Tobacco-derived cellulose material and products formed thereof

• US 9,950,858 B2
• Filed: 01/16/2015
• Issued: 04/24/2018
• Est. Priority Date: 01/16/2015
• Status: Active Grant

• Current Assignee: R J Reynolds Tobacco Company (R. J. Reynolds Tobacco), North Carolina State University (University of North Carolina System)
• Original Assignee: R J Reynolds Tobacco Company (R. J. Reynolds Tobacco), North Carolina State University (University of North Carolina System)
• Inventors: Byrd, Jr., Medwick Vaughan, McClanahan, David Neil, Debusk, Samuel Mark
• Primary Examiner(s): HUG, JOHN ERIC
• Application Number:
  US14/599,258
• Publication Number:
  US 20160208440A1
• Time in Patent Office: 1,194 Days
• Field of Search: 162139, 131365, 131358, 131275, 131105, 131374
• CPC Class Codes: A24C 1/26 Applying the wrapper
• CPC Class Codes: A24C 5/005 Treatment of cigarette paper
• CPC Class Codes: A24D 1/02 with special covers
• CPC Class Codes: A24D 3/00 Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes for pipes, for cigar or cigarette holders A24F7/00
• CPC Class Codes: B65D 85/1018 Container formed by a flexible material, i.e. soft-packages
• CPC Class Codes: B65D 85/1045 having a cap-like lid hinged to an edge
• CPC Class Codes: D21H 11/12 Pulp from non-woody plants or crops, e.g. cotton, flax, straw, bagasse
• CPC Class Codes: D21H 17/64 Alkaline compounds
• CPC Class Codes: D21H 27/10 Packing paper packaging materials of special type or form B65D65/38
• CPC Class Codes: D21H 5/16 Tobacco or cigarette paper

Abstract

A paper material is provided herein, wherein the paper material includes a fibrous material including at least 5 dry weight percent of fibers derived from a plant of the Nicotiana species; wherein the paper material has a basis weight ranging from about 5 g/m² to about 450 g/m²; and wherein the paper material has a caliper ranging from about 0.01 mils to about 200 mils. The paper material can be suitable for use in a smoking article in the form of at least one of a tipping material, a plug wrap and a wrapping material. The paper material can be suitable for use in at least one of a soft carton container suitable to house smoking articles, a label, a paper substrate of a barrier layer, a hard carton suitable to house smoking articles and a container suitable to house smokeless tobacco products.

Claims

1. A paper material comprising:

a fibrous material comprising at least 5 dry weight percent of fibers derived from a plant of the Nicotiana species;

wherein the paper material has a basis weight ranging from about 5 g/m² to about 450 g/m²; and

wherein the paper material has a caliper ranging from about 0.01 mils to about 200 mils;

wherein the paper material has a tearing index ranging from about 4.0 mN*m²/g to about 6.5 mN*m²/g.

2. The paper material of claim 1, wherein the fibrous material comprises at least 50 dry weight percent of fibers derived from a plant of the Nicotiana species.

3. The paper material of claim 1, wherein the paper material has a tensile index ranging from about 35 Nm/g to about 70 Nm/g.

4. The paper material of claim 1, wherein the paper material has a Tensile Energy Adsorption ranging from about 0.1 J/g to about 1.0 J/g.

5. The paper material of claim 1, wherein the paper material has a bursting index ranging from about 3.0 kPa*m²/g to about 5.0 kPa*m²/g.

6. The paper material of claim 1, wherein the paper material has a Scott internal bond ranging from about 1.0 to about 6.0.

7. The paper material of claim 1, wherein the paper material has a bending resistance ranging from about 0.1 Tabor Stiffness units to about 2.0 Tabor Stiffness units.

8. The paper material of claim 1, wherein the paper material has a bending resistance ranging from about 55 Tabor Stiffness units to about 90 Tabor Stiffness units.

9. The paper material of claim 1, wherein the paper material has a folding endurance ranging from about 3000 to about 20,000 MIT double folds at 0.5 kg loading.

10. The paper material of claim 1, wherein the paper material has a folding endurance ranging from about 2000 to about 5000 MIT double folds at 1.0 kg loading.

11. The paper material of claim 1, wherein the paper material has a Parker roughness value ranging from about 5.0 to about 8.0.

12. The paper material of claim 1, wherein the paper material has a Cobb value ranging from about 50 g/m² to about 200 g/m².

13. The paper material of claim 1, wherein the basis weight ranges from about 10 g/m² to about 150 g/m² and the caliper ranges from about 0.1 mils to about 6.0 mils;

and wherein the paper material is suitable for use in a smoking article in the form of at least one of a tipping material, a plug wrap and a wrapping material.

14. The paper material of claim 13, wherein the paper material comprises about 55-70 dry weight percent of the fibrous material, and wherein the fibrous material comprises about 40-60 dry weight percent of fibers derived from a plant of the Nicotiana species.

15. The paper material of claim 13, wherein the paper material comprises about 55-90 dry weight percent of the fibrous material, and wherein the fibrous material comprises about 40-60 dry weight percent of fibers derived from a plant of the Nicotiana species.

16. The paper material of claim 13, wherein the paper material comprises about 55-70 dry weight percent of the fibrous material, and wherein the fibrous material comprises about 5-20 dry weight percent of fibers derived from a plant of the Nicotiana species.

17. The paper material of claim 1, wherein the basis weight ranges from about 10 g/m² to about 150 g/m² and the caliper ranges from about 1.0 mils to about 200 mils;

and wherein the paper material is suitable for use in at least one of a soft carton container suitable to house smoking articles, a label, and a paper substrate of a barrier layer.

18. The paper material of claim 17, wherein the paper material comprises about 80-95 dry weight percent of the fibrous material, and wherein the fibrous material comprises about 75-100 dry weight percent of fibers derived from a plant of the Nicotiana species.

