Patent Application
20220369693
Conventional smoking articles combust a material at temperatures that release active compounds, which are inhaled through the mainstream smoke. The mainstream smoke delivered to the user not only has a characteristic, enjoyable, taste, but also can deliver to the user active compounds that are absorbed into the blood through the lungs that can provide the smoker with a pleasant and calming effect. In addition to smoking articles that are consumed with a lit end, other aerosol-producing articles also exist in which an aerosol, such as a vapor, is produced without igniting the material. For example, heat but not burn sticks are consumed similar to conventional smoking articles without igniting a filler contained in the stick.
In the past, problems have been experienced in delivering active compounds from a smoking article or heat but not burn stick to a use in controlled amounts and in a uniform manner. For example, it has been difficult to control the amount of active compounds delivered to a user by an article, and harder yet to maintain good sensory characteristics, such as taste and smell, while modifying the amount of active compounds contained in the article.
In the past, for instance, active compounds were applied to aerosol-producing fillers, such as tobacco, using a spray or brush method. In other embodiments, various additives were combined with tobacco in a rotating drum for applying the additive to the plant material. These past processes have various drawbacks, however. For example, the processes described above have limitations on how much additive can be applied to the filler material. In addition, additive losses can be significantly high in that the processes are relatively inefficient. Finally, many of the above processes require significant amounts of time, thus reducing throughput and increasing costs.
Additional problems have been encountered when attempting to incorporate active compounds derived from cannabis materials into smoking articles or heat but not burn sticks. For example, metering levels of tetrahydrocannabinol (THC) and/or cannabidiol (CBD) while maintaining a good or authentic taste has been difficult to achieve. For instance, THC and/or CBD deliveries can vary dramatically depending upon the particular plant and the particular plant parts being burned, further increasing the difficulty in controlling delivery.
In view of the above, a need currently exists for a method of incorporating an additive into an aerosol-producing material. More particularly, a need exists for a method that can not only efficiently incorporate an additive into an aerosol-producing material but also in a manner such that the additive is uniformly dispersed throughout the material. In one aspect, a need also exists for a method of incorporating an additive into an aerosol-producing material at relatively high levels that were difficult to obtain using past processes.
In general, the present disclosure is directed to a method for incorporating an additive into an aerosol-producing material, such as a filler, that is well suited for use in smoking articles, heat but not burn sticks, and the like. The method of the present disclosure is generally directed to a vacuum infusion method that is capable of achieving 100% or more application efficiency without any losses of the additive and in a very short amount of time, such as less than ten minutes. Further, the infusing liquid does not change significantly in additive concentration after the infusion process. Consequently, the infusing liquid can be re-used in multiple infusion processes until it is completely consumed leading to zero waste.
For example, in one embodiment, the present disclosure is directed to a process for incorporating an additive into an aerosol-producing filler. The process includes combining the aerosol-producing filler with an infusing liquid. The infusing liquid comprises the additive dissolved in a solvent. The solvent, for instance, can be an alcohol or acetone. In one particular aspect, the solvent is ethanol. In accordance with the present disclosure, the aerosol-producing filler and infusing liquid mixture are subjected to pressures sufficient to cause the additive to infuse into the aerosol-producing filler. After infusion, the aerosol-producing filler is dried causing the solvent to evaporate and leaving behind the additive uniformly dispersed within the material.
As described above, after the infusion process, the infusing liquid can be re-used in further infusion processes. The additive concentration in the infusing liquid does not change by more than about 5% between each infusing cycle. Thus, the infusing liquid can be subjected to multiple infusing cycles with new substrate until the infusing liquid is completely consumed.
The process of the present disclosure can be used to incorporate all different types of additives into the aerosol-producing filler. In one embodiment, for instance, the additive can be a cannabinoid. For example, the additive can be cannabidiol. Other cannabinoids that can be incorporated into the aerosol-producing filler include cannabichromene, cannabinol, cannabigerol, tetrahydrocannabivarin, cannabidivarin, cannabidiolic acid, or mixtures thereof. In still another embodiment, the additive can be tetrahydrocannabinol.
Other additives that can be incorporated into the aerosol-producing filler of the present disclosure include flavorings and casings. Exemplary additives include a sugar, a licorice extract, honey, a coffee extract, maple syrup, a tea extract, a botanical extract, a plant extract, a tobacco extract, or a fruit extract. The additive can also comprise one or more terpenes.
The process of the present disclosure is not only efficient but can incorporate additives into the aerosol-producing filler in relatively great amounts. For example, in one embodiment, the additive, such as a cannabinoid, can be incorporated into the aerosol-producing filler in an amount greater than about 3.1% by weight, such as in an amount greater than about 3.3% by weight, such as in an amount greater than about 3.5% by weight, and generally less than about 70% by weight, such as less than about 50% by weight.
The aerosol-producing filler treated in accordance with the present disclosure can comprise any suitable material. For example, the aerosol-producing material can be a tobacco, a cannabis material, a botanical material, or mixtures thereof. The aerosol-producing material can also comprise a reconstituted material made from any of the plant materials described above.
In one particular embodiment, the process of the present disclosure can be used to incorporate a cannabinoid, such as cannabidiol, into a tobacco and/or hemp material.
