Nonwoven containing a uniform arrangement of discrete hotmelt material with heat sealing properties

Abstract

This disclosure generally pertains to the field of pouched products for oral use, specifically to sealable wrapper materials used in the manufacture of said pouched product. The wrapper material comprising a nonwoven material having a hotmelt material. The hotmelt material has a uniform arrangement of discrete specks.

Description

NONWOVEN CONTAINING A UNIFORM ARRANGEMENT OF DISCRETE HOTMELT MATERIAL WITH HEAT SEALING PROPERTIESTechnical Field

[0001] This disclosure generally pertains to the field of pouched products for oral use, specifically to sealable wrapper materials used in the manufacture of said pouched product.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 which can be homogeneously distributed across the material. These thermoplastic fibers 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 heat or ultra-sonic waves. The desired pouched product for oral use can be manufactured from the wrapper material by unwinding it and wrapping it 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 seal 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 instance pressurized air. Finally, the remaining open end is sealed, again by activating the adhesive. Cutting can be done at the same time or afterwards, forming the finished pouched product for oral use.

[0005] The final pouched product can thus incorporate activable adhesive throughout the entire surface of the nonwoven material used in the wrapper. The activable adhesive can be in the form of thermoplastic fibers directly integrated within the nonwoven material, or it can be an adhesive applied all over the nonwoven material. These activable adhesives can negatively impact the flexibility and porosity of the wrapper material. Additionally, such pouched products require a substantial amount of activable adhesive, which is sometimes not derived from biosourced materials, contributing to environmental concerns.

[0006] Therefore, there is a pressing need to develop a pouched product for oral use that utilizes lower amount of activable adhesive while still ensuring effective sealability and maintaining porosity and flexibility of the pouched product.

[0007] The inventors solve this issue by providing a pouched product for oral use comprising: a wrapper material forming a pouch; anda composition enclosed within the wrapper material;wherein the wrapper material comprises a sealed region and an unsealed region,the wrapper material comprising a nonwoven material and a hotmelt material,wherein the hotmelt material has a uniform arrangement of discrete specks in the unsealed region, having a mean coverage ratio MCR of at least 30 %,wherein the coverage ratio is defined bysurface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

[0008] The pouched product for oral use of the present disclosure comprises a lower amount of hotmelt material in comparison to wrapper materials that incorporate a large amount of activable adhesive, such as a film of adhesive all over the nonwoven material or thermoplastic fibers within the nonwoven material, while maintaining the permeability, flexibility and sealability desired for such pouched product.

[0009] Advantageously, the pouched product for oral use allows for the use of wrapper material comprising a nonwoven material that is free of synthetic fibers, such as thermoplastic fibers. For instance, the pouched product for oral use comprises a wrapper material comprising a nonwoven material consisting entirely of natural fibers.

[0010] In addition, the hotmelt material can advantageously be biosourced, and / or industrial or home compostable.

[0011] This not only enhances the environmental sustainability of the product but also can participate in ensuring that the wrapper material maintains a desired flexibility, porosity, and overall user comfort.

[0012] According to another aspect, the present invention is directed to a wrapper material for pouched product for oral use comprising:a nonwoven material having a permeability from 1 000 to 80000 CORESTA Units (CU), a hotmelt material,wherein the hotmelt material has a uniform arrangement of discrete specks, having a mean coverage ratio MCR of at least 30 %, wherein the coverage ratio is defined by:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

[0013] The wrapper material of the invention features a sealable surface, such as by heat, with small amount of hotmelt material and without compromising its permeability or flexibility compared to conventional coating techniques. This ensures that the wrapper material can retain its desired properties, providing both effective sealing and user comfort.

[0014] Additionally, the wrapper material can be sealed at various or even any location on its surface, thanks to the uniform arrangement of discrete specks of hotmelt material. This uniform coverage allows for consistent and reliable sealing across the entire nonwoven material.

[0015] According to another aspect, the present invention is directed to a roll of the wrapper material defined above.

[0016] The roll of wrapper material is beneficial for manufacturers of pouched products for oral use. It facilitates the rapid production of a large number of pouched products by allowing the roll to be unwound and processed, streamlining the manufacturing process and increasing overall productivity.

[0017] According to another aspect, the present invention is directed to a method to manufacture a wrapper material for a pouched product for oral use, the method comprising the following steps: - providing a nonwoven material having a permeability from 1 000 to 80000 CORESTA units, - coating one surface of the nonwoven material with a hotmelt material,wherein the hotmelt material has a uniform arrangement of discrete specks, having a mean coverage ratio MCR of at least 30 %, wherein the coverage ratio is defined by:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

[0018] The method can reduce the amount of hotmelt material used to reach a desired uniform sealability across most or the entire surface of the wrapper material.

