Sealable nonwoven with activable adhesive

Abstract

The inventors have developed a pouched product for oral use and a process for manufacturing a wrapper material for pouched products for oral use that addresses the need for a method that uses less adhesive while ensuring good sealability and maintaining the desired levels of permeability and porosity of a pouched product.

Description

Technical Field

[0001] The present disclosure relates to packaging technologies, specifically to sealable nonwoven materials used in the manufacture of pouched products for oral use.Background Art

[0002] A pouched product for oral use can comprise a sealed wrapper material enclosing a composition, in particular a powder or a fibrous support such as for instance tobacco, a plant, microcrystalline cellulose, containing an active ingredient such as nicotine, caffeine and / or ascorbic acid. The pouched product can be a small, soft, flexible packet designed to be placed in the mouth of a consumer and delivers the active ingredient into the saliva.

[0003] For a satisfying consumer experience, the pouched product should be soft and flexible enough to be comfortable in the mouth and robust enough to prevent tearing, which could lead to composition loss through the wrapper material and seals. Additionally, composition loss during storage can lead to wasted enclosed composition and consumer dissatisfaction. Inconsistent delivery of the active ingredient due to composition loss can also negatively impact the consumer's experience.Summary

[0004] In some cases, the wrapper material used to make a pouched product is composed of a nonwoven material that incorporates thermoplastic fibers and / or heat sealable material which are homogeneously distributed across the material. These thermoplastic fibers and / or heat sealable material render the nonwoven material heat-sealable. Alternatively, the nonwoven material can be homogeneously impregnated or coated with an activable adhesive, such as one that can be activated by UV light or ultrasounds or that can be heat sealed.

[0005] The desired pouched product for oral use can be manufactured from a wrapper material by unwinding the wrapper material and wrapping the unwound wrapper material around a rod of a specified diameter, forming a longitudinal seal on the tube by activating the adhesive, for example, by contacting the tube with a hot plate and thus heat-sealing the wrapper material. One of the two open ends is then sealed by activating the adhesive. The desired composition, such as tobacco powder, is then injected through the remaining open end using, for example, pressurized air. Finally, the remaining open end is sealed, again by activating the adhesive, while simultaneously cutting the wrapper material to produce the finished pouched product for oral use.

[0006] The desired pouched product for oral use can also be manufactured by placing a composition in the center of a first wrapper material. A second wrapper material is then placed over the composition, akin to the process of making "ravioli." The edges of the wrapper materials are sealed together, enclosing the composition and forming the final pouched product that can optionally be cut to a predetermined shape.

[0007] Regardless of the method used to produce the pouched product for oral use, known pouched product for oral use incorporates activable adhesive throughout the entire nonwoven material used in the wrapper. This adhesive can be integrated in the form of thermoplastic fibers and / or heat sealable material within the nonwoven material or as an activable adhesive applied across the nonwoven material.

[0008] Consequently, the entire surface of the oral pouch contains activable adhesive, even outside the sealed area, which presents several drawbacks.

[0009] These activable adhesives can negatively impact the flexibility, porosity, and even the haptic properties and off note of the pouched product. Additionally, such pouched products require a substantial amount of activable adhesive, which is sometimes not derived from bio-sourced materials, contributing to environmental concerns.

[0010] There is therefore a strong need for a method that uses less adhesive while ensuring good sealability and maintaining the desired levels of permeability and porosity of the pouched product.

[0011] The inventors have developed a pouched product for oral use and a process for manufacturing a wrapper material for pouched products for oral use that addresses these problems

[0012] According to a first aspect, a pouched product for oral use is provided, comprising: a wrapper material forming a pouch, and a composition enclosed in the wrapper material forming a pouch; wherein the wrapper material comprises a nonwoven material having a sealed area and an unsealed area, and whereby more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of the unsealed area is unsealable and in a very preferred embodiment almost 100% of the unsealed area is unsealable.

[0013] The composition can be a tobacco-derived product, a particulate material containing an active ingredient, a reconstituted plant sheet containing an active ingredient, cellulose containing an active ingredient, a cellulose derivative containing an active ingredient or mixtures thereof

[0014] The composition enclosed within the pouch can have a weight (not on a dry basis) ranging from 0.2 to 3 grams, particularly from 0.3 to 2.0 grams, even more particularly from 0.35 to 1.5 grams.

[0015] The inner volume of the pouch can range from 3 to 5 cubic centimeters, preferably from 3 to 4 cubic centimeters, for instance around 3.6 cubic centimeters.

[0016] The composition can comprise from 3 % to 45 % water by weight of the composition, preferably from 5 % to 30 % water by weight of the composition.

[0017] The basis weight of the nonwoven material can be from 14 to 35 g / m 2< , preferably from 18 to 31g / m 2< and even more preferably from 20 to 27 g / m 2< .

[0018] The thickness of the nonwoven material can be from 50 µm to 130 µm measured at 100 Kpa, preferably 60 µm to 120 µm measured at 100 Kpa.

[0019] The air permeability of the nonwoven material in the unsealable area can be from 1 000 to 80 000 CORESTA UNITS (CU), preferably from 5000 to 70 000 CU, even more preferably from 10 000 to 55 000 CU.

[0020] The nonwoven material can be a wetlaid nonwoven material.

[0021] The sealed area can have a sealing strength of at least 250 cN / 30mm, preferably at least 350 cN / 30mm, and even more preferably at least 450 cN / 30mm.

[0022] The pouched product can comprise from 0.5 mg to 15 mg, preferably from 1 mg to 10 mg, and even more preferably 1 mg to 8 mg of activable adhesive.

[0023] The activable adhesive can comprise a water-based adhesive or a hotmelt adhesive.