In one embodiment, during the process of the present disclosure, the aerosol-producing filler is immersed or submerged in the infusing liquid. After being subjected to a pressure sufficient to cause the additive to infuse into the aerosol-producing filler, the aerosol-producing filler can be dried.
In one aspect, the additive can be incorporated into the aerosol-producing filler without the use of an oil. For instance, the resulting aerosol-producing filler can be oil-free.
The present disclosure is also directed to an aerosol-producing material containing an additive. The aerosol-producing material comprises an aerosol-producing filler comprising a strip, strips, shreds, or mixtures thereof. In accordance with the present disclosure, an additive is infused into the aerosol-producing filler and may comprise, for instance, a cannabinoid, such as cannabidiol. The additive can be present in the aerosol-producing filler in an amount greater than about 3.1% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 70% by weight. The aerosol-producing filler can comprise a tobacco or a cannabis.
Other features and aspects of the present disclosure are discussed in greater detail below.
A full and enabling disclosure of the present disclosure is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present invention.
As used herein, a “reconstituted plant material” refers to a material formed by a process in which a plant feed stock, such as cocoa shells, tobacco or reconstituted tobacco, herbal plants, cannabis and/or hemp, for example, is extracted with a solvent to form an extract of solubles, such as water solubles, and an extracted insoluble portion or residue comprising fibrous material. The extracted and insoluble fibrous material is then formed into a sheet or web through any suitable process and the extract may either be discarded or reapplied to the formed sheet. The extract can be fed through various processes for concentrating the extract and optionally removing or adding various components prior to being recombined with the fibrous material. In the present disclosure, the reconstituted material is formed from extracted plant fiber fibers optionally combined with web building fibers, such as delignified cellulose fibers. The extract of solubles obtained from the plant fiber fibers is optionally reapplied to the sheet.
As used herein, an “aerosol-producing material” is meant to include both a combustible material that undergoes combustion in a smoking article and to an aerosol-forming material that is heated but not combusted to form an inhalable aerosol. Combustible smoking articles can include cigarettes, cigarillos and cigars. In a cigarette, the aerosol-producing material is generally surrounded by a wrapping material to form a smokable rod, but may also be included in the wrapping material itself. Aerosol-producing devices for generating an aerosol include, for instance, devices in which an aerosol is generated by electrical heating or by the transfer of heat from a combustible fuel element or heat source to heat but not burn the aerosol generating material, which releases volatile compounds. As the released compounds cool, they condense to form an aerosol that is inhaled by the consumer. In one embodiment, the aerosol-producing material is a filler that can be in the form of a strip, strips, shreds, or mixtures thereof.
As used herein, “cannabis” may refer to any variety of the Cannabis plant, such as Cannabis sativa or Cannabis indica, for instance. More particularly, the present disclosure may refer to leaves, stems, seeds and flowers or any other part of the Cannabis plant, as cannabis. Nonetheless, cannabis, as referred to herein, includes cannabis that contains average or high levels of THC and/or CBD (usually known as marijuana), hemp, which may contain low, or very low, levels of THC, industrial hemp, which may refer to a cannabis plant that contains less than 0.3% THC, or combinations thereof.
As used herein, “extracted plantfibers”, such as extracted hemp fibers, tobacco fibers or the like refer to plant fibers that have been subjected to an extraction process in which the plant fibers has been contacted with an aqueous solution to remove water soluble components contained in the fibers. The extraction process is different from a delignification process and from a bleaching treatment.
As used herein, “delignified” cellulosic fibers (e.g. pulp fibers) refers to fibers that have been subjected to a pulping or delignification process by which the cellulose fibers are separated from the plant material through chemical means, mechanical means, or through a combination of chemical and mechanical means.
As used herein, the term “refine” is used to mean that the plant material is subjected to a mechanical treatment that modifies the fibers of the material so that they are better suited to forming a fibrous sheet or substrate. Refining can be accomplished using a conical refiner, a disk refiner or a Valley beater. The mechanical process exerts an abrasive and bruising action on the plant material such that the plant material is deformed and declustered. Refining is a different process than delignification and pulping.
As used herein, the “amount of water soluble extracts” present in a substrate or reconstituted plant material or in an aerosol generating material is determined by placing 5 grams of a sample in boiling distilled water for 10 minutes to obtain an extract containing water soluble components. The weight of dry matter of the extract that is soluble in the solvent is calculated by the difference between the dry weight of the sample and the dry weight of the sample after extraction. The difference in dry weight is then used to determine the percentage of water soluble extracts in the sample.
It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present disclosure.
The present disclosure is generally directed to a process for incorporating additives into aerosol-producing substrates, such as aerosol-producing fillers that are used in smoking articles, heat but not burn sticks, and the like. In accordance with the present disclosure, one or more additives are infused into the aerosol-producing substrate while under vacuum or being subjected to reduced pressures. All different types of additives can be incorporated into the aerosol-producing substrate. For instance, the additive can be a flavoring, a casing, a terpene, a pharmaceutical agent, an aroma agent, or the like. In one embodiment, the additive is a cannabinoid, such as a cannabinoid that can be extracted from cannabis or hemp plants. The cannabinoid, in one aspect, can be cannabidiol (CBD).