[0019] This method allows for the production of long lengths of wrapper material, spanning several meters, at a high-speed rate.

[0020] According to another aspect, the present invention is directed to a method for manufacturing the pouched product comprising the following steps:providing a tube made of the wrapper material of the invention,wrapping a composition between two ends thereof, andsealing the end(s) of the tube to manufacture the pouched product

[0021] The method ofthe invention enables the manufacture ofa large number of pouched products at a high-speed rate, while reducing or suppressing difficulties in sealing the parts that need to be sealed due to the uniform arrangement of discrete specks of hotmelt material.Brief Description of Drawings

[0022] Other features, details and advantages will be shown in the following detailed description and on the figures, on which:Fig. 1

[0023] [Fig. 1] is an example of uniform arrangement of discrete specks of the present disclosure.Fig. 2

[0024] [Fig. 2] is another example of uniform arrangement of discrete specks of the present disclosure.Fig. 3

[0025] [Fig. 3] is another example of uniform arrangement of discrete specks of the present disclosure.Fig. 4

[0026] [Fig. 4] is a block diagram illustrating the method of the present disclosure.

[0027] The figures are not drawn to scale. An illustrative scale of 1 cm is provided to facilitate example calculations.Description of Embodiments

[0028] The pouched product for oral use comprises a wrapper material forming a pouch and a composition enclosed within the wrapper material.

[0029] The pouch forms an inner volume. The composition enclosed within the wrapper material is contained in the inner volume of the pouch.

[0030] 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 product extracted from tobacco or synthetic nicotine or nicotine salts. In another example embodiment the composition is a powder with nicotine salts.

[0031] 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.

[0032] The composition enclosed within the pouch can include various additives such as a pH corrector, humectant, and flavors to change its properties and user experience.

[0033] 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.

[0034] The composition enclosed within the pouch (without the weight of the pouch) typically has 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.

[0035] The composition enclosed within the pouch can comprise from 3 % to 45 % water by weight of the dry composition, preferably from 5 % to 30 % water by weight of the dry composition.

[0036] The composition comprises less than 70 % shredded plant material and preferably does not include natural shredded leaves, such as tea leaves.

[0037] According to an embodiment, the pouched product for oral use has a substantially rectangular pattern with a length L and a width w.

[0038] The length L ranges 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.

[0039] The width w ranges 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.

[0040] The aspect ratio w / L can be from 0.1 to 1 , preferably from 0.1 to 0.6, for instance 0.4.

[0041] The pouched product, due to its oral use, may have an elongated aspect ratio facilitating its location along the gum of a user, such elongated ratio corresponding to a relatively long length and to a relatively short width. It is important to note that such elongated aspect ratio leads to a particularly reduced width, as mentioned above, whereby such constraint on a reduced width leads to manufacturing constraints as to seal placement, in particular placement of a longitudinal seal. Example pouches as hereby described are particularly suited to such manufacturing constraint and to such elongated pouches by compensating potential dimensional or placement lack of precision through their uniform configuration, while maintaining desired flexibility through their discrete configuration.

[0042] The pouched product for oral use has a (‘a’ meaning ‘at least one’ in the whole present disclosure) sealed region that corresponds to two surfaces of the nonwoven material that have been brought into contact and sealed, for example heat-sealed.

[0043] 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.

[0044] One seal can have a width ranging from 1 mm to 6 mm, preferably around 3 mm.

[0045] The pouched product has a pattern that is substantially rectangular, meaning it can be inscribed within a rectangle. The pouched product may, for example, have transversal sealed regions that have been cut in a zig-zag manner. Even with a zig-zag width, the pouched product can still be inscribed within a greater rectangular pattern, enabling measurement.

[0046] The wrapper material comprises a nonwoven material and a hotmelt material, wherein the hotmelt material has a uniform arrangement of discrete specks in the unsealed region.

[0047] A person skilled in the art will clearly understand the meaning of a uniform arrangement of discrete specks when referring to hotmelt material. This concept is distinct from a continuous film of activable adhesive. The present disclosure specifically addresses discrete uniform arrangements of hotmelt material specks, rather than continuous film of hotmelt material that might negatively impact permeability and flexibility of a wrapper material.

[0048] In the context of the present disclosure, "discrete" refers to individual elements that are distinct and not connected from one another. For example, discrete specks of hotmelt material are individual dots or spots that are not connected to each other. This discrete nature ensures that each speck functions independently, contributing to the overall performance of the nonwoven material without compromising its flexibility and porosity. Variations in speck size, shape or placement may occur due to the manipulation of the wrapper material or conventional machine coating tolerances. In some examples, 1 cm2of unsealed wrapper material comprises at least 40 specks. In some examples, 1 cm2of unsealed wrapper material comprises at least 400 specks. In some examples, 1 cm2of unsealed wrapper material comprises at least 4000 specks. In some examples, 1 cm2of unsealed wrapper material comprises at least 30 000 specks.

