Patent Application
20250012013
Cellulose products or additives derived from one or more microbes grown in a symbiotic colony of bacteria and yeast (SCOBY) formed during Kombucha culture and/or fermentation.
The invention described herein includes a cellulose product or additive derived from one or more microbes grown in a symbiotic colony of bacteria and yeast (SCOBY) formed during Kombucha culture and/or fermentation, wherein the cellulose product is substantially free of lignin and hemicellulose, and wherein the cellulose product is used as an additive to a different product to change one or more properties of that different product, and wherein the one or more properties are chosen from at least one of: a physical property, a chemical property, a morphological property, a rheological property, or a biological property.
Kombucha is a fermented tea that has been enjoyed in various cultures across the eastern hemisphere for thousands of years. These cultures often claim health benefits from drinking Kombucha, attributing its nutritional value and probiotic activity as key factors. The name Kombucha often translates to “tea fungus” or “tea mushroom” in many languages, due to the presence of a gelatinous biofilm (also called a pellicle) that forms at the liquid-gas interface during fermentation. Despite its name, the biofilm is not actually a mushroom. The biofilm has been named a SCOBY (Symbiotic Colony of Bacteria and Yeast), comprised of a biopolymer based pellicle and a microbial composition. The microbial composition varies based on the origin of the culture; some of the common microorganisms found in a SCOBY include Saccharomyces and Gluconacetobacter xylinus (renamed Komagataeibacter xylinus).
Traditionally, the SCOBY produced during the fermentation of Kombucha is discarded as a waste product in its natural form due to no existing avenue for alternative uses. However, the SCOBY consists of high-quality bacterial cellulose, and has numerous potential applications. The SCOBY requires multiple novel refining and processing steps to successfully achieve said applications. The further refinement of the SCOBY leads to products such as, but not limited to, microfibrillated cellulose (MFC), nano fibrillated cellulose (NFC), and nanocrystalline cellulose, or other derivatives of cellulose.
Cellulose strands are essentially packages of microfibrils, which are each individual packages of elementary fibrils which are nano-scale fiber units. The manufacturing of cellulose is an ancient practice that has been well documented and industrialized; it is only in recent years however (e.g., the 21st century) that plant-based cellulose has been purposefully microfibrillated. Different high value cellulosic derivatives made from digested wood pulp have been developed. Some of the cellulose derivatives that can be made from digested wood pulp include but are not limited to Cellulose nanocrystals (CNC), nanofibrillated cellulose (NFC), microfibrillated cellulose (MFC), nanocellulose (NC), dissolving cellulose, and regenerated cellulose, all of which are herein generally referred to as Cellulose Derivatives.
Traditional plant matrices from which cellulose is derived from complex intercalated networks with molecules like lignin, hemicellulose, and pectin. The purification of the cellulose by the removal of those other biomolecules, followed by the subsequent nano fibrillation of the cellulose to obtain nanocellulose and other cellulose derivatives, is water, chemical, and energy intensive. A tree or other plant based material must be ground down into chips and chemically and mechanically digested in order to remove lignin, hemicellulose and other materials to isolate alpha-cellulose. That alpha-cellulose must then go through multiple rounds of high-pressure, energy intensive processing. Therefore, traditional production of nanocellulose and other Cellulose Derivatives is cost-prohibitive for industrial applications.
Art pertaining to bacterial cellulose (“BC”) and microfibrillated cellulose “(MFC”) exists, such as bacterial cellulose based ‘green’ composites (see, e.g., U.S. Patent Publication No. 2014/0083327), but the specific use of Kombucha-derived Bacterial Cellulose (“KBC”) in whole or as a component within any of the applications as described herein is new and non-obvious. Please also see References section for related art.
Stora Enso holds a large number of patents for various methodologies of producing MFC and claims to employ an MFC additive in a portion of a commercial paper products. Stora Enso also includes in some of its patents that its MFC can be used for “Fibrous materials such as filaments or mats, and polymer composites comprising such materials are also described” (see, e.g., U.S. Patent Publication No. 2020/0339783). Stora Enso also holds a patent for use of MFC as a surface coating on cardboard (see U.S. Patent Publication No. 2020/0171796) though it is worth noting that this patent neither mentions MFC from KBC, which is quite distinct from synthesized MFC from plant fiber, nor the use of the MFC as a fiber additive; instead this patent describes a “packaging material comprising a layer of microfibrillated cellulose (MFC) and an aluminum layer . . . wherein that layer comprising MFC and/or the aluminum layer has been laminated or extrusion coated on at least one side with a thermoplastic polymer.” The use of bacterial cellulose as a cosmetic additive has not yet been practiced on a commercial scale although since 2017, numerous patents have been filed toward the pursuit.
However, the specific use of and practice of using KBC in whole or as an additive to any of the applications as described herein is novel and non-obvious. KBC represents a unique form of and source of cellulose products to be used alone or in conjunction to create other value added products.
The production of bacterial cellulose is traditionally limited to a monoculture, where a single species of bacteria is grown and its resulting cellulose formation is harvested. It is non-obvious as to why one would want cellulose grown with co-cultures such as Kombucha, as defined below, because the growth processes is more complex and less standardized than cellulose grown from a monoculture. However, it has been shown that different combinations of strains had varied effects on the chemical structure of bacterial cellulose, which was probably dependent on the difference of metabolites in the co-culture system. These differences lead to novel and unexpected properties as compared to other types of bacterial cellulose, and other types of plant-based cellulose, as described by the invention taught herein. These differences also indicate the tunability of the chemical structure of bacterial cellulose based on the specific organisms selected to grow in a co-culture, and the specific feedstock used for the organisms. The tunability of the chemical structure is heretofore unreported in the literature. Accordingly, there is room for improvement in this industry and the invention described herein is such an improvement.