[0024] The water-based adhesive can be an acrylic emulsion, an ethylene acrylic copolymers dispersion, or a suspension or an emulsion of an element chosen among the list consisting of a latex, a polyester (PLA, PBS, PBSA, PHA), a polyurethane, a vinyl acetate and ethylene copolymers, a vinylacetate and acryl acid esters copolymers, a vinyl acetate and methacrylic esters copolymers.

[0025] The hotmelt adhesive can comprise thermoplastics polymers such as ethyl vinyl acetate (EVA), thermoplastic rubbers, polyamide, polyurethane, polyester (PLA, PBS, PHA, PBSA, PHB), polyolefines (such as polyethylene PE, low density polyethylene LDPE).

[0026] According to another aspect of the present invention, a wrapper material for a pouched product for oral use is provided, the wrapper material comprising: a nonwoven material and an activable adhesive that partially covers the nonwoven material, the activable adhesive delineating a sealable area of the wrapper material, while the wrapper material remains unsealable outside of the sealable area, wherein the nonwoven material carries a pattern of a desired pouched product for oral use and whereby more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of the pattern of the desired pouched product for oral use is unsealable.

[0027] A web of a nonwoven material comprising an activable adhesive that partially covers said nonwoven material is provided, wherein the web comprises at least two wrapper materials that each carries a pattern of a desired pouched product for oral use and the activable adhesive delineating respective sealable areas of respective wrapper materials, while each wrapper material remains unsealable outside the sealable area, and more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of each wrapper material are unsealable.

[0028] According to another aspect, a method for manufacturing a web or a bobbin of wrapper material for a pouched product for an oral use is provided, the wrapper material comprising a nonwoven material, the method comprising the following step of depositing on a surface of a nonwoven material an activable adhesive that partially covers the nonwoven material, the activable adhesive delineating a sealable area of the wrapper material, while the wrapper material remains unsealable outside of the sealable area, wherein the nonwoven material carries at least two patterns of a desired pouched product for oral use and whereby more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of each of the at least two patterns of the desired pouched product for oral use are unsealable.

[0029] The activable adhesive can be deposited by flexography, by jet printing, by gravure printing, by slot die printing, more preferably by flexography or slot die printing.

[0030] The hotmelt adhesives can be added by extrusion printing or by extrusion slot die printing.

[0031] By having more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of the nonwoven material of the wrapper material being unsealable or of the unsealed area of the pouch product for oral use being unsealable, the present disclosure minimizes the use of activable adhesive, which not only reduces material costs but also maintains the flexibility and porosity of the nonwoven material and addresses environmental concerns.

[0032] The placement of sealable and unsealable areas ensures that the pouched product remains soft and flexible, enhancing comfort when placed in the mouth of a consumer.

[0033] Additionally, by reducing the amount of adhesive used and potentially utilizing bio-sourced materials, the invention addresses environmental concerns associated with traditional pouched products.

[0034] This approach not only contributes to sustainability, but also offers customization potential, allowing the creation of various nicotine pouch shapes and sizes to meet different consumer preferences.Brief Description of Drawings

[0035] Other features, details and advantages will be shown in the following detailed description and on the figures, on which: Fig. 1 [Fig. 1] shows a pouched product for oral use according to prior art; Fig. 2 [Fig. 2] shows different shapes of pouched product for oral use according to the present disclosure; Fig. 3 [Fig. 3] shows a web of wrapper material and one pattern of a pouched product according to one embodiment of the present disclosure; Fig. 4 [Fig. 4] shows a web of wrapper material and pattern of one pouched product according to another embodiment of the present disclosure; Fig. 5 [Fig. 5] shows a web of wrapper material and pattern of one pouched product according to another embodiment of the present disclosure; Fig. 6A [Fig. 6A] shows a web of wrapper material and pattern of one pouched product according to another embodiment of the present disclosure; Fig. 6B [Fig. 6B] shows a pattern of a square pouched product wherein activable adhesive has been coated on both surfaces Fig. 7 [Fig. 7] shows examples of activable adhesive coatings. Fig. 8 [Fig. 8] shows examples of web of wrapper material comprising Fig. 9 [Fig. 9] shows other examples of web of wrapper material comprising Fig. 10 [Fig. 10] shows other examples of web of wrapper material comprising Description of Embodiments

[0036] Reference is made to FIG. 1, which illustrates a pouched product for oral use that is not in accordance with the present disclosure.

[0037] The depicted pouched product includes both sealed (10) and unsealed area (20). However, the unsealed area (20) remains sealable because it either contains thermoplastic fibers and / or heat sealable material within the wrapper material or are coated with activable adhesive.

[0038] The unsealed area (20) could thus still be sealed by activating the adhesive, for example by melting the thermoplastic fibers and / or heat sealable material with heat.

[0039] Such a pouched product presents several drawbacks, as previously discussed. The unnecessary use of activable adhesive on all the surface of the pouch wrapper can negatively impact the softness and permeability of the product. This excessive adhesive application can lead to a less comfortable user experience and may change or affect the product's overall performance.

[0040] Such a pouched product also needs an unnecessary amount of activable adhesive that will not be activated, thereby addressing environmental concerns.

[0041] It is now made reference to figure 2.

[0042] Figure 2 illustrates different shapes of a pouched product for oral use according to the present disclosure.

[0043] The pouched product for oral use comprises a wrapper material forming a pouch and a composition enclosed within the wrapper material.

[0044] The pouch forms an inner volume. The composition enclosed within the wrapper material is contained in the inner volume of the pouch.