[0049] In the context of the present disclosure, a "uniform arrangement" means that the discrete elements (specks) are distributed in a consistent and, in some cases, orderly manner across the surface. Uniformity can in some cases imply that a pattern is repeated throughout the surface of the nonwoven material. This ensures that the specks are evenly spaced and cover the material in a predictable pattern. Forinstance, a pattern could consist of fourspecks, each centered atthe vertices of a square or diamond. In some examples, if a first 1 cm2of unsealed wrapper material comprises N1 specks, and if a second, different 1 cm2of the same unsealed wrapper material comprises N2 specks, N1 and N2 differ by less than 40 %. In some examples, if a first 1 cm2of unsealed wrapper material comprises N1 specks, and if a second, different 1 cm2of the same unsealed wrapper material comprises N2 specks, N1 and N2 differ by less than 30 %. In some examples, if a first 1 cm2of unsealed wrapper material comprises N1 specks, and if a second, different 1 cm2of the same unsealed wrapper material comprises N2 specks, N1 and N2 differ by less than 20 %. In some examples, if a first 1 cm2of unsealed wrapper material comprises N1 specks, and if a second, different 1 cm2of the same unsealed wrapper material comprises N2 specks, N1 and N2 differ by less than 10 %.

[0050] In the context of the present disclosure, "specks" refers to small, distinct spots or dots of hotmelt material applied to the nonwoven material. These specks are typically small in size in comparison to the size of the pouched product for oral use (its length or width) and are used to create a pattern that provides the desired properties, such as sealability and particularly heat-sealability, while maintaining permeability and flexibility. Due to the nature of the hotmelt material, particularly its viscosity and the method of application, each speck can have a substantially circular shape with a greater concentration of hotmelt material near the center of the circular shape and a thinner layer towards the edges.

[0051] When sealed, for example through heat-sealing, the specks can spread and cover a larger surface area of the nonwoven material. When two surfaces of the nonwoven material are brought into contact and for instance heat-sealed, the specks of hotmelt material can spread. This spreading action can enhance the strength and integrity of the seal.

[0052] In an embodiment, the uniform arrangement of discrete specks is a matrix of dots. The four closest dots are positioned at the vertices of the same parallelogram, with a preference for the parallelogram being a square or a diamond.

[0053] This matrix pattern ensures that the specks are evenly distributed across the surface of the nonwoven material, providing consistent sealing properties and maintaining the material's flexibility and porosity.

[0054] The discrete uniform arrangement can be a matrix of hotmelt material specks placed equidistantly, with the closest specks centered at the vertices of the same square. The specks can have a diameter ranging from 0.05 mm to 2 mm, and the width of the square (i.e., the distance between the centers of two closest specks) can range from 0.05 mm to 10 mm.

[0055] The discrete uniform arrangement can be a matrix of hotmelt material specks placed equidistantly, with the closest specks centered at the vertices of the same diamond. The specks can have a diameter ranging from 0.05 mm to 2 mm, and the diagonals of the diamond can have a (i.e., the distances between the centers of two opposite closest specks) can range from 0.05 mm to 2.5 mm and 0.05 mm to 2.5 mm.

[0056] The mean density of the uniform arrangement of discrete specks of hotmelt material can range from 40 specks / cm2to 30 000 specks / cm2, for instance 100, 1 000, 10 000, 20 000 or 25000 specks / cm2. This density range can ensure that there are enough specks to provide effective sealing without compromising the material's flexibility and porosity.

[0057] To measure the density of the specks, one can cut an unsealed region of, for example 0.5 cm2or 1 cm2, of a pouched product or a 0.5 cm2or 1 cm2square section of the wrapper material and count the number of specks within that area. The density can be expressed as a decimal, as some specks may only partially fall within the measured square. To obtain an accurate mean density, it is recommended to take at least two measurements, preferably at least five, and even more preferably at least ten measurements from different areas.

[0058] The results can be considered relevant if the standard deviation is below 20 % of the mean density, preferably less than 10 %, and even more preferably less than 5 % of the mean density. This ensures that the speck distribution is consistent and uniform across the nonwoven material.

[0059] The pouched product for oral use features a hotmelt material with a uniform arrangement of discrete specks in the unsealed region, having a mean coverage ratio (MCR) of at least 30 %, preferably at least 40 %, even more preferably at least 50 %.