The process of the present disclosure offers various advantages and benefits. For instance, the process is well suited to incorporating an additive into an aerosol-producing substrate in a uniform manner. For example, the concentration of the additive throughout the aerosol-producing substrate can be relatively the same and exhibit concentration variations of less than about 5%, such as less than about 2%, such as less than about 1%, such as less than about 0.25% by weight. The process of the present disclosure is also very efficient. Additives can be incorporated into aerosol-producing substrates not only uniformly but very quickly. For example, in one embodiment, the process can take less than about 15 minutes, such as less than about 10 minutes, such as even less than about 5 minutes in order to incorporate the additive into the material.
The process of the present disclosure also allows for precise control over the amount of additive incorporated into the aerosol-producing substrate. For example, the additive concentration within the resulting material can be easily adjusted and controlled according to the process with a high degree of efficacy, especially in relation to conventional methods where additives were simply sprayed onto the material.
In addition, additives can be incorporated into the aerosol-producing substrate without waste. Many additives, for instance, are relatively expensive and various benefits are obtained if waste is minimized. For example, the infusing liquid containing the additive, in one embodiment, does not significantly change in additive concentration after the infusion process. Consequently, infusing liquid left over from an infusion can be re-used in a new infusion process without any modifications. In this manner, the infusing liquid can be used in multiple infusion cycles until completely exhausted. The additive added to the infusing liquid is completely consumed, ending up in the final product. The number of infusion cycles needed to consume the infusing liquid can depend on various factors. For example, an infusing liquid can be re-used in from about 3 to about 8 different infusing cycles in one embodiment.
In general, the process of the present disclosure involves contacting an aerosol-producing material with an infusing liquid that contains an additive. The resulting liquid and solid mixture is then subjected to reduced pressures that cause the infusing liquid to impregnate or infuse into the aerosol-producing material. For example, by reducing the pressure, air and other gases contained within the aerosol-producing material are displaced by the infusing liquid. The aerosol-producing material is then dried in order to remove any solvents leaving behind the additive contained within the aerosol-producing material.
For example, referring to
The infusing liquid 32 can contain various different components depending upon the particular application and the desired result. In one aspect, the infusing liquid 32 includes one or more additives dissolved in a solvent. The solvent, for instance, can be a liquid having a relatively low boiling point. For instance, the solvent can have a boiling point of less than about 120° C., such as less than about 100° C., such as less than about 80° C., such as less than about 60° C. The boiling point of the solvent is generally greater than about 40° C. Examples of solvents that can be used include one or more alcohols, acetone, or mixtures thereof. In one particular embodiment, the solvent is ethanol.
The additive contained in the infusing liquid can vary depending upon the particular application. In one aspect, the additive can be dissolved in the infusing liquid. After infusion, the solvent can be evaporated from the aerosol-generating filler 12 leaving the additive within the material. Alternatively, the additive can be a liquid that is miscible or immiscible within the solvent. The additive, for instance, can be a liquid having a higher boiling point than the solvent. Thus, the solvent can be evaporated from the aerosol-producing filler leaving behind the additive.
Examples of additives that can be incorporated into the aerosol-producing filler include flavorings, casings, pharmaceutical agents, aroma agents, and mixtures thereof.
In one embodiment, for instance, the additive can be derived from cannabis plants. For example, the additive can be a cannabinoid.
Cannabinoids that can be incorporated into the aerosol-producing filler of the present disclosure include cannabidiol (CBD) and tetrahydrocannabinol (THC). THC contained in cannabis acts on specific receptors in the brain which lead to a feeling of euphoria and a relaxed state. CBD, on the other hand, also interacts with pain receptors in the brain but does not create the same euphoric feeling caused by THC. In accordance with the present disclosure, in one embodiment, THC can be applied to the aerosol-producing filler of the present disclosure, CBD can be applied to the aerosol-producing filler or, alternatively, both THC and CBD can be applied to the aerosol-producing filler.
In addition to THC and CBD, various other cannabinoids can also be incorporated into an infusing liquid and applied to the aerosol-producing filler in accordance with the present disclosure. For instance, other cannabinoids contained in cannabis include cannabichromene, cannabinol, cannabigerol, tetrahydrocannabivarin, cannabidivarin, cannabidiolic acid, other cannabidiol derivatives, and other tetrahydrocannabinol derivatives. The above cannabinoids can be used singularly or in any combination and applied to the aerosol-producing filler.
When incorporating a cannabinoid into the aerosol-producing filler, in one embodiment, the cannabinoid can be a solid that is dissolved in a solvent to form the infusing liquid. For example, in one aspect, cannabidiol particles can be dissolved in ethanol. The particles dissolved in the solvent can be relatively small in order to facilitate the formation of a solution. For example, the additive particles can have an average particle size of less than about 2 microns, such as less than about 1 micron, such as less than about 0.5 microns, such as less than about 0.1 micron. The average particle size, for instance, can generally be greater than about 20 nm, such as greater than about 50 nm.
In one aspect, the infusing liquid only contains a solvent and the additive dissolved in the solvent. In other embodiments, however, the additive can be combined with the solvent in conjunction with other components. For example, in one embodiment, the additive, such as a cannabinoid, can be contained in an emulsion that then is combined with the solvent. The emulsion, for instance, can contain one or more emulsifiers and water. Emulsifiers that may be used include esters of fatty acids, such as triglycerides. Other emulsifiers that may be used include one or more polysorbates. For instance, the polysorbate may be polyoxyethylene (20) sorbitan monooleate. Typically, however, emulsifiers and water are present in the infusion liquid in minor amounts compared to the amount of solvent present, such as in amounts (total) less than about 10% by weight, such as in amounts less than 5% by weight, such as in amounts less than 1% by weight.
