Nonwoven fabric for oral pouched product, and methods of manufacturing a nonwoven fabric

Abstract

A nonwoven fabric for manufacturing an oral pouched product, where the nonwoven fabric comprises a web of staple fibres in which a relative proportion of staple fibres with different linear densities is selected to achieve a fabric that provides improved sieving properties.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority from UK Patent Application No. GB2501069.5 filed Jan. 24, 2025, the contents and elements of which are herein incorporated by reference in its entirety for all purposes.FIELD OF THE INVENTION

[0002] The present invention relates to a nonwoven fabric for use in manufacturing oral pouched products and particularly, although not exclusively, to a nonwoven fabric with enhanced sieving properties to be suitable for use with modern oral products.BACKGROUND

[0003] It is known to use such nonwoven fabrics to manufacture a pouch for containing an individual portion of a product, such as smokeless tobacco (also known as “snus”), coffee, tea, etc., from which flavour is to be extracted. Examples of pouched products formed from a nonwoven fabric can be found in US 2014 / 0026912 A1 and US 2012 / 0103353 A1.

[0004] Nonwoven fabrics have been used for many years to produce pouches for traditional smokeless tobacco product, such as snus. More recently, the market for this type of oral pouched product has expanded to encompass so-called “modern oral” products, in which the contents of the pouch can comprises a wide variety of materials, e.g. non-tobacco nicotine, flavourings, and / or other food-grade products.

[0005] Nonwoven fabrics are typically produced using one of three processes: dry-laid, wet-laid or spun melt. Each process entangles fibres or filaments into a web in a manner that does not require weaving or knitting.

[0006] A dry-laid process typically comprises forming a loose web of staple fibres, which are subsequently bonded together to create the fabric. The web may be formed by an air laying process, whereby the fibres are randomly orientated in the web. Alternatively, forming the web may include carding the fibres, which aligns their orientation. The air laid or consolidated web can be bonded using mechanical (e.g. hydroentanglement or needle punching), thermal (e.g. where the web includes thermoplastic fibres) or chemical techniques (e.g. using an adhesive binder), or a combination thereof.

[0007] A wet-laid process typically comprises forming a slurry of fibres in water or other suitable liquid, which is deposited on a screen or mesh and then dried to form the web.

[0008] A spun melt process typically forms a web from continuous filaments spun directly from liquid (i.e. melted) plastic materials.

[0009] One known type of nonwoven fabric for use in pouched products is a dry-laid carded nonwoven fabric comprises staple fibres formed from regenerated cellulose (also known as viscose or rayon) together with a thermoplastic acrylic copolymer binder which facilitates the ability of the fabric to be heat sealed and provides a soft mouth feel.

[0010] Typically, the nonwoven fabrics used to produce pouched products are water-permeable, in order to permit substances (e.g. flavour) from the contents of the pouch to flow out. WO2022167454 provides examples of nonwoven fabrics used for oral pouched products where the composition of the nonwoven fabric is selected to yield a desired permeability.SUMMARY OF THE INVENTION

[0011] At its most general, the present invention provides a nonwoven fabric for manufacturing an oral pouched product, where the nonwoven fabric comprises a web of staple fibres in which a relative proportion of staple fibres with different linear densities is selected to achieve a fabric that provides improved sieving properties. When the nonwoven fabric forms a pouch, it may suitably control the release of substances from within the pouch.

[0012] Herein, “sieving properties” may mean the ability of a fabric to permit passage of particles below a certain size, whilst retaining particles having a size (e.g. diameter or other major dimension) above a predetermined threshold. In some cases, the sieving properties of a nonwoven fabric may be quantified by the air permeability of that fabric. In other cases, it may be quantified by the fabric having an average pore size less than a predetermined threshold, or a combination of pore size and air permeability. The “sieving properties” of a fabric may be assessed by measuring the proportion of a sample of glass microspheres (e.g. ~100 μm microspheres) that pass through the fabric after agitation (e.g. with an amplitude of 1.5 mm and an rpm of 30) for a certain period of time (e.g. 5 minutes). Typically, retention of particles having a minimum size of 90 μm to 200 μm is desired. Accordingly, the average pore size of the fabric is preferably less than or equal to 200 μm, more preferably less than or equal to 150 μm, or less than or equal to 90 μm.