[0060] The coverage ratio is defined by the following formula:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

[0061] The Coverage Ratio (CR) is a ratio between two surface area measurements, expressed in units such as square meters (m2) or its subunits, including square decimeters (dm2), square centimeters (cm2), and square millimeters (mm2), making CR a dimensionless quantity that is preferably expressed as a percentage. A coverage ratio of 100 % indicates that the entire surface of the nonwoven material is covered by the hotmelt material, forming a continuous band or film. This extreme is avoided in the present disclosure, as the hotmelt material is applied in a uniform arrangement of discrete specks.

[0062] Conversely, a coverage ratio of 0 % means that the nonwoven material is not covered by any hotmelt material. This other extreme is also avoided, as the minimum CR in the present disclosure is 30 %, preferably 40 % and even more preferably 50 %. This ensures that the nonwoven material maintains its essential properties of flexibility and porosity while providing effective sealability.

[0063] In one example embodiment, the considered surface area of the nonwoven material to measure CR is 0.5 cm2and thus the covering ratio CR is defined by the following formula:surface of the discrete uniform pattern of specksCR = lOOx - 5 - - - - - 0.5cm of the nonwoven material

[0064] In another example embodiment, the considered surface area of the nonwoven material to measure CR is 1 cm2and thus the covering ratio CR is defined by the following formula:surface of the discrete uniform pattern of specksCR=100x- lcm2of the nonwoven - material - -

[0065] The skilled person knows how to measure a coverage ratio, they can for instance measure the CR following method defined in ISO 13655:2017.

[0066] Software-based image analysis tools such as MATLAB® or Imaged® can also be used to analyze the coverage ratio by calculating the area percentage covered in an optical or microscopic image.

[0067] Method for measuring the coverage ratio can be a Micro attenuated total reflection infrared spectroscopy (ATR FTIR) mapping that allows to give a picture of the surface covered by the hotmelt coating on nonwoven material defined surface.

[0068] Sample is fixed on rigid paper with double face tape ensuring that no tape is in the analyzed area.

[0069] Mapping:

[0070] ATR FTIR spectra can be acquired in the range 4 000-675 cm1on thermo-spectrometer connected to a IR microscope fitted with a MCT type A detector cooled by liquid nitrogen. For ATR measurements a diamond crystal can be connected to the objective. Single point ATR measurements can be performed by recording a total of 8 scans, preferably 16 scans and theresulting interferogram averaged, the opening can be 100 pm x 100 pm with an angle of 0°. The spectral resolution is set to normal with a step size of 100 pm.

[0071] Acquisition and post-run processing can be carried out using Nicolet “Omnic” software.

[0072] ATR mapping can be performed on selected areas by placing samples on a motorized XY microscope stage with a pressure of 10 or 20 applied for each measure. For each analysis a surface of 0.5 cm x 0.5 cm (or of 1 cm x 1 cm) can be measured, the analysis being performed at least in duplicate, preferably triplicate.

[0073] Mapping data treatment:

[0074] The interferograms are transformed into absorbance spectra, with atmospheric suppression and automatic baseline corrections applied. By placing the cursor on a significant band (wavelength) of the hotmelt coating, the coating appears on the XY mapping.

[0075] The mapping is normalized with a predefined colored scale after autocorrelation with a reference spectrum of the hotmelt coating. The resulting image provides the relative absorbance of the coating product on the surface of the nonwoven material, indicating the concentration at the surface.

[0076] Mapping images are calibrated using Imaged® software and analyzed to measure:Total surface area analyzedTotal surface area covered by specksMean area of specks with standard deviationDistribution of speck areas

[0077] If the uniform arrangement of discrete specks of hotmelt material is a matrix of hotmelt material circular dots, it means that within a surface of S cm2, S being a reel positive, there are N specks with an average radius r, so the coverage ratio CR can be given by the formula:N. it. r2CR = lOOxScm2

[0078] If the surface considered is equal to 1 cm2, for example a square or a circle surface area of 1 cm2, the coverage ratio CR can be given by the formula:N. it. r2CR = lOOxlcm2

[0079] When sealed, for example through heat-sealing, the hotmelt material can expand and spread out over the surface of the nonwoven material. The nonwoven material can also absorb an amount of the hotmelt material.

[0080] The inventors have discovered that a minimum coverage ratio of 30 %, preferably at least 40 %, even more preferably 50 %, can ensure that, when sealed, the pouched product is resistant to tearing or ripping while maintaining satisfactory permeability and flexibility in a unsealed region. Thiscoverage ratio can also provide a good compromise between the permeability of the pouched product and the retention of the composition within the pouch.

[0081] The term "mean" refers to the average value obtained from multiple measurements. To ensure accuracy and reliability, at least two measurements should be taken, preferably three, preferably at least five measurements, and even more preferably at least ten measurements from same or different pouches.

