CN117295411A

CN117295411A - High strength packaging material comprising extracted tobacco

Info

Publication number: CN117295411A
Application number: CN202280018163.5A
Authority: CN
Inventors: H·阿尔瓦雷斯
Original assignee: Swamont Luxemburg
Current assignee: Swamont Luxemburg
Priority date: 2021-03-02
Filing date: 2022-03-01
Publication date: 2023-12-26
Also published as: EP4301166A1; JP2024508145A; KR20230152061A; CA3210042A1; AU2022228734A1; US20220279835A1; WO2022185217A1

Abstract

A wrapper for an aerosol-generating product is disclosed, the wrapper comprising an extracted tobacco material in combination with a strength building fiber. The strength building fibers are refined and optionally bleached bast fibers. In one aspect, the bast fiber may be a hemp fiber. The wrapper may comprise the extracted tobacco material in an amount of greater than 40% by weight.

Description

High strength packaging material comprising extracted tobacco

RELATED APPLICATIONS

This application is based on and claims priority from U.S. provisional patent application No. 63/155,518, having application day 2021, 3, 2, which provisional patent application is incorporated herein by reference.

Background

There are a variety of different aerosol generating products that generate aerosols for enjoyment by a user. Such products include, for example, smoking articles, heated but non-burning rods, and the like. Aerosol-generating products typically comprise a rod-shaped aerosol-generating filler covered by an outer wrapper.

Traditionally, the outer wrapper of aerosol-generating products is made from papermaking fibers, such as pulp fibers. The use of papermaking fibers, for example, provides a package having sufficient strength to pass through high-speed machinery used to produce aerosol-generating products.

While papermaking fibers provide a number of advantages in producing packaging materials for aerosol-generating products (e.g., smoking articles), papermaking fibers can negatively impact the overall taste of the product. Thus, in the past, those skilled in the art have attempted to incorporate tobacco materials into wrapper paper. However, the incorporation of large amounts of tobacco material in the wrapper can negatively impact the strength of the product. In particular, wrappers containing substantial amounts of tobacco material that have been manufactured in the past have not exhibited sufficient strength for use in high speed machines, such as cigarette making machines.

In view of the foregoing, there is a need for a packaging material containing a substantial amount of tobacco that has sufficient strength for use in constructing aerosol-generating products.

Disclosure of Invention

The present disclosure relates generally to a wrapper made of tobacco material for an aerosol-generating product. More particularly, the present disclosure relates to a high strength packaging material comprising a substantial amount of tobacco material. The wrapper of the present disclosure may be used to produce all different types of products, including cigarettes and other smoking articles, heated but non-burning rods, and the like.

For example, in one embodiment, the present disclosure relates to a packaging material for covering an aerosol-generating filler. The wrapper comprises a web comprising at least about 40% by weight of extracted tobacco material. The extracted tobacco material is mixed with strength building fibers (strength building fibers). The strength building fibers include refined bast fibers. The refined bast fibers have an average fiber length of less than about 4 millimeters. The wrapper has a basis weight of about 15gsm to about 45 gsm.

In certain aspects, the web may comprise at least about 50% by weight, such as at least about 60% by weight, such as at least about 70% by weight, such as at least about 80% by weight, of extracted tobacco material. The tobacco material is extracted in such a way that the tobacco material and/or the web has a water-soluble substance content of less than about 20 wt%, such as less than about 17 wt%, such as less than about 15 wt%, such as less than about 12 wt%, such as less than about 10 wt%, such as less than about 8 wt%. The refined bast fibers may include hemp fibers and may be present in the web in an amount greater than about 10 wt%, such as greater than about 12 wt%, such as greater than about 14 wt%, such as greater than about 16 wt%. In one aspect, the refined bast fiber is also bleached.

In accordance with the present disclosure, the packaging material may have a tensile strength of greater than about 2100cN/30 mm, such as greater than about 2200cN/30 mm, such as greater than about 2300cN/30 mm, such as greater than about 2400cN/30 mm, and generally less than about 3400cN/30 mm, as measured in accordance with ASTM test D828-97. The packaging material may also have an elongation (stretch) of greater than about 1%, such as greater than about 1.2%, such as greater than about 1.5%, as measured according to ISO test 1924 (2008).

Optionally, the packaging material may further comprise wood pulp fibers. The wood pulp fibers may be, for example, softwood fibers, hardwood fibers, or a mixture thereof. The wood pulp fibers may be present in the web in an amount up to about 10% by weight, typically less than about 8% by weight, such as less than about 6% by weight.

In one aspect, the tobacco material contained in the wrapper has been treated by an extraction process to remove water soluble components, and has also been refined. However, in one embodiment, the tobacco material has not been subjected to a pulping process, which refers to mixing the tobacco material with a base (e.g., sodium hydroxide) and cooking in a digester. The use of refined bast fibers allows the use of extracted but not pulped tobacco fibers while still providing adequate strength and forming characteristics.