[0013] According to a first aspect of the invention, there is provided a nonwoven fabric for forming an oral pouched product, the nonwoven fabric comprising a chemically bonded web of staple fibres, wherein the staple fibres comprise a first component of fibres with a linear density equal to or greater than 0.9 dtex and a second component of fibres with a linear density of less than 0.9 dtex. Such a fabric has improved sieving properties. For example, the air permeability of the fabric may be less than or equal to 6000 l / m2 / s, preferably in any one of the ranges 2000-6000 l / m2 / s, 2500-5900 l / m2 / s, 3000-5700 l / m2 / s, 3500-5500 l / m2 / s, 4000-5300 l / m2 / s, or more preferably 5000-5200 l / m2 / s, such as about 5100 l / m2 / s.

[0014] When the nonwoven fabric forms a pouch, it may suitably control the release of substances from within the pouch.

[0015] Herein, an “oral pouched product” may mean a fabric container, pocket, or pouch that defines a sealed volume for enclosing a substance, for example a powdered material, and which is intended to be held in the mouth. The powdered material may be any material suitable for delivery of a substance, e.g. pharmaceutical, flavourings or nicotine, inside a user's mouth.

[0016] The proportion of the staple fibres in the nonwoven fabric may be at least 50 wt % (on a dry fabric mass basis). The proportion of the staple fibres in the nonwoven fabric may be no more than 75 wt % (on a dry fabric mass basis). For example the staple fibres may provide 50 wt % to 75 wt % (on a dry fabric mass basis), more preferably 60 wt % to 75 wt % (on a dry fabric mass basis), more preferably 70 wt % to 75 wt % (on a dry fabric mass basis) of the nonwoven fabric.

[0017] The first component of fibres may consist of any one of at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% by weight of the staple fibres (on a dry mass basis). The first component of fibres may form a majority of the staple fibres by weight.

[0018] The second component of fibres may consist of any one of less than 50%, less than 40%, less than 30%, less than 20%, and less than 10% by weight of the staple fibres. The second component of fibres may form a minority of the staple fibres by weight.

[0019] The first component of fibres may include fibres with a linear density in a range from greater than or equal to 0.9 dtex to less than or equal to 3.5 dtex, preferably greater than or equal to 1.2 dtex to less than or equal to 2.5 dtex, and more preferably greater than or equal to 1.4 dtex to less than or equal to 2 dtex, such as about 1.7 dtex.

[0020] The first component of fibres may comprise or consist of fibres of regenerated cellulose. Using regenerated cellulose not only has advantages for sustainability but also may provide a fabric with desirable mouthfeel (low friction, low surface roughness). Herein, “fibres of regenerated cellulose” may include any one or more of fibres of viscose, lyocell, modal or rayon.

[0021] The first component of fibres may include thermoplastic fibres, e.g. blended with fibres of regenerated cellulose. Using thermoplastics may provide a fabric with desirable heat sealability. Example thermoplastic materials are polyethylene, polyester and PET.

[0022] The second component of fibres may include fibres with a linear density less in a range from greater than or equal to 0.3 dtex to less than 0.9 dtex, preferably greater than or equal to 0.4 dtex to less than or equal to 0.6 dtex, such as about 0.5 dtex. As discussed in more detail below, the second component of fibres may be obtained by splitting a splitable fibre.

[0023] The second component of fibres may comprise or consist of thermoplastic fibres, such as polyester and / or PET fibres.

