JP7481331B2 - A packaging material for cigarettes having a white and bright appearance - Google Patents

Description

(Related Applications)
This application claims priority to U.S. Patent Application No. 62/741,898, filed October 5, 2018, the disclosure of which is incorporated herein by reference.

Smoking articles, such as cigarettes and little cigars, are traditionally manufactured by wrapping a column of tobacco in a wrapping material made from cigarette paper or homogenized tobacco. One end of the smoking article typically includes a filter or tip for smoking the smoking article. The filter is attached to the smoking article using tipping paper that is glued to the wrapping material (wrapper). Smoking the smoking article produces mainstream smoke that is drawn through the filter. Mainstream smoke can contain a number of components that give the smoking article a particular taste, including sensations detected by the smoker's sense of smell as well as taste.

To produce a quality product, the wrapping material, when made of cigarette paper, should generally have a white, "clean" appearance. The wrapping material should also have the material and porosity to produce mainstream smoke with sufficient burnability and taste desired by the user. In addition, it is desirable for the wrapping material to produce a cohesive ash with a white appearance.

Traditionally, those skilled in the art have attempted to produce packaging materials that improve the overall smoking experience of a smoking article. Tobacco packaging materials are typically produced by combining pulp fibers, such as wood or flax fibers, with filler particles. Tobacco packaging materials (wrappers) can be produced to have a white color, but such wrappers have a "papery" taste. On the other hand, homogenized tobacco packaging materials are typically made with more than 50% of the material from processed tobacco by-products, which fails to achieve a satisfactory ash appearance or burn characteristics.

In view of the above, there is a need for packaging materials for smoking articles that can improve the taste of the smoking articles. In particular, there is a need for packaging materials that can reduce the paper-like taste of conventional cigarette paper materials. In addition, there is a need for packaging materials that can be used with a variety of smoking articles and that can have a white appearance.

In general, the present disclosure relates to a packaging material for smoking articles that has a unique natural appearance and a less papery taste than conventional packaging materials. In accordance with the present disclosure, the packaging material of the present disclosure is comprised, in part, of tobacco material. The tobacco material is combined with pulp fibers (cellulose fibers) and a filler material. In accordance with the present disclosure, the tobacco material, when combined with the pulp fibers (cellulose fibers), is in a relatively unrefined state and has a relatively large particle size that has been found to provide numerous benefits and advantages.

In one embodiment, for example, the present disclosure relates to a wrapping material for smoking articles. The wrapping material of the present disclosure is made from a web containing tobacco material in an amount of at least 10% by weight. The tobacco material may be substantially unrefined and/or have a particle size distribution such that more than 80% of the tobacco material has a maximum diameter of about 0.012 inches, e.g., about 0.015 inches. The tobacco material includes tobacco fibers, tobacco particles, or mixtures thereof. In one embodiment, more than 50% of the tobacco material includes flue-cured stems, e.g., more than 60% of the tobacco material. The tobacco material is typically included in the web in an amount of more than about 10% by weight, e.g., from about 10% to about 60% by weight, e.g., from about 20% to about 40% by weight.

According to the present disclosure, the tobacco material is combined with bleached pulp fibers and a filler when producing a web. The bleached pulp fibers are present in the web in an amount greater than about 20% by weight, such as from about 20% to about 50% by weight, or such as from about 20% to about 40% by weight. Meanwhile, the filler comprises white particles and is present in the web in an amount greater than about 10% by weight, such as from about 10% to about 30% by weight, or such as from about 15% to about 25% by weight. In one embodiment, the filler comprises calcium carbonate particles.

Packaging materials produced according to the present disclosure have a bright white appearance. For example, at least one side of the packaging material of the present disclosure exhibits an L value (whiteness value) of greater than about 65, such as greater than about 70, such as greater than about 78. The packaging materials of the present disclosure have excellent whiteness. The packaging materials of the present disclosure also have relatively high strength, with a tensile strength of greater than about 1500 cN/15 mm.