In one aspect, the wrapper has a basis weight of about 25gsm to about 38 gsm. The packaging material may have a permeability of about 5Coresta to about 80Coresta, such as about 8Coresta to about 38 Coresta. The packaging material may optionally comprise a filler. For example, in one embodiment, the packaging material does not contain filler particles. Alternatively, filler particles may be present in the packaging material in an amount of about 0.5% to about 30% by weight, for example about 1% to about 12% by weight.

In one aspect, the packaging material may be treated with a burn control agent to better control the burn characteristics. For example, the combustion control agent may comprise a carboxylate salt, such as a citrate or succinate salt. The combustion control agent may be present on the packaging material in an amount of about 0.3% to about 3% by weight, for example about 1% to about 2% by weight.

The packaging material may also be treated with a wetting agent and/or glue. The humectant may include, for example, glycerin, propylene glycol, or mixtures thereof. In another aspect, the gum may include guar gum, alginate, carboxymethyl cellulose, or mixtures thereof. The glue may be present on the packaging material in an amount of about 0.1% to about 2% by weight.

When used in a smoking article, the wrapper may optionally further comprise a plurality of discrete reduced ignition areas spaced apart along the first direction of the wrapper. The reduced ignition areas may have a diffusivity of less than about 0.5 cm/sec at 23 ℃. The plurality of reduced ignition areas may be formed by applying a reduced ignition composition to the web. The reduced ignition composition may include, for example, cellulosic fibers, film forming materials, or mixtures thereof.

Other features and aspects of the disclosure will be discussed in more detail below.

Brief description of the drawings

The full and enabling disclosure of the present disclosure will be set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

FIG. 1 is a perspective view of one embodiment of an aerosol-generating product incorporating the packaging material of the present disclosure; and

fig. 2 is an exploded view of the aerosol generating product shown in fig. 1.

Reference numerals have been repeated among the specification and the drawings to represent the same or analogous features or elements of the invention.

Definition of the definition

As used herein, "aerosol-generating material" is meant to include combustible materials that undergo combustion in a smoking article and aerosol-forming materials that are heated but do not burn to form an inhalable aerosol. Combustible smoking articles may include cigarettes, cigarillos and cigarillos, pre-rolled cones and the like. In cigarettes, the aerosol-generating material is generally wrapped by a wrapper to form a smokable rod. Aerosol-generating devices for generating aerosols include, for example, devices that generate aerosols by electrical heating or by transferring heat from a combustible fuel element or heat source to heat but not burn an aerosol-generating material that releases volatile compounds. As the released compounds cool, they condense to form an aerosol that is inhaled by the consumer.

As used herein, "extracted tobacco fibers" refers to tobacco fibers that have undergone an extraction process in which the tobacco is contacted with an aqueous solution to remove more than 40%, such as more than 50%, such as more than 60%, such as more than 70%, such as more than 75%, of the water soluble components contained in the tobacco. The extraction process results from a delignification process and a bleaching treatment.

"delignified" cellulose fibers as used herein refers to fibers that have undergone a pulping or delignification process in which the cellulose fibers are separated from the plant material by chemical means, mechanical means, or by a combination of chemical and mechanical means.

The term "refining" as used herein is used to denote the mechanical treatment of plant material to alter the fibers of the material to make them more suitable for forming a fibrous sheet or substrate. Refining may be accomplished using a cone refiner or a disc refiner or a tile Li Dajiang machine. The mechanical process exerts a grinding and rolling action on the plant material such that the plant material is defibrated. Refining is a process different from delignification and pulping.

The "amount of water-soluble extract" present in the matrix or reconstituted plant material or aerosol-generating material as used herein is determined by taking 5 grams in a sample boiling in distilled water for 10 minutes to obtain an extract containing water-soluble components. The dry matter weight of the solvent-soluble extract is calculated from the difference between the dry weight of the sample and the dry weight of the sample after extraction. The difference in dry weight is then used to determine the percentage of water soluble extract in the sample.

Detailed Description

It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present disclosure.

The present disclosure relates generally to a packaging material for aerosol-generating products formed from a web comprising extracted tobacco fibers in combination with strength building fibers. The strength building fibers include refined bast fibers, such as hemp fibers. In accordance with the present disclosure, the wrapper may contain greater than 40% by weight of tobacco material and still have sufficient strength and other characteristics to be required for mass production of aerosol-generating products, such as smoking articles, heated but non-burning rods, and the like.

The plurality of tobacco fibers contained in the wrapper produce a natural and pleasing tobacco taste when consumed in the aerosol-generating product. In addition, the tobacco material is extracted by removing water-soluble components. Removing the water-soluble components may remove unwanted components. In one aspect, the water-soluble ingredients may optionally be concentrated and/or filtered and reapplied. In another aspect, a flavorant may be applied to the packaging material. The wrapper of the present disclosure also has good performance characteristics on conventional cigarette making machines due to its mechanical properties. The packaging material of the present disclosure can be used to produce all different types of aerosol-generating products, such as cigarettes, cigarillos, and the like. The packaging material may also be combined with a quantity of a humectant for heated but non-burning applications.