[0082] The formula that gives the mean coverage ratio of n different measures of coverage ratio CR is given by the following formula:Wherein n is an integer greater or equal to 2; / is an integer from 1 to n,CRi is the coverage ratio of one sample / .

[0083] The "standard deviation" quantifies the amount of variation or dispersion in a measured set of MCR. For the purposes of the present disclosure, it is preferred that the standard deviation of the measurements be less than 20 %, more preferably less than 15 % and even more preferably less than 10 % of the mean value.

[0084] The sealed regions of the pouched product for oral use according to the present disclosure can be further characterized by their tensile strength.

[0085] Tensile strength is the maximum amount of tensile (pulling or stretching) force that a material, in the present disclosure the sealed regains, can withstand before breaking. It measures the material's resistance to being pulled apart and is typically expressed in units of force per unit width, such as centinewtons per 30 millimeters (cN / 30mm).

[0086] The pouched product for oral use of the present disclosure can have sealed regions with a tensile strength of at least 150 cN / 30mm, preferably at least, 250 cN / 30mm, preferably at least 350 cN / 30mm, and even more preferably at least 450 cN / 30mm.

[0087] Tensile strength in this range renders the seal strong and resistant to breaking during manufacture and oral use. The longitudinal seal can have the same tensile strength as the transversal seal regions, or their tensile strengths may differ.

[0088] The tensile strength of the sealed regions of the pouched product can be measured using a tensile testing machine, following standardized methods such as ISO 1924-2 or ASTM D882.

[0089] The method can be described as follows. First, prepare a sample of the sealed region, ensuring it has a uniform width of 30 mm and includes the seal to be tested.

[0090] For example, sealing 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 tensile strength.

[0091] Then, place the sample in the grips of the tensile testing machine, making sure the sealed region is centered and aligned properly. Set the machine to apply a tensile force at a constant rate from 5 mm / min to 60 mm / min, preferably 30mm / min) in the machine sense of the nonwoven material serving as a wrapper material, and start the test. The machine will pull the sample until it breaks, and the maximum force applied before breaking is recorded.

[0092] The tensile strength is then calculated by dividing the maximum force recorded by the width of the sample (30 mm), resulting in a value expressed in centinewtons per 30 millimeters (cN / 30 mm). This method can ensure accurate measurement of the tensile strength, confirming the strength and reliability of the seals in the pouched product.

[0093] The wrapper material comprises a nonwoven material.

[0094] "Nonwoven material" denotes a manufactured sheet consisting of a web or ply of directionally or randomly oriented fibers bonded together by friction and / or cohesion and / or adhesion.

[0095] The nonwoven material, without hotmelt material may have permeability from 1 000 to 80000 CORESTA Units, preferably from 5 000 to 70 000 CU, even more preferably from 10 000 to 55000 CU.

[0096] The permeability of the wetlaid material is determined by ISO 2965:2009. The wetlaid material is conditioned for at least 30 min at 23 °C (+ / - 1 °C) and 50 % (+ / - 4 %) relative humidity before the measurement.

[0097] After coating the uniform arrangement of discrete specks of hotmelt material, 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 uniform arrangement of discrete specks of hotmelt material has not affected the material's permeability.

[0098] The nonwoven material comprising the uniform arrangement of discrete specks of hotmelt material according to the present disclosure may have a permeability greater than or equal to 60 % of the initial permeability, preferably more than 70 %, preferably more than 80 % of the initial permeability, and even more preferably more than 90 % of the initial permeability. The initial permeability refers to the permeability of the nonwoven material without the hotmelt material.

[0099] The nonwoven material can comprise natural fibers and synthetic fiber.

[0100] For the purposes of the present application, the term "natural fiber" denotes a fiber of natural origin.

[0101] For example, the 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, leaffibers, seed fibers, bast fibers, and mixtures thereof, more particularly from wood fibers, bast fibers and mixtures thereof.

[0102] 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 (H2SO4) 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.

[0103] For the purposes of the present application, "bast fiber" denotes a plant fiber contained in the bast of the plants.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] The natural fibers may have a length of from 10 mm to 150 mm, in particular from 15 mm to 100 mm, very particularly from 20 mm to 60 mm.

[0110] 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.

[0111] The length of the natural fibers can be measured by microscopic measurement using a projection microscope by means of the necessary magnification.

[0112] The natural fibers may also be cut so as to have a length within the ranges mentioned above. Conventional 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.

[0113] According to an embodiment, the nonwoven material comprises less than 30 wt% of synthetic fibers, based on a wt % of a total weight of solid of said nonwoven material, preferably less than 15 wt%, even more preferably less than 1 wt% of synthetic fibers.