In addition to the tobacco material, bleached pulp fibers (bleached cellulose fibers), and filler, the packaging material of the present disclosure can include various other additives and components. For example, in one embodiment, the packaging material of the present disclosure contains a humectant and/or a burn control agent. Humectants can include, for example, glycerol, propylene glycol, or mixtures thereof, while burn control agents can include citrates, such as sodium citrate or potassium citrate, or mixtures thereof.

The packaging material or web produced typically has an inherent porosity of about 30 Coresta units to about 80 Coresta units, for example about 40 Coresta units to about 60 Coresta units. The web typically has a basis weight of about 30 gsm to about 50 gsm. In one embodiment, the packaging material of the present disclosure is calendered to provide a smooth, uniform finish.

The packaging material of the present disclosure can be incorporated into various types of smoking articles. In one embodiment, a smoking article is formed by wrapping a column of smokable tobacco filler with the packaging material of the present disclosure. Smoking articles include, for example, cigarettes or cigarillos.

Other features and aspects of the present invention are described in more detail below.

A complete and enabling disclosure of the present invention, directed to one of ordinary skill in the art, is described in more detail in the remainder of this specification, with reference to the accompanying drawings.

FIG. 1 is a perspective view of one embodiment of a smoking article incorporating the wrapping material of the present disclosure. FIG. 2 is an exploded view of the smoking article shown in FIG. FIG. 3 is another embodiment of a smoking article incorporating a wrapping material made in accordance with the present disclosure.

Repeated use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.

Those skilled in the art will appreciate that this disclosure is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the present invention.

Generally, the present disclosure relates to packaging materials for smoking articles such as cigarettes, little cigars, cigarillos, and larger cigars. The packaging materials of the present disclosure package tobacco material in a relatively unrefined state having a relatively large particle or fiber size. The tobacco material is combined with other materials to provide an overall wrapper that has a less papery taste than conventional cigarette wrappers. Of particular advantage, the packaging materials of the present disclosure have a natural appearance and bright white color as well as improved taste. The packaging materials of the present disclosure also produce a cohesive white ash and have better burn characteristics than many reconstituted cigarette wrappers made in the past.

In accordance with the present disclosure, the extracted tobacco material is combined with bleached pulp fibers and fillers to produce a packaging material. Optionally, the packaging material of the present disclosure can include various other additives and components. For example, in one embodiment, a humectant can be added to the packaging material of the present disclosure. In another embodiment, a burn control agent can be added to the packaging material of the present disclosure.

Tobacco materials to be incorporated into the packaging materials of the present disclosure are first subjected to an extraction process that removes water-soluble components from the tobacco material. For example, in one embodiment, tobacco furnish, which contains tobacco stems (e.g., flue-cured stems), fines, and/or other tobacco by-products obtained during the tobacco manufacturing process, is first mixed with a solvent (e.g., water and/or other compounds). In one embodiment, the solvent includes only water. In another embodiment, various water-miscible solvents, such as alcohol (e.g., ethanol), are combined with water to form an aqueous solvent. The water content of the aqueous solvent may be greater than 50% by weight of the solvent in some instances, and more particularly greater than 90% by weight of the solvent. Deionized water, distilled water, tap water, and the like may be used. The amount of solvent in the suspension may range widely, but generally may be in an amount of about 50% to about 99% by weight of the suspension, in some embodiments from about 60% to about 95% by weight, and in some embodiments from about 75% to about 90% by weight. However, the amount of solvent may vary depending on the nature of the solvent, the temperature at which the extraction is carried out, and the type of tobacco furnish.

After the mixture of solvent and tobacco furnish is made, some or all of the soluble fraction of the mixture is separated from the mixture. The mixture of aqueous solvent and tobacco furnish is agitated using stirring, shaking, or other mixing methods to increase the rate of solubilization. Typically, the process is carried out for about 30 minutes to about 6 hours. The process temperature can range from about 10°C to about 100°C, for example, from about 40°C to about 80°C.

After the tobacco material is immersed in the extractant, a press is used to mechanically separate the tobacco material from the tobacco liquid. After the soluble fraction is separated from the tobacco furnish or insoluble fraction, the soluble fraction is concentrated. The soluble fraction is concentrated using any known type of concentrator, such as a vacuum evaporator. In one embodiment of the present disclosure, the soluble fraction can be highly concentrated. In one embodiment, for example, the tobacco soluble fraction is evaporated to have a final brix of about 20% to about 40%, e.g., about 25% to about 35%.