In addition to the advantages described above, the packaging materials of the present disclosure also have excellent aesthetic properties. For example, because of the large amount of tobacco material contained in the product, the packaging material may have a visual association with the identity of the tobacco. In addition, the wrapper may be treated with a colorant (e.g., dye) to further enhance the natural tobacco appearance.

As described above, the wrapper of the present disclosure comprises a mixture of extracted tobacco material and strength building fibers. Optionally, the packaging material may further comprise pulp fibers and/or filler particles.

The tobacco material that can be used to produce the wrapper can comprise any suitable type of tobacco ingredient. The tobacco ingredients may include, for example, tobacco stems (e.g., cured tobacco stems), tobacco leaves, tobacco dust, and/or other tobacco byproducts. According to the present disclosure, the tobacco material may be subjected to an extraction process to remove water soluble components. In particular, solvent-soluble (e.g., water) compounds naturally present in tobacco materials can cause problems, for example, during the manufacture of the wrapper or later in the manufacture of the aerosol-generating product. Thus, the tobacco material incorporated into the wrapper is preferably subjected to an extraction process. The extraction process may include placing the tobacco material in water and causing the water soluble portion to be extracted into the water. In an alternative embodiment, various water-miscible solvents (e.g., alcohols (e.g., ethanol)) and/or suitable oils and fats may be combined with water to form an aqueous solvent. In some cases, the aqueous solvent may have a water content of greater than about 50% by weight of the solvent, such as greater than about 90% by weight. Deionized water, distilled water, or tap water may be used. The amount of solvent in the suspension of tobacco material may vary widely, but is typically added in an amount of from about 50% to about 99% by weight of the suspension, such as from about 60% to about 95% by weight, and in one aspect, from about 75% to about 90% by weight of the suspension. In one embodiment, the solvent may be heated prior to or during contact with the tobacco material. For example, in one aspect, the extraction solution may be a hot aqueous solution.

The tobacco material and solvent may optionally be agitated by stirring, shaking or otherwise mixing the suspension to increase the dissolution rate. Typically, the process may be conducted for about ten minutes to about six hours. The process temperature may range from about 10 ℃ to about 100 ℃, such as from about 23 ℃ to about 80 ℃. In one aspect, the temperature of the suspension may be about 40 ℃ to about 80 ℃.

After the tobacco material is soaked and optionally agitated, the insoluble portion of the tobacco material may be mechanically separated from the soluble portion of the tobacco material using a press or centrifuge or any other suitable device or method. Once the soluble fraction is separated from the insoluble fraction, the soluble fraction may be discarded or further processed, for example by concentration. Any known type of concentrator (e.g., vacuum evaporator) may be used to concentrate the soluble fraction. In some applications, the water-soluble portion may be discarded or used in other processes. However, if desired, a portion or all of the soluble portion may be concentrated and reapplied to the web formed from the extracted tobacco material.

The extraction process performed on the tobacco material removes soluble compounds, which facilitates processing of the tobacco material into a web. The extraction process may also be used to remove unwanted compounds. For example, various components, such as nitrosamines, may be removed from the tobacco material by an extraction process. The extraction process may also remove nicotine if desired.

The resulting water-insoluble extracted tobacco material is typically in an unrefined state. The tobacco material may comprise particles and fibers. In one embodiment, the insoluble and extracted tobacco material may optionally be subjected to a refining process. For example, the extracted tobacco material may be passed through any suitable refining apparatus, such as a cone refiner or a disc refiner. Other refining apparatus that may be used include beaters, such as a tile Li Dajiang machine (Valley beater). The refining may be performed while the tobacco material is in a moist state or after mixing with water. For example, in one embodiment, the refining may be performed when the consistency of the tobacco material is less than about 10%, such as less than about 5%, such as less than about 3%.

In one aspect, the extracted and refined tobacco material may contain relatively small amounts of water-soluble components. For example, the extracted tobacco material may comprise less than about 30 wt%, such as less than about 20 wt%, such as less than about 17 wt%, such as less than about 15 wt%, such as less than about 12 wt%, such as less than about 10 wt%, such as less than about 8 wt%, such as less than about 6 wt%, and typically greater than about 2 wt% of the water soluble component. As described above, the water-soluble ingredients may optionally be concentrated or otherwise treated and reapplied to a web formed of tobacco material. However, in a preferred embodiment, the water-soluble component is not reapplied to the extracted tobacco material.

According to the present disclosure, the extracted tobacco material or tobacco fibers are combined with strength building fibers (especially refined bast fibers). The extracted tobacco fibers may be non-pulped, meaning that the fibers have not been subjected to a pulping process that combines the fibers with an alkaline material (Kraft process) or with an acidic material (Sulfite process) and cooked in a digester. On the other hand, the strength building fibers may be pulped or delignified. In one aspect, the extracted tobacco material may be combined with water or an aqueous solution to form a slurry. The strength building fibers (e.g., delignified cellulosic bast fibers) may be combined with the tobacco material when forming the slurry. The fibrous slurry is then used to form a continuous web having the characteristics of paper. For example, in one embodiment, the fiber slurry may be supplied to a papermaking process, which may include a forming wire, a gravity discharge, a suction discharge, a press felt machine, and a dryer, such as a yankee dryer or a tumble dryer, or the like. In one aspect, the fiber slurry is formed into a continuous sheet on a fourdrinier table (Fourdrinier table).