In one aspect, the infusing liquid is formulated to be oil-free. For instance, the infusing liquid can be free of hydrocarbon oils. Oils that can be absent from the infusing liquid, for instance, include animal oils, vegetable oils, and/or petroleum-derived oils. Such oils can include, for instance, cannabis oil, olive oil, sunflower oil, corn oil, essential oils, coconut oil, almond oil, black seed oil, and the like. In other embodiments, the above oils may be present and infused into the substrate.
In addition to cannabinoids, various other additives can also be incorporated into the aerosol-producing filler. For example, other additives that can be incorporated into the filler include nicotine, corn syrup, sugars, licorice extracts, menthol, honey, coffee, maple syrup, tobacco extracts, botanical extracts, plant extracts, tea, fruit extracts, flavorings such as clove, anise, cinnamon, sandalwood, geranium, rose oil, vanilla, caramel, cocoa, lemon oil, cassia, spearmint, fennel, or ginger, fragrances or aromas such as cocoa, vanilla, and caramel, medicinal plants, vegetables, spices, roots, berries, bar, seeks, essential oils and extracts thereof, such as anise oil, clove oil, carvone and the like, artificial flavoring and fragrance materials such as vanillin, and mixtures thereof.
Another additive that can be incorporated into the aerosol-producing filler is one type of flavoring known as a terpene and/or a terpenoid. A terpene or a blend of terpenes, for instance, can be used to develop desirable aromas and indicate to the user the quality of the product. One or more terpenes can also improve the sensory reaction to inhaling an aerosol created by the aerosol-producing filler.
Various different terpenes can be applied to the aerosol-producing filler. Such terpenes include but are not limited to pinene, humulene, b-caryophyllene, isopulegol, guaiol, nerylacetate, neomenthylacetate, limonene, menthone, dihydrojasmone, terpinolene, menthol, phellandrene, terpinene, geranylacetate, ocimene, myrcene, 1,4-cineole, 3-carene, linalool, menthofuran, perillyalcohol, pinane, neomenthylaceta, alpha-bisabolol, borneol, camphene, camphor, caryophyllene oxide, alpha-cedrene, beta-eudesmol, fenchol, geraniol, isoborneol, nerol, sabinene, alpha-terpineol, and mixtures thereof.
In one embodiment, various different terpenes can be blended together in order to mimic the ratios of terpenes found in natural cannabis plants. For instance, from about 2 to about 12 terpenes can be blended together and applied to the aerosol-producing filler.
Exemplary blends of terpenes include alpha-pinene, beta-caryophyllene, and beta-pinene; alpha-humulene, alpha-pinene, beta-caryophyllene, beta-pinene, and guaiol; beta-caryophyllene, beta-pinene, and d-limonene; beta-caryophyllene, beta-pinene, and nerolidol; beta-caryophyllene, beta-pinene, d-limonene, and terpinolene; alpha-bisabolol, alpha-pinene, beta-caryophyllene, beta-myrcene, beta-pinena, and d-limonene; beta-caryophyllene, beta-pinena, and p-cymene; alpha-humulene, beta-caryophyllene, beta-pinene, d-limonene, linalool, and nerolidol; beta-caryophyllene and beta-pinene; beta-caryophyllene, beta-myrcene, and terpinolene; alpha-pinene, beta-caryophyllene, beta-pinene, d-limonene; alpha-humulene, alpha-pinene, beta-caryophyllene, beta-myrcene, beta-pinena, d-limonene, and guaiol.
Once the infusing liquid is formulated, the infusing liquid 32 is combined with the aerosol-producing filler 12. As shown in
For example, in one embodiment, the infusing liquid and filler mixture are added to the degassing chamber 30 and sealed. The vacuum pump 38 is then designed to reduce the pressure within the vessel 34. For example, in one aspect, for instance, the vacuum pump 38 is used to maintain an atmosphere within the vessel 34 at a pressure of less than about 700 mmHg, such as less than about 650 mmHg, such as less than about 600 mmHg, such as less than about 550 mmHg, such as less than about 500 mmHg, such as less than about 450 mmHg. The pressure can generally be greater than about 250 mmHg, such as greater than about 350 mmHg, such as greater than about 450 mmHg, such as greater than about 550 mmHg. In one aspect, the pressure within the degassing chamber 30 during the process can be from about 600 mmHg to about 670 mmHg.
Reducing the pressure within the degassing chamber 30 causes air and other gases contained within the aerosol-producing filler 12 to be released and replaced with the infusing liquid 32. The infusing liquid and filler mixture can be subjected to lower pressures for a relatively short amount of time. For instance, the infusing process can take less than about an hour, such as less than about 30 minutes, such as less than about 20 minutes, such as less than about 10 minutes, such as less than about 8 minutes, such as less than about 5 minutes, such as even less than about 3 minutes. The infusing time is generally greater than about 30 seconds, such as greater than about one minute.
