WO2025041259A1 - Material for smoking article containing tobacco extraction residue, method for producing said material, and smoking article containing said material - Google Patents

Abstract

The present invention provides a material for a smoking article containing a tobacco extraction residue obtained by extracting a tobacco raw material. The material for a smoking article preferably contains a fibrous reinforcing material, a binder, or a filler.

Description

Material for smoking articles containing tobacco extract residue, method for producing same, and smoking article containing same

The present invention relates to a material for smoking articles containing tobacco extract residue, a method for producing the same, and smoking articles containing the same.

A known method for producing tobacco sheets is the so-called papermaking method, which involves subjecting tobacco raw materials to water extraction to separate the extraction water and a residue, papermaking the residue into a sheet, and pouring the extraction water back onto the sheet (e.g., Patent Document 1).

JP 2010-88381 A

Various materials are used in smoking articles, but there is a demand for a shift to materials that do not place a burden on the environment. In light of this situation, the objective of the present invention is to provide materials for smoking articles that place a low burden on the environment.

As mentioned above, the residue obtained by subjecting tobacco raw materials to water extraction has been used as a base material for tobacco papermaking sheets. The inventors have found that the above-mentioned problem can be solved by using the residue as a material for smoking articles. That is, the above-mentioned problem is solved by the following invention.
Aspect 1
A material for smoking articles comprising tobacco extract residue obtained by extracting tobacco raw material.
Aspect 2
2. The material of embodiment 1, comprising a fibrous reinforcement, binder, or filler.
Aspect 3
The material according to claim 1 or 2, wherein the nicotine content of the extraction residue is 1% by weight or less of the nicotine content of the tobacco raw material.
Aspect 4
4. The material of any of the preceding claims, wherein the extraction residue has been digested.
Aspect 5
Aspect 5. The material of any of aspects 2 to 4, wherein the binder comprises starch.
Aspect 6
A wrapper, a paper tube, a filter, or a pulp molded cup formed from the material of any one of claims 1 to 4.
Aspect 7
A step of subjecting a tobacco raw material to extraction with a medium to obtain a tobacco extraction residue; and a molding step of molding the tobacco extraction residue.
A method for producing the material according to any one of aspects 1 to 6, comprising:
Aspect 8
The method according to claim 7, wherein the medium is water or a medium containing water.
Aspect 9
9. The method of claim 7 or 8, wherein the forming step comprises papermaking or pulp molding.
Aspect 10
A smoking article comprising the material of any one of aspects 1 to 5.
Aspect 11
The smoking article according to claim 10, further comprising an extract obtained by extracting a tobacco raw material.

The present invention provides materials for smoking articles that have a low environmental impact.

Diagram explaining pulp molding FIG. 1 shows an example of a smoking article. Diagram explaining caps and cups A graph showing the relationship between the amount of carbonized components and the TPM reduction rate.

In this disclosure, "X-Y" includes the extreme values X and Y. Weights are dry weights unless otherwise noted.

1. Tobacco Extraction Residue Tobacco extraction residue is a solid obtained by subjecting tobacco raw materials to extraction. The extraction method can be carried out as known in the art, and examples thereof include the following methods. 1) A method in which tobacco raw materials are subjected to extraction using a medium to obtain a tobacco extract and a tobacco extract residue, 2) A method in which a medium is added to a tobacco raw material and heated, and the generated steam is collected to obtain a tobacco extract and a tobacco extract residue, and 3) A method in which a medium that has been vaporized by heating is passed through a tobacco raw material, and the vapor after the passage is collected to obtain a tobacco extract and a tobacco extract residue. Examples of the medium include water, a hydrophilic organic solvent such as alcohol, or a combination thereof, and it is preferable that the medium is water or contains water.

In method 1), it is preferable to use water as the medium from the viewpoint of workability, etc. In method 2) or 3), it is preferable to use glycerin, propylene glycol, triacetin, 1,3-butanediol, or an alcohol such as ethanol as the medium from the viewpoint of work efficiency. Acid or alkali can also be used for extraction as necessary. The liquid obtained by extraction, which contains the tobacco extract and the medium, is called tobacco extract.

Tobacco raw materials can be, for example, Nicotiana tabacum or Nicotiana rustica. Nicotiana tabacum can be, for example, Burley or flue-cured varieties. In addition, Orient or native Burley varieties of the Nicotiana genus can also be used.

