Method of making a tobacco product

Abstract

A tobacco product is formed by rolling a sheet of material supplied by a roll or rolls (e.g. moistened tobacco leaves) and/or homogenized sheet tobacco about a slit mandrel to form a shaped tube. The shaped tube is then packaged for shipment to an end user or consumer. The shaped tube remains in the rolled, shaped tube form inside the package. After the shaped tube is removed from the package, a consumer can fill the tube with crushed tobacco leaves or other tobacco filler material of a favorite blend, thereby eliminating some steps in the making of a “roll-your-own” tobacco product. A liquid can be added to the sheet or to the finished tube to moisturize same. The liquid can include flavoring. The tubes are unfilled when packaged and sent to a consumer/end user in tube form so that they have a “memory” that helps hold a tubular cigar shape after they are filled with selected tobacco fill material.

1 . A method of constructing a cigar comprising the steps of:
 a) providing a sheet of material that includes tobacco material;   b) rolling the sheet of material into a shaped tube that has a longitudinal bore and at least two edges that can be moved apart so that tobacco fill material can be added to the bore;   c) packaging the shaped tube in a wrapper for sale to a consumer and without filling the tube bore with tobacco fill material, and wherein the tube has a memory that retains a tube shape after removal from the wrapper; and   d) enabling a consumer to fabricate a cigar by enabling a removal of the tube from the wrapper and a subsequent filling of the tube bore with tobacco.   
     
     
         2 . The method of  claim 1  wherein in step “b” the sheet of material is comprised of tobacco leaves. 
     
     
         3 . The method of  claim 1  wherein in step “a” the sheet of material is comprised of tobacco leaves. 
     
     
         4 . The method of  claim 1  wherein in step “a” the sheet of material has a plurality of edges and in step “b” two of the edges are brought together. 
     
     
         5 . The method of  claim 1  further comprising the step of packaging a plurality of the shaped tubes in a single packaging unit for sale to a consumer. 
     
     
         6 . The method of  claim 1  further comprising the step of moistening the sheet of material with liquid. 
     
     
         7 . The method of  claim 6  wherein the liquid is flavored. 
     
     
         8 . The method of  claim 6  wherein the liquid is flavored with a flavor selected from the group of vanilla, honey, berry, chocolate, peach, champagne, cognac and menthol. 
     
     
         9 . The method of  claim 6  wherein the liquid is between about 0.01-45% by weight of the shaped tube. 
     
     
         10 . The method of  claim 6  wherein the liquid is between about 0.1-10% by weight of the shaped tube. 
     
     
         11 . A method of constructing a cigar tube product comprising the steps of:
 a) providing a sheet of material that includes tobacco material;   b) rolling the sheet of material into a shaped tube that has a memory that retains a generally tubular shape and a longitudinal bore, the tube having a plurality of edges, including two edges that can be moved apart so that tobacco fill material can be added to the bore;   c) packaging the shaped tube in a wrapper for sale to a consumer and without filling the tube bore with tobacco fill material; and   d) wherein the shaped tube of steps “b” and “c” has a memory that retains a tube shape after removal of the shaped tube from the wrapper.   
     
     
         12 . The method of  claim 11  wherein the tube has a generally cylindrical shape. 
     
     
         13 . The method of  claim 11  wherein the sheet of material is comprised of tobacco leaves. 
     
     
         14 . The method of  claim 11  wherein the sheet of material has a plurality of edges and in step “c” two of the edges are brought together with a slit therebetween. 
     
     
         15 . The method of  claim 11  further comprising the step of packaging a plurality of the shaped tubes in a single packing unit for sale to a consumer. 
     
     
         16 . The method of  claim 11  further comprising the step of moistening the sheet of material with liquid. 
     
     
         17 . The method of  claim 16  wherein the liquid is flavored. 
     
     
         18 . The method of  claim 16  wherein the liquid includes at least in part, alcohol. 
     
     
         19 . The method of  claim 16  wherein the liquid includes a solvent. 
     
     
         20 . The method of  claim 16  wherein the liquid includes at least in part, oil. 
     
     
         21 . The method of  claim 16  wherein the liquid includes at least in part, propylene glycol. 
     
     
         22 . The method of  claim 16  wherein the liquid includes at least in part, ethyl alcohol.