[0114] 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, nylon, acrylic, and polypropylene.

[0115] The synthetic fibers in the nonwoven of the present disclosure can be thermoplastic fibers.

[0116] 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.

[0117] For instance, the thermoplastic fibers may be polybutylene succinate (PBS) fibers, polybutylene adipate terephthalate (PBAT) fibers, polyhydroxyalkanoate (PHA) fibers, copolymers of PHA fibers or mixtures thereof, in particular polyhydroxyalkanoate (PHA) fibers or mixtures thereof.

[0118] 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 or mixtures thereof, in particular PLA fibers or mixtures thereof.

[0119] Advantageously, PBS fibers, PLA fibers, P3HB fibers, P3HV fibers and P5HV fibers are biobased thermoplastic fibers.

[0120] In a preferred embodiment, the nonwoven material of the present disclosure is free of synthetic fibers.

[0121] The basis weight of the nonwoven material can be from 14 to 35 g / m2, preferably from 18 to 31g / m2and even more preferably from 20 to 27 g / m2.

[0122] The standard ISO 536:2012 is 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.

[0123] The thickness of the nonwoven material can be from 50 pm to 130 pm measured at 100 Kpa, preferably 60 pm to 120 pm.

[0124] 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.

[0125] According to an embodiment, the nonwoven material is an airlaid, dry laid orwetlaid material, preferably wetlaid material.

[0126] The wetlaid material may further comprise regenerated cellulose fibers.

[0127] 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 have the advantage that they can be produced from renewable cellulose sources, which contributes 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.

[0128] 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 (H2SO4) for the purpose of obtaining fibers with a cross section of variable shape (round, oval, crossshaped, 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.

[0129] Typically, the wetlaid 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.

[0130] According to another aspect, the nonwoven material is provided as a roll of wrapper material coated with uniform arrangement of discrete specks of hotmelt material as defined above.

[0131] The roll can be designed with a long length and a width that is a multiple of the width of the final pouched product to be manufactured.

[0132] This configuration facilitates efficient unwinding and processing during the production of pouched products, enabling high-speed manufacturing and consistent quality.

[0133] The hotmelt material as used herein is a type of activable adhesive that melts when heated and solidifies upon cooling.

[0134] The hotmelt material can be bio-sourced and compostable, contributing to the environmental sustainability of the pouched product. It is designed to enhance the sealability of the nonwovenmaterial while maintaining its essential properties, making it suitable for applications such as oral pouches.

[0135] The hotmelt material can be biosourced, industrially compostable, and / or home compostable.

[0136] In the context of the present disclosure, a hotmelt material that is compostable is a material complying with the EN 13432 standard.

[0137] 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. The hotmelt material must decompose into water, carbon dioxide, and biomass within a specific time frame under composting conditions, which include the presence of microorganisms, moisture, and oxygen.

[0138] The hotmelt material can be a thermoplastic resin having a melting point from 50 °C to 300 °C. In some examples, the hotmelt material can be a thermoplastic resin having a melting point of more than 50 °C and of less than 250 °C, particularly from 100 °C to 250 °C, to avoid melting at an oral temperature while reducing an amount of thermal energy used during sealing.

[0139] The thermoplastic resin can comprise:Polyesters, such as PLA, PBS or PBAT,Polyolefins, such as instance polyvinyl-polyacrylate copolymer or Low-density polyethylene, polypropylene,Polyamides, such as Ethylene acrylic copolymers,Phenoxy resins, Polyesteramides, Polyurethanes, Butyl rubbers, Polyvinyl acetate, Polyacrylate,or their mixtures.

[0140] Paraffin waxes can be excluded. Polyvinyl-polyacrylate copolymer can be preferred.

[0141] In a particular embodiment, the thermoplastic resin can comprise polyesters, polyolefins, polyurethane, phenoxy resin or their mixtures, and even more preferably polyurethane, polyesters, and their mixtures.

[0142] The thermoplastic resin can further comprise additives such as plasticizers, tackifiers, stabilizers, nucleating agent or other improving heat-sealing properties and modifying melting temperature.

[0143] The basis weight of the uniform arrangement of discrete specks can be from 1.0 to 5.0 g / m2, for instance around 3.0 g / m2.

[0144] The total add-on of hotmelt material for a single pouched product for oral use can be from 2 mg to 15 mg, preferably from 3 mg to 12 mg, and even more preferably 4 mg to 10 mg.

[0145] The deposition rate of the hotmelt material in the present disclosure can range from 1 % to 30% , preferably 1 to 20 % , preferably from 2 % to 15 % , and even more preferably from 3 % to 13 %.

