Rectangular Loose-leaf System and Method of Use

Abstract

A rectangular loose-leaf system is described, including extracting the best parts of a leaf such as tobacco and storing them to be rolled at a later time. Sheets are cut from the larger leaf so that large stems are not in the sheets. The sheets are selected so that no tears, damage, rot, or other defects are present. The sheets could be stacked and protected before storage. A rectangular loose-leaf wrapper includes a tobacco loose-leaf sheet that is rectangular in shape and substantially flat, where the tobacco loose-leaf sheet is removed from a portion of a tobacco leaf that does not have a central stem and the loose-leaf sheet has at least one primary vein running parallel to a length of the sheet. The sheets has been flattened by a process that removes predisposition to curl.

Description

This application claims the benefit of co-pending U.S. application Ser. No. 18/054,124 filed Nov. 9, 2022. These and all other referenced extrinsic materials are incorporated herein by reference in their entirety. Where a definition or use of a term in a reference that is incorporated by reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein is deemed to be controlling.

FIELD OF THE INVENTION

The field of the invention relates generally to smoking systems and methods, and more specifically, to a flat and rectangular loose-leaf wrapper.

BACKGROUND

The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

Inhalatory systems are well known in the art and are effective means to prepare and facilitate the ingestion of smoke that results from the combustion of a material selected to be combusted and inhaled. Common inhalatory systems include cigarettes, cigars, vaporizers, and the like. For example, cigars are formed from rolled tobacco leaves. The leaves have stems and other deformities from when they are grown.

The cutting of tobacco leaves to form cigar wrappers is also well-known in the art. US2022/0338531 to Newman teaches a modular cigar, having an inner bound module and removable outer wrapper, each with a predisposed curl. (Newman, abstract). The predisposed curl of Newman's cigar modules are introduced during cutting. Specifically, “[t]he outer wrapper is cut . . . to bias the longitudinally extending sides of the wrapper to curl or curve towards each other . . . . By using a single leaf, this curling [bias] can be leveraged to roll the cigar and avoid the use of adhesive. [emphasis added]” (Newman, para. [0016]). Newman does not contemplate removing curling from any portion of the cigar. Instead, Newman focuses on “rendering the outer wrapper 16 predisposed to curl in on itself with longitudinally sides 30, 32 curling in towards each other. In this manner, the outer wrapper 16 is predisposed to curling in the direction that it is rolled around the inner bound module 14 and biased towards the rolled position.” (Newman, 0014]).

U.S. Pat. No. 4,203,453 to Leclerc teaches flattening tobacco leaves and cutting multiple sheets out of tobacco leaves to make cigar wrappers (Leclerc, abstract). Leclerc also teaches identifying defects and avoid using areas of the leaf that have defects (Leclerc, col. 1, In. 17-40). Leclerc also teaches orienting the secondary veins to be parallel to the axis of the cigar (Leclerc, col. 4, In. 24-25). However, Leclerc does not appear to teach removing a predisposition to curl from the leaves and merely discloses elongated strips as cigar wrappers.

Indeed, the current inventive subject matter includes methods of removing a predisposed curl from a tobacco loose-leaf sheet. These systems and methods keep the loose-leaf sheet flat, even under humidified conditions. In contrast, the teachings of Newman and Leclerc are limited to sheets having predisposition to curl, such that they will re-curl when moistened.

All publications identified herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

SUMMARY OF THE INVENTION

The inventive subject matter provides devices, systems, and methods in which a rectangular loose-leaf wrapper is prepared from a tobacco loose-leaf sheet that is substantially rectangular in shape and substantially flat. In addition, the tobacco loose-leaf sheet is removed from a portion of a tobacco leaf that does not have a central stem. In some embodiments, the tobacco loose-leaf sheet is also removed from a portion of a tobacco leaf that does not have a primary vein, or it has a primary vein that extends longitudinally along a length of the sheet. It is also contemplated that the loose-leaf sheet does not have a defect, such as a hole, a tear, a blotch, a discoloration, a mark, a disease, or a mold.

In another aspect of some embodiments, the tobacco loose-leaf sheet is stored in an air-sealed container that has substantially no oxygen. The air-sealed container preferably contains nitrogen rather than oxygen. The air-sealed container preferably contains a plurality of substantially flat tobacco loose-leaf sheets, and the plurality of sheets can be stacked.

From a methods perspective, the inventive subject matter includes a method of making a loose-leaf wrapper that is substantially flat. The method includes the steps of: (i) moistening and stretching a tobacco leaf, (ii) selecting an area of the tobacco leaf that does not include a central stem; (iii) placing the area onto a first vacuum surface of a work table; (iv) cutting the area with a cutter to form a tobacco loose-leaf sheet; (v) grabbing and removing the sheet from the tobacco leaf using a repositioning tool having a second vacuum surface; (vi) placing the sheet onto a web coupled with a first roller and a second roller using the repositioning tool; and (vii) rolling the sheet onto the second roller.