The resulting concentrated tobacco soluble fraction may be discarded, used in another process, or may be subsequently coated onto a packaging material of the present disclosure, as described in more detail below.

The resulting tobacco insoluble fraction is generally in an unrefined state. The tobacco material may include tobacco particles and tobacco fibers. Tobacco materials include, for example, stems, scraps, dust, tobacco leaves, and the like. In one embodiment, the tobacco material includes a significant amount of flue-cured stems. For example, in one embodiment, the tobacco material includes flue-cured stems in an amount greater than about 50% by weight, such as greater than about 60% by weight, such as greater than about 70% by weight, such as greater than about 80% by weight, or such as greater than about 90% by weight. The presence of a significant amount of flue-cured stems is believed to improve the appearance of the produced packaging material as well as various other properties, including mechanical properties and taste.

The insoluble fraction or extracted tobacco material is then mixed with pulp fibers, such as wood pulp fibers. More specifically, the water-insoluble tobacco material is combined with bleached pulp fibers, which can be obtained, for example, from flax, softwoods, or hardwoods. The pulp fibers are bleached to lighten the color of the fibers and increase the whiteness of the final product. Bleached pulp fibers can also be used to improve the brightness of packaging materials.

The tobacco material can generally be combined with the bleached pulp fibers in a weight ratio of about 1:5 to about 3:1. For example, the weight ratio of tobacco material to bleached pulp fibers can generally be greater than about 2:5, such as greater than about 4:5 by weight, and generally less than about 2:1, such as less than about 3:2, such as less than about 5:4.

After mixing the tobacco material with the bleached pulp fibers, the resulting mixture can optionally be refined using a disc refiner. For example, the resulting mixture can be refined to control the final porosity of the wrapping material.

According to the present disclosure, in addition to refining the tobacco material and bleached pulp fibers, the particle size of the tobacco material can be controlled by screening the tobacco material and bleached pulp fibers. For example, only the mixture or the tobacco material is fed through a screening process to remove larger sized tobacco particles and fibers. In one embodiment, for example, the tobacco material or the mixture of tobacco material and bleached pulp fibers is fed through a screening device having an opening size of about 0.012 inches to about 0.015 inches.

The resulting tobacco material has a particle size distribution such that more than 70% of the tobacco particles and fibers therein have a maximum dimension greater than 0.012 inches. For example, the tobacco material has a particle size distribution such that more than about 80%, such as more than about 90%, of the tobacco particles and fibers have a maximum particle dimension greater than about 0.012 inches. In another embodiment, the tobacco material has a particle size distribution such that more than about 70%, such as more than about 80%, or such as more than about 90% of the tobacco particles and fibers have a maximum dimension greater than about 0.015 inches. In yet another embodiment, the tobacco material has a particle size distribution such that more than about 70%, such as more than about 80%, or such as more than about 90% of the tobacco particles and fibers have a maximum dimension greater than about 0.025 inches.

Typically, the tobacco particles and fibers contained in the tobacco material have a maximum dimension of less than about 0.1 inches, such as less than about 0.08 inches, or such as less than about 0.05 inches. For example, in one embodiment, more than about 80%, such as more than about 90%, or such as more than about 95% of the tobacco particles and fibers have a maximum dimension of less than about 0.05 inches.

The above particle size distribution of tobacco material is believed to provide various benefits and advantages. It is believed that the above particle size distribution, when combined with pulp fibers, along with the use of refined tobacco material, produces a packaging material with improved sensory characteristics and improved appearance. The above particle size distribution of tobacco material, for example, produces a packaging material that has a natural appearance and exhibits a white color.

When producing the packaging material of the present disclosure, a filler is incorporated into the tobacco material described above mixed with the bleached pulp fibers. The filler generally comprises white particles. Examples of filler particles include calcium carbonate particles, titanium oxide particles, clay particles, magnesium oxide particles, and any combination thereof.