One advantage of the process of the present disclosure is that the infusing process can occur at reduced pressure but at ambient temperature. Thus, the infusing liquid 32 can be infused into the aerosol-producing filler 12 without having to use heat or subjecting the mixture to higher temperatures. Higher temperatures, for instance, can cause some additives to degrade. Thus, the infusing process can occur at a temperature of less than about 50° C., such as less than about 40° C., such as less than about 30° C., and generally greater than about 10° C., such as greater than about 20° C. In one aspect, the infusion process occurs at a temperature of from about 20° C. to about 28° C.
Once the infusing liquid and filler mixture are subjected to lower pressures, the degassing chamber 30 can be restored to atmospheric pressure and the infusing liquid 32 and aerosol-producing filler 12 can be separated. For example, in one embodiment, the infusing liquid 32 can be drained from the degassing chamber 30 using a liquid outlet 40. The infused aerosol-producing filler 12 can then be removed from the degassing chamber 30 and dried. The filler 12 can be removed from the degassing chamber 30 manually or using any suitable automated machinery or conveyor.
Of particular advantage, the infusing liquid 32 drained from the degassing chamber 30 can be reused on future batches of filler. For instance, as shown in
Once the aerosol-producing filler 12 is removed from the degassing chamber 30, the filler can be dried using any suitable method or process. For instance, the filler 12 can be air-dried or dried using heated air. The temperature to which the filler 12 is heated during drying can depend upon the additive contained in the filler in order to prevent degradation. In one embodiment, the aerosol-producing filler 12 is conveyed through an oven and dried while being subjected to a temperature that does not degrade the additive or the filler. The temperature, for instance, in one embodiment, can be less than about 200° C., such as less than about 150° C. Alternatively, the filler can be dried at a temperature of less than about 100° C., such as less than about 80° C. In still another embodiment, the filler can be dried at a temperature of from about 23° C. to about 45° C.
The amount of additive contained in the aerosol-producing filler 12 can vary depending upon various factors including the type of additive being incorporated into the filler and the desired result. In one aspect, the amount of additive contained in the infusing liquid 32 can generally match the amount of additive incorporated into the aerosol-producing filler 12. Alternatively, the aerosol-producing filler 12, can contain the additive after the infusion process at a concentration that is greater than the concentration of the additive in the infusing liquid. In general, the additive can be contained in the infusing liquid in an amount from about 0.01% by weight to about 90% by weight including all increments of 0.5% by weight therebetween.
When incorporating a cannabinoid into the aerosol-producing filler, for instance, the infusing liquid can contain the cannabinol in an amount greater than about 0.25% by weight, such as in an amount greater than about 0.5% by weight, such as in an amount greater than about 1% by weight, such as in an amount greater than about 1.5% by weight, such as in an amount greater than about 2% by weight, such as in an amount greater than about 2.5% by weight, such as in an amount greater than about 3% by weight, such as in an amount greater than about 3.5% by weight, such as in an amount greater than about 4% by weight, such as in an amount greater than about 5% by weight, such as in an amount greater than about 6% by weight, such as in an amount greater than about 8% by weight, such as in an amount greater than about 10% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 40% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 60% by weight, such as in an amount greater than about 70% by weight. The infusing liquid can contain one or more cannabinoids generally in an amount less than about 80% by weight, such as in an amount less than about 70% by weight, such as in an amount less than about 50% by weight, such as in an amount less than about 20% by weight, such as in an amount less than about 10% by weight. The amount that one or more cannabinoids can be incorporated into the aerosol-producing filler, as described above, can generally have the same ranges as described above. For instance, the resulting dried aerosol-producing filler can contain one or more cannabinoids in an amount generally greater than about 0.25% and generally in an amount less than about 80% by weight. In one particular embodiment, one or more cannabinoids, such as cannabidiol, can be incorporated into the aerosol-producing filler in an amount greater than about 3.1% by weight, such as in an amount greater than about 3.3% by weight, such as in an amount greater than about 3.5% by weight, such as in an amount greater than about 4% by weight, such as in an amount greater than about 10% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 40% by weight, such as in an amount greater than about 50% by weight. The one or more cannabinoids can be incorporated into the aerosol-producing filler generally in an amount less than about 70% by weight, such as in an amount less than about 50=% by weight, such as in an amount less than about 10% by weight, such as in an amount less than about 8% by weight, such as in an amount less than about 5% by weight.
When incorporating a flavoring or a casing into the aerosol-producing filler, the amount of flavoring or casing contained in the infusing liquid and contained in the resulting filler can generally be from about 0.05% by weight to about 70% by weight. One or more terpenes can be incorporated into the aerosol-producing filler at relatively low amounts. In this regard, the infusing liquid and the resulting filler can contain one or more terpenes in an amount less than about 2% by weight, such as less than about 1.5% by weight, such as less than about 1% by weight, such as less than about 0.5% by weight. One or more terpenes can be incorporated into the filler, for instance, in an amount from about 0.1% by weight to about 1.2% by weight.
Other flavorings can be incorporated into the infusing liquid and into the resulting filler generally in an amount from about 0.1% by weight to about 70% by weight. For example, one or more flavorings can be incorporated into the filler in an amount greater than about 0.5% by weight, such as in an amount greater than about 1% by weight, such as in an amount greater than about 1.5% by weight, such as in an amount greater than about 2% by weight, and generally less than about 50% by weight, such as less than about 10% by weight.