In some embodiments, the web is disposed on a conveyor belt that has a third vacuum surface between the first roller and the second roller. The conveyor belt is configured to assist in advancing the web from the first roller to the second roller. The third vacuum surface holds the sheet against the web.

In other aspects of some embodiments, the repositioning tool comprises a robotic arm coupled with the second vacuum surface. The second vacuum surface of the repositioning tool provides greater suction than the first vacuum surface of the work table. Placing the sheet onto the web using the grabbing tool comprises turning off the second vacuum.

The web is preferably moist, breathable, and elastic so that it provides tension on the second roller. The tension of the web helps to press each sheet flat when the sheets are tightly wound on the second roller with the web. The sheets can be stored on the second roller for a period of time such as thirty minutes, one hour, eight hours, a working shift, one day, or any time suitable for removing predisposition to curl from the sheet.

As a final step, the sheets can be unwound from the web and the second roller. The sheets can then be stacked into one group our pile and stored in a container. Storing the sheets in an air-tight container with nitrogen rather than oxygen will keep the sheets flat and fresh.

Contemplated methods also include the step of cutting the rectangular area from the tobacco leaf by tracing, lasing, or stamping a peripheral boundary of the rectangular area. The step of selecting an area of the tobacco leaf that does not include a central stem can include imaging the tobacco leaf with an imaging device, such as an optical camera, a scanner, or an x-ray machine. The method can further include analyzing an image from the imaging device.

In yet other aspects, the inventive subject matter also includes a method of making a loose-leaf wrapper that is substantially flat. The method includes the steps of (i) moistening and stretching a tobacco leaf, (ii) selecting an area of the tobacco leaf that does not include a central stem; (iii) cutting the area with a cutter to form a tobacco loose-leaf sheet; and (iv) pressing the sheet between a first flat surface and a second flat surface.

As used herein, “substantially rectangular” means the edges are about 90 degrees, plus or minus 5 degrees. As used herein, “substantially flat” tobacco wrapper, leaf, or sheet means substantially no curl and no predisposition for curling, even if moistened. It is contemplated that a predisposition for curling can be revealed by changes in pressure, temperature, and/or moisture. As used herein, “flattened” means something has gone through a process that has removed substantially curling and all predisposition to curl. It is contemplated that a flat surface will not necessarily be a smooth surface, as a flat surface can have some wrinkles. As used herein, a “wrapper” means a sheet that has been prepared and configured for use as an outer layer of a cigar.

Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front view of a rectangular loose-leaf system in accordance with a preferred embodiment of the present application.

FIG. 2A is a front view of a tobacco leaf that has a defect.

FIG. 2B is a front view of the tobacco leaf of FIG. 2A being cut by a rectangular cutter.

FIG. 2C is a front view of the tobacco leaf of FIG. 3B with a rectangular sheet being removed.

FIG. 2D is a plurality of rectangular sheets collected to form a stack for storage.

FIG. 2E is the plurality of rectangular sheets of FIG. 2D partially stacked.

FIG. 2F is a front view of a plurality of stacked sheets being placed inside a cover and a container.

FIG. 2G is a front view of the container of FIG. 2F with the plurality of stacked sheets partially inside the container.

FIG. 2H is a front view of the container of FIG. 2F with the plurality of stacked sheets inside the container.

FIG. 3 is a flowchart of a method of producing rectangular loose-leaf sheets.

FIG. 4A is an isometric view of a tobacco leaf from which a loose-leaf sheet will be removed.

FIG. 4B is an isometric view of a tobacco leaf having a tracer.

FIG. 4C is an isometric view of a tobacco leaf where a knife is tracing about the tracer.

FIG. 4D is an isometric view of a tobacco leaf where a rectangular loose-leaf sheet has been cut and removed from the leaf.

FIG. 5A is an alternative embodiment to FIG. 4A and depicts a tobacco leaf where the boundary of a rectangular loose-leaf sheet has been traced.

FIG. 5B is an isometric view of a tobacco leaf where a laser is tracing the boundary of a rectangular loose-leaf sheet.

FIG. 5C is an isometric view of a tobacco leaf where a rectangular loose-leaf sheet has been laser-traced and removed from the leaf.

FIG. 6A is an isometric view of a tobacco leaf in a crumpled state and disposed within a pressing apparatus.

FIG. 6B is an isometric view of a tobacco leaf in a flattened state and disposed within an opened pressing apparatus.

FIG. 6C is an isometric view of a tobacco leaf being pressed within a closed pressing apparatus.

FIG. 6D is an isometric view of a tobacco leaf in a flattened state and disposed within an opened pressing apparatus.

FIG. 7A is an isometric view of a tobacco leaf processing assembly and vacuum table.

FIG. 7B is an isometric view of the tobacco leaf processing assembly with a tobacco leaf disposed atop the vacuum table.