[0024] The staple fibres of the nonwoven fabric may be carded staple fibres. The presence of carded staple fibres may ensure an equal distribution of fibres and improved uniformity of the resulting fabric. The uniformity of the resulting fabric may be represented by the variation in the density of the fabric between samples taken from across the fabric, the variation in the composition of the fabric (i.e. the proportion of different fibres) between samples taken from across the fabric, or the variation in the air permeability of the fabric between samples taken from across the fabric.

[0025] Herein, “carded staple fibres” may mean staple fibres which have gone through a carding process, in which fibres are combed into a web by a carding machine, which is a rotating drum or series of drums covered by card wire.

[0026] Herein, “chemically bonded” may mean a matrix of staple fibres that are secured together by adhesion, e.g., by a binder that acts to physically interconnect the staple fibres. The chemically bonded web may thus comprise a binder. A binder may contribute to achieving a heat sealable fabric that provides a soft (e.g. low friction, low surface roughness) mouthfeel, a wet strength capable of withstanding manipulation in a user's mouth (e.g. chewing, sucking or the like), and a resistance to unwanted leaching or leaking of flavouring or other fine particle substances used in modern oral products.

[0027] In some examples, the binder may comprise any one or more of a synthetic acrylic binder, polylactic acid (PLA), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA), a vinyl acetate copolymer, a vinyl acrylic copolymer and a styrene-butadiene copolymer.

[0028] The binder may make up less than 50 wt % of the nonwoven fabric. For example, the amount of binder in the nonwoven fabric may be in the range 20-40 wt %, e.g. 25 wt %.

[0029] The nonwoven fabric may be used to fabricate an oral pouched product, i.e. a pouch formed from the nonwoven fabric discussed above, wherein the pouch encloses a non-tobacco composition, e.g. a powdered non-tobacco composition.

[0030] Herein, a “non-tobacco composition” includes non-tobacco nicotine, flavourings, and / or other food-grade products.

[0031] According to a second aspect of the invention, there is provided a nonwoven fabric for forming an oral pouched product, the nonwoven fabric comprising a chemically bonded web of staple fibres, wherein the staple fibres comprise a first component of non-splitable fibres and a second component of split fibres. Such a fabric has improved sieving properties. When the nonwoven fabric forms a pouch, it may control the release of substances from within the pouch.

[0032] Herein, the term “split fibre” is used to mean a sub-fibre that is the result of splitting a splitable fibre. A “splitable fibre” may mean a fibre which can separate into smaller sub-fibres under certain conditions, e.g. application of physical force or exposure to certain chemicals. For example, a mechanical splitable fibre may separate into its sub-fibres either by exposure to physical forces experience during a carding process or by being subject to a needling process, e.g. using physical needles or a plurality of water jets (i.e. hydroentanglement).

[0033] In contrast to a splitable fibre, the term “non-splitable fibres” is used herein to mean a fibre which retains its integrity throughout the formation of the nonwoven fabric. For example, a non-splitable fibre may not be divisible into a plurality of sub-fibres.

[0034] Features of the first aspect discussed above may also apply to the second aspect. For example, the proportion of the staple fibres in the nonwoven fabric may be at least 50 wt %. The proportion of the staple fibres in the nonwoven fabric may be no more than 75 wt %. For example the staple fibres may provide 50 wt % to 75 wt %, more preferably 60 wt % to 75 wt %, more preferably 70 wt % to 75 wt % of the nonwoven fabric.

[0035] The first component of non-splitable fibres may consist of any one of: at least 50%, at least 60%, at least 70%, at least 80%, or at least 90% by weight of the staple fibres. The first component of non-splitable fibres may form a majority of the staple fibres by weight.

[0036] The second component of split fibres may consist of any one of less than 50%, less than 40%, less than 30%, less than 20%, and less than 10% by weight of the staple fibres. The second component of fibres may form a minority of the staple fibres by weight.

[0037] The first component of non-splitable fibres may include fibres with a linear density less in a range from 0.9 dtex to 3.5 dtex, preferably 1.2 dtex to 2.5 dtex, and more preferably 1.4 dtex to 2 dtex, such as 1.7 dtex.