[0146] The ‘deposition rate’ of the hotmelt material is the ratio of the basis weight of the nonwoven material to the basis weight of the hotmelt material. This ratio is expressed as a mass per square meter over another mass per square meter, making it a dimensionless quantity. It is preferably expressed as a percentage.

[0147] According to another aspect, the present disclosure refers to a method to manufacture a wrapper material for a pouched product for oral use, the method comprising the following steps: - providing a nonwoven material having a permeability from 1 000 to 80 000 CU, preferably from 5 000 to 70 000 CU, even more preferably from 10 000 to 55 000CU,- coating one surface of the nonwoven material with a hotmelt material,wherein the hotmelt material has a uniform arrangement of discrete specks, having a mean coverage ratio MCR of at least 30 %, preferably at least 40 %, even more preferably at least 50 %, wherein the coverage ratio is defined by:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

[0148] The coating can be applied using methods such as extrusion or hotmelt, with hotmelt being the preferred method. This process allows for precise and efficient application of the hotmelt material.

[0149] The method can be performed at a high-speed rate, coating up 200 to 500 meters / min, particularly from 250 to 450 m / min and even more particularly from 300 to 400 m / min of nonwoven material per second. This ensures rapid production while maintaining the quality and consistency of the coating.

[0150] The nonwoven material, hotmelt material, uniform arrangement of discrete specks and mean coverage ratio are as defined above.

[0151] It is also proposed a method for manufacturing a pouched product for oral use comprising following steps:- providing a tube made of the nonwoven material as defined above,- wrapping the composition between two ends thereof, and- sealing the end(s) of the tube to manufacture the pouched product.

[0152] Sealing the end(s) of the tube may be done for example by heat. At the step of sealing, one end or two ends are sealed.

[0153] The composition can be as already defined above. The pouched product for oral use can be the pouched product for oral use of the present disclosure, as defined above.

[0154] Typically, for manufacturing the pouched products of the invention, a roll of the nonwoven material of the present invention may be used. This roll may be loaded on a manufacturing equipment, which unwinds the nonwoven material, forms a tube, seals this tube longitudinally and seals one open end of the tube. Then the manufacturing equipment may inject, for example with pressurizedair, the composition into the tube through the remaining open end of the tube. The tube may then be cut and sealed to form the pouched product.Examples

[0155] Referring now to Figure 1 , it illustrates an example of a uniform arrangement of discrete specks. In this arrangement, the specks are organized in a grid pattern. Each speck has a diameter D.The specks are equidistantly spaced apart by a distance I, meaning that the centers of the specks are positioned at the vertices of a square with a width I.

[0156] The surface of the nonwoven material in figure 1 is a square of 1cm2. This surface is covered by 25 specks, not comprised within the range of the present invention.

[0157] The coverage ratio can thus be given thanks to the following formula:N.it. R2CR = lOOxlcm2

[0158] In the present example, N=25 and R=D / 2, the coverage ratio, here depending on the diameter of the speck is thus equal to:25.TT. D2CR lOOx4

[0159] Given an example of a coverage ratio being equal to 54%, diameter of the speck should be around 0.33cm.

[0160] Referring now to Figure 2, it illustrates another example of a uniform arrangement of discrete specks. In this arrangement, the specks are organized in a matrix wherein four closest dots are positioned at the vertices of the same parallelogram where each speck has the same diameter D. In Figure 2, it can be seen that the density of the specks is 12 specks / cm2, outside the range of the present invention.

[0161] It is now made reference to figure 3 which illustrates a uniform arrangement of discrete specks that are not dots or sport but irregular specks while still being a discrete uniform arrangement.

[0162] It is now made reference to figure 4 that illustrates a block diagram for performing the method of the present disclosure. S1 corresponds to the step of providing a nonwoven material having a thickness from 50 to 130 pm measured at 100 Kpa and block S2 corresponds to coating one surface of the nonwoven material with a uniform arrangement of discrete specks of hotmelt material, wherein the hotmelt material has a uniform arrangement of discrete specks, having a mean coverage ratio MCR of at least 30 %,wherein the coverage ratio is defined by:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven materialExamples

[0163] A series of tests were conducted to assess the performance of nonwoven materials coated with a hotmelt material arranged in a uniform pattern of discrete specks, achieving a mean coverage ratio (MCR) of at least 30%.

[0164] The hotmelt material used was a polyolefin, especially polyvinyl-polyacrylate copolymer, while the nonwoven substrates consisted of wood fibers.

[0165] Two types of nonwoven materials were evaluated: one with a basis weight of 17.7 g / m2and another with a basis weight of 15.3 g / m2. For each nonwoven type, varying amounts of hotmelt material were applied, resulting in several coated samples (A.1 , A.2, A.3 for the heavier nonwoven; B.1 , B.2, B.3 for the lighter nonwoven).