For example, a fibrous slurry comprising extracted tobacco material and strength building fibers may be laid on a porous forming surface and formed into a sheet. Excess water may be drained through gravity drains and/or suction drains. In addition, various presses may be used to facilitate dewatering. The formed sheet may be dried and further processed.

As described above, the strength building fibers are refined bast fibers. The bast fibers may also be pulped or delignified and/or bleached. Examples of bast fibers that may be used in the present disclosure include hemp fibers, flax fibers, abaca fibers, ramie fibers, cotton fibers, bamboo fibers, needle-cogongrass fibers, and mixtures thereof. For example, the bast fibers may be highly refined using a netherlands tile Li Dajiang machine (Dutch Valley Beater). In a particular embodiment, the bast fiber is a hemp fiber alone or in combination with other bast fibers.

As described above, the bast fibers may be highly refined. The average fiber length of the bast fibers may generally be greater than about 0.5 millimeters, such as greater than about 0.8 millimeters, such as greater than about 1 millimeter, such as greater than about 1.2 millimeters, such as greater than about 1.5 millimeters. The average fiber length of the refined bast fibers is typically less than about 4 millimeters, such as less than about 3.6 millimeters, such as less than about 3.3 millimeters, such as less than about 3 millimeters, such as less than about 2.8 millimeters, such as less than about 2.5 millimeters, such as less than about 2.3 millimeters, such as less than about 2.1 millimeters. In a particular aspect, the bast fiber can be delignified hemp fiber having an average fiber length of about 1.5 millimeters to about 2 millimeters.

Optionally, webs formed in accordance with the present disclosure may also include wood pulp fibers and/or plant fibers. The wood pulp fibers may include, for example, delignified fibers, such as softwood fibers, hardwood fibers, or mixtures thereof.

The extracted tobacco material, strength building fibers, and optionally wood pulp fibers may be combined together to form a web. In one aspect, all of the fibers are combined together in an aqueous suspension and used to form a web by a wet-laid process. In this way a substantially uniform fibre distribution is achieved. The content of each fiber in the resulting web may vary. In general, webs formed in accordance with the present disclosure contain greater than about 40% by weight and up to about 90% by weight of extracted tobacco material, including all 1% increments therein. For example, the extracted tobacco material may be present in the web in an amount greater than about 45 wt%, such as greater than about 50 wt%, such as greater than about 55 wt%, such as greater than about 60 wt%, such as greater than about 65 wt%, such as greater than about 70 wt%, such as greater than about 75 wt%, such as greater than about 80 wt%, such as greater than about 85 wt%. The extracted tobacco material may be present in the web in an amount of less than about 80 wt%, such as less than about 75 wt%, such as less than about 70 wt%.

The strength building fibers are typically present in the web in an amount up to about 50% by weight. The strength building fibers are typically present in the web in an amount greater than about 5 wt%, such as greater than about 10 wt%, such as greater than about 15 wt%, such as greater than about 17 wt%, such as greater than about 20 wt%, such as greater than about 23 wt%, such as greater than about 25 wt%, such as greater than about 28 wt%, such as greater than about 30 wt%. The strength building fibers are typically present in an amount of less than about 35 wt.%, such as less than about 30 wt.%, such as less than about 25 wt.%, such as less than about 20 wt.%. As described above, in one embodiment, the strength building fiber is a refined hemp fiber.

Optionally wood pulp fibers may be present in the web. For example, in one aspect, the web may be produced without using any wood pulp fibers. However, in other embodiments, the wood pulp fibers may be present in an amount up to about 12% by weight, such as up to about 10% by weight, such as up to about 8% by weight. The wood pulp fibers may generally be present in an amount greater than about 2 wt.%, such as greater than about 5 wt.%, such as greater than about 7 wt.%. In one particular aspect, wood pulp fibers and extracted tobacco fibers can be pre-mixed and then mixed with the strength building fibers. For example, the extracted tobacco material and wood pulp fibers may be pre-mixed in a weight ratio of about 85:15 to about 95:5 and then mixed with the strength building fibers.

In one aspect, the extracted tobacco material, strength building fibers, and optionally wood pulp fibers can be combined together and refined together prior to forming the web. Alternatively, each fiber may be refined independently. In another embodiment, each fiber may be refined separately, combined together, and then further refined.

Optionally, the web may further comprise filler particles. Filler particles that may be used include carbonate particles, oxide particles, and mixtures thereof. Specific filler particles include, for example, calcium carbonate particles, magnesium oxide particles, and mixtures thereof. The filler particles are typically present in the web in an amount of about 0.5% to about 30% by weight, including all 0.5% increments therebetween. For example, the filler particles may be present in an amount greater than about 1 wt%, such as greater than about 2 wt%, such as greater than about 5 wt%, and typically less than about 25 wt%, such as less than about 20 wt%, such as less than about 15 wt%, such as less than about 12 wt%, such as less than about 8 wt%. In one aspect, where the web comprises about 50% or more by weight of extracted tobacco material, the filler particles may be present in an amount of about 0.5% to about 5% by weight, such as about 0.5% to about 2% by weight. In another aspect, the web may be completely free of any filler particles, especially aluminum oxide particles or other aluminum-containing filler particles.