The tobacco raw material may be shredded or powdered tobacco raw material (hereinafter also referred to as "raw material pieces"). In such a case, the particle size of the raw material pieces is preferably 0.5 to 1.18 mm. Such raw material pieces are obtained, for example, by sieving in accordance with JIS Z 8815 using a stainless steel sieve conforming to JIS Z 8801. For example, 1) using a stainless steel sieve with 1.18 mm openings, the raw material pieces are sieved for 20 minutes by a dry mechanical shaking method to obtain raw material pieces that pass through the stainless steel sieve with 1.18 mm openings. 2) Next, using a stainless steel sieve with 0.50 mm openings, the raw material pieces are sieved for 20 minutes by a dry mechanical shaking method to remove the raw material pieces that pass through the stainless steel sieve with 0.50 mm openings. In this way, raw material pieces can be prepared that pass through the stainless steel sieve (mesh size = 1.18 mm) that defines the upper limit, but do not pass through the stainless steel sieve (mesh size = 0.50 mm) that defines the lower limit.

In one embodiment, the tobacco raw material is treated with alkali. Through this treatment, flavor components are generated, which are collected to prepare a tobacco extract and a tobacco extract residue. At this time, the flavor components are extracted as a gas from the alkali-treated tobacco raw material, and the gas can be introduced into water to transfer the flavor components into a liquid.

The alkaline substance is preferably an alkaline liquid such as an aqueous solution of potassium carbonate. In this case, the alkaline substance is supplied until the pH of the tobacco raw material falls within a specific range. The pH is preferably 8.0 or higher, more preferably 8.9 to 9.7. The pH of the tobacco raw material is the pH of the water when the tobacco raw material is mixed with 10 times the amount of water.

The moisture content in the tobacco raw material used for extraction is not limited, but from the viewpoint of efficiently extracting flavor components, it is preferable that the moisture content is approximately 5 to 30% by weight. The moisture content in the tobacco raw material is measured by a known method, for example, a 1 g sample is taken, heated at 105°C, and the weight loss amount when heated until the weight change rate is 1 mg/min or less is taken as the moisture content. For example, a halogen heating moisture meter (Ohaus MB45, etc.) can be used for this measurement.

The tobacco extract preferably contains a large amount of nicotine. From this perspective, the amount of nicotine in the extraction residue is preferably 1% by weight or less of the amount of nicotine in the tobacco raw material, and preferably 0.5% by weight or less. In one embodiment, the amount of nicotine in the extraction residue is 0 to 0.1% by weight (based on the extraction residue).

The tobacco extract residue is preferably subjected to a cooking process. Cooking is a process that mainly removes lignin. Cooking is carried out in a known manner, for example by adding a cooking agent such as sodium sulfide to the tobacco extract residue, and then heating and pressurizing it.

2. Materials for smoking articles Tobacco extract residues are useful as materials that can be used in smoking articles, i.e., materials for smoking articles. Usually, materials for smoking articles contain tobacco extract residues and other components. Materials for smoking articles may be in various forms, and the components used vary depending on the form, but representative components are described below. Materials for smoking articles preferably do not contain a substrate of a tobacco paper sheet. In one embodiment, the nicotine content of the material for smoking articles is 0 to 0.1% by weight (based on the material).

(1) Fibrous Reinforcement The fibrous reinforcing material is not limited, but is preferably a non-wood fiber. The non-wood fiber is a fiber not derived from wood, and may be tobacco fiber or a fiber other than tobacco fiber. From the viewpoint of imparting strength, the non-wood fiber is preferably a dietary fiber. The dietary fiber is a food component that is not digested by human digestive enzymes, and is more preferably an insoluble dietary fiber that does not dissolve in water. The dietary fiber may be porous, i.e., spongy. From the viewpoint of availability, the fiber is preferably citrus fiber. The citrus fiber is a fiber whose main raw material is the albedo of citrus fruits. The dietary fiber may also be short fiber or columnar particles with a small aspect ratio. In particular, citrus fiber is preferable because it can impart strength to the material for smoking articles with a small amount of use. In one embodiment, the content of the fibrous reinforcing material in the material for smoking articles is 10 to 30% by weight.

(2) Binder The binder is not limited, but examples thereof include starch, carboxyalkyl cellulose, guar gum, etc. Among them, starch is preferred as the binder from the viewpoint of availability, etc. In one embodiment, the content of the binder in the material for smoking articles is 5 to 30% by weight.