[0045] The composition may be a tobacco-derived product, a particulate material containing an active ingredient, a reconstituted plant sheet containing an active ingredient, cellulose containing an active ingredient, a cellulose derivative containing an active ingredient or mixtures thereof, in particular a tobacco-derived product, a cellulose derivative containing an active ingredient or mixtures thereof. In an example embodiment the pouched product comprises a tobacco-derived product. In another example embodiment the pouched product comprises nicotine extracted from tobacco or synthetic nicotine or nicotine salts. In another example embodiment the composition is a powder with nicotine salts.

[0046] The active ingredient may be, but is not limited to, nicotine, cannabinoids, an antiaging ingredient, a stress / anxiety managing ingredient, a sleep managing ingredient, an immunity boosting ingredient, an energy boosting ingredient, a cognitive health ingredient, a sexual wellbeing ingredient, a digestion helping ingredient, an allergy handling ingredient or mixtures thereof. In a preferred embodiment, the active ingredient is nicotine.

[0047] The composition enclosed within the pouch can include various additives such as a pH corrector, humectants and flavors to improve consumer experience.

[0048] The inner volume of the pouch can range from 3 to 5 cubic centimeters, preferably from 3 to 4 cubic centimeters, for instance around 3.6 cubic centimeters.

[0049] The composition enclosed within the pouch (without the weight of the pouch wrapper) has typically a weight ranging from 0.2 to 3 grams, particularly from 0.3 to 2.0 grams, even more particularly from 0.35 to 1.5 grams.

[0050] The composition enclosed within the pouch can comprise from 3 % to 45 % water by weight of the composition, preferably from 5 % to 30 % water by weight of the composition.

[0051] The composition comprises less than 70 % shredded plant material and preferably does not include natural shredded leaves, such as tea leaves.

[0052] A pouched product for oral use can be designed in various geometric shapes as illustrated in figure 2, including but not limited to triangles, rectangles, squares, circles, and semicircles.

[0053] According to an embodiment, the pouched product for oral use has a substantially rectangular pattern with a length L and a width w.

[0054] The pouched product has a pattern that is substantially rectangular, meaning the pattern may be inscribed within a rectangle, or meaning that the pattern is delimited by a perimeter comprised along sides of a rectangle. The pouched product may, for example, have transversal sealed area that have been cut in a zig-zag manner as illustrated in the right of figure 2. Even with a zig-zag width, the pouched product can still be inscribed within a greater rectangular pattern, enabling measurement as illustrated in the right of figure 1.

[0055] The length L can range from 10 mm to 45 mm, preferably from 20 mm to 40 mm, and even more preferably from 30 mm to 36 mm, for instance 34 mm.

[0056] The width w can range from 1 mm to 30 mm, preferably from 8 mm to 20 mm, and even more preferably from 12 mm to 18 mm, for instance 14 mm.

[0057] The aspect ratio w / L can be from 0.1 to 1, preferably from 0.1 to 0.6, for instance 0.4.

[0058] According to another embodiment whereby the pouched product for oral use does not have a substantially rectangular pattern, it can still be characterized by a longest length L which can be a diameter for a circle or a hemi-circle, the longest sides of a triangle, the diagonal of a square. In this case, the longest length L can range from 10 mm to 45 mm, preferably from 20 mm to 40 mm, and even more preferably from 30 mm to 36 mm, for instance 34 mm.

[0059] The pouched product for oral use has a ('a' meaning 'at least one' in the whole present disclosure) sealed area (10) that corresponds to two surfaces of one same nonwoven material or from two different nonwoven material, that have been brought into contact and sealed, for example heat-sealed.

[0060] In case the pouched product for oral use has generally a rectangular shape, the pouched product can have one longitudinal seal and two transversal seals. The longitudinal seal is parallel to the length L of the pouched product, and the two transversal seals are perpendicular to the length L of the pouched product.

[0061] In case the pouched product for oral use has generally a circular shape, the pouched product can have one circular seal. The circular seal is formed at the perimeter of the circular shape of the pouched product for oral use.

[0062] In case the pouched product for oral use has generally a semicircular shape, the pouched product can have one semicircular seal letting the diameter unsealed (except near the extremities of the diameter) or the pouched product can have one semicircular seal with the diameter fully sealed. The semicircular seal is formed at the perimeter of the semicircular shape of the pouched product for oral use.

[0063] In case the pouched product for oral use has generally a triangular shape, the pouched product can have one triangular seal letting one side unsealed (except near the extremities of the diagonal) or the pouched product can have one triangular seal with all the sides of the triangle sealed. The seal being formed at the perimeter of the triangle shape of the pouched product for oral use.

[0064] The semicircular and triangle shape can have one side or diameter unsealed except in the case, for example, when the wrapper material has been folded.

[0065] Whatever the shape of the pouched product for oral use, a seal can have a width ranging from 1 mm to 6 mm, preferably around 3 mm.

[0066] The seal is not limited to a band. The seal might be provided in undetermined shape such as in the form of commercial logos or parallel lines or discrete specks.

[0067] As illustrated in figure 2, a pouched product comprises a wrapper material forming a pouch wherein the wrapper material comprises a nonwoven material having sealed area (10) and unsealed area (20, 30), and whereby more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of the unsealed area (20, 30) are unsealable (30). According to a particular embodiment, almost 100% of the unsealed area can be unsealable.

[0068] A sealable area (20) of the pouched product for oral use is an area on the nonwoven wrapper material where activable adhesive has been coated. The coating itself of activable adhesive delineated the so called sealable area (20).

[0069] Within a sealable area (20), sealed area (10) can be formed by activating the adhesive, creating what are commonly referred to as "seals" of the pouched product.

[0070] One sealed area (10) does not necessarily correspond to the sealable area (10, 20). Indeed, a sealable area (20) of the wrapper material can be larger than a sealed area (10) of the pouched product, as a sealable area may not be fully activated, leaving some portions unsealed.

