particles of encapsulated flavorants or chemesthetic agents,
made by a process comprising: (a) forming an emulsion comprising:
(i) a first aqueous solution, comprising one or more
polysaccharides; and (ii) a hydrophobic additive; (b) atomizing the
emulsion in an atomizer into droplets; (c) introducing the droplets
into a second aqueous solution, comprising one or more metal
cations, to form particles comprising one or more cross-linked
polysaccharides and said additive encapsulated therein; (d)
removing the particles from said second aqueous solution; and (e)
drying the particles.
2. The particles of claim 1, wherein the process further comprises:
(d2) introducing the particles removed from the second aqueous
solution into a third aqueous solution, comprising one or more
polysaccharides, for a time period sufficient to further coat the
particles, and removed from the third aqueous solution.
3. The particles of claim 2, wherein the process further comprises:
(d1) washing the particles removed from the second aqueous solution
with a first aqueous washing liquid, prior to the introducing the
particles in the third aqueous solution.
4. The particles of claim 1, wherein the atomizer is selected from
the group consisting of a pressure atomizer, an air atomizer, a
centrifugal atomizer, an electrostatic atomizer, and an ultrasonic
atomizer.
5. The particles of claim 4, wherein the atomizer is an
air-atomizer.
6. The particles of claim 1, wherein the emulsion further comprises
a surface active agent.
7. The particles of claim 6, wherein the surface active agent
comprises an emulsifier or wetting agent.
8. The particles of claim 3, further comprising washing the
particles removed from the third aqueous solution in a second
aqueous washing liquid to obtain washed particles.
9. The particles of claim 8, wherein the first and second aqueous
washing liquids are water.
10. The particles of claim 8, wherein the process further comprises
removing the second aqueous washing liquid from the washed
particles to obtain dried particles.
11. The particles of claim 1, wherein the one or more
polysaccharides are selected from the group consisting of
alginates, pectins, or carageenans.
12. The particles of claim 1, wherein the one or more metal cations
are selected from the group consisting of monovalent metal cations,
divalent metal cations, and trivalent metal cations.
13. The particles of claim 12, wherein the monovalent metal cations
are potassium cations, said divalent metal cations are calcium
cations, and said trivalent metal cations are aluminum cations.
14. The particles of claim 1, wherein the forming of the emulsion
comprises homogenizing a mixture of the aqueous solution and the
hydrophobic additive in a homogenizer.
15. The particles of claim 1, wherein the particles have an average
diameter ranging between about 400 .mu.m and about 550 .mu.m.
16. The particles of claim 15, wherein the particles have an
average diameter of about 479 .mu.m.
17. The particles of claim 1, wherein the particles comprise a
solid shell surrounding an interior comprising said hydrophobic
additive.
18. The particles of claim 17, wherein the solid shell has a
thickness ranging between about 15 .mu.m and about 20 .mu.m.
19. The particles of claim 1, wherein the hydrophobic additive
comprises one or more flavorants or chemesthetic agents.
20. The particles of claim 19, wherein the one or more flavorants
or chemesthetic agents comprise one or more of menthol, peppermint
oil, spearmint oil, rosemary oil, cherry oil, wintergreen flavor,
and citrus flavor.
21. The particles of claim 20, wherein the flavorant comprises
menthol,
22. The particles of claim 19, wherein the one or more flavorants
or chemesthetic agents are dissolved in an oil.
23. A smoking article comprising: (a) a rod comprising a smokable
composition; and (b) the particles of claim 1.
24. The smoking article of claim 23, wherein the particles are
disposed in said rod.
25. The smoking article of claim 23, wherein the smokable
composition comprises tobacco.
26. The smoking article of claim 23, wherein the smokable
composition comprises a tobacco substitute.
27. An oral sensorial product, comprising: (a) a filling material;
and (b) the particles of claim 1.
28. The oral sensorial product of claim 27, which is a pouch
product further comprising a wrapper at least partially surrounding
the filling material.
29. The oral sensorial product of claim 28, wherein the particles
are disposed in or on the filling material, the wrapper, or a
combination of these.
30. The oral sensorial product of claim 27, wherein the filling
material comprises tobacco or a tobacco substitute.
31. The oral sensorial product of claim 30, which is a chewing
tobacco product.