Homogenized Tobacco Leaf (HTL) is a tobacco-based product that results in a more consistent texture and flavor compared to traditional tobacco leaves and that can be produced through many manufacturing techniques, some of which are similar to industrial papermaking processes. The process involves converting tobacco leaves into functional paper sheets that still maintain the authentic taste and aroma of natural tobacco. In the tobacco industry, HTL is used as an alternative to traditional cigarette paper and as an internal supporting layer and or external wrapper for cigars. In cigars, the wrapper is the outermost layer that provides the finished product with its appearance, texture, and initial flavor profile. When made from HTL, the wrapper offers a uniform and consistent aesthetic while still delivering the authentic experience of natural tobacco. This consistency is particularly valuable in large-scale production, ensuring each cigar maintains the same look and feel.
The internal supporting layer is the inner layer of a cigar that holds the filler tobacco together and contributes to the burn quality and overall structure. HTL serves as an effective alternative to traditional tobacco supporting layers, offering a reliable and cohesive construction that enhances the cigar's stability and burn performance without compromising flavor.
Using a restructured tobacco sheath and supporting layer (or just the sheath) marks a shift from the pure, unprocessed tobacco leaves traditionally used in premium handmade cigars. Examples include brands like Dutch Masters, Century Sam, White Owl, and Phillies. These cigars are known for their smooth surface, lacking the veins and irregularities of natural tobacco leaves. Their affordability and the parchment-like texture of the Homogenized Tobacco Leaf (HTL) wrapper make them popular among cannabis users, who often remove the original tobacco filling and use the wrapper to create “blunts” by rolling cannabis inside.
Homogenized Tobacco Leaf (HTL) is manufactured using tobacco scraps, waste, and trimmings from processing, or from other tobacco sources. The process begins with separating the fibrous portion of the tobacco from its soluble components. The fibrous material is then processed through a paper-making method to form a base sheet.
To create HTL, tobacco scraps and dust are mixed with water to form a slurry. The particle size of the tobacco dust, typically separated by using mesh ranging from 60 mesh to 400 mesh, allows for a higher solid content in the slurry without increasing its viscosity. This high solid content reduces the drying load, enabling faster production. Binding agents such as cellulose fibers (from wood pulp or other plant sources), food-grade starch, and pectin are added to the slurry to hold the fibers together and obtain sufficient mechanical integrity for end use and handling.
Fillers like calcium carbonate and magnesium carbonate are often incorporated to improve the texture, appearance, and burning properties by altering porosity of the HTL. Additionally, flavorings and additives such as natural tobacco extracts, sugars, humectants (like glycerol or propylene glycol), and preservatives such as sodium benzoate and potassium sorbate are included to enhance the HTL's qualities. These flavorings can be obtained from the extracted soluble components that are purified and concentrated from evaporation.
The slurry is then processed through a series of rollers and dryers, which press and dry it into a thin, uniform sheet. These sheets are further dried and cut into the desired shapes, forming the final HTL product.
There are several methods for producing homogenized tobacco leaves, commonly referred to as reconstituted tobacco or “recon.” While these methods result in similar products, they utilize different processes and equipment. The most widely used methods include the paper-making technique and band cast (or slurry-type recon). Paper recon and slurry recon are the most common, but they require significant space and energy, and managing taste, drying, and tensile strength can present challenges.
One alternative method, known as the Tobacco Dust Amalgamation (TDA) process, builds on slurry technology but with important distinctions. In TDA, raw materials such as tobacco, hemp, or clove are ground into a powder, and moist components like glycerin, water, and binders are added to form a dough. Microfiber cellulose, a stabilizer not used in the slurry method, is then mixed in. The dough is pressed into pellets via an extruder and passed through a rolling mill, where high-pressure rollers flatten the paste into a sheet before it is dried. This process allows for precise control of the tobacco foil's thickness, which is crucial for applications like heat-not-burn tobacco (HTP) products. Additionally, TDA uses less water—only 20% to 40% moisture content compared to the 60%- 70% in slurry recon—resulting in faster drying, better retention of nicotine and flavor, and reduced water and energy consumption.
In terms of equipment, paper recon production shares similarities with traditional papermaking. Key machinery includes pulping machines for breaking down tobacco leaves into pulp, screens for removing large particles, and beating equipment for further fiber breakdown and additive mixing. Paper-making machines spread the pulp onto a wire mesh to form a sheet, and drying machines remove excess moisture before cutting machines and quality control systems prepare the final product for packaging.
For slurry-type recon, equipment includes grinders to pulverize tobacco leaves and stems, mixers to combine the ground tobacco with water, glycerin, and binding agents, and a conveyor belt to spread the slurry evenly. Rollers apply pressure to ensure uniform thickness, and drying equipment, whether a long drying line or more compact dryers, solidifies the slurry into sheets. Cutting machines, quality control systems, and packaging machines finalize the process in both methods.
Though different, these methods all aim to produce a consistent, uniform tobacco product for use in a variety of applications, from cigarette paper to cigar wrappers, offering flexibility in flavor, strength, and burn properties.