[0071] In contrast, an unsealable area (30) cannot be bonded because an unsealable area (30) lacks sufficient activable adhesive. Even if a small amount of adhesive is present, it is insufficient to form a bond upon activation.

[0072] To determine if an area is sealable, reference can be made to ISO 1924-2. The method can comprise the following steps: activating the area to be tested, for example the area is folded then activating, measuring the sealing strength of the area after activation, if the measured sealing strength is above a predetermined value, it means that enough activable adhesive was present within the area to be tested, the area is sealed, meaning the area to be tested was sealable, otherwise it is not sealed meaning the area to be tested was unsealable.

[0073] Activating can be done by heat, UV, ultrasounds, and / or pressure, preferably by heat and pressure.

[0074] For example, activating by heat could comprise folding the area of the wrapper material to be tested under 250 KPa for 0.7 seconds at a temperature of approximately 250°C and then measuring the sealing strength.

[0075] The procedure for measuring the sealing strength (resistance of the sealed area) of the activated area can involve using a dynamometer, for instance models 200 MC and SYNERGIE 100. The activated area is positioned between the jaws of the dynamometer. The device can be programmed with specific settings: the jaws can be opened to 18cm, the width can be set to 30.0mm, and the speed can be adjusted to 10mm / min. Once the setup is complete, the measurement is initiated, and the dynamometer records the maximum energy exerted and the elongation percentage at the point of rupture.

[0076] The sealing strength can be at least 250 cN / 30mm, preferably at least 350 cN / 30mm, and even more preferably at least 450 cN / 30mm. Under these ranges, the area is said to be unsealed.

[0077] An unsealable area can also be defined by the minimal presence of activable adhesive within the wrapper material. To qualify as unsealable, the area should contain less than a specified percentage of thermoplastic fibers and / or heat sealable material within the nonwoven material and / or less than a specified amount of activable adhesive coated on the nonwoven material.

[0078] The activable adhesive is designed to initiate the sealing process upon activation.

[0079] The activable adhesive can be activated by heat, UV, ultrasounds, and / or pressure, preferably by heat and pressure.

[0080] The pouched product can comprise from 0.7 to 9 mg of activable adhesive.

[0081] The activable adhesive can be home compostable and / or industrial compostable and / or bio-sourced.

[0082] In the context of the present disclosure, a material that is compostable is a material complying with the EN 13432 standard.

[0083] This standard specifies the requirements for packaging recoverable through composting and biodegradation. It ensures that the material can break down into natural elements within a composting environment, leaving no toxic residues.

[0084] The activable adhesives can comprise a water-based adhesive or a hotmelt adhesive.

[0085] The water-based adhesive can be an acrylic emulsion, an ethylene acrylic copolymers dispersion, or a suspension or an emulsion of an element chosen among the list consisting of a latex, a polyester (PLA, PBS, PBSA, PHA), a polyurethane, a vinyl acetate and ethylene copolymers, a vinyl acetate and acryl acid esters copolymers, a vinyl acetate and methacrylic esters copolymers.

[0086] The hotmelt adhesive can comprise thermoplastics polymers such as ethyl vinyl acetate (EVA), thermoplastic rubbers, polyamide, polyurethane, polyester (PLA, PBS, PHA, PBSA, PHB), polyolefines (such as polyethylene PE, low density polyethylene LDPE).

[0087] The wrapper material comprises a nonwoven material.

[0088] "Nonwoven material" denotes a manufactured web or ply of directionally or randomly oriented fibers bonded together by friction and / or cohesion and / or adhesion.

[0089] The nonwoven material can comprise natural fibers and synthetic fibers, preferably the nonwoven material does not comprise synthetic fibers but only natural fibers.

[0090] For the purposes of the present application, the term "natural fiber" denotes a fiber of natural origin.

[0091] For example, natural fibers can be chosen from wood fibers, leaf fibers, fruit fibers, seed fibers, bast fibers, stalk fibers, reed fibers, and mixtures thereof, in particular from wood fibers, leaf fibers, seed fibers, bast fibers, and mixtures thereof, more particularly from wood fibers, bast fibers and mixtures thereof.

[0092] Examples of wood fibers which may be present in the nonwoven material can be hardwood pulp, softwood pulp, softwood fluff pulp, bleached hardwood pulp, bleached softwood pulp, bleached softwood fluff pulp, lyocell fibers (cellulose fibers which are ground and dissolved in N-methylmorpholine N-oxide monohydrate for the purpose of obtaining fibers with a cross section of variable shape (round, oval, cross-shaped, circular, lamellar cross section) with calibrated length and mass per unit length, which the person skilled in the art can choose depending on their needs), viscose fibers (fibers obtained by dissolving cellulose by means of modification of its hydroxyl groups by carbon disulfide (CS2) and then its precipitation in the presence of sulfuric acid (H 2 SO 4 ) for the purpose of obtaining fibers with a cross section of variable shape (round, oval, cross-shaped, circular, lamellar cross section) with calibrated length and mass per unit length, which the person skilled in the art can choose depending on their needs), and mixtures thereof, in particular hardwood pulp, softwood pulp, softwood fluff pulp, lyocell fibers, viscose fibers, and mixtures thereof, more particularly softwood pulp, softwood fluff pulp, lyocell fibers, and mixtures thereof.

[0093] For the purposes of the present application, "bast fiber" denotes a plant fiber contained in the bast of the plants.

[0094] As bast fiber, mention may be made of hemp fiber, Indian hemp fiber, jute fiber, kenaf fiber, kudzu fiber, coin vine fiber, flax fiber, okra fiber, nettle fiber, papyrus fiber, ramie fiber, sisal fiber, esparto fiber, and mixtures thereof, in particular hemp fiber, flax fiber, and mixtures thereof, more particularly flax fiber.