[0038] The first component of non-splitable fibres may comprise or consist of fibres of regenerated cellulose. Using regenerated cellulose not only has advantages for sustainability but also may provide a fabric with desirable mouthfeel (low friction, low surface roughness). Herein, “fibres of regenerated cellulose” may include any one or more of fibres of viscose, lyocell, modal or rayon.

[0039] The first component of non-splitable fibres may include thermoplastic fibres, e.g. blended with fibres of regenerated cellulose. Using thermoplastics may provide a fabric with desirable heat sealability. Example thermoplastic materials are polyester and PET.

[0040] The second component of split fibres may include fibres with a linear density less in a range from 0.3 dtex to 0.9 dtex, preferably 0.4 dtex to 0.6 dtex, such as 0.5 dtex. The second component of split fibres may comprise or consist of thermoplastic fibres, such as polyethylene, polyethylene terephthalate (PET) fibres, and / or co-polymerised PET (Co-PET) (e.g. terephthalic acid (or dimethyl terephthalate) and mono-ethylene glycol copolymerised with one or more other diols or diacids (e.g. cyclohexanedimethanol and / or isophthalic acid). For example, the split fibres may be obtained by splitting a splitable fibre that consists of two or more types of sub-fibre made from polymers with low mutual affinity. In another example, the split fibres may be obtained by splitting a splitable fibre that consists of a core sub-fibre and one or more sheath sub-fibres. In another example, the split fibres may be obtained by splitting a splitable fibre that consists of a core sub-fibre and one or more lobe sub-fibres. For example, the split fibres may be obtained by splitting a splitable fibre that consists of a polyethylene or co-PET core and four separable sub-fibre lobes of PET. The splitable fibre may have a linear density greater than 2.0 dtex, e.g. in the range 2.0 to 4.0 dtex, preferably in the range 2.2 to 3.0 dtex.

[0041] Similar to the first aspect, the chemically-bonded web of the second aspect may also include a binder. The binder may comprise any one or more of a synthetic acrylic binder, polylactic acid (PLA), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA), a vinyl acetate copolymer, a vinyl acrylic copolymer and a styrene-butadiene copolymer. The binder may make up less than 50 wt % of the nonwoven fabric. For example, the amount of binder in the nonwoven fabric may be in the range 20-40 wt %, e.g. 25 wt %.

[0042] According to a third aspect of the present invention, there is provided a method of manufacturing a nonwoven fabric (e.g. a nonwoven fabric according to the second aspect set out above) for forming an oral pouched product, the nonwoven fabric comprising a chemically bonded web of staple fibres, the method comprising mixing splitable fibres and non-splitable fibres, splitting a proportion of the splitable fibres to form split fibres, forming a web by arranging a plurality of staple fibres into a sheet, wherein the resulting web comprises a first component of the non-splitable fibres and a second component of the split fibres and applying a binder to the web to bond the staple fibres together in a nonwoven fabric. Such a manufacturing process produces nonwoven fabric with improved sieving properties, without having to process fine fibres throughout manufacture. Therefore, when the nonwoven fabric forms a pouch, it may control the release of substances from within the pouch.

[0043] Herein, “splitting a proportion of the splitable fibres to form split fibres” may mean separating the splitable fibre into predetermined sub-components (e.g. sub-fibres) by mechanical splitting (e.g. carding, needling, or hydroentanglement), or chemical splitting.

[0044] The web forming step may comprise carding the staple fibres, e.g., by combing fibres into a web by a carding machine, which is a rotating drum or series of drums covered by card wire. The carding step may ensure an equal distribution of fibres and improved uniformity.

[0045] Splitting the splitable fibres may be done mechanically. For example, the step of splitting the splitable fibres to form split fibres may occur during the carding step. By splitting the splitable fibres during the carding step the cost and complexity of the manufacture of the nonwoven fabric may be reduced by removing the need for additional processes and steps to split the splitable fibre.