Referring to
Tobacco materials for use in the present disclosure, for instance, may include cut leaf tobacco, cast leaf tobacco, a reconstituted tobacco material, or mixtures thereof. The tobacco material may include tobacco hurds, stalks, leaves, as well as scraps.
Cannabis materials for use in the present disclosure include hurds, buds, flowers, seeds, and any by-products of cannabis extraction, such as cannabis residues, THC, and CBD, and optionally stalk components. In one embodiment, the cannabis components are obtained from cannabis plants that have a relatively low THC and/or CBD content. For instance, the amount of THC in the cannabis components can be less than about 1% by weight THC, such as less than about 0.3% by weight THC, such as less than about 0.2% by weight THC, such as less than about 0.1% by weight THC. Using cannabis components from low THC plants can offer various advantages and benefits. Selecting a cannabis material low in THC, for instance, allows for better control over THC deliveries when the THC is applied to the material. In addition, a reconstituted material can be produced that contains no detectable amounts of THC so that the material can deliver other active agents, such as CBD, flavorants, nicotine, or the like. It should be understood, however, that in other embodiments the reconstituted cannabis material can be made from high THC or CBD containing plants, such as from the species Cannabis Indica or Cannabis Sativa.
The cannabis material (which can be a reconstituted material) of the present disclosure can be produced from various parts of the cannabis plant, including the hurds, leaves, buds, and flowers. These different parts of the plant can be combined in different ratios and amounts depending upon the particular application and the desired result. Although the cannabis material can be made exclusively from cannabis leaves and hurds or can be made exclusively from cannabis buds and flowers, in one embodiment, the material is made from a mixture of leaves and hurds combined with buds and/or flowers. For example, in one embodiment, the weight ratio between the leaves and hurds and the buds and/or flowers is from about 1:8 to about 8:1, such as from about 1:5 to about 5:1, such as from about 1:4 to about 4:1, such as from about 2:1 to about 1:2. In one embodiment, the ratio can be about 1:1.
In one embodiment, the cannabis material may contain cannabis leaves and hurds in an amount greater than about 10% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 30% by weight, and generally in an amount less than about 70% by weight, such as in an amount less than about 60% by weight, such as in an amount less than about 50% by weight, such as in an amount less than about 40% by weight. Similarly, the cannabis material may contain buds and/or flowers in an amount greater than about 10% by weight, such as in an amount greater than about 20% by weight, such as in an amount greater than about 30% by weight, such as in an amount greater than about 40% by weight, such as in an amount greater than about 50% by weight, such as in an amount greater than about 60% by weight, and generally in an amount less than about 80% by weight, such as in an amount less than about 70% by weight, such as in an amount less than about 60% by weight, such as in an amount less than about 50% by weight.
In one embodiment, the aerosol-producing filler 12 contains cocoa materials. Cocoa materials for use in the present disclosure are obtained from Theobroma cacao, which is also referred to as the cacao tree. The cacao tree is in the evergreen family and is native to tropical regions. The cacao tree produces a fruit, referred to as a cacao pod. Cacao pods are generally yellow to orange in color and can weigh over one pound when ripe. The pod contains anywhere from 10 to about 80 cocoa beans that are used to produce chocolate, juices, jelly, and the like. After the beans are removed from the cacao pod, the cocoa beans are dried and cured or fermented by being exposed to sunlight and/or ultraviolet light. Each individual bean is covered in a husk or shell. The husk or shell is removed from the bean prior to using the bean for producing food products. The plant material of the present disclosure is made from the cocoa shells or husks, although other components of the cacao pod may also be used.
Other botanical plant materials for use in the present disclosure include herbs, plants and trees that may be used to form an aerosol-producing filler. The materials may be obtained from a coffee tree or coffee bean, tea tree or tea leaf, vine, ginger, ginkgo, chamomile, tomato, ivy, mate, rooibos, cucumber, mint, a cereal such as wheat, barley or rye, or other trees such as broadleaved or resinous trees, and the like, as well as combinations thereof.
Once the aerosol-producing filler 12 as shown in
Various different humectants can be incorporated into the aerosol-producing filler. The humectant, for instance, may comprise glycerol, propylene glycol, or mixtures thereof. Other humectants that may be used include sorbitol, triethylene glycol, lactic acid, glyceryl diacetate, glyceryl triacetate, triethyl citrate, isopropyl myristate, and mixtures thereof including mixtures with glycerol and/or propylene glycol.
As described above, the amount of humectant applied to the aerosol-producing filler can depend upon various factors. In one embodiment, for instance, the humectant is present on the aerosol-producing filler in an amount less than about 5% by weight, such as in an amount less than about 3% by weight, and generally in an amount greater than about 0.5% by weight, such as in an amount greater than about 1% by weight. In other embodiments, the humectant may be present on the aerosol-producing filler in an amount greater than about 5% by weight, such as in an amount greater than about 10% by weight, such as in an amount greater than about 15% by weight, such as in an amount greater than about 20% by weight, and generally in an amount less than about 50% by weight, such as in an amount less than about 40% by weight, such as in an amount less than about 30% by weight, such as in an amount less than about 25% by weight. When added to the aerosol-producing filler in an amount from about 10 to 40% by weight, such as in an amount from about 12 to about 30% by weight, such as in an amount from about 15 to about 25% by weight, the humectant serves as an aerosol generating agent that facilitates formation of an aerosol when the aerosol-producing filler is heated without being combusted.