32. The oral sensorial product of claim 29, wherein the particles
are disposed in interstices between fibers of non-woven polymeric
material forming the wrapper.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional patent application of U.S.
patent application Ser. No. 12/748,227, filed Mar. 26, 2010, the
content of which are incorporated herein by reference in its
entirety.
SUMMARY
[0002] A method for providing tobacco products including particles
of encapsulated flavorants or chemesthetic agents, comprising:
(a) forming an emulsion comprising:
[0003] (i) a first aqueous solution, comprising one or more
polysaccharides; and
[0004] (ii) a hydrophobic additive;
(b) atomizing said emulsion in an atomizer into droplets; (c)
introducing said droplets into a second aqueous solution,
comprising one or more metal cations, to form particles comprising
one or more cross-linked polysaccharides and said additive
encapsulated therein; (d) removing said particles from said second
aqueous solution; (e) drying said particles; and (f) adding a
quantity of said dried particles to one or more of a smoking
article and oral pouch products.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0005] FIG. 1 is a flowchart schematically illustrating one
embodiment of a process for making microparticles as described
herein.
[0006] FIG. 2 is a photomicrograph from a scanning electron
microscope of alginate-menthol microparticles as described
herein.
[0007] FIG. 3 is a photomicrograph from a scanning electron
microscope of alginate menthol microparticles as described
herein.
[0008] FIG. 4 is an illustration of a smoking article including the
microparticles formed as described herein.
[0009] FIG. 5A is an illustration of an oral pouch product
comprising microparticles formed as described herein.
[0010] FIG. 5B is a cross-sectional view of the oral pouch product
of FIG. 5A comprising microparticles formed as described herein
[0011] FIG. 6 is a schematic illustration of a machine for forming
the pouch product of FIG. 5A.
DETAILED DESCRIPTION
[0012] When additive materials, in particular, flavorants and/or
chemesthetic agents, such as menthol, are incorporated into smoking
articles, such as by incorporation into the rod of smoking
composition in cigarettes, the premature release and migration of
the additive can become problematic. Because the additive materials
are often volatile, they can migrate and/or escape from the
cigarette during manufacture or storage, so that when the user
smokes the cigarette, the desired effect of the additive can be
decreased, resulting in a less desirable experience. In order to
attempt to compensate for this loss of additive, manufacturers
often include more additive material in the cigarette, which adds
to the cost thereof. In addition, in smoking articles that have
filter systems containing sorbents, such as activated carbon,
migration of additives to the sorbent, and sorption thereon, can
both decrease the amount of additive available to the user, and
result in a decreased level of sorption sites available for the
removal of targeted constituents.
[0013] The method described herein, the encapsulated additives
produced by this method, and smoking articles containing these
encapsulated additives, attempt to minimize or reduce these
potential problems with additive migration.
[0014] In one embodiment described herein, the method of
encapsulating an additive involves producing one or more particles
within which one or more additives have been encapsulated, In a
particular embodiment, these particles can be in the form of
powders, granules, agglomerations, or combinations of these. In a
particular embodiment, the particles contains a matrix of one or
more cross-linked polysaccharides, within which is encapsulated one
or more additive materials.
[0015] More particularly, in one embodiment, the method of
producing the particles includes (a) forming an emulsion containing
a first aqueous solution, which in turn contains one or more
cross-linkable polysaccharides, and also containing a additive; (b)
atomizing said emulsion using a spray atomizer into a second
aqueous solution, said second aqueous solution comprising one or
more metal cations; and (c) cross-linking at least a portion of
said one or more cross-linkable polysaccharides, thereby forming a
cross-linked particles comprising cross-linked polysaccharide and
additive encapsulated therein.
[0016] As used herein, the term "emulsion" denotes a stable mixture
of two or more immiscible liquids held in suspension. An emulsion
may, but need not, include added emulsifier.
[0017] As used herein, the term "aqueous solution" denotes a
solution where the solvent contains, but need not be limited to,
water.
[0018] As used herein, the term "cross-linkable polysaccharide"
denotes a combination of monosaccharides linked together by
glycosidic bonds, and capable of being cross-linked by an
appropriate cross-linking agent. The term is intended to include
polysaccharides such as pectins, alginates, and carageenans, which
are cross-linkable by monovalent or polyvalent metal cations.
Particularly suitable cross-linking metal cations include sodium
ions, potassium ions, calcium ions, and aluminum ions.