[0166] For each sample, coverage ratio, porosity and tensile strength were measured in accordance with the methods described in the present disclosure. The tensile strength assessment was performed after heat sealing the coated samples.

[0167] The nonwoven material A comprises 27% PLA thermoplastic fibers. This material therefore possesses an intrinsic heat-sealable property.

[0168] The results are summarized in the following table:;0169] In conclusion, a polyvinyl-polyacrylate hotmelt was applied in a uniform discrete speck pattern (MCR > 30%) onto two wood-fiber nonwovens (basis weights 17.7 g / m2and 15.3 g / m2).

[0170] Increasing add-on (deposition = 11-23%; coverage = 39-70%) produced the following outcomes:

[0171] Heat-sealed tensile strength increased with coverage, upto 451 cN / 30 mm (sample A.3, 70% CR) forthe heavier nonwoven and 228 cN / 30 mm (B.3, 70% CR) forthe lighter nonwoven, evidencing robust thermoseals enabled by the specked hotmelt.

[0172] Permeability remained high and declined moderately as coverage increased. For the 17.7 g / m2nonwoven: 25,000 CU (uncoated) to 23,747 CU at 70% CR; for the 15.3 g / m2nonwoven: 22,360 CU (uncoated) to 18,621 CU at 70% CR, consistent with retention of breathability due to the discrete pattern.

[0173] Examples validate that with a discrete uniform speck pattern at MCR > 30%, strong heat-sealed seals are achieved while substantially preserving the nonwoven’s porosity and flexibility.

Claims

Claims

1. A pouched product for oral use comprising:a wrapper material forming a pouch; anda composition enclosed within the wrapper material;wherein the wrapper material comprises a sealed region and an unsealed region,the wrapper material comprising a nonwoven material and a hotmelt material,wherein the hotmelt material has a uniform arrangement of discrete specks in the unsealed region, having a mean coverage ratio MCR of at least 30 %,wherein the coverage ratio is defined by:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

2. The pouched product for oral use according to claim 1 , wherein the pouched product has a substantially rectangular pattern with a length L from 10 mm to 45 mm and a width w from 1 mm to 30 mm and a ratio w / L from 0.1 to 1.

3. The pouched product for oral use according to claim 1 or 2, 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

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

5. The pouched product for oral use according to any one of claims 1 to 4, wherein the composition comprises from 3 % to 45 % water by weight of the dry composition.

6. A wrapper material for pouched product for oral use comprising:a nonwoven material having a permeability from 1 000 CU to 80 000 CU,a hotmelt material,wherein the hotmelt material has a uniform arrangement of discrete specks, having a mean coverage ratio MCR of at least 30 %,wherein the coverage ratio is defined by:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

7. A wrapper material according to claim 6, wherein the permeability of the nonwoven material comprising hotmelt material having a uniform arrangement of discrete specks is greater or equal to 60% of the permeability of the nonwoven material.

8. A wrapper material according to claim 6 or 7, wherein the deposition rate of the hotmelt material in the present disclosure is from 1 % to 30 % and wherein the deposition rate of the hotmelt material is the ratio of the basis weight of the nonwoven material to the basis weight of the hotmelt material.

9. A wrapper material according to any one of claims 6 to 8, wherein the thickness of the nonwoven material is from 50 to 130 pm measured at 100 Kpa.

10. A wrapper material according to any one of claims 6 to 9, wherein the hotmelt material is a thermoplastic resin having a melting point from 50 °C to 300 °C

11. A wrapper material according to claim 10, wherein the thermoplastic resin comprises Polyesters, Polyolefins, Polyamides, Phenoxy resins, Polyesteramides, Polyurethanes, Butyl rubbers, Polyvinyl acetate, Polyacrylate , or their mixtures.

12. A roll of a wrapper material for pouched product according to any one of claims 6 to 11.

13. A method to manufacture a wrapper material fora pouched product for oral use according to claim 6, the method comprising the following steps:- providing a nonwoven material having a permeability from 1 000 to 80000 CU,- coating one surface of the nonwoven material with a hotmelt material,wherein the hotmelt material has a uniform arrangement of discrete specks, having a mean coverage ratio MCR of at least 30 %,wherein the coverage ratio is defined by:surface of the discrete uniform pattern of specksCR = lOOx - - - — - - - — - - surface of the nonwoven material

14. A method according to claim 13, wherein the coating is done by hotmelt.

15. A method for manufacturing a pouched product according to any one of claims 1 to 5, the method comprising the following steps:providing a tube made of the wrapper material according to any one of claims 6 to 11 , wrapping a composition between two ends thereof, andsealing the end(s) of the tube to manufacture the pouched product.

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