Homogenized Tobacco Leaf (HTL) offers several notable benefits, making it a versatile and cost-effective option in the tobacco industry. One of the primary advantages is its consistency; HTL ensures uniformity in texture and taste, providing a more reliable and predictable smoking experience. This uniformity extends to the composition, appearance, and texture of the tobacco. Additionally, flavor additives and casings can be applied more uniformly to homogenized tobacco, such as humectants, preservatives, and binders, offering a consistent and enhanced flavor profile, while the aroma of the tobacco is similarly improved.
Furthermore, the manufacturing process allows for reduced tar and nicotine content, as these substances can be controlled more precisely during production. This, along with greater control over product characteristics like flavor, strength, and burn rate, gives manufacturers flexibility in meeting consumer preferences. From an environmental standpoint, HTL production also supports sustainability by utilizing tobacco waste materials, reducing overall waste.
The specifications of Homogenized Tobacco Leaf (HTL) are carefully controlled to ensure consistency and quality across different tobacco products. Tobacco blends are specifically selected to create a uniform flavor and smoking experience, often combining varieties like Virginia, Burley, or Oriental tobaccos. The moisture content is crucial for proper combustion and freshness, typically maintained within a range of 12-18% but varies depending on numerous factors.
Sheet thickness is tailored to the intended use, ranging from thin sheets for cigarette paper to thicker sheets for cigar wrappers, typically measured in grams per square meter (GSM). The sheet dimensions are customized to match the size requirements of the product, such as the length of a cigarette or the ring gauge of a cigar, with measurements typically specified in millimeters (mm).
HTL's combustion properties are fine-tuned to ensure a consistent burn rate and ash formation, which may involve adjusting the tobacco blend, sheet thickness, or additives. The physical properties of HTL, including but not limited to tensile strength (in pascals), tensile force (in newtons), and porosity (in Coresta units, CU), are specified to ensure optimal performance.
The color of HTL is managed to maintain uniform appearance across different batches, achieved through either the use of dyes or adjustments to the tobacco blend. Shelf life is another key specification, with packaging and storage conditions optimized to preserve freshness and maintain desired characteristics during transport and storage.
An object of the present invention is to use Kombucha cellulose product as a unique form of and source of cellulose to be used alone to create stand-alone products, or in conjunction with other ingredients as a component of existing products.
Kombucha is the name for a fermented tea that has been popular in many cultures throughout the eastern hemisphere for thousands of years. These cultures claim a significant health benefit to be gained by drinking Kombucha, namely due to the high nutritional content and probiotic activity of the beverage. Various health benefits of Kombucha tea have been claimed, such as an analgesic (pain reliever), anti-arthritic and anti-spasmodic agents, liver-protective compounds, and several antibacterial substances. The final product is a rich blend of probiotics (beneficial bacteria and yeast), along with acids, enzymes, vitamins, and nutrients that support digestion, detoxification, and overall health.
The name of the beverage in many cultures translates into “tea fungus” or “tea mushroom” due to the growth of a gelatinous biofilm (also known as a pellicle) at the liquid-gas interface. The biofilm is not a mushroom, but instead is what is known as a SCOBY, or a Symbiotic Colony of Bacteria and Yeast. While the microbial makeup of the SCOBY varies depending on the source of the culture, some of the more persistent organisms contained within Kombucha include Saccharomyces and Gluconacetobacter xylinus.
The Kombucha bacterial culture is a symbiotic colony comprising at least two of the following microorganisms Komagataeibacter xylinus, Gluconacetobacter xylinus, any yeasts, including Saccharomyces cerevisiae, Brettanomyces bruxellensis, Candida stellata, Schizosaccharomyces pombe, and Zygosaccharomyces bailli and any other microorganism derived from the genera Acetobacter, Azotobacter, Rhizobium, Agrobacterium, Pseudomonas, Gluconacetobacter, Alcaligenes, Lactobacillus, Lactococcus, Leuconostoc, Bifidobacterium, Thermus, Allobaculum, Ruminococcaceae, Incertae Sedis, Enterococcus, Salmonella, Sarcina, and Propionibacterium.
KBC is bacterial cellulose produced by the Kombucha Culture. The inventors have determined that the industrial production of KBC offers a sustainable, affordable, high purity and environmentally friendly alternative to wood for the production of Cellulose Derivatives. Further, as determined by the inventors, novel and unique growth methods of KBC allow for the production of specialty cellulose that can be processed directly rather than be converted to Cellulose Derivatives. The use of KBC as described herein would thus be commercially, economically and environmentally beneficial and promote the development of the circular economy. Accordingly, it is an object of the present invention to establish industrial production of KBC in order to offer a sustainable, affordable, high purity and environmentally friendly alternative to wood for the production of Cellulose Derivatives. Further, it is an object of the current invention to provide novel and unique growth methods of KBC in order to allow for the production of specialty cellulose that can be processed directly and/or converted to Cellulose Derivatives.
The manufacturing of KBC and Cellulose Derivatives, however, is non-trivial KBC has particularly high water retentivity due to the microscopic scale of its fiber. This leads to production complications when incorporating KBC in large scale manufacturing due to long drainage times in the paper formation stage, for example. As a result of its unique drainage properties, KBC, while structurally preferable to plant-based cellulose according to the present invention, is typically considered to be not commercially viable to produce, including by those skilled in the art of cellulosic fiber manufacturing. Complications in manufacturing products that include or are made entirely of KBC arise due to water retentivity, unique dimensions of KBC fibers, difficulty of the fibers to disperse evenly in plant-based cellulose, and difficulty to analyze the quality and dispersion of the fibers at scale.