The filler particles can have any suitable particle size and shape. For example, in one embodiment, the filler particles have a particle size of more than about 0.1 μm (micrometer), such as more than about 0.2 μm, or such as more than about 0.3 μm. The particle size of the filler particles is generally about 2 μm or less, such as about 1.5 μm or less, such as about 1 μm or less, or such as about 0.8 μm or less. In one embodiment, the median filler particle size is about 0.1 μm to about 0.5 μm, such as about 0.2 μm to about 0.4 μm. The filler particles can further improve the whiteness (brightness) and brightness of the produced packaging material. In addition, the filler particles can also adjust the final porosity and flammability of the packaging material.

In one embodiment, the filler incorporated into the packaging material of the present disclosure consists of calcium carbonate particles. In one embodiment, the calcium carbonate particles can include precipitated particles. The calcium carbonate particles can have a rhombohedral shape in one embodiment. In another embodiment, the calcium carbonate particles can have a non-isometric shape with an average diameter of about 50 nm (nanometers) to about 3 μm. The particles can have, for example, an aspect ratio generally greater than about 1, such as greater than about 2, or such as greater than about 5, and generally less than about 15, such as less than about 12, or such as less than about 10.

The filler is combined with the tobacco material and bleached pulp fibers in the presence of water to form a slurry. The formed fiber slurry is then used to form a continuous sheet. For example, in one embodiment, the fiber slurry is fed into a papermaking process that may include forming wires, gravity drains, suction drains, felt presses, and dryers such as Yankee dryers and drum dryers. For example, in one embodiment, the fiber slurry is formed into a continuous sheet on a Fourdrinier table.

In one embodiment, for example, the fiber slurry is placed on a porous forming surface and formed into a sheet (wet laid web). Excess water is removed by gravity drain and/or suction drain. In addition, various presses can be used to facilitate water removal. The formed sheet can be dried and then subjected to further processing.

In one embodiment, for example, a humectant can be incorporated into the packaging material. The humectant can include, for example, glycerol, propylene glycol, or a combination thereof.

In addition to the humectant, one or more burn control agents can be incorporated into the manufactured packaging material or wrapper. Burn control agents can include, for example, salts of carboxylic acids, alkali metals, and/or alkaline earth metals. For example, burn control agents can include salts of 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, phosphoric acid, or any combination thereof. Specific burn control agents that can be used include potassium citrate, sodium citrate, potassium succinate, sodium succinate, or any combination thereof.

Optionally, the manufactured packaging material can also be treated with a tobacco soluble portion, such as a concentrated tobacco soluble portion separated from the insoluble fraction. The tobacco soluble portion can be applied to the web using various application methods, such as spraying, using a size press, saturating, etc. In one embodiment, the tobacco soluble portion can be applied to the formed web in an amount greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, or such as greater than about 18% by weight, based on the dry weight of the web. Typically, the tobacco soluble portion or tobacco extract is applied to the packaging material in an amount of about 20% or less, based on the dry weight of the web.

In addition to the humectants, burn control agents, and/or tobacco extracts, packaging materials produced in accordance with the present disclosure can be treated with a variety of other agents and ingredients. For example, in one embodiment, one or more flavoring agents can be added to the web.

After the finished web or packaging material is dried, it is wound into a roll. For example, in one embodiment, the dried sheet is wound onto a bobbin having a width of about 15 mm to about 54 mm, such as about 19 mm to about 28 mm. Before winding onto the bobbin, the web may be calendered to enhance the smoothness and runnability of the packaging material. In one embodiment, for example, a multi-nip calendering device may be used.

Wrapping materials produced according to the present disclosure typically contain tobacco material in an amount greater than about 10% by weight. For example, the tobacco material is present in the wrapping material in an amount greater than about 15% by weight, such as greater than about 20% by weight, or such as greater than about 25% by weight. The tobacco material is typically present in the wrapping material in an amount less than about 60% by weight, such as less than about 50% by weight, such as less than about 40% by weight, or such as less than about 30% by weight.