[0095] Typically, the bast fibers may have undergone prior treatment. Thus, the bast fibers may be cottonized bast fibers, individualized bast fibers, bast fibers which have undergone retting, bleached bast fibers, and mixtures thereof, in particular cottonized bast fibers, individualized bast fibers and mixtures thereof.

[0096] For the purposes of the present application, "seed fiber" denotes a fiber obtained from seeds of a plant. Examples of seed fibers can be cotton fiber, kapok fiber, luffa fiber, milkweed fiber, and mixtures thereof, in particular kapok fiber.

[0097] The natural fibers may have a length of from 1 mm to 10 mm, in particular from 1.5 mm to 8 mm, very particularly from 2 mm to 5 mm.

[0098] An airlaid process is particularly suitable for these sizes of natural fibers. Thus, the nonwoven material of the present disclosure can be obtained by an airlaid process and is thus said to be an airlaid nonwoven material.

[0099] The natural fibers may have a length of from 1 mm to 40 mm, in particular from 1.5 mm to 25 mm, even more particularly from 2 mm to 15 mm.

[0100] A drylaid process is particularly suitable for these sizes of natural fibers. Thus, the nonwoven material of the present disclosure can be obtained by a drylaid process and is said to be a drylaid nonwoven material.

[0101] The length of the natural fibers can be measured by microscopic measurement using a projection microscope by means of the necessary magnification.

[0102] The natural fibers may also be cut so as to have a length within the ranges mentioned above. Cutting techniques which can be used are guillotine cutting of natural fibers, grinding of the natural fibers with or without a system for removing excessively short and excessively long fibers of air cyclone or screen type.

[0103] According to an embodiment, the nonwoven material comprises less than 18 wt% of synthetic fibers, based on a wt % of a total weight of solid of said nonwoven material, preferably less than 14 wt%, even more preferably less than 10 wt% of synthetic fibers. The nonwoven material can also be free of synthetic fibers.

[0104] The term "synthetic fiber", as used herein, refers to man-made fibers produced from chemical substances, typically derived from petrochemicals or derived from bioresources. These fibers are created through various chemical processes and are designed to mimic the properties of natural fibers while offering additional benefits such as increased strength, durability, and resistance to environmental factors. Common examples of synthetic fibers include polyester, polyolefins, polyacrylates, polyurethanes, polyamides, nylon, acrylic, polyethylene and polypropylene fibers.

[0105] The synthetic fibers in the nonwoven of the present disclosure can be thermoplastic fibers.

[0106] The term "thermoplastic fibers ", as used herein, denotes fibers that soften and / or partly and / or fully melt when exposed to heat and are capable to bind with each other or to other non-thermoplastic fibers, such as cellulose fibers, upon cooling and resolidifying.

[0107] For instance, the thermoplastic fibers may be polybutylene succinate (PBS) fibers, polybutylene succinate adipate (PBSA) fibers, polybutylene adipate terephthalate (PBAT) fibers, polyhydroxyalkanoate (PHA) fibers, Polyhydroxybutyrate (PHB) fibers, copolymers of PHA fibers or mixtures thereof, polyethylene teraphtalate (PET) fibers, in particular PHA, PBS fibers or mixtures thereof.

[0108] The PHA fibers may be poly(lactic acid) (PLA) fibers, poly(glycolic acid) (PGA) fibers, poly(3-hydroxybutyrate) (P3HB) fibers, poly(3-hydroxyvalerate) (P3HV) fibers, poly(5-hydroxyvalerate) (P5HV) fibers, poly3-hydroxybutyrate-co-3-hydroxyvalerate (PHVB) or mixtures thereof, in particular PLA fibers or mixtures thereof.

[0109] Advantageously, PBS fibers, PBSA fibers, PLA fibers, P3HB fibers, P3HV fibers and P5HV fibers are biobased thermoplastic fibers.

[0110] In a preferred embodiment, the nonwoven material of the present disclosure is free of synthetic fibers.

[0111] The nonwoven material, in the unsealable area may have permeability from 1 000 to 80 000 CORESTA Units, preferably from 5 000 to 70 000 CU, even more preferably from 10 000 to 55 000 CU.

[0112] The permeability of the nonwoven material is determined by ISO 2965:2009. The nonwoven material is conditioned for at least 30 min at 23 °C (+ / - 1 °C) and 50 % (+ / - 4 %) relative humidity before the measurement.

[0113] After coating the nonwoven material with activable adhesive, the permeability of the nonwoven material can be measured again using the same standardized method. The permeability remaining nearly the same as before the coating was applied indicates that the coated activable adhesive has not affected the material's permeability.

[0114] The basis weight of the nonwoven material can be from 14 to 35 g / m 2< , preferably from 18 to 31g / m 2< and even more preferably from 20 to 27 g / m 2< .

[0115] The standard ISO 534 can be used to determine the basis weight of the nonwoven material. The nonwoven material is conditioned for at least 30 min at 23 °C and 50 % relative humidity before the measurement.

[0116] The thickness of the nonwoven material can be from 50 µm to 130 µm measured at 100 Kpa, preferably 60 µm to 120 µm.

[0117] A nonwoven material having thickness, permeability and basis weight as above described is particularly satisfactory to make a wrapper material of a pouched product for oral use.

[0118] According to an embodiment, the nonwoven material is an airlaid, dry laid or wetlaid nonwoven material, preferably the nonwoven material is wetlaid nonwoven material.

[0119] The wetlaid nonwoven material may further comprise regenerated cellulose fibers.