Cellulose is an important structural component of the primary cell wall of green plants, many forms of algae and the oomycetes. Cellulose, being one of the most abundant natural polymers on Earth, is present in many objects, both naturally occurring and synthetic, that humans interact with nearly daily. The material is non-toxic, relatively inert, and any form of allergy to cellulose is exceedingly rare. Cellulose can even be harmlessly absorbed by pores in the skin. KBC is ideal to use in the cosmetics industry due to its purity and its smaller dimensions, which facilitate absorption into the skin.
BC fibers offer distinct material properties such as high length to width ratio, high water retention, high crystallinity index, high purity, and customizable surface chemistry that are unlike plant based cellulose. The chemical structure of BC is identical to its plant counterpart which is typically purified during the Kraft process. Specifically, BC is a linear polysaccharide chain consisting of D-glucose units connected by beta-linkages on the order of hundreds to thousands of units long.
BC fiber structure is considered ultra fine and ribbon-shaped with a width of 0.1-0.01 micrometers (obtained using SEM) or approximately 100 times thinner than plant cellulose (Backdahl, Henrik et al., 2005; Abitbol, Tiffany, et al., 2016). While orders of magnitude finer than plant cellulose fiber, BC fiber exhibits similar fiber lengths of around 2-0.1 mm when compared with plants fiber lengths ranging from 2-0.8 mm (Choi et al., 2020; Ververis et al., 2003). Due to the fine nature of BC, the polar fiber possesses a high water retention two to three orders of magnitude larger than typical plant cellulose fibers (Karippien, 2017; Ververis et al., 2003). Additionally, the crystallinity index is higher (67-96%) (Andritsou et al, 2018; Dima et al., 2017). This crystallinity index is in aspects attributable to the purity of BC. There also exist other nanoscale cellulose fibers derived from plant matter that exhibit similar nano properties which are typically referred to as MFC. Since MFC is plant derived cellulose it initially contains other biopolymers such as lignin, hemicellulose, and pectin.
Typically, plant matter undergoes a purification process known as the sulphate or Kraft process to remove the biopolymer impurities lignin, hemicellulose, and pectin in order to produce cellulosic pulp. In cases, this purification aspect of the Kraft process accounts for around 50% of the pulping operation's energy consumption. At the magnitude of this industry the Department of Energy estimated that for the United States in 2006, 500 trillion BTU's (an energy equivalence of 90M barrels of oil) was used for chemical preparation and recovery in the pulping process alone (Jacobs, 2006). While chemical recovery has improved, noxious chelating agents, chlorates, and dioxins can still be discharged in effluent from pulp mills which disproportionately affect local communities. In 2015, the Environmental Protection Agency (EPA) estimated that the paper and pulp industry accounted for 20% of all toxic air emissions in the United States (EPA, 2017). Compounded on top of the energy and environmental costs, the chemical refinement also degrades the cellulose reducing yield by up to 50% (EPA, 2017; Broten, 2012).
Traditionally, the SCOBY formed on top of the Kombucha culture is a discarded waste product of Kombucha fermentation. However, the SCOBY is considered a high quality and high purity form of bacterial cellulose that is constructed from a woven mesh of crystalline cellulose tendrils measuring nanometers in diameter and with an unknown length, thought to be in micrometers, giving the SCOBY strength. It is an object of the present invention to show unique growth, manufacturing and treatment processes, as described herein, to enable the KBC to be used in many potential industries, including but not limited to, paper and packaging, biomedical and pharmaceuticals, food and cosmetics, biosensors and energy storage, and/or textiles and materials.
The refinement and processing of the KBC includes physical, chemical, enzymatic, and/or thermo-based breakdown and or degradation of the original pellicle, to achieve randomized or uniform sized fibers. Further, these fibers can be refined and purified further to remove all excess biological material, or other undesirable material. The refinement and purification processes include chemical, mechanical, enzymatic and/or thermo-based purification processes to dissolve, separate, isolate, and/or precipitate the undesirable material. Finally, the fiber can be passed through a filtering and/or separation process to isolate the purified fibers from the undesirable by-products.
Cellulose is also an edible, inert organic that is used in food packaging and as filler in food products to bolster volume, fiber content of food and preservation. Fiber is of significant nutritional benefit for its positive effect on the digestive tract and the potential improvement to internal regulation of sugar and cholesterol as the fiber passes through the human body.
Cellulose, being extremely rich in dietary fiber, aids in metabolism and can bond to excess sugars and cholesterol in the bloodstream, effectively regulating internal body conditions for overall improved health and metabolism.
KBC has unique properties and dimensions compared to the standard accepted values for typical plant-based fiber types. Many factors such as climate, age of organism at time of harvest, and part of organism harvested all have significant impact on the exact dimensions reported. Because the growth conditions of Kombucha SCOBY can be controlled, the properties of the resulting KBC can be kept consistent or highly consistent and is tunable depending on the conditions provided. The growth conditions of the KBC has several variables that can be modified, including but not limited to nutrient substrate, carbon source, temperature, humidity, gas content, pH, microorganism selection, growth time, light exposure, and sound frequency.
