Smokeless tobacco products and processes

Abstract

A smokeless tobacco product is provided. The tobacco product is configured for insertion into the mouth of a user of that product, which includes a water-permeable pouch containing a tobacco formulation that includes a granular tobacco composition, wherein the pouch is constructed of a spunlaid fleece material, which may be thermally sealed for closure and which may be formed of biodegradable polymer fiber.

We claim: 
     
         1 . A tobacco product configured for insertion into the mouth of a user of that product, the tobacco product comprising:
 a liquid-permeable fleece material pouch containing a tobacco formulation, the tobacco formulation including a granular tobacco composition, wherein material forming the fleece pouch comprises nonwoven spunlaid fabric.   
     
     
         2 . The tobacco product of  claim 1 , further comprising a hydrophilic surface coating. 
     
     
         3 . The tobacco product of  claim 2 , wherein the hydrophilicity of the hydrophilic surface is conferred by a food-grade surfactant that comprises one or more of sorbitan aliphatic acid ester, polyglycerin aliphatic acid ester, and sucrose aliphatic acid ester. 
     
     
         4 . The tobacco product of  claim 1 , wherein fiber used to form the spunlaid fabric is selected from polyhydroxyalkanoates, polylactic acid, polycaprolactone, and any combination thereof including a bicomponent fiber with two thereof. 
     
     
         5 . The tobacco product of  claim 1 , wherein the fleece material comprises nonwoven spunlaid fabric prepared by a process of being meltblown, nonwoven spunlaid fabric prepared by a process of being spunbonded, or a combination thereof. 
     
     
         6 . The tobacco product of  claim 1 , wherein the nonwoven spunlaid fabric comprises a food-grade low-melting biodegradable polymer coating an underlying polymer. 
     
     
         7 . The tobacco product of  claim 1 , wherein the nonwoven spunlaid fabric of the fleece pouch comprises a bi-component material comprising one or more of regenerated cellulose, a polyhydroxyalkanoate, polylactic acid, plasticized cellulose acetate, and polycaprolactone. 
     
     
         8 . The tobacco product of  claim 1 , wherein the nonwoven spunlaid fabric of the fleece pouch includes at least one biodegradable polymer. 
     
     
         9 . The tobacco product of  claim 8 , wherein the biodegradable polymer comprises regenerated cellulose, a polyhydroxyalkanoate, polylactic acid, polycaprolactone, or any combination thereof. 
     
     
         10 . The tobacco product of  claim 8 , further comprising at least one flavorant. 
     
     
         11 . The tobacco product of  claim 10 , wherein the flavorant is incorporated into the fleece. 
     
     
         12 . The tobacco product of  claim 10 , wherein the flavorant is provided as a coating on the fleece, a fiber of the fleece fabric, or both. 
     
     
         13 . A method of making a tobacco product according to  claim 1 , said method comprising:
 providing fiber for making the fleece material and forming the nonwoven fabric by a spunbond process, a meltblown process, or both;   applying an aqueous solution comprising a food-grade surfactant to the fiber of the material.   
     
     
         14 . The method of  claim 13 , further comprising applying heat to the fleece material. 
     
     
         15 . The method of  claim 13 , further comprising:
 a step of forming the spunlaid nonwoven fabric fleece material;   a step of forming the fleece material into the pouch; and   thermally bonding the pouch closed around the granular tobacco composition.   
     
     
         16 . The method of  claim 13 , further comprising a step of forming the spunlaid nonwoven fabric fleece material wherein the fleece material formed comprises a biodegradable polymer. 
     
     
         17 . An oral use device comprising spunlaid nonwoven fabric fleece material formed as a pouch encompassing granular tobacco, where the spunlaid nonwoven fabric fleece material comprises a biodegradable polymer and a flavor-enhancing material. 
     
     
         18 . The device of  claim 17 , wherein the spunlaid nonwoven fabric fleece material is configured to comprise a hydrophilic surface. 
     
     
         19 . The device of  claim 17 , comprising a thermally-bonded seal of the pouch. 
     
     
         20 . A tobacco product comprising:
 a spunlaid nonwoven fabric fleece pouch comprising a biodegradable polymer;   a hydrophilic surface of the fleece pouch; and   a flavorant incorporated into the fleece.