[0019] As used herein, the term "additives" denotes a material
included in a smoking article to modify one or more characteristics
of the smoke obtained when a smokable composition is heated or
combusted. The term is intended to include flavorant agents, such
as menthol, and oil-based flavorants, such as peppermint oil,
spearmint oil, rosemary oil, cherry oil, citrus flavorants, and
wintergreen type flavorants, such as methyl- or ethyl salicylates
and the like. In a particularly advantageous embodiment, the
additive comprises a flavorant agent. Menthol is a particularly
preferred flavorant agent for encapsulation as described herein.
Citrus flavorants are also particularly suitable, as they typically
have a shorter shelf life which can be prolonged by the methods and
compositions disclosed herein.
[0020] As used herein, the term "atomizing" denotes a process
whereby a liquid or gel, which may contain molten material, a
solution, an emulsion, or a combination of these, is caused to flow
through one or more orifices in a sprayer, and broken into
droplets.
[0021] As used herein, the term "particle" denotes a solid, gel, or
semisolid material having a relatively small size. Desirably, the
particle is a solid, free-flowing powder having a moisture content
of less than about 4% by weight.
[0022] As used herein, the term "metal cation" denotes a metal
cation of a metallic element that is capable of cross-linking a
cross-linkable polysaccharide. The term is intended to include
monovalent and polyvalent metal cations, as well as cations that
can take more than one valency. The term is particularly intended
to include the cations of elements in Groups 1, 2, 8, 11, 12, and
13 of the Periodic Table, and particularly intended to include
sodium, potassium, calcium, magnesium, and aluminum cations.
[0023] An exemplary embodiment of the method described herein is
presented with reference to FIG. 1. This Figure provides a
flowchart that schematically illustrates the preparation of
polysaccharide-menthol microparticles; however, the steps
illustrated are equally applicable to the preparation of
polysaccharide microparticles containing other flavorants, which
can be substituted for some or all of the menthol in the
flowchart.
[0024] As indicated in FIG. 1, a hydrophobic additive, such as
menthol or other flavorant, is added to a first aqueous solution
comprising one or more polysaccharides, and the resulting mixture
is heated (e.g., to about 60 C) or otherwise processed to form an
emulsion (e.g., by high speed mixing in a homogenizer). One or more
emulsifying agents may be added to increase the stability or ease
of formation of the resulting emulsion, if desired or
necessary.
[0025] The resulting polysaccharide-additive emulsion is then
sprayed through an atomizer into a second aqueous solution, which
can contain calcium chloride or other metal cations, which are
capable of causing ionic gelation or crosslinking of at least some
of the polysaccharides present in the emulsion. The atomizer breaks
up the bulk liquid emulsion into droplets of appropriate size to
form particles, in particular microparticles having an average
diameter ranging between about 400 .mu.m and about 550 .mu.m, even
more particularly around 479 .mu.m. The atomizer typically results
in a spray of droplets having more or less spherical shapes, which
shapes result primarily from the surface tension of the liquid
emulsion in the droplet. Several different types of atomizer can be
used to obtain the spray of droplets, including pressure (or
airless) atomization, air atomization, centrifugal atomization,
electrostatic atomization, and ultrasonic atomization.
[0026] Pressure, or airless, atomization uses relatively high
pressure to force a liquid through a small nozzle, resulting in a
stream or sheet of liquid moving at high speed through a gas,
typically air. As this high speed stream moves through lower
velocity air upon its exit from the nozzle, drag on the liquid
stream by the air through which it moves disrupts the stream,
breaking it into small droplets. Droplet size in such an atomizer
is generally a result of the atomizer nozzle orifice diameter, the
density of the gas into which the liquid stream exits, and the
velocity difference between the liquid stream and the gas. In
general, a larger orifice diameter produces a larger average
droplet size, and decreased liquid pressure in the atomizer, which
generally results in decreased liquid velocity for the same nozzle
orifice size, also causes a larger average droplet size.
[0027] Air atomizers force liquid through a nozzle at relatively
low speed, surrounded by a relatively high speed stream of gas,
typically air. The interaction between the liquid and the air
accelerates and disrupts the liquid, forming a spray of droplets.
Again, the relative velocity difference between the liquid and the
gas bring about atomization. Because air atomization allows
separate control of both the flow rate of the liquid stream (via
control of pressure and nozzle orifice size) and the air stream
(via control of air pressure), this technique allowsfor better
control of droplet size, and for the production of fine droplets
suitable for forming microparticles using the processes described
herein.