(3) Filler Fillers are inorganic materials used in paper, such as calcium carbonate, titanium dioxide, kaolin, etc., and calcium carbonate is preferred from the viewpoint of enhancing flavor and whiteness. Therefore, fillers are useful when the material for smoking articles is made into a nonwoven fabric such as paper. In one embodiment, the content of the filler in the material for smoking articles is 10% by weight or more and less than 60% by weight.

(4) Form As described above, the material for smoking articles may be in various forms. It is preferable that the material for smoking articles is manufactured through a process of subjecting a tobacco raw material to extraction with a medium to obtain a tobacco extract residue, and a molding process of molding the tobacco extract residue. The medium is as described above.

Smoking article materials are broadly divided into combustion-type smoking articles, which are used by burning, and non-combustion-type smoking articles, which are used by heating a flavor source without burning. Non-combustion-type smoking articles are classified into non-combustion-type indirectly heated smoking articles, which heat a liquid with a heater or the like, generate steam, which is passed through the flavor source to indirectly heat the flavor source, and non-combustion-type directly heated smoking articles, which directly heat the flavor source. In one embodiment, the smoking article material is formed by pulp molding, which is particularly useful as a cup (container) that holds the flavor source in a non-combustion-type indirectly heated smoking article. In another embodiment, the smoking article material is in the form of a nonwoven fabric, which is suitable for a wrapper in a combustion-type smoking article or a non-combustion-type directly heated smoking article. These will be described below.

1) Pulp Molded Product Pulp molding refers to molding a pulp slurry. The molded product obtained by this molding is called a pulp molded product. Since the tobacco extract residue of this embodiment contains tobacco-derived fibers, the molded product obtained by molding a slurry containing tobacco extract residue is called a pulp molded product. The slurry for pulp molding preferably contains a medium, the tobacco extract residue, the fibrous reinforcing material, and the binder. The blending amounts of each component are as described above. The medium is preferably water. The solid content concentration in the slurry is not limited, but is preferably 0.5 to 10% by weight, more preferably 1 to 5% by weight. The slurry for pulp molding may also contain a water resistance improver described later, and known water repellents, sizing agents, etc., as necessary.

The molding can be carried out as is well known. For example, the slurry can be filled into a female mold, and the slurry can be compressed and dehydrated using a male mold to form the desired shape. Figure 1 is a schematic diagram showing this embodiment. In the figure, 1 is the slurry, 2 is the male mold, 3 is the female mold, 4 is a through hole, and 10 is the pulp molded product. Specifically, the slurry is filled into the female mold 3, and the male mold 2 applies pressure to the slurry and the slurry is removed. The female mold 3 may be formed of a mesh. The pulp molded product 10 obtained in this manner may be heated, coated with a coating agent, or other processes may be carried out.

The pulp molding may also be pulp injection molding. Pulp injection molding comprises the following steps: 1) The tobacco extract residue is mixed with a binder (preferably starch) and then pellets are produced. 2) The pellets are mixed with water to form a pulp slurry, and the pulp slurry is injected into a mold. 3) At the same time as the injection molding, heat is applied to the pulp slurry to remove moisture in the mold and dry it.

As mentioned above, it is more preferable that the pulp molded product 10 is in the shape of a cup (container). The cup is useful as a material for retaining a flavor source in a non-combustion indirectly heated smoking article or a non-combustion directly heated smoking article. The pulp molded cup will be described below.

[How the cup is used]
FIG. 2 shows an example of a smoking article equipped with the cup. In the figure, 5 is a non-combustion heating smoking article, 10 is a pulp molded cup, 11 is a chamber that houses the cup, 12 is a coil, 14 is a control device, 16 is a power source, and 18 is a cap, which is the mouth end. FIG. 3 is a diagram further explaining the cap 18 and the pulp molded cup 10. In the figure, 182 is an opening, 184 is a tube, 186 is a mouth hole, 102 is a seal, and 104 is a contained object. The tip of the tube 184 has a shape that can penetrate the seal 102. The cap 18 can be joined to the pulp molded cup 10, and is integrated as shown in the right figure. When the non-combustion heating smoking article 5 is used, air taken in from the opening 182 passes through the contained object 104 and flows to the mouth hole 186 via the tube 184 located in the center. In the embodiment of FIG. 2, a susceptor is placed in the cup, and the contained object 104 is heated by electromagnetic induction heating. Alternatively, the coil 12 can be replaced by a heater.