Incorporating Kombucha-derived cellulose product (KCP) into the fiber furnish of homogenized tobacco or other reconstituted plant matter sheets represents a significant, non-obvious innovation. KCP offers a higher length-to-width ratio compared to traditional plant-based cellulose fibers. This elongated, finer structure enables KCP to effectively fill the interstitial spaces between thicker plant fibers, which conventional cellulose fibers cannot do as efficiently. By occupying these spaces, KCP enhances the uniformity of the sheet formation process, leading to improved mechanical strength and durability of the final product.
The higher surface area and fine microfibrils of KCP offer enhanced fiber bonding without the need for large quantities of synthetic binders. This is significant because conventional binders, though effective in improving structural integrity, often compromise the flavor of the smoking product. In contrast, KCP's microfibrillated structure provides the necessary binding strength while preserving the full, unaltered flavor profile of the tobacco. This unique property of KCP improves the smoking experience, maintaining both mechanical strength and the integrity of flavor.
Additionally, the integration of KCP as a fiber in the sheet formation process allows for “light-weighting” of reconstituted smoking articles. KCP's finer fiber structure increases the achievable density of the material while maintaining or even enhancing its structural properties. This innovation enables the production of a lighter product with greater strength, which is advantageous for improving the feel and performance of the smoking article.
Moreover, the use of KCP improves the ability to control the porosity of the material. Typically, achieving controlled porosity requires additives like precipitated calcium carbonate, which can alter the burning characteristics and potentially introduce undesirable flavors. The finer fiber morphology of KCP allows manufacturers to fine-tune the porosity of the tobacco sheet without needing such additives. Porosity is critical in regulating the burn rate of smoking articles, and by controlling it more precisely with KCP, the burn rate can be optimized for a consistent smoking experience without detracting from the flavor. Optimized burn rate is a desirable feature for the consumer that enhances and extends the smoking experience beyond the burn rate of the smoking article.
KCP's active surface chemistry, combined with its high surface area, offers significant improvements in flavor retention and application efficiency. The increased surface interaction allows for more efficient binding of psychoactive compounds and flavor additives, leading to better flavor delivery and a more satisfying smoking experience. This characteristic is particularly valuable when KCP is used as a surface coating. By applying KCP in this manner, psychoactive and flavor compounds can be efficiently absorbed and retained on the surface, enhancing the sensory profile of the smoking article.
Furthermore, bacterial cellulose, including KCP, possesses properties that provide strategic advantages over plant-based cellulose. Its superior tensile strength, higher water retention capacity, and exceptional durability, translate into stronger, more resilient smoking products. KCP's moisture retention properties also help to maintain freshness and prolong shelf life. Additionally, it is sourced as a byproduct of a food production process that makes it non-toxic in nature, and makes it an environmentally friendly alternative to currently used additives, promoting sustainability in the production of smoking articles.
In summary, the introduction of KCP into homogenized tobacco leaves offers multiple benefits: improved mechanical strength, enhanced flavor retention, optimized porosity for burn control, and the potential for lighter yet more robust smoking products. Its natural microfibrillated structure not only strengthens the bulk but also provides manufacturers with greater control over the product's properties, all while preserving or even improving the smoking experience. This innovative use of bacterial cellulose from kombucha fermentation marks a significant advancement in the design and performance of reconstituted tobacco products.
While kombucha cellulose product (KCP), offers many benefits, some of its intrinsic properties present notable challenges, particularly in the context of reconstituted plant matter sheets. One key property is its high water retention capacity. This characteristic, while useful in certain applications, can significantly increase drying time during production, thereby reducing manufacturing speed and efficiency. Extended drying periods lead to higher energy consumption and delayed throughput, which is undesirable in high-volume production environments like those for smoking products.
Additionally, excessive water retention in the final product can compromise shelf life. Elevated water activity creates a more favorable environment for microbial growth, which accelerates spoilage and increases the risk of contamination. The retained moisture may also alter the physical properties of the sheet, making it prone to degradation or deformation over time. For these reasons, manufacturers may be hesitant to incorporate bacterial cellulose into smoking articles, as its water-retentive nature poses practical difficulties, both in production and in the product's longevity. These drawbacks could easily dissuade individuals with experience in reconstituted tobacco production from considering bacterial cellulose as a viable fiber option.
The incorporation of Kombucha Cellulose Product (KCP) into foam formulations presents an opportunity to address several of the key challenges facing modern foam materials. KCP's high length-to-width ratio makes it an ideal reinforcement material for foam products. The microfibrillation of KCP allows it to fill interstitial spaces enhancing mechanical strength without significantly increasing density. Tests such as tensile strength analysis (including but not limited to ISO 1926) and compression resistance tests are used when verifying the improved load-bearing capacity and durability of KCP-enhanced foams.
Another major advantage of KCP is its biodegradability and sustainability. Unlike synthetic reinforcements or petrochemical-based foams, KCP can contribute to a fully biodegradable foam structure. As a result, KCP-enhanced foams could help reduce the overall environmental footprint of foam production, making them more attractive for eco-conscious consumers and industries.
Despite these advantages, there are challenges to implementing KCP in foam products. Water retention is a significant concern. KCP's high capacity for holding moisture, while beneficial in certain applications, could extend the drying time during manufacturing, reducing production speed and increasing energy consumption. This could be evaluated through moisture content analysis (including but not limited to ASTM D4442) to monitor and manage water activity during production. Excessive water retention in the final product could also lead to reduced shelf life by promoting microbial growth and accelerating material degradation. Water activity testing (including but not limited to ISO 18787) would be essential in assessing these risks and determining if additional processing or coatings are necessary to mitigate moisture-related issues.