Although the web may contain filler particles, in one aspect the web is made primarily of fibers, such as tobacco fibers, strength building fibers, and optionally pulp fibers. For example, the fiber content of the web may be greater than about 90 wt%, such as greater than about 92 wt%, such as greater than about 95 wt%, and typically less than about 99 wt%, such as less than about 98 wt%, such as less than about 97 wt%.

As described above, in one aspect, the extracted tobacco material is combined with the strength building fibers and formed into a web using a wet-laid process. Webs made in accordance with the present disclosure have good strength, are smooth, and can be formed to have optimal basis weight and permeability. Thus, the wrapper made in accordance with the present disclosure is able to withstand the mechanical stresses of the papermaking process and mass production of smoking articles, while also having improved organoleptic and combustion properties.

For example, packaging materials made in accordance with the present disclosure have excellent mechanical properties and have a very desirable and aesthetic appearance. Typically, the basis weight of the wrapper is greater than about 15gsm, such as greater than about 18gsm, such as greater than about 20gsm, such as greater than about 23gsm, such as greater than about 25gsm. The basis weight of the wrapper is typically less than about 100gsm, such as less than about 50gsm, such as less than about 45gsm, such as less than about 43gsm, such as less than about 40gsm, such as less than about 38gsm, or any range therebetween. Within the above-described basis weight range, the packaging material is very strong and is capable of exhibiting a tensile strength of greater than about 2100cN/30 mm, such as greater than about 2200cN/30 mm, such as greater than about 2300cN/30 mm, such as greater than about 2400cN/30 mm, and typically less than about 4000cN/30 mm. Tensile strength may be measured using ASTM test D828-97.

In addition to a higher tensile strength, the packaging material may also have excellent elongation properties. For example, the packaging material can exhibit an elongation of greater than about 1%, such as greater than about 1.2%, such as greater than about 1.4%. The elongation of the packaging material is typically less than about 4%, for example less than about 2%.

The wrapper of the present disclosure may also have a permeability that promotes suitable smoking characteristics, such as good mainstream smoke control or good smoking comfort. For example, the packaging materials of the present disclosure may have a permeability, measured in Coresta units, of from below the detectable limit (i.e., 0 Coresta) to about 100Coresta, such as from about 5Coresta to about 80Coresta, such as from about 8Coresta to about 38Coresta, or any range therebetween. The permeability may be greater than about 8Coresta, such as greater than about 10Coresta, such as greater than about 15Coresta, such as greater than about 20Coresta, such as greater than about 25Coresta, and generally less than about 65Coresta, such as less than about 55Coresta, such as less than about 45Coresta. The above-mentioned air permeability characteristics refer to the inherent permeability of the paper, i.e., the permeability of the paper without any treatment (e.g., perforation) that changes the air permeability characteristics.

While the packaging materials of the present disclosure may naturally or inherently have a desired permeability, in one embodiment, it may also be desirable to perforate the packaging material after forming. The perforations may be made as known in the art, and the number and size of the perforations may be selected according to the needs of the desired application.

In addition to the physical properties described above, packaging materials made in accordance with the present disclosure can exhibit a unique natural appearance, with natural specks and/or colors from one or more tobacco fibers or particles. Optionally, the packaging material may be formulated with pigments (natural or synthetic) to adjust its final color. For example, a colorant (e.g., dye) may be applied to the fibers in the headbox in an aqueous solution or applied to the web using a size press during web formation and prior to drying. For example, in one aspect, one or more colorants can be used to provide a natural tobacco color, such as brown, to the web.

Furthermore, the packaging material of the present disclosure may have a pleasant texture in addition to having a natural appearance. The wrapper may have a rougher surface which can accentuate its natural appearance, or the wrapper may be further calendered to provide a smoother texture.

The wrapper of the present disclosure may also be used to produce smoking articles having better taste and organoleptic properties. For example, the wrapper of the present disclosure produces less paper-like taste than conventional cigarette paper. In contrast, a pleasant neutral or unique natural tobacco taste is observed even when the wrapper contains cellulose strength building fibers. In one aspect, one or more flavorants may also be applied to the fibers and/or web during or after formation of the web. The flavorant may include sweeteners, terpenes, and the like.

The wrapper made in accordance with the present disclosure may be incorporated into all different types of smoking articles and aerosol-generating products. One such smoking article is shown in figures 1 and 2 for exemplary purposes only. As shown, the smoking article 10 includes a smokable rod 12. For example, the smokable column 12 may be in the shape of a cylindrical rod containing aerosol generating filler. The smoking article 10 may further comprise a wrapper 100 defining an outer peripheral surface 16 when wrapped over the smokable rod 12. The packaging material 100 may include overlapping edges 114 and 116 that are sealed together. The article 10 may also include a filter 26 that may be enclosed by tipping paper (tipping paper), however, depending on the material of the smokable column, the filter may be optional or omitted.