[Cup contents]
The contents 104 contained in the pulp molded cup 10 may be a molded body containing a tobacco extract and an aerosol source. The molded body may be in the form of granules or a sheet. The pulp molded cup 10 may also contain a carrier carrying a tobacco extract or an aerosol source. The carrier may be the tobacco extract residue. For example, the carrier may be a paper filter formed from the tobacco extract residue. As described above, a susceptor may be contained in the pulp molded cup 10. The susceptor may be plate-shaped or cylindrical. The cylindrical susceptor may be placed in the cup by insert molding when the cup is manufactured using a pulp mold. The pulp molded cup 10 may also contain a tobacco material. In this case, an aerosol source storage section may be provided upstream of the pulp molded cup 10, and the aerosol generated by heating the aerosol source may be introduced into the pulp molded cup 10. That is, the pulp molded cup 10 may also be used for a non-combustion indirectly heated smoking article.

[Cup shape]
Prior to use, the pulp molded cup 10 is sealed by a seal 102. As previously mentioned, during use, holes are provided in the seal 102 to provide an air passageway.

In another embodiment, an opening for introducing air is provided in the bottom or side of the pulp molded cup 10. In this embodiment, there is no need to provide a tube 184 in the cap 18.

[Characteristics of the cup]
From the viewpoints of heating efficiency and strength, the thickness of the pulp molded cup 10 is preferably 0.2 to 1.0 mm. From the same viewpoints, the specific gravity of the cup 10 is preferably 0.8 to 1.5 ^cm3 .

2) Nonwoven fabric As described above, the material for smoking articles can be in the form of a nonwoven fabric, which is suitable for wrappers, paper tubes, filters (e.g., paper filters) in combustion-type smoking articles or non-combustion directly heated smoking articles. The nonwoven fabric can be obtained by papermaking the material for smoking articles. Papermaking can be performed as known in the art. For example, the slurry can be spread on a substrate such as a wire part, and dehydrated and dried to obtain a nonwoven fabric.

The wrapper preferably contains a filler. The filler content is preferably 10% or more and less than 60% by weight, more preferably 15-45% by weight, based on the weight of the wrapper. Preferred embodiments include a basis weight of 25-45 gsm and a filler content of 15-45% by weight, a basis weight of 25-35 gsm and a filler content of 15-45% by weight, or a basis weight of 35-45 gsm and a filler content of 25-45% by weight.

The wrapper may contain other auxiliary agents. For example, a water resistance improver may be added as an auxiliary agent. The water resistance improver includes a wet strength agent (WS agent) and a sizing agent. Examples of the wet strength agent include urea formaldehyde resin, melamine formaldehyde resin, polyamide epichlorohydrin (PAE), etc. Examples of the sizing agent include rosin soap, alkyl ketene dimer (AKD), alkenyl succinic anhydride (ASA), and highly saponified polyvinyl alcohol with a saponification degree of 90% or more.

The wrapper may also be coated. At least one surface may be coated. The coating agent is not limited to, but is preferably a coating agent capable of forming a film on the surface of the paper and reducing the permeability to liquids. Examples of coating agents include alginic acid and its salts (e.g., sodium salt); polysaccharides such as pectin; cellulose derivatives such as ethyl cellulose, methyl cellulose, carboxymethyl cellulose, and nitrocellulose; starch and its derivatives (e.g., ether derivatives such as carboxymethyl starch, hydroxyalkyl starch, and cationic starch, and ester derivatives such as starch acetate, starch phosphate, and starch octenyl succinate).

The nonwoven fabric is also useful as a paper filter. For example, a paper filter can be produced by filling a wrapper with the nonwoven fabric. In this case, the ridges formed by folding the nonwoven fabric are approximately parallel to the longitudinal direction of the filter. The nonwoven fabric may be subjected to a crimping treatment.