The aerosol-producing filler of the present disclosure may also optionally contain filler particles. Filler particles that may be incorporated into the aerosol-producing filler can be made from calcium carbonate, magnesium oxide, titanium dioxide, kaolin clay, barium sulfate, a silicate, bentonite, mica, or mixtures thereof. Filler particles can optionally be incorporated into the aerosol-producing filler in an amount greater than about 1% by weight, such as in an amount greater than about 5% by weight, such as in an amount greater than about 10% by weight, and generally in an amount less than about 30% by weight, such as in an amount less than about 25% by weight, such as in an amount less than about 20% by weight, such as in an amount less than about 15% by weight.
Once the aerosol producing filler has been formed into a fibrous substrate, the material can be used as an aerosol generating material for use in any suitable smoking article or in a device that heats but does not combust the material.
For instance, the smoking article shown in
Filler material made in accordance with the present disclosure can have a filling power of greater than about 4 cm3/g, such as greater than about 5 cm3/g, such as greater than about 6 cm3/g, and generally less than about 10 cm3/g, such as less than about 8 cm3/g. The aerosol-producing filler can have excellent burn properties. For instance, the aerosol-producing filler can have a static burn rate of greater than about 4 mm/mm, such as greater than about 5 mm/mm, and generally less than about 8 mm/mm, such as less than about 7 mm/mm.
The aerosol-producing filler of the present disclosure can be used in all different types of aerosol generating products. In one embodiment, for instance, the aerosol generating material of the present disclosure can be formed into a smokable rod and surrounded by an outer wrapper as shown in
In addition to cigarettes, aerosol generating materials made according to the present disclosure can also include cigars and cigarillos. In another embodiment, the filler can be used in heat but not burn applications.
The aerosol-producing filler of the present disclosure can also be used to produce a snuff product and/or Shisha fillers. The snuff product can be a dry product or can contain substantial amounts of moisture.
When producing a snuff product, the product can be made exclusively from the aerosol-producing filler of the present disclosure or can be formed from the aerosol-producing filler of the present disclosure blended with other filler materials.
In order to form a snuff product, the aerosol-producing filler of the present disclosure is ground or cut to a desired size. For instance, the particle size can be relatively small or can be made into strips depending upon the end use application. In one aspect, for instance, the material is cut or ground so as to have an average particle size of greater than about 50 microns, such as greater than about 100 microns, and generally less than about 3 mm, such as less than about 2 mm. Alternatively, the material can be ground into a powder or a granular material wherein the average particle size is less than about 100 microns.
In one aspect, the filler can be placed in an oral pouch that is intended for use in the oral cavity, such as by placing the pouch between the upper and lower gum of the lip or cheek. The oral pouched product may have an oblong shape, such as a rectangular shape. The total weight of the oral pouch can generally be in the range of from about 0.1 g to about 2.5 g, such as from about 0.2 g to about 0.8 g. The pouch can be made of any suitable saliva-permeable pouch material, such as a nonwoven. A binder may be included in the pouch to facilitate sealing of the material by ultrasonic welding. The binder, for instance, can be an acrylate polymer. In one aspect, the pouch can be formed from a nonwoven material containing regenerated cellulose fibers, such as viscose rayon staple fibers and a binder. If desired, the pouch material may also contain additional flavoring agents and/or colorants.
The present disclosure may be better understood with reference to the following examples.
A 2.5% by weight CBD isolate solution was combined with ethanol and then infused into a hemp filler. The CBD particles contained in the solution had an average particle size of less than about 100 nm. The 2.5% by weight CBD solution was diluted by a factor of 10 in ethanol to make a 100 mL solution with a concentration of 0.25% by weight CBD. The following process was followed in order to infuse the material into the hemp filler.
10 g of hemp fillers were submerged in a plastic bag that contained the 0.25% CBD solution; the contents were thoroughly mixed by shaking the bag with its contents.
The bag was sealed and placed in the vacuum chamber for 10 minutes at 25 inHg. The bag was then removed after 5 minutes to mix the fillers around, then placed in the chamber for another 5 minutes to complete the infusion.
When the infusion had been completed, the solution was drained out and the fillers were placed on a mesh wire and left to dry at room temperature for 24 hours.
Once the 10 g of infused hemp fillers were completely dry, they were divided into 7 samples of equal mass and tested for CBD content analysis.
The results obtained showed that the 0.25% CBD isolate solution used for the infusion had a concentration of 0.20%.
Hemp raw material had an average value of 0.27% of CBD.
The following results were obtained:
Hemp plant naturally contains CBD and the amount of CBD in the raw material varies. To avoid any variations in the CBD levels in the raw material, a more controlled method is needed to ensure reproducibility. Tobacco naturally contains no CBD and can be considered a control. In the next tests tobacco and hemp fillers were infused side by side under the same conditions, where the results for both materials could be compared.
Reagent Alcohol from Fisher Scientific
CBD Isolate provided by CraftAg
Vacuum chamber
Vacuum pump
Tobacco fillers
Hemp Fillers
A solubility test was performed on the CBD Isolate provided by CraftAg by dissolving 0.5 grams of CBD isolate in 5 mL of ethanol. This CBD Isolate was highly soluble in ethanol and it was used for all the infusion tests.