The smoking article shown in figures 1 and 2 may be a cigarette, cigar, cigarillo or the like. Alternatively, the article may be a heated but non-burning rod.

In another aspect, the wrapper may be formed as a booklet of individual webs of wrapper. For example, a smokable or edible adhesive may be used to adhere the sheets of packaging material to one another. The booklet of wrapper may be used in a self-wrapping application in which a user uses the wrapper to make his own smoking article or a heated but non-burning rod.

In one aspect, the packaging material of the present disclosure may be treated with glue. In one aspect, the glue may be used as an adhesive. In one embodiment, the gums may include alginates, gum arabic, guar gum, pectin, polyvinyl alcohol, polyvinyl acetate, cellulose derivatives (e.g., ethylcellulose, methylcellulose, and carboxymethylcellulose), starches, starch derivatives, and the like.

In a particular embodiment, the gum may include gum arabic, cellulose, and/or cellulose derivatives. In one embodiment, the cellulose derivative comprises carboxymethyl cellulose (CMC), methyl Cellulose (CM), hydroxypropyl methylcellulose (HPMC).

Regardless of the glue used, the glue may be present on the packaging material or web in an amount of from about 0.1% to about 15% by weight, for example from about 2% to about 5% by weight. In one embodiment, the glue may be applied using a direct or indirect coating method. The glue may be applied by spraying (e.g. micro-spraying) or may be applied by other means to form a thin coating on the desired area using means such as gravure printing.

In one embodiment, smoking articles made in accordance with the present disclosure may also have reduced ignition proclivity characteristics. For example, the wrapper of the present disclosure may be used as an overwrap for a smoking article, and may have inherent reduced ignition characteristics, or may optionally include a plurality of discrete reduced ignition regions spaced apart in the axial direction of the smoking article. For example, in one embodiment, the discrete reduced ignition areas may be in the form of an annular band. The band may have a width such that oxygen is limited to maintaining combustion of the fuel for a sufficient period of time to extinguish the fuel in the event that the smoking article is in a static combustion state. For example, the width of the belt is typically greater than about 3 millimeters, such as greater than about 4 millimeters, such as greater than about 5 millimeters, and is typically less than about 10 millimeters, such as less than about 8 millimeters, such as less than about 7 millimeters.

The spacing between the reduced ignition areas may also vary depending on a number of variables. The spacing should not be so great that the cigarette burns long enough to ignite the substrate before the fuel burns to the reduced ignition areas. The spacing also affects the thermal inertia of the burning fuel or the ability of the fuel to burn through the reduced ignition region without self-extinction. The spacing of the bands should generally be greater than about 5 millimeters, such as greater than about 10 millimeters, such as greater than about 15 millimeters, and generally should be less than about 50 millimeters, such as less than about 40 millimeters, such as less than about 30 millimeters. Each smoking article may comprise from about 1 to about 3 bands.

In general, any suitable ignition reducing composition may be applied to the outer wrapper/wrapper of the smoking article. For example, in one embodiment, the ignition reducing composition comprises a film forming material. For example, film-forming materials that may be used in accordance with the present invention include alginate, guar gum, pectin, polyvinyl alcohol, polyvinyl acetate, cellulose derivatives (e.g., ethylcellulose, methylcellulose, and carboxymethylcellulose), starch derivatives, and the like.

In a particular embodiment, the film-forming material may comprise alginate alone or in combination with starch. In general, alginate is a derivative of an acidic polysaccharide or gum that exists in brown algae in the form of insoluble mixed calcium, sodium, potassium and magnesium salts. In general, these derivatives are calcium, sodium, potassium and/or magnesium salts of high molecular weight polysaccharides consisting of D-mannuronic acid and L-guluronic acid in different proportions. Exemplary alginates or derivatives include ammonium alginate, potassium alginate, sodium alginate, propylene glycol alginate, and/or mixtures thereof.

In one embodiment, a lower molecular weight alginate may be used. For example, the viscosity of the alginate may be less than about 500 centipoise when contained in a 3 wt% aqueous solution at 25 ℃. More specifically, under the above conditions, the alginate may have a viscosity of less than 250 centipoise, particularly less than 100 centipoise, and in one embodiment, a viscosity of about 20 to 60 centipoise. As used herein, "viscosity" is measured by a Brookfield LVF viscometer with a suitable spindle based on viscosity. At the lower viscosity levels described above, alginate compositions having a higher solids content can be formed, but the solution viscosity is still low enough to allow the composition to be applied to a wrapper using conventional techniques. For example, the solids content of an alginate solution prepared according to the invention may be greater than about 6%, particularly greater than about 10%, more particularly from about 10% to about 20% by weight.

At the solids level described above, the alginate compositions used in accordance with the invention may have a solution viscosity of greater than about 250 centipoise, specifically greater than about 500 centipoise, more specifically greater than about 800 centipoise, and in one embodiment, a viscosity of greater than about 1000 centipoise at 25 ℃. In general, the solution viscosity of the alginate film-forming composition can be adjusted depending on the manner in which the composition is applied to the wrapper. For example, the solution viscosity of the composition may be adjusted depending on whether the composition is sprayed or printed onto paper.