(5) Carbonized components It is preferable that the material for smoking articles containing tobacco extract residue does not contain an excessive amount of carbonized components. The carbonized components are components that do not become carbonized at temperatures below 250°C, but become carbonized when maintained at a temperature of 250°C for a predetermined time. When the material for smoking articles is heated during production or use, the carbonized components may burn and adhere to the production equipment or the smoking article. As a result, the aroma and taste of the smoking article may be deteriorated. From this viewpoint, the amount of the carbonized components is preferably 30 mg or less, more preferably 10 mg or less, and even more preferably 6 mg or less per 1 g of the material for smoking articles.

The amount of carbonized components contained in the material for smoking articles can be determined, for example, by the following measurement method.
An immersion liquid (propylene glycol 47.5% by weight, glycerin 47.5% by weight, water 5% by weight) is prepared, which is 5 times the weight of the smoking article material. The smoking article material is immersed in the immersion liquid and left to stand at 60°C for 1 hour. The smoking article material and the immersion liquid are then separated, and the immersion liquid is heated to 180°C to volatilize the solvent (liquid component) contained in the immersion liquid to obtain a "non-volatile residue". This residue is then heated to 250°C to carbonize the residue, obtaining a carbonized component, and the weight of the carbonized component is measured. The amount of carbonized component measured in this manner is the amount of carbonized component contained in the smoking article material.

By keeping the amount of carbonized components within the above range, adhesion of components to the manufacturing equipment and heating equipment during pulp mold manufacturing and heating can be suppressed. To reduce the amount of carbonized components, it is preferable to wash the extraction residue with water, for example. This makes it possible to obtain an extraction residue with fewer carbonized components.

The carbonized components of the smoking article material also affect the amount of TPM produced during smoking. Fig. 4 shows the results of measuring the TPM reduction rate relative to the amount of carbonized components contained in 1 g of aerosol liquid. The horizontal axis of Fig. 4 shows the amount of carbonized components contained in 1 g of aerosol liquid, and the vertical axis shows the TPM reduction rate ( _RTPM ) (%).

The TPM reduction rate (RTPM:%) in Figure 4 was measured using the following method. First, several smoking article materials (samples SA1 to SA5) with different amounts of carbonized components contained in 1 g of aerosol liquid were prepared. These five samples were prepared using the following process.

(Step 1)
To a tobacco raw material consisting of tobacco leaves, 20% by dry weight of potassium carbonate was added, and then a heat distillation treatment was performed. The distillation residue after this heat distillation treatment was immersed in water in an amount 15 times the weight of the tobacco raw material before the heat distillation treatment for 10 minutes, dehydrated in a dehydrator, and then dried in a dryer to obtain a tobacco residue.

(Step 2)
Next, a portion of the tobacco residue obtained in step 1 was washed with water to prepare a tobacco residue containing a low amount of carbonized matter.

(Step 3)
Next, 25 g of immersion liquid (propylene glycol 47.5 wt %, glycerin 47.5 wt %, water 5 wt %) was added to 5 g of the tobacco residue obtained in step 2, and the temperature of the immersion liquid was adjusted to 60° C. and the residue was allowed to stand. By varying the standing time (i.e., the immersion time in the immersion liquid), the amount of carbonized components dissolved in the immersion liquid was varied.

Next, the samples prepared in the above steps were subjected to automatic smoking using an automatic smoking machine (Borgwaldt's "Analytical Vaping Machine") under "CRM (Coresta Recommended Method) 81 smoking conditions." CRM 81 smoking conditions involve inhaling 55 cc of aerosol over 3 seconds, multiple times every 30 seconds.

Next, the amount of total particulate matter trapped in the Cambridge filter of the automatic smoking machine was measured. Based on the measured amount of total particulate matter, the TPM reduction rate ( _RTPM ) was calculated using the following formula (1). The TPM reduction rate ( _RTPM ) in Figure 4 was measured using the above method.

R _TPM (%) = (1-TPM (201puff ~ 250puff) / TPM (1puff ~ 50puff)) x 100... (1)

TPM (Total Particle Molecule) refers to the total particulate matter captured by the Cambridge filter of an automatic smoking machine. "TPM (1 puff-50 puff)" in formula (1) refers to the amount of total particulate matter captured by the Cambridge filter between the 1st and 50th puffs of an automatic smoking machine. "TPM (201 puff-250 puff)" in formula (1) refers to the amount of total particulate matter captured by the Cambridge filter between the 201st and 250th puffs of an automatic smoking machine.