Two infusions were performed side by side. The first infusion was of a hemp filler and the second was of a tobacco filler.
Five samples of hemp raw material were tested for CBD content analysis.
Two separate CBD solutions were prepared by dissolving 3 g of CBD isolate in 97 g of reagent alcohol to create a solution with a target concentration of 3% w/w.
8 g (per infusion) of hemp fillers/tobacco fillers were submerged in separate plastic bags that contained the 3% CBD solution.
The bags were sealed, and the contents were thoroughly mixed by shaking the bags with its contents and then they were placed in the vacuum chamber for 10 minutes at 25 inHg.
Once the infusion had been completed, the solution was drained out and the fillers were placed on a mesh wire and left to dry at room temperature for 24 hours.
Once the infused fillers were completely dry, both the hemp filler and tobacco filler samples were each divided into 7 samples of equal mass and tested for CBD content analysis.
CBD analyses were done on the solutions before they were used for the infusion and after they were used to see if there were any changes in the concentrations.
Average CBD content in hemp raw material measured to be 0.30%.
The CBD solution used to infuse hemp fillers had a concentration of 3.07%, confirming that the preparation procedure was accurate.
The average CBD % added to the infused hemp fillers was 3.40%. Since the CBD solution used for this infusion had a concentration of 3.07% CBD, this means the hemp fillers picked up 110.7% of the CBD in the solution.
The concentrations of the CBD solutions before and after the infusion were almost the same.
The solution used to infuse tobacco fillers had a concentration of 3.10%.
Since the starting CBD solution was 3.10% CBD, and the average CBD % added to the infused tobacco fillers was 3.88%, this means the hemp fillers picked up 125.2% of the CBD in the original solution.
The concentrations of the CBD solutions before and after the infusion were almost the same.
Additional infusion tests were done on tobacco and hemp filler to ensure results are reproducible.
Two hemp infusions were performed side by side along with one tobacco infusion.
Three separate CBD solutions were prepared based on w/w. One solution had a target concentration of 3.6%, and the other two solutions had a target concentration of 3.3%. These solutions were placed in three separate plastic bags.
8 g (per infusion) of hemp fillers were submerged into two plastic bags that contained the CBD solutions of target concentration of 3.3% and 3.6%.
8 g of tobacco fillers were submerged into the third plastic bag that contained the CBD solution of target concentration of 3.3%.
The bags were sealed, and the contents were thoroughly mixed by shaking the bag with its contents and placing it in the vacuum chamber for 10 minutes at 25 inHg (two bags of hemp were infused at the same time).
Once the infusions had been completed the solutions were drained out and the fillers were placed on a mesh wire and left to dry at room temperature for 24 hours.
Once the infused fillers were completely dry, they were divided into 6 samples of equal mass and tested.
Six samples of hemp raw material were also tested.
CBD analyses were done on the solutions before they were used for the infusions and after they were used to see if there were any changes in the concentrations.
Average CBD content in hemp raw material measured to be 0.26%.
The solution used for the first hemp infusion showed to have a concentration of 3.62%, and the added CBD on the infused hemp filler had an average concentration of 3.40%, resulting in an average of 94.0% CBD added to hemp fillers when compared to the original solution.
The solution used for the second hemp infusion showed to have a concentration of 3.23%, and the added CBD on the infused hemp filler had an average concentration of 3.07%, resulting in an average of 95.0% CBD added to hemp fillers when compared to the original solution.
The CBD solution used to infuse tobacco fillers had a concentration of 3.29%. The infused tobacco filler had an average concentration of 4.30%, resulting in an average of 130.7% CBD added to tobacco fillers when compared to the original solution.
Additional tests were performed on hemp and tobacco fillers to determine the CBD add on range on fillers.
Two infusions on hemp filler were performed at the same time following the procedure in section 2.6.1. Each infusion had 8 g of material that was infused with CBD solution with concentrations of 3.77%, each infused material was divided into 13 subsamples and tested.
One infusion on tobacco filler was performed following the procedure in section 2.6.1. The sample had 8 g of material that was infused with 4.35% CBD solution, the infused material was divided into 14 subsamples and sent for analysis.
Two additional experiments were done to determine how much CBD can be added to the hemp fillers if the material was soaked in 4.35% CBD solution without applying any vacuum.
Average CBD content in hemp raw material measured to be 0.32%.
The average CBD % added to the infused hemp filler from the two infusions was 3.85%, resulting in an average of 102.4% CBD added to hemp fillers when compared to the original solution of 3.77% CBD.
The average CBD % added to the infused tobacco filler was 5.01% from a solution of 4.35% CBD resulting in an average of 115.2% CBD added to tobacco fillers.
The average CBD % for the soaked hemp filler was 3.47% from a CBD solution of 4.35% CBD, resulting in an average of 79.8% CBD added to hemp fillers when compared to the original solution.
These and other modifications and variations to the present invention may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present invention, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged both in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only and is not intended to limit the invention so further described in such appended claims.
The present application is based on and claims priority to U.S. Provisional Patent Application Ser. No. 63/191,541, filed on May 21, 2021, which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63191541 | May 2021 | US |