In other embodiments, it will also be appreciated that higher molecular weight alginates may be used depending on the application. For example, the viscosity of the alginate may be greater than about 500 centipoise when contained in a 3 wt% aqueous solution at 25 ℃.

The reduced ignition compositions applied to the wrapper may contain various other ingredients in addition to the film forming material.

For example, in one embodiment, a filler may be included in the composition. The filler may be, for example, calcium carbonate, calcium chloride, calcium lactate, calcium gluconate, or the like. In addition to the calcium compound, various other particles may be used, including magnesium compounds, such as magnesium oxide, clay particles, and the like.

In one embodiment, the ignition reducing composition may be water-based. In particular, the ignition reducing composition may comprise an aqueous dispersion or an aqueous solution. Alternatively, the ignition reducing composition may comprise a non-aqueous solution or dispersion prior to application to the wrapper. In this embodiment, for example, an alcohol may be present to apply the composition to the package.

The ignition reducing composition may also comprise a cellulosic slurry (a dispersion), as opposed to a film-forming composition. A slurry containing papermaking material as used herein is not a film forming composition. The cellulosic slurry applied to the paper substrate may comprise fibrous cellulose, one or more fillers and/or cellulose particles. Cellulose fibers and cellulose particles as used herein are different from derivatized cellulose, such as carboxymethyl cellulose. For example, cellulose fibers and cellulose particles are insoluble in water. In one embodiment, the cellulosic slurry applied to the paper substrate may comprise microcrystalline cellulose.

After the ignition reducing composition is formulated, the composition can be applied to discrete areas of the wrapper. The manner in which the composition is applied to the wrapper may vary. For example, the composition may be sprayed, brushed, applied with a moving orifice, or printed onto the package. The composition may be applied in one or more process operations in order to form the treated region. For example, the composition may be applied to the wrapper in successive steps to form areas of reduced ignition proclivity on the paper. Generally, the treated areas can be formed by applying the composition during about 2 to about 8 passes during a multi-pass process.

The amount of reduced ignition composition applied to the wrapper may also vary. For example, the amount of composition applied to the package may be less than about 15 wt%, such as less than about 10 wt%, such as less than about 8 wt%. Generally, the composition is applied in an amount greater than 1% by weight based on the weight of the composition in the reduced ignition areas.

The above weight percentages as used herein are based on the area treated with the chemical composition. In other words, the weight percent of the reduced ignition composition described above is the amount applied in the treated area, not the total amount applied over the entire surface of the wrapper.

By the process of the present disclosure, a reduced ignition region can be created that has a higher permeability while also having a lower diffusivity. For example, the reduced ignition areas can have a permeability greater than 10CORESTA while still being able to produce a smoking article that passes ASTM test E2187-09 at least 75% of the time.

In general, the diffusion rate of the reduced ignition areas or the natural packages themselves is low. The diffusivity can be measured at room temperature (23 ℃). In general, the diffusivity of the reduced ignition section or the diffusivity of the original wrapper (uncoated or treated) can be less than about 0.5 cm/sec, such as less than 0.4 cm/sec, such as less than 0.3 cm/sec, such as less than 0.1 cm/sec, such as less than 0.08 cm/sec, at 23 ℃. In one embodiment, the reduced ignition areas may have a diffusivity greater than about 0.01 cm/sec, such as greater than about 0.03 cm/sec, such as greater than 0.05 cm/sec, such as greater than 0.1 cm/sec, while still having the desired reduced ignition proclivity characteristics. Diffusivity was measured using a Sodim carbon dioxide diffusivity tester.

While additives may not be necessary in the packaging materials, as the packaging materials of the present disclosure naturally have good manufacturing characteristics (e.g., tensile strength) and organoleptic properties, in general, the packaging materials of the present disclosure may include one or more additives. The additives may be used in the manufacture of packaging paper to develop or impart new properties to the packaging material, such as chemical, optical, organoleptic or mechanical properties, such as tear strength or folding endurance. In one embodiment, the additive may be a humectant, a combustion control additive, a wet strength agent, an oil and grease repellent, an anti-caking agent, a dry strength agent, a softening agent, a flavoring agent, a humectant, or a latex agent.

In one embodiment, the web may further comprise a humectant. The wetting agent may be incorporated into the packaging material for a variety of different reasons to provide different benefits and advantages. For example, in one embodiment, a wetting agent may be incorporated into the packaging material to improve the processing and handling properties of the resulting fibrous substrate.

While various humectants may be incorporated into the packaging materials of the present disclosure, the humectants may include polyols, non-polyols, or mixtures thereof. Typically, the polyol generator may be sorbitol, glycerol, propylene glycol, triethylene glycol or mixtures thereof. Typically, the non-polyol generator may be lactic acid, diacetin, triacetin, triethyl citrate or isopropyl myristate or mixtures thereof. In one embodiment, the humectant is glycerin, propylene glycol or a mixture of glycerin and propylene glycol, with glycerin being preferred among glycerin, propylene glycol or mixtures thereof. Whatever the humectant chosen, the humectant may be present in the packaging material in an amount of from 0.1% to about 30% by weight of the packaging material, for example from about 1% to about 10% by weight of the packaging material, for example from about 2% to about 8% by weight, or any range therebetween.