In other words, the TPM reduction rate (R _TPM ) in equation (1) is calculated by subtracting from 1 the value obtained by dividing the amount of total particulate matter trapped by the Cambridge filter of the automatic smoking machine between the 201st and 250th puffs by the amount of total particulate matter trapped by the Cambridge filter of the automatic smoking machine between the 1st and 50th puffs, and multiplying this value by 100.

As can be seen from Figure 4, the amount of carbonized components contained in 1 g of aerosol liquid is proportional to the TPM reduction rate. As can be seen from Figure 4, particularly from samples SA1 to SA4, when the amount of carbonized components contained in 1 g of aerosol liquid is 6 mg or less, the TPM reduction rate can be suppressed to 20% or less.

3. Smoking Articles The material for smoking articles is useful for smoking articles. Smoking articles include combustion-type smoking articles and non-combustion-heating smoking articles, and the material for smoking articles can be used for both. For example, the smoking article can be provided with a wrapper or paper filter of the material for smoking articles. In this case, a tobacco extract can be added to the flavor source. It is more preferable that the tobacco extract is derived from the same raw material as the tobacco extract residue contained in the material for smoking articles, since the tobacco raw material can be effectively utilized.

Furthermore, among non-combustion heated smoking articles, there are articles (non-combustion indirectly heated smoking articles) that carry flavor by heating an aerosol source arranged separately from the flavor source to generate vapor or aerosol, which is passed through the flavor source. The pulp molded cup is useful as a cup for holding the flavor source. In this case, tobacco extract can be added to the flavor source. It is more preferable if the tobacco extract is derived from the same raw material as the tobacco extract residue contained in the smoking article material, since this allows for effective use of the tobacco raw material.

The following describes an embodiment.
Aspect 1
A material for smoking articles comprising tobacco extract residue obtained by extracting tobacco raw material.
Aspect 2
2. The material of embodiment 1, comprising a fibrous reinforcement, binder, or filler.
Aspect 3
The material according to claim 1 or 2, wherein the nicotine content of the extraction residue is 1% by weight or less of the nicotine content of the tobacco raw material.
Aspect 4
4. The material of any of the preceding claims, wherein the extraction residue has been digested.
Aspect 5
Aspect 5. The material of any of aspects 2 to 4, wherein the binder comprises starch.
Aspect 6
A wrapper, a paper tube, a filter, or a pulp molded cup formed from the material of any one of claims 1 to 4.
Aspect 7
A step of subjecting a tobacco raw material to extraction with a medium to obtain a tobacco extraction residue; and a molding step of molding the tobacco extraction residue.
A method for producing the material according to any one of aspects 1 to 6, comprising:
Aspect 8
The method according to claim 7, wherein the medium is water or a medium containing water.
Aspect 9
9. The method of claim 7 or 8, wherein the forming step comprises papermaking or pulp molding.
Aspect 10
A smoking article comprising the material of any one of aspects 1 to 5.
Aspect 11
The smoking article according to claim 10, further comprising an extract obtained by extracting a tobacco raw material.

Reference Signs List 1 Slurry 2 Male mold 3 Female mold 4 Through hole 5 Non-combustion heating type smoking article 10 Pulp molded product, pulp molded cup 102 Seal 104 Content 11 Chamber 12 Coil 14 Control device 16 Power source 18 Cap 182 Opening 184 Tube 186 Mouth hole

Claims (11)

A material for smoking articles that contains tobacco extract residue obtained by extracting tobacco raw materials. The material of claim 1, comprising a fibrous reinforcing material, a binder, or a filler. The material according to claim 1 or 2, wherein the amount of nicotine in the extraction residue is 1% by weight or less of the amount of nicotine in the tobacco raw material. The material according to any one of claims 1 to 3, wherein the extraction residue has been digested. The material according to any one of claims 2 to 4, wherein the binder comprises starch. A wrapper, paper tube, filter, or pulp molded cup formed from the material described in any one of claims 1 to 4. A step of subjecting a tobacco raw material to extraction with a medium to obtain a tobacco extraction residue; and a molding step of molding the tobacco extraction residue.
A method for producing the material according to any one of claims 1 to 6, comprising: The method according to claim 7, wherein the medium is water or a medium containing water. The manufacturing method according to claim 7 or 8, wherein the molding step includes papermaking or pulp molding. A smoking article comprising the material described in any one of claims 1 to 5. The smoking article of claim 10, further comprising an extract obtained by extracting tobacco raw materials.