19. The paper material of claim 1, wherein the basis weight ranges from about 50 g/m² to about 275 g/m² and the caliper ranges from about 3.0 mils to about 200 mils;

and wherein the paper material is suitable for use in a at least one of a hard carton suitable to house smoking articles and a container suitable to house smokeless tobacco products.

20. The paper material of claim 19, wherein the paper material comprises about 80-95 dry weight percent of the fibrous material, and wherein the fibrous material comprises about 75-90 dry weight percent of fibers derived from a plant of the Nicotiana species.

21. A container, comprising:

a body having a bottom wall and a side wall, the bottom wall and the side wall defining an internal storage compartment adapted for storage of a product;

and a top configured to be engaged with the body,

wherein at least one of the bottom wall, side wall, and top comprises the paper material of claim 1;

wherein the paper material has a basis weight ranging from about 10 g/m² to about 350 g/m²; and

wherein the paper material has a caliper ranging from about 1.0 mils to about 200 mils.

22. The container of claim 21 further comprising a barrier material suitable to prevent moisture from reaching contents of the container, wherein the barrier material comprises a paper substrate comprising about 85-90 dry weight percent of a second fibrous material, and wherein the second fibrous material comprises about 5-100 dry weight percent of fibers derived from a plant of the Nicotiana species.

23. The container of claim 21, further comprising a wrapping material extending about a perimeter of the container.

24. The container of claim 21, wherein the internal storage compartment contains a plurality of products selected from the group consisting of cigarettes, smokeless tobacco products, and food products.

25. The container of claim 21, wherein the top is removable from the body.

26. The container of claim 21, wherein the top is engaged with the body.

27. The container of claim 21, wherein the container is a smokeless tobacco container or a cigarette pack.

28. The container of claim 21, wherein the top and body are generally cylindrical.

29. A method of producing a fibrous material comprising:

combining a tobacco input from a plant of the Nicotiana species with a strong base;

heating the combined tobacco input and strong base to form a tobacco pulp;

forming at least one layer of tobacco pulp;

drying the at least one layer of tobacco pulp;

pressing the at least one layer of tobacco pulp to form a paper material comprising a fibrous material comprising at least 5 dry weight percent of fibers derived from a plant of the Nicotiana species;

wherein the paper material has a basis weight ranging from about 5 g/m² to about 450 g/m²;

wherein the paper material has a caliper ranging from about 0.01 mils to about 200 mils;

wherein the paper material has at least one of a tearing index ranging from about 4.0 mN*m²/g to about 6.5 mN*m²/g, a tensile index ranging from about 35 Nm/g to about 70 Nm/g, and a Tensile Energy Adsorption ranging from about 0.1 J/g to about 1.0 J/g; and

constructing at least one of a smoking article and a container that comprises the paper material.

30. The method of claim 29, wherein the strong base is selected from the group consisting of sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, ammonium hydroxide, ammonium bicarbonate, ammonium carbonate, and combinations thereof.

31. The method of claim 29, wherein the tobacco pulp is exposed to a bleaching agent.

32. The method of claim 29, wherein the layer of tobacco pulp is dried to at least 10% moisture content or less.

33. The method of claim 29, wherein a plurality of layers are pressed into a single paper product.

34. The method of claim 29, wherein a binder solution is applied to a surface of the layer of tobacco pulp to improve binding properties of the fibrous material.

35. A paper material comprising:

a fibrous material comprising at least 5 dry weight percent of fibers derived from a plant of the Nicotiana species;

wherein the paper material has a basis weight ranging from about 5 g/m² to about 450 g/m²;

wherein the paper material has a caliper ranging from about 0.01 mils to about 200 mils; and

wherein the paper material has at least one of a tensile index ranging from about 35 Nm/g to about 70 Nm/g, a Tensile Energy Adsorption ranging from about 0.1 J/g to about 1.0 J/g, and a bursting index ranging from about 3.0 kPa*m²/g to about 5.0 kPa*m²/g.

36. The paper material of claim 35, wherein the basis weight ranges from about 10 g/m² to about 150 g/m² and the caliper ranges from about 1.0 mils to about 200 mils;

and wherein the paper material is suitable for use in at least one of a soft carton container suitable to house smoking articles, a label, and a paper substrate of a barrier layer.

37. The paper material of claim 36, wherein the paper material comprises about 80-95 dry weight percent of the fibrous material, and wherein the fibrous material comprises about 75-100 dry weight percent of fibers derived from a plant of the Nicotiana species.

38. The paper material of claim 35, wherein the basis weight ranges from about 50 g/m² to about 275 g/m² and the caliper ranges from about 3.0 mils to about 200 mils;

and wherein the paper material is suitable for use in a at least one of a hard carton suitable to house smoking articles and a container suitable to house smokeless tobacco products.

39. The paper material of claim 38, wherein the paper material comprises about 80-95 dry weight percent of the fibrous material, and wherein the fibrous material comprises about 75-90 dry weight percent of fibers derived from a plant of the Nicotiana species.

40. A container, comprising:

a body having a bottom wall and a side wall, the bottom wall and the side wall defining an internal storage compartment adapted for storage of a product;

and a top configured to be engaged with the body,

wherein at least one of the bottom wall, side wall, and top comprises the paper material of claim 35;

wherein the paper material has a basis weight ranging from about 10 g/m² to about 350 g/m²; and

wherein the paper material has a caliper ranging from about 1.0 mils to about 200 mils.

41. The container of claim 40, wherein the internal storage compartment contains a plurality of products selected from the group consisting of cigarettes, smokeless tobacco products, and food products.

42. The container of claim 40, wherein the top is removable from the body.

43. The container of claim 40, wherein the top is engaged with the body.