The bleached pulp fibers and fillers are included in the packaging materials of the present disclosure in various concentrations depending on the particular application and the desired results. For example, the bleached pulp fibers are typically included in the packaging materials in an amount greater than about 20% by weight, such as greater than about 25% by weight, and typically less than about 50% by weight, such as less than about 40% by weight, or such as less than about 35% by weight. The fillers are typically included in the packaging materials in an amount greater than about 10% by weight, such as greater than about 15% by weight, or such as greater than about 20% by weight, and typically less than about 35% by weight, such as less than about 30% by weight, or such as less than about 25% by weight.

When a humectant and/or burn control agent is included in the packaging material of the present disclosure, the humectant and/or burn control agent is typically included in the packaging material in an amount less than about 5% by weight, such as less than about 3% by weight, such as less than about 2% by weight, such as less than about 1.5% by weight, or such as less than about 1% by weight. The humectant and/or burn control agent is typically included in the packaging material in an amount greater than about 1% by weight, such as greater than about 1.5% by weight.

Packaging materials produced according to the present disclosure have excellent mechanical properties and a very pleasing aesthetic appearance. Typically, packaging materials of the present disclosure have a basis weight of about 30 gsm, such as about 35 gsm, or such as greater than about 40 gsm. The basis weight of packaging materials of the present disclosure is typically less than about 55 gsm, such as less than about 50 gsm, or such as less than about 45 gsm. Within the above basis weight ranges, packaging materials of the present disclosure have very high strength, having a tensile strength of more than about 1,000 cN/15 mm, such as more than about 1,500 cN/15 mm, and typically less than about 3,000 cN/15 mm. Tensile strength can be measured using ASTM test D828-97.

In addition to the physical properties described above, packaging materials produced in accordance with the present disclosure can exhibit a unique natural appearance. Additionally, the packaging materials (wrappers) of the present disclosure can have a brighter and whiter appearance than many conventional tobacco wrappers made from homogenized tobacco materials.

In one embodiment, to characterize the color of at least one surface of the packaging material of the present disclosure, the color of at least one surface of the packaging material of the present disclosure can be objectively expressed by assigning values for L, a, and b using the Hunter Lab color scale. The Hunter Lab color scale was created by Richard S. Hunter in 1948 and is described in "The Measurement of Appearance," 2nd Addition, John Wiley and Sons, New York, New York, 1987. This color scale describes all colors visible to the human eye and was created to serve as a device-independent model and to be used as a reference.

The three coordinates of the Hunter Lab scale represent the color's lightness (L=0 is black, L=100 is diffuse white; specular white can be higher), its position between red/magenta and green (a, negative values are green, positive values are magenta), and its position between yellow and blue (b, negative values are blue, positive values are yellow).

According to the present disclosure, at least one side of the packaging material (wrapper) of the present disclosure generally has an L value (whiteness value) of greater than about 60, such as greater than about 70, such as greater than about 75, or such as greater than about 78. When the packaging material of the present disclosure is treated with a tobacco soluble portion or tobacco extract, the L value of the packaging material is somewhat reduced. For example, when the packaging material of the present disclosure is treated with a tobacco soluble portion, the packaging material of the present disclosure may have an L value of greater than about 65, such as greater than about 70. On the other hand, when the packaging material of the present disclosure is not treated with a tobacco soluble portion, the L value of the packaging material of the present disclosure is generally greater than about 75, such as greater than about 78. Also, the L value of the packaging material of the present disclosure is generally less than about 98, such as less than about 95.

In addition to exhibiting a bright white color, the packaging material of the present disclosure has a speckled appearance due to the presence of larger tobacco particles and fibers. The speckled appearance due to the presence of tobacco material, combined with the increased whiteness of the appearance, creates a unique natural look.

The packaging materials of the present disclosure also produce smoking articles with improved taste characteristics. For example, the packaging materials of the present disclosure taste less papery compared to conventional cigarette paper. In addition, the packaging materials of the present disclosure produce a smoother smoke. Furthermore, the packaging materials of the present disclosure produce a cohesive ash with an improved appearance relative to conventional tobacco packaging materials.