[0046] The proportion of splitable fibres which are split may be changed by adjusting the speed of carding, may be adjusted by adjusting the degree of carding, or may be adjusted by adjusting the degree of draft of the carding. By adjusting the proportion of splitable fibres which are split, the proportion of low linear density fibres can be adjusted, therefore adjusting the sieving properties as required. Herein, “speed of carding” may mean the speed at which the fibres are drawn through the carding machine, “degree of carding” may refer to the spacing and type of the card wire on the rotating drum or series of drums, the degree of draft of the carding (i.e. the ratio of the speed at which the fibres exit a drafting section of the carding machine to the speed at which the fibres enter the drafting section of the carding machine). A higher speed of carding, a higher degree of carding, and / or a higher degree of draft of the carding may correspond to a greater proportion of splitable fibres being split.

[0047] The invention includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided.SUMMARY OF THE FIGURES

[0048] Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which:

[0049] FIG. 1 is a schematic drawing of apparatus for manufacturing a nonwoven fabric according to a method that is an embodiment of the invention.

[0050] FIG. 2 is a flowchart of a method for manufacturing a nonwoven fabric that is an embodiment of the invention.DETAILED DESCRIPTION OF THE INVENTION

[0051] Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0052] A method of manufacturing a nonwoven fabric according to an embodiment of the present invention is now described with reference to FIG. 1. FIG. 1 is a schematic diagram showing an apparatus 100 for manufacturing a dry-laid carded nonwoven. However, it is to be understood that the invention need not be limited to this type of manufacturing technique.

[0053] In the apparatus 100 shown in FIG. 1, a first conveyor 102 transports fibre bales 104 to a bale opener 106, which separates and blends the fibres from each bale.

[0054] The staple fibres in the fibre bales 104 may have any suitable cross-section. In some examples, the staple fibres consist or comprise multilobal fibres, e.g. fibres exhibiting a cross-section comprises three or more lobes. Multilobal fibres may further assist in the transfer of micro-sized materials through the nonwoven fabric.

[0055] The bale opener 106 is connected to a feed hopper 108 that discharges the blended fibres as a loose fibre web 112 on a second conveyor 110. The loose fibre web 112 is conveyed to a carding machine 114 that combs the web to apply a desired orientation or plurality of orientations to the fibres in the web. The carding machine 114 thus outputs a consolidated web 116 on to a third conveyor 118.

[0056] The carding process may be optional. For example, the consolidated web 116 may be formed directly by air laying suitable staple fibres. In this example, the staple fibres may be crimped during manufacture to facilitate web formation in an air stream. Alternatively, the consolidated web 116 may be formed directly by a wet laying process.

[0057] The fibres in the consolidated web 116 may subsequently be bonded together by any conventional method. For example, a binder may be applied to the consolidated web, e.g. by conveying it using deflector 134 into a pan 136 filled with liquid binder or binder precursor, so that the binder impregnates or saturates the consolidated web 116. The consolidated web 116 is then transported to a fourth conveyor 120 via nip rollers 138, which operate to remove or squeeze excess liquid from the consolidated web 116. The web 116 is then carried through a dryer 122, which operates to dry the web and cure or stabilise the binder. In other examples, the binder may be applied by coating or spraying.

[0058] The binder may be applied as in an aqueous solution, where the water is subsequently removed by the drying process. However, other solvents may also be used.

[0059] It may be desirable for the binder or binder precursor to emit zero or a negligible amount of volatile organic compounds (VOCs).

[0060] Other additives may be added to the consolidated web. For example, a triglyceride additive may be used to further improve the wet strength of the resulting fabric. The presence of triglyceride in the nonwoven fabric may also assist in preventing unwanted leakage of flavour particles from the contents of an oral pouched product made using the fabric.