[0028] Centrifugal atomizers introduce liquid through a nozzle into
a spinning cup, or onto a spinning disk. The liquid moves to the
lip of the cup or the edge of the disk, from where it is thrown off
in the form of streams or sheets that break up into fine droplets.
Both flow rate of liquid through the nozzle and the rotational
velocity of the cup or disk can be independently controlled to
control droplet size, and the technique can be combined with the
application of electrostatic charge to the already formed droplets
to attract them to a grounded target substrate (such as the aqueous
crosslinker solution). In addition, an air stream can be applied to
the region around where the droplets are being thrown off in order
to modify their direction, and move them more rapidly in the axial
direction.
[0029] Electrostatic atomizers are charged, and expose the liquid
to an electric field between the atomizer and the destination
(e.g., the aqueous crosslinker solution). The liquid becomes
charged, and this charge cause it to move through the electric
field away from the atomizer, causing the liquid to stream and
break up into droplets. For a given fluid, the droplet size can be
varied by varying the electric field strength and/or the liquid
flow rate.
[0030] Ultrasonic atomizers use an ultrasonic transducer vibrating
at a high frequency to break a fluid stream passing nearby into
droplets. Droplet size can be varied by varying the frequency of
vibration of the transducers. Ultrasonic atomizers are generally
only used with low-viscosity, Newtonian fluids.
[0031] The droplet size attainable with a particular atomizing
technique is also dependent on the liquid being atomized, and in
particular on the surface tension, viscosity, and density
properties of the liquid.
[0032] In general, high surface tension tends to stabilize a
liquid, helping to prevent its breakup into droplets. Liquids with
higher surface tensions tend to have larger average droplet sizes
after undergoing a particular atomization process. Surface tension
of liquids can be decreased by the addition of surfactants,
detergents, emulsifiers, or other surface active agents. In
addition, surface tension tends to decrease with increasing
temperature of the liquid.
[0033] In general, high viscosity tends to stabilize a liquid as
well, leading to a larger average particle size. Lower viscosity
liquids tend to atomize at a closer distance to the nozzle orifice
than higher viscosity fluids, and to form smaller droplets.
[0034] In general, higher liquid density tends to cause liquids to
resist acceleration, which is part of the process of droplet
formation. As with surface tension and viscosity, higher density
tends to result in higher average droplet particle size. Both
density and viscosity are properties of the composition of the
liquid, and are more difficult to vary than surface tension.
[0035] In a particular embodiment, the atomizer used is an air
atomizer, in order to provide better control of both the direction
of the spray of droplets, and the average size of the droplets and
the particles formed from them.
[0036] As indicated in FIG. 1, the emulsion is atomized and forms a
spray directed toward a aqueous solution of calcium chloride or
other metal cation ionic crosslinking agent suitable for
crosslinking at least some of the polysaccharide in the emulsion.
The droplets form particles in the second aqueous solution as the
result of this gelation or crosslinking. The particles contain a
polysaccharide shell surrounding or encapsulating the hydrophobic
additive. These particles are then removed from the second aqueous
solution, and washed with a first aqueous washing liquid, such as
distilled water. The washed particles can be dried and used, or can
be suspended in a third aqueous solution, comprising one or more
polysaccharides, in order to thicken the polysaccharide shell
surrounding the hydrophobic additive, or to provide multiple layers
of polysaccharide shell. The particles can then be removed from
this third aqueous solution, and washed with a second aqueous
washing liquid, such as distilled water.
[0037] These washed particles can then be dried and incorporated
into products in need of hydrophobic flavorants. Any suitable
drying process can be used, and drying is generally carried out
until the particles are in the form of a free-flowing powder. In a
particular embodiment, the particles are dried until they have a
moisture content of less than about 4% by weight. SEM
photomicrographs of the particles prepared using alginate as the
polysaccharide, menthol as the hydrophobic additive, and calcium
chloride as the crosslinking agent are shown in FIGS. 2 and 3. The
particles contained solid shells having a wall thickness ranging
from about 15 .mu.m to about 20 .mu.m, and an average diameter of
around 479.+-.68 .mu.m. Particularly visible in FIG. 3 is the
random internal pore structure, surrounded by a solid shell. These
pores are believed to form as the result of the sublimation of
trapped menthol, which occurred during sample preparation for the
SEM procedure. It will be understood that the particular
polysaccharide, hydrophobic additive, and crosslinking agent used
herein are exemplary, and may be varied in accordance with the
disclosure herein.