[0120] The term "regenerated cellulose fibers", as used herein, denotes fibers manufactured by the conversion of natural cellulose to a soluble cellulosic derivative and subsequent regeneration into cellulose fibers. Regenerated cellulose fibers can have the advantage that they can be produced from renewable cellulose sources, which could contribute to the environmental sustainability of the wetlaid material. Furthermore, regenerated cellulose fibers may improve the experience of the user of a pouched product comprising a pouched product for oral use made of the wetlaid material of the present disclosure. Indeed, these fibers enhance the comfortability of the feel of the pouched products when placed in the oral cavity.

[0121] The regenerated cellulose fibers may be lyocell fibers (cellulose fibers which are ground and dissolved in N-methylmorpholine N-oxide monohydrate for the purpose of obtaining fibers with a cross section of variable shape (round, oval, cross-shaped, circular, lamellar cross section) with calibrated length and mass per unit length, which the person skilled in the art can choose depending on the needs), viscose fibers (fibers obtained by dissolving cellulose by means of modification of its hydroxyl groups by carbon disulfide (CS2) and then its precipitation in the presence of sulfuric acid (H 2 SO 4 ) for the purpose of obtaining fibers with a cross section of variable shape (round, oval, cross-shaped, circular, lamellar cross section) with calibrated length and mass per unit length, which the person skilled in the art can choose depending on the needs) or mixtures thereof, in particular viscose fibers.

[0122] Typically, the wetlaid nonwoven material may comprise from 1 to 10 wt %, preferably from 3 to 8 wt %, more preferably from 4 to 6 wt % of regenerated cellulose fibers, based on a wt % of a total weight of solid of said wetlaid material.

[0123] It is now made reference to figures 3 to 6.

[0124] Figures 3, 4, 5, 6A and 6B illustrate four different embodiments.

[0125] Figures 3, 4, 5, 6A and 6B illustrate examples of a web of wrapper material with activable adhesive applied to delineate nine patterns for pouched products for oral use. In these examples, the adhesive is coated in bands, creating a square pattern that can be folded along a symmetric axis or paired with another web, which may or may not carry the same pattern.

[0126] In Figure 3, the adhesive is applied in continuous bands to form a square or rectangular pattern, allowing the wrapper material to be folded so that two opposite sides come into contact, with at least one side containing the adhesive. Alternatively, a second web of wrapper material can be placed over the first, with the composition sandwiched in between. The second web may feature a "negative", complement or supplementary pattern feature of the first web's pattern, meaning the second web may have adhesive where the first web does not, ensuring complete coverage and sealing when combined. This is illustrated in figure 6B.

[0127] In each figure, one pattern for a rectangular pouched product comprising one longitudinal seal and two transversal seals is illustrated on the right. On the left of the figure, one web of a nonwoven material comprising nine wrapper materials each carrying the pattern illustrated on the right of the respective figure is illustrated. The folding lines and cutting lines are also provided in these figures.

[0128] One pattern comprises one folding line. One web comprises 2 longitudinal cutting lines and 3 transversal cutting lines that will lead to 9 wrapper material each carrying a pattern of one pouched product.

[0129] A wrapper material comprises a nonwoven material and an activable adhesive that partially covers the nonwoven material, the activable adhesive delineating sealable area of the wrapper material, while the wrapper material remains unsealable outside the sealable area, wherein the wrapper material carries a pattern for a desired pouched product for oral use and whereby more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of the wrapper material is unsealable.

[0130] A skilled person unambiguously understands what is meant by a "pattern for a desired pouched product for oral use". The pattern of a pouched product for oral use, as illustrated in figures 3, 4, 5, 6A and 6B, 8, 9 and 10 could be compared to a pattern used in tailoring a piece of clothing. In both cases, specific areas are designated for different functions, ensuring the final product meets its intended purpose.

[0131] A "pattern for a desired pouched product for oral use" can refer to the specific arrangement and configuration of sealable and unsealable area on the wrapper material that define the shape and structure of the final pouched product. One pattern comprises one or more web of nonwoven material (one web in case of folding and at least two webs in case for example of the "ravioli" method), one pattern corresponding to a single pouched product, which when overlayed, form the pouch whereby a perimeter of the pouch comprises either a portion of one or more of the web folded onto itself (see for example the triangle and semicircle embodiments illustrated in figure 2) or a sealed area. The perimeter of the pouched product thus comprises in some examples a single segment whereby a web is folded onto itself and other segments are sealed.

[0132] The pattern ensures that the wrapper material can be, for example, folded and sealed to form the intended shape of the pouched product, accommodating the enclosed composition while maintaining the desired properties of flexibility and permeability.

[0133] The pattern ensures that the wrapper material can be, in another example, combined with another wrapper material and sealed to form the intended shape of the pouched product, similar to the process of making 'ravioli'.

[0134] According to another aspect, the present disclosure concerns a web of a nonwoven material and an activable adhesive that partially covers the nonwoven material, wherein the web comprises at least two wrapper materials that each carries a pattern for a desired pouched product for oral use, and the activable adhesive delineating respective sealable area of respective wrapper material, while each wrapper material remains unsealable outside of the sealable area, and whereby more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of the pattern of the desired pouched product for oral use is unsealable.

[0135] According to another aspect, the present disclosure concerns a bobbin of a nonwoven material and an activable adhesive that partially covers the nonwoven material, wherein the bobbin comprises at least two wrapper materials that each carries a pattern of a desired pouched product for oral use , and the activable adhesive delineating respective sealable area of respective wrapper material, while each wrapper material remains unsealable outside the sealable area, and whereby more than 50% of the pattern of the desired pouched product for oral use is unsealable.