Furthermore, KCP's porosity control properties may offer improvements in foam performance by allowing for more precise control over airflow, filtration, thermal resistance, electrical resistance, cell migration. The high surface area of KPC also opens up possibilities for it to act as a carrier for active ingredients within the foam, such as antimicrobial agents, UV protectants, or even scents. The porous nature of the material would allow for controlled release of these agents, adding functionality to the foam that goes beyond simple mechanical properties.
Finally, KCP's high surface area and active surface chemistry make it a promising candidate for incorporating active ingredients into foam products. Its ability to bind and retain compounds like antimicrobial agents or flame retardants could improve the functionality of foams in specialized applications. However, this same characteristic could present a challenge if the cellulose interacts negatively with other foam components or additives, requiring compatibility testing through chemical interaction analysis (such as FTIR spectroscopy) to ensure a stable final formulation.
Most if not all of the above, as it pertains to the invention(s) described herein, were determined through trial-and-error and significant testing to determine if such cellulose products and related products described herein would work for the purposes explained herein.
The following properties are measurably modified and altered by the inclusion or use of KCP according to testing performed as part of the invention disclosure herein:
Density as measured by grams per cubic meter (g/m3).
Water retention as measured by percentage (%), g/g, or water retention value as described by ISO 23714:2007.
Shelf stability is based on unacceptable changes that could be sensory characteristics, a loss of chemical stability, and defined as a change in physical properties, microbial growth, vitamin degradation, water activity and more.
Air permeability as measured by liters per second per square meter (L/s·m2). Air permeability is measured using the Frazier test method, following standard test procedures like ASTM D737 and DIN 53887. Specifically for nonwoven fabrics, the airflow per unit area through the sample is recorded under a set differential pressure, typically around 200 Pa. Several factors impact air permeability, with basis weight, thickness, and porosity being the most significant. Additionally, fiber size, pore size, and the structure of the nonwoven material play key roles in influencing the results. Many fabrics are coated in order to modify their permeability to both air and water vapor, while maintaining insulation and other properties.
Insulative strength as measured by watts per meter kelvin (W/m·K).
Pathogen resistance or antimicrobial properties as measured by log reduction value (LRV), Agar diffusion based screening of antimicrobial activity, Cross streak method, Co-culture assay, Poisoned food technique, Time kill kinetics, Agar dilution and broth dilution methods, Resazurin assay.
Water vapor permeability as measured by water vapor transmission rate in grams per square meter per day (g/m2·day), ISO 15106-1:2003, ISO 12572:2001, or TAPPI T523.
Moisture barrier properties as measured by water vapor transmission rate of plastic film and sheeting include cup method (gravimetric method), electrolytic sensor method, infrared sensor method, humidity sensor method, or grams per square meter per 24 hours (g/m2·24 h).
Porosity as measured by percentage (%), coresta units, or micrometers/nanometers (μm/nm) relating to pore size.
Hydrophobicity as measured by contact angle in degrees (°).
Thermal insulative stability as measured by thermal conductivity (W/m·K).
Burst strength as measured by pascals (Pa), kilograms per square centimeter (Kg/cm2) or newtons per square meter (N/m2).
In another aspect, the invention alters or modifies compression strength as measured by newtons (N) or Pascals (P) when normalizing for cross sectional area.
In another aspect, the invention alters or modifies tensile strength or tensile index as measured by pascals (Pa) and newtons per square meter (N/m2) or tensile strength/grammage respectively.
Elongation as measured by percentage (%).
Tear strength as measured by newtons (N) or pascals (Pa), for rubber related products tear strength is calculated by force over thickness (N/cm) and depends on the way the force is applied and structure of the material.
Stiffness as measured by newtons per meter (N/m).
Elastic modulus as measured by pascals (Pa).
Surface roughness in micrometers (μm) using profilometers or laster scanners.
Electrostatic stability as measured by volts per meter (V/m).
Radiation absorption as measured by gray (Gy).
Shelf life as measured by months or years.
Bioavailability as measured by percentage (%) of the active compound. Bioavailability refers to the extent and rate at which the active moiety (drug or metabolite) enters systemic circulation, thereby accessing the site of action. The bioavailability of a drug is primarily influenced by the characteristics of its dosage form, which are shaped by its design and manufacturing process. Variations in bioavailability between different formulations of the same drug can have important clinical implications, making it crucial to determine whether drug formulations are equivalent. Bioavailability is usually assessed by determining the area under the plasma concentration-time curve. The most reliable measure of a drug's bioavailability is AUC (area under curve).
Sublingual absorption as measured by percentage (%), moles (mol), molar (M), or concentration (mg/L). Drug absorption is determined by the drug's physicochemical properties, formulation, and route of administration
Pharmacokinetic profile and pharmacodynamics profile as measured by time (hours) and concentration (mg/L). As measured by the area under the curve of plasma drug concentration over time.
Controlled release profile as measured by release rate in milligrams per hour (mg/h).
Solubility as measured by the mass of solute per volume (g/L) and may incorporate time (seconds or minutes) to get a rate of solubility.
Binding affinity in micromolar (μM) or percentage (%).
Physical stability. Physical stability refers to a formulation's ability to retain its physical characteristics, such as appearance, texture, and particle size, over time. Significant research has been dedicated to developing preparation methods that enhance physical stability, as instability can result in issues like sedimentation, creaming, and caking. These stability problems can negatively impact both the effectiveness and safety of the product.