[0038] Such products may include smoking articles, oral sensorial
products, such as smokeless products containing tobacco and/or
tobacco substitutes, in particular pouch products or chewing
tobacco, food products, cosmetic formulations, nutraceutical
products, and pharmaceutical products. In a particular embodiment,
the products include smoking articles and smokeless products
containing tobacco and/or tobacco substitutes.
[0039] In a particularly preferred embodiment, a quantity of the
microparticles formed as described herein are incorporated into a
smoking article 10, such as a cigarette, as shown in FIG. 4. The
cigarette may be a traditional cigarette, and may comprise a rod 12
of smokable material, such as tobacco or tobacco substitute,
generally enclosed within a smokable wrapper, such as a paper
wrapper. Optionally, the traditional cigarette can include a filter
14, which typically comprises a plug of fibrous material, such as
cellulose acetate treated with triacetin, that is attached to the
rod of smokable material via a tipping paper. In such products, the
particles can be incorporated into the rod 12 of smokable material,
the filter plug 14, the tipping paper 18, the wrapper 16, or a
combination of these. Alternatively, the smoking article 10 may be
a nontraditional cigarette. Non-traditional cigarettes can include,
e.g., electrically heated cigarettes and/or fuel element heated
cigarettes.
[0040] As used herein, the term "electrically heated cigarette"
denotes an alternative to the traditional cigarette used in used in
electrical smoking systems. Electrical smoking systems can
generally include an electrically powered lighter and an
electrically heated cigarette, which can be constructed to
cooperate with the lighter, and which generally contains a rod or
column of smoking composition. Electrical smoking systems generate
only small amounts of sidestream smoke, and also permit consumers
to suspend and reinitiate smoking as desired. Exemplary electrical
smoking systems are described in U.S. Pat. Nos. 6,026,820;
5,988,176; 5,915,387; 5,692,526; 5,692,525; 5,666,976; 5,499,636;
and 5,388,594. Other non-traditional cigarettes include those
having a fuel element in the tobacco rod as described in U.S. Pat.
No. 4,966,171.
[0041] As used herein, the term "smokable material" is intended to
include tobacco (i.e., cut filler, tobacco powder, etc.), tobacco
substitute materials (i.e., vegetable or plant products like
shredded lettuce) or a mixture of both. Specific examples of
smoking compositions may include, but are not limited to,
flue-cured tobacco, Burley tobacco, Maryland tobacco, Oriental
tobacco, rate tobacco, specialty tobacco, reconstituted tobacco,
genetically modified tobacco, and blends thereof. Smoking
compositions can include these materials in any suitable form,
including, but not limited to: lamina, such as tobacco lamina;
processed materials, such as volume expanded or puffed tobacco;
ground materials, such as ground tobacco; processed stems, such as
cut-rolled or cut-puffed tobacco stems, reconstituted material,
such as reconstituted tobacco; and blends thereof.
[0042] When incorporated into the filter of a traditional or
nontraditional cigarette, the particles can be dispersed through
the filter material, e.g., in the interstices between fibers of a
fibrous filter, or may be primarily located in a chamber or space
in a "plug-space-plug" filter configuration, or a combination of
these.
[0043] As indicated above, the filter rod 14 can be provided with
an outer layer 18 (e.g., plug wrap or tipping paper) to help to
maintain its shape, The outer layer 18 can comprise a wrapping of
cigarette paper or other sheet material; the material of the outer
layer can include any wrapping suitable for surrounding the filter
material, including wrappers containing flax, hemp, kenaf, esparto
grass, rice straw, cellulose, and so forth. Optional filler
materials, flavor additives, and burning additives can be included
in the cigarette wrapper. The wrapper can have more than one layer
in cross-section, such as in a bi-layer wrapper disclosed in
commonly-owned U.S. Pat. No. 5,143,098.
[0044] The resulting cigarettes can be manufactured to desired
specifications using standard or modified cigarette making
techniques and equipment. In a particular embodiment, cigarettes
generally range in length from about 50 mrn to about 120 mm, and
range in circumference from about 15 mm to about 30 mm, preferably
around 25 mm, The tobacco packing density is typically between
about 100 mg/cm.sup.3 and about 300 mg/cm.sup.3, and preferably
between about 150 mg/cm.sup.3 and about 275 mg/cm.sup.3.