Wrapping materials produced in accordance with the present disclosure can be incorporated into various types of smoking articles. For purposes of illustration only, one example of such a smoking article is shown in FIGS. 1 and 2. As shown, the smoking article 10 includes a smokable column 12. The smoking article 10 also includes a wrapping material 14 that, when wrapped around the smokable column 12, defines an outer circumferential surface 16. The smoking article 10 may also include a filter 26 surrounded by tipping paper.

Smoking articles 10 shown in Figures 1 and 2 generally include cigarettes. However, in other embodiments, the packaging materials of the present disclosure can be used to produce cigarillos and little cigars. For example, referring to Figure 3, an example of a cigarillo 30 is shown. The cigarillo 30 includes a column of smokable filler material 32 surrounded by a packaging material 34 made in accordance with the present disclosure. Optionally, the cigarillo 30 can include a plastic tip 36.

Those skilled in the art will appreciate that the present invention is susceptible to various modifications and variations without departing from the spirit and scope of the invention. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those skilled in the art will appreciate that the detailed description and examples provided above are for illustrative purposes only and are not intended to limit in any way the scope of the invention as set forth in the appended claims.

Claims (19)

A packaging material for smoking articles, comprising:
a web containing tobacco material in an amount of at least 10% by weight;
the tobacco material comprises tobacco particles or fibers having a particle size distribution such that greater than 80% of the tobacco material has a maximum diameter greater than 0.012 inches, and is mixed with bleached pulp fibers and a filler;
The bleached pulp fibers are present in the web in an amount of greater than 20% by weight,
The filler comprises white particles and is contained in the web in an amount of more than 10% by weight ;
The packaging material further comprises a combustion retardant . 2. The packaging material of claim 1,
10. A packaging material, wherein at least one surface of the packaging material has a white color having an L value of greater than 65. 3. The packaging material according to claim 1 or 2,
A packaging material, characterized in that the web contains the tobacco material in an amount of 10% to 60% by weight, or in an amount of 20% to 40% by weight. The packaging material according to any one of claims 1 to 3,
A packaging material, wherein more than 50% of the tobacco material comprises flue-cured stems. The packaging material according to any one of claims 1 to 4,
The packaging material, wherein the web contains the bleached pulp fibers in an amount of 20% to 50% by weight, or in an amount of 20% to 40% by weight. The packaging material according to any one of claims 1 to 5,
The web comprises the filler in an amount of 10% to 30% by weight, or in an amount of 15% to 25% by weight. The packaging material according to any one of claims 1 to 6,
The packaging material, wherein the filler comprises calcium carbonate particles. The packaging material according to any one of claims 1 to 7,
The packaging material is characterized in that the filler has a particle size of 0.1 μm to 2 μm. The packaging material according to any one of claims 1 to 8,
The packaging material further comprises a moisturizer. 10. The packaging material of claim 9,
The packaging material, wherein the humectant comprises glycerol, propylene glycol, or a combination thereof. 2. The packaging material of claim 1 ,
The packaging material, wherein the burn retardant comprises a citrate. The packaging material according to any one of claims 1 to 11 ,
The web has a porosity of 30 Coresta units to 80 Coresta units, or a porosity of 40 Coresta units to 60 Coresta units, and a basis weight of 30 gsm to 50 gsm. The packaging material according to any one of claims 1 to 12 ,
The packaging material, wherein the web has a tensile strength of greater than 1500 cN/15 mm. The packaging material according to any one of claims 1 to 13 ,
The packaging material, wherein the web is a calendered web . The packaging material according to any one of claims 1 to 14 ,
A wrapping material, wherein greater than 90% of said tobacco material has a maximum diameter greater than 0.015 inches. The packaging material according to any one of claims 1 to 15 ,
the web is treated with a tobacco soluble portion extracted from the tobacco material by an aqueous solvent;
A wrapping material, characterized in that the tobacco soluble portion is topically applied to the web. The packaging material according to any one of claims 1 to 16 ,
The wrapping material, wherein the tobacco material has a particle size distribution such that greater than 80% of the tobacco material has a maximum diameter greater than 0.025 inches. The packaging material according to any one of claims 1 to 17 ,
A packaging material, wherein one side of the packaging material has an L value of greater than 70. A packaging material according to any one of claims 1 to 18 ,
The packaging material, wherein the web comprises a wet laid web.

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