[0061] The process is configured such that it is able to use staple fibres comprising a first component of fibres with a linear density equal to or greater than 0.9 dtex and a second component of fibres with a linear density of less than 0.9 dtex. The first component may include fibres with a linear density less than 3.5 dtex. Such a mixture of staple fibres results in a fabric with advantageous sieving properties. For example, the air and liquid permeability of the fabric is in a desire range such that when the material forms a pouch enclosing a composition, a non-tobacco composition remains inside the pouch but nicotine and flavourings for example can be released. Air permeability may be important if the fabric is subsequently used in a pouching process, i.e. to form an enclosure for a substance for oral delivery.

[0062] Liquid permeability may be important for the ability of the fabric to release substances into a user's mouth.

[0063] The apparatus 100 includes a fibre mixing zone 126 and a fibre splitting zone 128. The fibre mixing zone 126 and the fibre splitting zone 128 are of importance for a nonwoven fabric comprising non-splitable fibres and split fibres. As shown in FIG. 1, the mixing of splitable fibres and non-splitable fibres can take place in the fibre mixing zone 126, which encompasses the bale opener 106 and feed hopper 108. This is only one of multiple possible options for mixing the splitable fibres and the non-splitable fibres. FIG. 1 also shows that the fibre splitting zone 128 encompasses the carding machine 114. In this example, the mechanical forces experience during the carding process cause the splitting of some or all of the splitable fibres into split fibres. This is only one of multiple possible options for splitting the splitable fibres into split fibres. The splitable fibres may be split by any one or combination of mechanical splitting, chemical splitting or through a water jet process. As such, the apparatus shown in FIG. 1 may be configured to manufacture a nonwoven fabric using staple fibres comprising a first component of non-splitable fibres and a second component of split fibres.

[0064] FIG. 2 is a flowchart of a method for manufacturing a nonwoven fabric that is an embodiment of the invention. In step 202, splitable fibres and non-splitable fibres are mixed. Mixing could be performed by a bale opener and feed hopper, for example. In step 204, a proportion of the splitable fibres are split to form split fibres. This step could be performed by a carding machine or any other apparatus for any one or combination of mechanical splitting, chemical splitting, or a water jet process. In step 206, a web is formed by arranging a plurality of staple fibres into a sheet. In a non-limiting example, this could comprise a carding process. In step 208, a binder is applied to the web. In a non-limiting example, this step could comprise the binder being applied by a deflector and pan arrangement.EXAMPLES

[0065] Two nonwoven fabrics A and B were manufactured according to the dry-laid carding technique discussed above with respect to FIGS. 1 and 2. Material A is an embodiment of the present invention. Material B is a comparative reference. The composition of the fabrics is summarised in Table 1.TABLE 1Fabric compositionsMaterialCompositionA75 wt % staple fibres (50% splitable Bico PET, 50% Viscose)25 wt % binder (vinyl acetate copolymer)B75 wt % staple fibres (80% Viscose, 20% Polyester)25 wt % binder (vinyl acetate copolymer)

[0066] Material A includes a splitable fibre (50% Bico PET). This splitable fibre has a core of polyethylene terephthalate and a sheath comprising four lobes of polyethylene, which can separate from the core to form independent polyethylene sub-fibres. The splitable fibre has a linear density of 2.2 dtex and the split fibres each have a minimum linear density of 0.4 dtex.

[0067] Material B is a nonwoven fabric composition with staple fibres that consist of a blend of regenerated cellulose and thermoplastic fibres.