[0045] If tobacco is present in the smoking composition, it is
typically added, at least in part, as cut filler. Tobacco cut
filler is normally in the form of shreds or strands, which have
been cut or otherwise processed so that they have widths which are
generally in the range from about 1/10 inch to about 1/40 inch,
more particularly from about 1/10 inch to 1/20 inch. The lengths of
the strands are generally in the range from about 0.25 inches to
about 3 inches. The cigarettes may further comprise one or more
flavorants or other additives (e.g, burn additives, combustion
modifying agents, humectants, sweeteners, aerosol formers, coloring
agents, binders, etc.).
[0046] When the product is a smokeless oral sensorial product 20,
such as a smokeless tobacco or tobacco-substitute pouch product as
shown in FIGS. 5A and 5B, the particles can be added to the filling
material 24, which can include tobacco or other plant material. In
addition, in a pouch-type product, where the tobacco or other plant
material is at least partially enclosed within a polymeric or paper
wrapper 22, the particles can also or alternatively be incorporated
within the wrapper material 22, e.g. by introducing them into the
interstices between the fibers of a nonwoven polymeric
material.
[0047] As shown in FIGS. 5A and 5B, the wrapper 22 is formed of a
permeable or semi-permeable material, such that saliva can pass
through the wrapper 22 to the interior of the pouch product 20, and
the flavors and juices from the filling material 24 contained
within the interior of the pouch product 20 can be drawn out of the
pouch and into the user's mouth.
[0048] In a preferred embodiment, wrapper 22 comprises paper
suitable for oral pouch products commonly referred to as "snus" or
snuff. For example, the wrapper can be formed of a cellulose fiber
material, such as tea bag material or materials typically used to
form snus pouches. Desirably, the wrapper 22 is made from a
material suitable for contact with food, such as materials used in
packaging or handling foods. Preferred porous materials include,
but are not limited to, films, gelatin, food casings, carrageenan,
biopolymers, fabric (woven or non-woven), and/or paper such as
filter paper, papers used to construct tea bags, coffee filters,
and the like. Preferably, the material used to form the wrapper 22
has a neutral or pleasant taste or aroma. Preferably, the material
used to form the wrapper 22 is selected to have desired properties
of stain resistance, water permeability and/or porosity, and/or
water insolubility.
[0049] Additionally, the materials used to form the wrapper 22 can
be provided with predetermined levels for basis weight and/or wet
strength in order to reduce occurrence of breakage of the wrapper
22 during manufacturing operations, storage and use. For example, a
wrapper 22 can be provided with a basis eight of about 5 to about
25 g/m.sup.2, such as 5-10, 10-15, 15-20, or 20-25 grams/meters'
(g/m.sup.2) depending upon the final usage requirements, and/or a
wet tensile cross-direction (CD) strength of about 15 to about 75
N/m, such as 15-30, 30-45, 45-60, or 60-75 Newtons/meter (N/m)
depending upon the final usage requirements. One exemplary material
is a tea bag material with a basis weight of about 16.5 g/m.sup.2
with a wet tensile CD strength of 68 N/m.
[0050] It is also noted that the thickness of the wrapper 22 can be
varied to achieve desired levels of solubility through the wrapper
22. For example, the paper can be about 0.1 mm to about 0.125 mm
thick or about 0.07 mm to about 0.08 mm thick.
[0051] In a preferred embodiment, the wrapper 22 maintains
sufficient structural integrity during the time period that the
wrapper 22 is used so that the filling material 24 is retained
therein. In an embodiment, flavorants may be added to the wrapper
22 to provide additional flavor to the user. For example,
peppermint oil can be applied to the wrapper 22 to deliver flavor
during use.
[0052] Preferably, the oral pouch product 20 weighs about 0.1 g to
about 5.0 g. These ranges for weight can be further restricted to
(a) about 0.1 g to about 1.0 g, (b) about 1.0 g to about 2.0 g, (c)
about 2.0 g to about 3.0 g, (d) about 3.0 g to about 4.0 g or (e)
about 4.0 g to about 5.0 g. Also preferably, the oral pouch product
20 is about 0.25 inch to about 2.0 inches in width, about 0.25 inch
to about 2.0 inches in length, and about 0.05 inch to about 2.0
inches thick. In an embodiment, the oral pouch product 20 is about
0.1 inch to about 2.0 inches in width, about 0.1 inch to about 2.0
inches in length and about 0.05 inch to about 1.0 inch thick.