Several factors, including temperature, humidity, and light exposure, can influence a product's physical stability. For instance, exposure to high temperatures during storage, transport, or use may cause phase separation or changes in particle size, which could affect both product performance and consumer satisfaction. Comprehending particle size is essential for assessing and predicting physical stability, as well as conducting rheological measurements to evaluate the physical and mechanical characteristics of the final product.
Chemical stability. Chemical stability refers to a formulation's ability to preserve its chemical composition and potency over time. This involves maintaining the molecular structure of the active ingredients without alteration or degradation. Chemical instability can result in the breakdown of these ingredients, negatively impacting the product's effectiveness, safety, and shelf life. Factors such as pH changes, oxidation, hydrolysis, and bacterial activity often contribute to chemical degradation. Oxygen is a significant threat to chemical stability, as many drug molecules react with it, leading to unwanted chemical changes. Such reactions cause degradation, producing impurities and byproducts. Hydrolysis, which occurs when a formulation is exposed to water, can similarly degrade active ingredients and produce unwanted compounds.
Chemical stability is typically evaluated using analytical techniques like liquid chromatography (HPLC), gas chromatography (GC), mass spectrometry (MS), and infrared spectroscopy (FTIR). These methods are instrumental in detecting and quantifying degradation products or impurities resulting from chemical instability. Additionally, stability studies are carried out under different conditions, including temperature, humidity, and light exposure, to assess the product's shelf life.
Reference will now be made in detail to various exemplary embodiments of the invention. It is to be understood that the following discussion of exemplary embodiments is not intended as a limitation on the invention. Rather, the following discussion is provided to give the reader a more detailed understanding of certain aspects and features of the invention.
All references cited herein are hereby incorporated in their entirety herein by reference.
In one aspect, KCP is a structural object that bears weight or provides form, including but not limited to a board, brick, or wall.
In another aspect, KCP is a moldable paste that can be used to mold and shape objects, including but not limited to lampshades, cell phone cases, or wall coverings.
In another aspect, the KCP can be integrated into foam structures to enhance mechanical strength, flexibility, electrical conductance, and thermal insulation.
In another aspect, the KCP integrated into foam structures increases elasticity and tensile strength, while also offering biodegradability and sustainability.
In another aspect, KCP can improve synthetic leather durability, breathability, and tensile strength, while its natural fibers enhance texture and flexibility.
In another aspect, KCP's biodegradability adds eco-friendly attributes, aligning with sustainable production needs.
In another aspect, the KCP can enhance encapsulating agents by improving barrier properties, such as moisture retention and controlled release, due to its dense fiber network. It also offers improved mechanical strength and biodegradability, which are beneficial for the stability and environmental impact of the encapsulation.
In another aspect, KCP enhances emulsifying agents by improving stability through its fine microfibrillated structure, which increases surface area for better dispersion of emulsified particles.
In another aspect, KCP strengthens the emulsion's resistance to separation and prolongs shelf life by reducing phase instability.
In another aspect, KCP improves the controlled release profile of an active compound carrier through enhanced bioavailability and surface area.
In another aspect, KCP enhances the mechanical strength and thermal stability of an aerogel while modifying density.
In another aspect, KCP increases the water retention capacity and mechanical resilience of a hydrogel.
In another aspect, KCP optimizes the interfacial bonding in a polymeric composite, improving durability and flexibility.
In another aspect, KCP enhances the tensile strength and uniformity of a sheet and can reduce porosity.
In another aspect, KCP improves adhesion and mechanical integrity in a coating, enhancing surface finish.
In another aspect, KCP enhances the durability, adhesion, and flexibility of
surface coatings, improving resistance to wear, moisture, and environmental degradation.
In another aspect, KCP improves active molecule retention in surface coatings by providing a higher surface area and better binding sites, which enhances the stability and controlled release of active compounds over time.
In another aspect, KCP provides a more stable matrix in a coating precursor, improving uniformity during application.
In another aspect, KCP modifies conductivity in a current or voltage carrier by providing a stable, flexible matrix and a fine fiber structure.
In another aspect, KCP improves filtration efficiency in a filter by enhancing pore
structure and surface area.
In another aspect, KCP improves selectivity and durability in a membrane by optimizing porosity and permeability.
In another aspect, KCP improves the catalytic performance of a resin catalyst by enhancing active surface area.
In another aspect, KCP optimizes surface area and stability in a catalyst substrate, improving reaction rates.
In another aspect, KCP enhances adhesion and structural stability when used as a coating additive.
In another aspect, KCP improves texture and drying properties as a paint additive.
In another aspect, KCP enhances the stability of paint additives by improving the dispersion of pigments and fillers, which results in a more uniform color and consistency. Additionally, its unique properties contribute to better resistance against settling and separation, ensuring prolonged shelf life and optimal performance during application.
In another aspect, KCP increases bonding strength and flexibility as an adhesive additive.
In another aspect, KCP improves setting time and mechanical properties as a cement additive.
In another aspect, KCP improves smoothness and durability in a paper coating while modifying water absorption.
In another aspect, KCP enhances viscosity and stability as a thickening agent.
In another aspect, KCP optimizes flow behavior and structural integrity as a rheology modifier.
In another aspect, KCP improves stability and suspension properties as a drilling fluid additive.
In another aspect, KCP enhances strength and flexibility in a bioplastic by acting as a reinforcing filler.
In another aspect, KCP improves mechanical properties and surface uniformity in paper or paperboard.