The combustion control agent may comprise, for example, a carboxylate salt. For example, the combustion control agent may comprise an alkali metal salt of a carboxylic acid, an alkaline earth metal salt of a carboxylic acid, or mixtures thereof. Examples of combustion control agents that may be used include acetic acid, citric acid, malic acid, lactic acid, tartaric acid, carbonic acid, formic acid, propionic acid, glycolic acid, fumaric acid, oxalic acid, malonic acid, succinic acid, nitric acid, salts of phosphoric acid, or mixtures thereof. Specific burn control agents that may be used include potassium citrate, sodium citrate, potassium succinate, sodium succinate, or mixtures thereof. When present, the combustion control agent may be applied to the packaging material generally in an amount greater than about 0.1 wt%, such as greater than about 0.5 wt%, such as greater than about 1 wt%, and generally less than about 5 wt%, such as less than about 4 wt%, such as less than about 3 wt%, such as less than about 2 wt%.

The finished web or wrapper is dried and wound into rolls. For example, in one embodiment, the dried sheet is wound into a roll having a width of about 15 millimeters to about 80 millimeters, such as about 19 millimeters to about 28 millimeters. The web may be calendered prior to winding it into a roll to improve the smoothness and runnability of the material. For example, in one embodiment, a multi-nip calendering apparatus may be used.

These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that features of the various embodiments may be interchanged both in whole or in part. Moreover, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to be limiting of the invention so limited.

Claims

1. The invention claims protection:

a packaging material for an aerosol-generating filler comprising:

a web comprising at least about 40% by weight of an extracted tobacco material mixed with strength building fibers comprising refined bast fibers having an average fiber length of less than about 4 millimeters, the wrapper having a basis weight of from about 15gsm to about 45 gsm.

2. A packaging material according to claim 1, wherein the web comprises the extracted tobacco material in an amount of more than about 50% by weight, such as more than about 60% by weight, such as more than about 70% by weight, such as more than about 80% by weight.

3. The packaging material of any of the preceding claims, wherein the web has a tensile strength of greater than about 2100cN/30 mm, such as greater than about 2200cN/30 mm, such as greater than about 2300cN/30 mm, such as greater than about 2400cN/30 mm, when tested according to ASTM test D828-97.

4. The packaging material according to claim 1, wherein the refined bast fiber is present in the web in an amount of more than about 10 wt%, such as in an amount of more than about 12 wt%, such as in an amount of more than about 14 wt%, such as in an amount of more than about 16 wt%.

5. The packaging material of any one of the preceding claims, wherein the refined bast fibers comprise refined hemp fibers.

6. The packaging material of any one of the preceding claims, wherein the packaging material further comprises wood pulp fibers in an amount of up to about 10% by weight.

7. The packaging material of any one of the preceding claims, wherein the refined bast fiber has been bleached.

8. A wrapper according to any one of the preceding claims, wherein the extracted tobacco material has been refined but not pulped.

9. A wrapper according to any one of the preceding claims, wherein the extracted tobacco material comprises a water-soluble component in an amount of less than about 20% by weight, such as in an amount of less than about 15% by weight, such as in an amount of less than about 10% by weight, such as in an amount of less than about 8% by weight.

10. The wrapper of any of the preceding claims, wherein the wrapper has a basis weight of about 25gsm to about 38 gsm.

11. The packaging material of any one of the preceding claims, wherein the packaging material has an elongation of greater than about 1%.

12. A packaging material as claimed in any one of the preceding claims, wherein the packaging material has a permeability of from about 5 to about 80Coresta, such as from about 8 to about 38 Coresta.

13. The packaging material of any one of the preceding claims, wherein the web further comprises filler particles in an amount of about 0.5 wt% to about 30 wt%, such as in an amount of about 1 wt% to about 12 wt%.

14. The packaging material of any one of claims 1-12, wherein the web is free of filler particles.

15. The packaging material of any one of the preceding claims, wherein the packaging material has been treated with a burn control agent.

16. The packaging material of claim 15, wherein the combustion control agent comprises a carboxylate salt, such as citrate or succinate, present in the web in an amount of about 0.3 wt% to about 3 wt%, such as in an amount of about 1 wt% to about 2 wt%.

17. The packaging material of any one of the preceding claims, wherein the packaging material has been treated with glue.

18. The packaging material of claim 17, wherein the gum comprises guar gum, alginate, carboxymethyl cellulose, or mixtures thereof.

19. The packaging material of any one of the preceding claims, wherein the packaging material has a diffusivity of less than about 0.5 cm/sec at 23 ℃.

20. The wrapper of claim 19, wherein the wrapper comprises a plurality of reduced ignition areas formed by applying a reduced ignition composition to the web.

21. An aerosol generating product comprising:

a cylindrical rod comprising an aerosol-generating filler surrounded by the wrapper of any one of the preceding claims.