[0136] In case the desired pouched product for oral use has a generally rectangular shape having a length L and a width w, the bobbin can be designed with a long length and a width that is a multiple of the width w of the final pouched product to be manufactured or a width that is greater than a multiple of the width w of the final pouched product to be manufactured to ensure a clearance.

[0137] This configuration facilitates efficient unwinding and processing during the production of pouched products, enabling high-speed manufacturing and consistent quality.

[0138] A skilled person can determine the placement of activable adhesive based on the desired configuration of the pouched product for oral use.

[0139] For instance, if the product is to be formed by folding and sealing the wrapper material into a rectangular shape, as illustrated in figure 4, 5 and 6, the adhesive could be applied to at least half of the area that will form the longitudinal seal. This ensures that when the material is folded, the adhesive is positioned correctly to create a secure bond.

[0140] The shape of the sealable area is not limited to continuous bands as illustrated in figure 3, 4, 5, 6A and 6B, their patterns can be successive dots, grids, checkerboard, sinusoidal bands, parallel straight lines, band aside a band of color, band with a logo as illustrated in figure 7.

[0141] The following table shows the adhesive coverage within the area of the wrapper material that will be sealed according to the different shape illustrated in figure 7. figureAdhesive coverage%figureAdhesive coverage%A10G45B21H40C64I24D32J46E22K90F45L39

[0142] It is even possible to apply the adhesive in the form of a logo, or to design unsealable area that form a logo when the sealable area are activated.

[0143] This flexibility in adhesive application allows customizing and optimizing the sealing process.

[0144] It is now made reference to figure 8, 9 and 10.

[0145] Figure 8 illustrates a wrapper material with a pattern for a rectangular pouched product, featuring sealable areas that are not in the form of continuous bands. The pouched product for oral use can be created by cutting the wrapper material along designated lines and then either folding it or sealing it with another wrapper material using a "ravioli" method.

[0146] Figure 9 depicts a wrapper material with a pattern for a circular pouched product, also having sealable areas that are not continuous bands. Similar to the rectangular version, the circular pouched product can be formed by cutting along the lines and folding or sealing with another wrapper material using the 'ravioli' method. In this figure, the wrapper material includes activable adhesive beyond the pattern of the pouched product.

[0147] In a variant shown in Figure 10, the wrapper material contains activable adhesive only within the pattern of the pouched product, further reducing adhesive usage.

[0148] Additionally, the wrapper material, web, or bobbin may include alignment marks to facilitate precise placement during manufacturing.

[0149] This can facilitate precise placement of the nonwoven material in machinery used to produce the final pouched product for oral use.

[0150] These marks can be visual indicators, such as printed lines as illustrated in figure 7, or symbols, that assist in the correct positioning of the wrapper material, web or bobbin in the machinery.

[0151] Additionally, the marks may be additives embedded within the nonwoven material, detectable by sensors such as UV or IR sensors, ensuring accurate alignment during automated processing.

[0152] A manufacturing method of a web or bobbin of wrapper material for a pouched product for an oral use is provided, the wrapper material comprising a nonwoven material, the method comprising the step of coating on a surface of a nonwoven material an activable adhesive that partially covers the nonwoven material, the activable adhesive delineating sealable area of the wrapper material, while the wrapper material remains unsealable outside the sealable area, wherein the nonwoven material carries at least two patterns for a desired pouched product for oral use and whereby more than 50%, for instance more than 60%, for instance more than 65%, for instance more than 70%, for instance more than 75%, for instance more than 80% and preferably more than 90% of each of the at least two patterns of the desired pouched product for oral use is unsealable.

[0153] A method for manufacturing a wrapper material for a rectangular pouched product for an oral use is also provided, the wrapper material comprising a nonwoven material, the method comprising the steps of: depositing on a surface of a nonwoven material an activable adhesive to N successive aeras extending in the machine direction and M successive area extending perpendicular to the machine direction, wherein the N x M areas together delineate a plurality of sealable areas carrying pattern for the rectangular pouched product for oral use, wherein the nonwoven material, outside of the sealable area, is unsealable

[0154] The machine direction can be parallel to the axis around which the wrapper material will be folded or rolled to form the pouch.

[0155] The covering by activable adhesive can comprise activable adhesive on a single face of the wrapper material.

[0156] The covering by activable adhesive can comprise activable adhesive on opposite faces of the wrapper material.

[0157] It is made reference to figure 6B that illustrates a pattern of a square pouched product wherein activable adhesive has been coated on both surfaces (upper surface is side 1 and lower surface is side 2) of the wrapper material so that when folded among the dotted line, the pouched product will comprise activable adhesive in its four sides.

[0158] The activable adhesive on opposite faces of the wrapper material can overlap on less than 10%, preferably less than 5% of the surface of the respective adhesive area.

[0159] The activable adhesives can be coated by flexography or jet printing or gravure printing or by hotmelt extrusion or hotmelt printing or hotmelt slot die printing, preferably by flexography for aqueous based adhesives and by hotmelt printing for thermoplastic polymers.

[0160] Different methods to produce a pouched product for oral use can be used. One comprising steps of unwinding, folding and sealing a wrapper material. Another method comprises the steps of providing two webs of wrapper material enclosing the composition in between before sealing and cutting the wrapper material to obtain the desired pouched product for oral use.

[0161] A method to manufacture a pouched product for oral use the method is also provided comprising the following steps: providing a tube made of a wrapper material as defined in the present disclosure wrapping a composition between two open ends thereof, and sealing each open end of the tube to manufacture the pouched product.