[0053] The oral pouch product 20 may have a square, rectangular,
quadrilateral, circular, moon, crescent, or oblong shape. The oral
pouch product 20 can also be shaped like a half-moon or D-shape, or
can take other shapes, including, without limitation oval,
pouch-shape, rod-shape, cylindrical, tea leaf, tear drop, or
hourglass shapes. In some embodiments, the pouch-shape can be
similar to a ravioli or pillow shape. Other shapes may be utilized
so long as the shapes fit comfortably and discreetly in a user's
mouth.
[0054] Preferably, sharp corners are avoided as sharp corners may
lead to oral discomfort. In a preferred embodiment, the wrapper 22
is sealed around one or more edges to contain the filling material
24 within the wrapper 22.
[0055] As shown in FIG. 5A, in one embodiment, the oral pouch
product 20 comprises a longitudinal seam 70. The longitudinal seam
70 can comprise overlapping sections of the wrapper 22. Preferably,
the oral pouch product 20 also includes at least one transverse
seam 60. The transverse seams 60 can be formed such that the inner
surface of the wrapper 22 contacts another section of the inner
surface of the wrapper 22 to form the transverse seam 60 (shown in
FIG. 5B).
[0056] As shown in FIG. 6, pouch forming operations can be executed
by feeding a ribbon of wrapper 22 through a poucher machine 50,
such as those manufactured by Merz Verpackungsmaschinen GmbH, Lich,
Germany. In an embodiment, a wrapper 22 can be fed through the
poucher machine 50. Such systems typically include a folding horn
or shoe 55, a cutter 65 and a feeder 61, which cooperate to
repetitively fold the ribbon of wrapper material into a tube,
close-off and seal an end portion of the tube, feed a measured
amount of pouch filling material into the closed-off tube to create
a filled portion of the tube and seal and sever the filled portion
of the tube to repetitively form individual pouches 20.
[0057] Preferably, the filling material is dispensed as a loose
filling material. Most preferably, the filling material is feed
into the pouches at a density of about 10 to about 50 pounds per
cubic foot or about 15 to about 30 pounds per cubic foot. The
filling material 24 can include microparticles as formed herein. In
other embodiments, the microparticles can be applied to the wrapper
24 before and/or after formation of the oral pouch products 20.
[0058] Oral pouch products 20 are continuously formed by
introduction of predetermined amounts of the filling material 24
into the tubular form above a transverse seam, formation of an
upper transverse seam above the filling and cutting the tubular
formation at locations along the length of the tubular formation to
form individual pouches.
[0059] Sealing may be accomplished by any suitable sealing method,
such as, for example, adhesive or by mutual sealing. Mutual sealing
may be thermal or sonic. Preferably, sealing is accomplished by
thermal sealing. Preferably, the inner web is paper with a flavor
coating on one side and is sized to avoid becoming part of the
longitudinal seam.
[0060] When used in cigarettes or smokeless oral sensorial
products, the particles described herein provide excellent flavor
stability, because migration and loss of volatile flavorants, such
as menthol, is reduced. In addition, particularly in smokeless oral
sensorial products, such as pouch products and chewing tobacco, the
particles also provide for controlled or prolonged release of the
flavorants, because the release profiles of the particles can be
controlled by changing the amount or identity of the polysaccharide
coating, the degree of crosslinking or gelation, and the like.
[0061] In this specification, the word "about" is often used in
connection with numerical values to indicate that mathematical
precision of such values is not intended. Accordingly, it is
intended that where "about" is used with a numerical value, a
tolerance of 10% is contemplated for that numerical value. In
addition, the use of geometric terms is intended to include not
only the precise geometric shapes, but also similar geometric
shapes that may, for example, have rounded or chamfered corners,
non-linear edges, and similar departures from strict geometrical
definitions.
[0062] It will be understood that the foregoing description is of
the preferred embodiments, and it, therefore, merely representative
of the articles and methods of manufacturing the same. It can be
appreciated that variations and modifications of the different
embodiments in light of the above teachings will be readily
apparent to those skilled in the art. Accordingly, the exemplary
embodiments, as well as alternative embodiments, may be made
without departing from the spirit and scope of the articles and
methods as set forth in the attached claims. Any references
mentioned herein are incorporated by reference into this disclosure
in their entirety.
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