In another aspect, KCP increases moisture retention and improves texture in a cosmetic skin care product.
In another aspect, KCP enhances barrier properties and durability in food packaging.
In another aspect, KCP optimizes structural integrity and flexibility in an edible food casing.
In another aspect, KCP improves texture and uniformity in an edible consumable filler.
In another aspect, KCP enhances thermal insulation properties in an insulation by improving the air retention within the structure.
In another aspect, KCP improves absorbency and durability in a sponge.
In another aspect, KCP strengthens the matrix and modifies conductivity in a carbon composite.
In another aspect, KCP enhances moisture retention and nutrient delivery in a growth medium substrate.
In another aspect, KCP improves moisture absorption, provides increased surface area for active compound delivery, and antimicrobial properties in a wound dressing.
In another aspect, KCP enhances dissolvability, stability, or bioavailability in a dissolvable buccal or sublingual lozenge.
In another aspect, KCP improves durability and flexibility in a synthetic fabric.
In another aspect, KCP improves texture, stability, and elasticity in gums.
In another aspect, KCP enhances moisture retention and structural stability or modifies porosity in a gel.
In another aspect, KCP improves dispersion or adhesion and suspension stability in an aerosolized spray.
In another aspect, the cellulose containing product is mixed or blended into a plant derived material that can constitute various forms from processes such as but not limited to: homogenization, powderization, reconstitution, micro fibrillation, shearing and other such forms of refinement.
In another aspect, these plant fibers may encompass a multitude of sources, notably, Tobacco, Hemp, Flax, eucalyptus, sisal, esparto, bamboo, perennial fibers, softwood and/or hardwood fibers, rag fibers, and cotton or any combination thereof. These plant fibers may or may not contain hemicellulose or lignin, depending on the process or refinement undergone by the fibers. However, purified or raw plant fibers are suitable for the bulk material that the KCP is incorporated into.
In another aspect, the KCP blended with plant fibers are formed into sheets, tubes, cylinders, or cones.
In another aspect, the KCP that incorporates homogenized plant fiber as a bulk material and consists of the aforementioned physical forms is used for smoking articles.
In aspects, the KCP can be an additive to a product from anything over 0% to 100% KCP in the product to which it is added, and any percentage in between. In aspects, the KCP can form its own object comprising anything over 0% to 100% KCP, and any percentage in between.
The following definitions are meant to illustrate, not limit, the present invention.
SCOBY means a Symbiotic Colony of Bacteria and Yeast and is comprised of a biopolymer based pellicle and a microbial composition. The microorganisms contained in the SCOBY include, but are not limited to any yeasts, including Saccharomyces cerevisiae, Brettanomyces bruxellensis, Candida stellata, Schizosaccharomyces pombe, and Zygosaccharomyces bailii and any other microorganism derived from the genera Acetobacter, Rhizobium, Agrobacterium, Pseudomonas, Gluconacetobacter, Alcaligenes, Lactobacillus, Lactococcus, Leuconostoc, Bifidobacterium, Thermus, Allobaculum, Ruminococcaceae, Incertae Sedis, Enterococcus, Komagataeibacter, and Propionibacterium.
Homogenized tobacco leaves, foils, sheets, or more generally put smoking articles may encompass several manufacturing methods which result in a similar end product, of which is a sheet or tube that comprises of plant matter, from various possible sources that may be refined or unrefined, that then undergo homogenization, reconstitution, powderization, pulverization, or other types of reformulation to ultimately form the end product. In the description, the process described centers around tobacco as an example of plant derived matter; however any type of smokable, consumable plant matter may be employed such as hemp etc.
The present invention has been described with reference to particular embodiments having various features. In light of the disclosure provided above, it will be apparent to those skilled in the art that various modifications and variations can be made in the practice of the present invention without departing from the scope or spirit of the invention. One skilled in the art will recognize that the disclosed features may be used singularly, in any combination, or omitted based on the requirements and specifications of a given application or design. When an embodiment refers to “comprising” certain features, it is to be understood that the embodiments can alternatively “consist of” or “consist essentially of” any one or more of the features. Other embodiments of the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention.
It is noted that where a range of values is provided in this specification, each value between the upper and lower limits of that range is also specifically disclosed. The upper and lower limits of these smaller ranges may independently be included or excluded in the range as well. The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It is intended that the specification and examples be considered as exemplary in nature and that variations that do not depart from the essence of the invention fall within the scope of the invention. Further, all of the references cited in this disclosure are each individually incorporated by reference herein in their entireties and as such are intended to provide an efficient way of supplementing the enabling disclosure of this invention as well as provide background detailing the level of ordinary skill in the art.
As used herein, the term “about” refers to plus or minus 5 units (e.g., percentage) of the stated value.
Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment” or “other embodiments” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily all embodiments, of the inventions.
As used herein, the term “substantial” and “substantially” refers to what is easily recognizable to one of ordinary skill in the art.
It is to be understood that the phraseology and terminology employed herein is not to be construed as limiting and are for descriptive purpose only.
It is to be understood that the details set forth herein do not construe a limitation to an application of the invention.] Furthermore, it is to be understood that the invention can be carried out or practiced in various ways and that the invention can be implemented in embodiments other than the ones outlined in the description above.
| Number | Date | Country | |
|---|---|---|---|
| 62572155 | Oct 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17346532 | Jun 2021 | US |
| Child | 18893880 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16159556 | Oct 2018 | US |
| Child | 17346532 | US |