[0068] Various properties of materials A and B were measured and are set out in Table 2. Wet strength was measured using the 20.2-89 EDANA test method. Air permeability was obtained using the 070.1.R3 (12) EDANA test method.TABLE 2Physical properties of materials.AirMDTDTDWet TDWeightThicknesspermeabilityMD TensileExtensionWet MDTensileextensionTensileMaterial(gsm)(microns)(l / m2 / s)(N)(%)Tensile (N)(N)(%)(N)A23.4202510042.013.526.96.435.84.8B23.8214610044.813.126.09.432.04.9

[0069] As shown in Table 2, there was a decrease in air permeability when using the splitable fibre (material A) compared to the standard composition (material B), while maintaining the other parameters. This reduction in air permeability is due to the presence of fine dernier fibres present in the material A fabric compared to the material B fabric. Such a reduction in air permeability demonstrates the ability to provide a fabric with improved sieving properties, which in turn may be advantageous for forming a pouch able to retain a non-tobacco composition with a smaller particle-size compared to conventional tobacco compositions.

[0070] The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

[0071] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

[0072] For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

[0073] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0074] Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0075] It must be noted that, as used in the specification and the appended claims, the singular forms “a,”“an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example + / −10%.

Claims

1. A nonwoven fabric for forming an oral pouched product, the nonwoven fabric comprising a chemically bonded web of staple fibres, wherein the staple fibres comprise:a first component of fibres with a linear density equal to or greater than 0.9 dtex; anda second component of fibres with a linear density of less than 0.9 dtex.

2. The nonwoven fabric of claim 1, wherein the first component includes fibres with a linear density less than 3.5 dtex.

3. The nonwoven fabric of claim 1, wherein at least one of the first component and the second component include fibres of regenerated cellulose.

4. A nonwoven fabric for forming an oral pouched product, the nonwoven fabric comprising a chemically bonded web of staple fibres, wherein the staple fibres comprise:a first component consisting of non-splitable fibres; anda second component consisting of split fibres.

5. The nonwoven fabric of claim 4, whereinthe first component of non-splitable fibres have a linear density equal to or greater than 0.9 dtex; andthe second component of split fibres have a linear density of less than 0.9 dtex.

6. The nonwoven fabric of claim 4, wherein the split fibres have a linear density less than 0.5 dtex.

7. The nonwoven fabric of claim 4, wherein the split fibres comprise thermoplastic fibres.

8. The nonwoven fabric of claim 7, wherein the split fibres include fibres of polyethylene terephthalate.

9. The nonwoven fabric of claim 7, wherein the split fibres include fibres of polyethylene or copolymerised polyethylene terephthalate.

10. The nonwoven fabric of claim 4, wherein the non-splitable fibres include fibres of regenerated cellulose.

11. The nonwoven fabric of claim 1, wherein:the chemically bonded web comprises a binder; andoptionally, the binder comprises any one or more of a synthetic acrylic binder, polylactic acid (PLA), polybutylene succinate (PBS), polyhydroxyalkanoate (PHA), a vinyl acetate copolymer, a vinyl acrylic copolymer and a styrene-butadiene copolymer.

12. A method of manufacturing a nonwoven fabric for forming an oral pouched product, the method comprising:mixing staple fibres that comprise splitable fibres and non-splitable fibres;splitting a proportion of the splitable fibres to form split fibres;forming a web of the staple fibres, the web comprising:a first component consisting of the non-splitable fibres; anda second component consisting of the split fibres; andapplying a binder to the web to bond the staple fibres together.

13. The method of claim 12 further comprising carding the mixed staple fibres, wherein the step of splitting the splitable fibres occurs during carding.

14. The method of claim 13 further comprising selecting a speed of carding to control a proportion of splitable fibres which are to be split.

15. The method of claim 13 further comprising selecting a degree of carding to control a proportion of splitable fibres which are to be split.

16. The method of claim 12, wherein the splitable fibres have a linear density greater than 2.0 dtex.

17. The method of claim 12, whereinthe first component of non-splitable fibres have a linear density equal to or greater than 0.9 dtex; andthe second component of split fibres have a linear density of less than 0.9 dtex.

18. The method of claim 12, wherein the split fibres have a linear density less than 0.5 dtex.

19. The method of claim 12, wherein the split fibres comprise thermoplastic fibres.

20. The method of claim 12, wherein the non-splitable fibres include fibres of regenerated cellulose.

Images