[0162] The method may also comprise a step of providing a first web of wrapper material, depositing a composition onto the designated pattern, and then overlaying the composition and the first web of wrapper material with a second web of wrapper material, which may optionally have the same pattern as the first web. The method then involves sealing the wrapper material within the sealable area and finally cutting the wrapper material into the desired shape for the pouched product for oral use.EXAMPLE

[0163] In the following example, a conventional circular pouched product for oral use was produced using a prior art method, alongside three examples created according to the invention. Each pouched product has a diameter of 3 cm. The wrapper material for the comparative example is a nonwoven material with a basis weight of 18 g / m 2< , while the examples according to the invention use a basis weight of 17 g / m 2< . Paper basis weight Coating width Coating grammage Coated rate Final basis weight Add-on Unitsg / m 2< mg / m 2< %g / m 2< mgComparative example 18 / 81002611Example 1 170.002813191.5Example 2 170.003819202.2Example 3 170.004825212.8

[0164] For each example, an activable adhesive is applied with a consistent coating grammage of 8 g / m 2< . In Example 1, the adhesive is applied only to the areas of the wrapper material that will be activated, specifically the future seals of the pouched product. In Example 2, the coating width is slightly increased, with a 1 mm margin of error applied. Example 3 applies a 2 mm margin of error.

[0165] In example 1, example 2 and example 3, the unsealed area is a circle of radius equal to R-1mm. 1mm being the width of the final seal.

[0166] The final pouched product for oral use comprises 100% of the unsealed area unsealable.

[0167] In example 1, the final pouched product for oral use comprises: 100 − 100 . 39 2 . π − 39 2 . π / 39 2 . π = 100 % of the unsealed area unsealable .

[0168] In example 2, the final pouched product for oral use comprises 100 − 100 . 39 2 . π − 38 2 . π / 39 2 . π = 95 % of the unsealed area unsealable .

[0169] In example 3, the final pouched product for oral use comprises 100 − 100 . 39 2 . π − 37 2 . π / 39 2 . π = 90 % of the unsealed area unsealable .

[0170] In the comparative example, the activable adhesive is applied across the entire surface, resulting in a 100% coating rate. In contrast, Example 1 coats only 13% of the wrapper material, leaving 87% unsealable. Example 2 coats 19% of the material, leaving 81% unsealable, and Example 3 coats 25%, leaving 75% unsealable.

[0171] Consequently, the comparative example requires a substantial 11 mg of activable adhesive for a circular pouched product with a 3 cm radius, whereas Example 1 requires only 1.5 mg, Example 2 requires 2.2 mg, and Example 3 requires 2.8 mg. Not only do the examples according to the invention use less activable adhesive, but they also maintain satisfactory sealing properties.

Claims

1. A pouched product for oral use (100) comprising: - a wrapper material forming a pouch, and - a composition enclosed in the wrapper material forming the pouch; wherein the wrapper material comprises a nonwoven material having a sealed area and an unsealed area, and whereby more than 50% of the unsealed area is unsealable.

2. The pouched product for oral use according to claim 1, wherein the composition is a tobacco-derived product, a particulate material containing an active ingredient, a reconstituted plant sheet containing an active ingredient, cellulose containing an active ingredient, a cellulose derivative containing an active ingredient or mixtures thereof.

3. The pouched product for oral use according to any one of claim 1 or 2, wherein the composition enclosed within the pouch has a weight ranging from 0.2 g to 3 g.

4. The pouched product for oral use according to any one of preceding claims, wherein the inner volume of the pouch ranges from 3 to 5 cubic centimeters.

5. The pouched product for oral use according to any one of preceding claims, wherein the composition comprises from 3 % to 45 % water by weight of the composition.

6. The pouched product for oral use according to any one of preceding claims, wherein the basis weight of the nonwoven material is from 14 to 35 g / m2.

7. The pouched product for oral use according to any one of preceding claims, wherein the thickness of the nonwoven material is from 50 to 130 µm measured at 100 kPa.

8. The pouched product for oral use according to any one of preceding claims, wherein the air permeability of the nonwoven material in the unsealable area is from 1000 to 80000 CORESTA Unit.

9. The pouched product for oral use according to any one of preceding claims, wherein the nonwoven material is a wetlaid material, an air lair material or a dry laid material, preferably a nonwoven wetlaid material.

10. The pouched product for oral use according to any one of preceding claims, comprising from 0.7 to 9 mg of activable adhesive.

11. The pouched product according to any one of preceding claims, wherein the activable adhesive comprises water-based adhesive or hotmelt adhesive.

12. A wrapper material for a pouched product for oral use, the wrapper material comprising: a nonwoven material and an activable adhesive that partially covers the nonwoven material, the activable adhesive delineating sealable area of the wrapper material, while the wrapper material remains unsealable outside the sealable area, wherein the nonwoven material carries a pattern for a desired pouched product for oral use and whereby more than 50% of the pattern of the desired pouched product for oral use is unsealable.

13. A web of a nonwoven material and an activable adhesive that partially covers the nonwoven material, wherein the web comprises at least two wrapper materials that each carries a pattern for a desired pouched product for oral use, and the activable adhesive delineating respective sealable area of respective wrapper material, while each wrapper material remains unsealable outside the sealable area, and whereby more than 50% of each wrapper material is unsealable.

14. A method for fabricating a web or bobbin of wrapper material for a pouched product for an oral use, the wrapper material comprising a nonwoven material, the method comprising the steps of: - coating on a surface of a nonwoven material an activable adhesive that partially covers the nonwoven material, the activable adhesive delineating a sealable area of the wrapper material, while the wrapper material remains unsealable outside the sealable area, wherein the nonwoven material carries at least two patterns of a desired pouched product for oral use and whereby more than 50% of each of the at least two patterns of the desired pouched product for oral use are unsealable.

15. The method according to claim 14, wherein the activable adhesive is coated by flexography or jet printing or gravure printing or slot die printing by hotmelt extrusion or hotmelt printing or hotmelt slot die printing.

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