FIG. 7C is an isometric view of the tobacco leaf processing assembly with the tobacco leaf being cut by a cutting tool.

FIG. 7D is an isometric view of the tobacco leaf processing assembly where a loose-leaf sheet has been cut from the tobacco leaf disposed atop the vacuum table.

FIG. 7E is an isometric view of the tobacco leaf processing assembly with the repositioning tool lowering to remove the cut loose-leaf sheet from the tobacco leaf.

FIG. 7F is an isometric view of the tobacco leaf processing assembly with the repositioning tool lowered onto the cut loose-leaf sheet to remove the sheet from the tobacco leaf.

FIG. 7G is an isometric view of the tobacco leaf processing assembly with the repositioning tool moving the loose-leaf sheet toward the rollers, as the rollers advance across the conveyor table.

FIG. 7H is an isometric view of the tobacco leaf processing assembly with the repositioning tool lowering to dispose the cut loose-leaf sheet onto the conveyor table.

FIG. 8A is an isometric view of an embodiment where the loose-leaf sheet to be removed from the tobacco leaf has an ovoid shape.

FIG. 8B is an isometric view of an alternative embodiment where the loose-leaf sheet to be removed from the tobacco leaf has a rectangular shape.

FIG. 8C is an isometric view of another alternative embodiment where the loose-leaf sheet to be removed from the tobacco leaf has a parallelogram shape.

FIG. 8D is an isometric view of an alternative embodiment where the loose-leaf sheet to be removed from the tobacco leaf has a length perpendicular to at least one primary vein.

FIG. 8E is an isometric view of an alternative embodiment where the loose-leaf sheet to be removed from the tobacco leaf has a length substantially parallel to at least one primary vein.

FIG. 8F is an isometric view of another alternative embodiment where the loose-leaf sheet to be removed from the tobacco leaf has a primary vein extending from a first edge to a second, non-parallel edge.

FIG. 8G is an isometric view of yet another possible embodiment where the loose-leaf sheet to be removed from the tobacco leaf has a trapezoidal shape.

FIG. 9 is a flowchart of a method for manufacturing a rectangular loose-leaf sheet.

DETAILED DESCRIPTION

The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

The system and method of use will be understood, both as to its structure and operation, from the accompanying drawings, taken in conjunction with the accompanying description. Several embodiments of the system are presented herein. It should be understood that various components, parts, and features of the different embodiments may be combined together and/or interchanged with one another, all of which are within the scope of the present application, even though not all variations and particular embodiments are shown in the drawings. It should also be understood that the mixing and matching of features, elements, and/or functions between various embodiments is expressly contemplated herein so that one of ordinary skill in the art would appreciate from this disclosure that the features, elements, and/or functions of one embodiment may be incorporated into another embodiment as appropriate, unless described otherwise.

Illustrative embodiments of the system and method of use of the present application are provided below. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

The system and method of use in accordance with the present application overcomes one or more of the above-discussed problems commonly associated with conventional inhalatory systems. Specifically, the present invention provides rollable tobacco sheets that are free of central stems, defects, curling, and predisposition to curl. These and other unique features of the system and method of use are discussed below and illustrated in the accompanying drawings.

The preferred embodiment herein described is not intended to be exhaustive or to limit the invention to the precise form disclosed. It is chosen and described to explain the principles of the invention and its application and practical use to enable others skilled in the art to follow its teachings.

Referring now to the drawings wherein like reference characters identify corresponding or similar elements throughout the several views, FIG. 1 depicts a front view of a rectangular loose-leaf system in accordance with a preferred embodiment of the present application. It will be appreciated that system 101 overcomes one or more of the above-listed problems commonly associated with conventional inhalatory systems. In the contemplated embodiment, system 101 includes a container 103 that holds a cover 105 with loose-leaf sheets 107 therein.

Referring to FIGS. 2A, 2B, 2C, 2D, 2E, 2F, 2G, and 2H the system is further depicted. In use, a leaf 201 is flattened so that a rectangular cutter 213 is placed on the bottom surface 203 thereof as depicted by motion A so that the sheet it cuts does not cover any part of the central stem 205. In the preferred embodiment, the sheet will have a secondary stem 207 (i.e., a primary vein) centered therein that runs parallel to the long edge of the sheet. Tears 209 and other defects 211 are also avoided. When placed, the rectangular cutter 213 is pushed down to cut the sheet. The rectangular cutter 213 is then moved as depicted by motion B, to a new place to produce a new sheet. Any number sheets could be cut from a single leaf 201 so long as the cutter is placed as described above.

The sheet 215 is removed as depicted by motion C and additional sheets are cut from the leaf 201. When no more sheets can be cut therefrom the remnants are discarded and any subsequent leaves are cut in the same way. When a number of sheets 215 are collected to form a stack 217 in preparation to be stored. The stack 217 is placed in a cover 105 that protects the outside of the stack 217, cover 105 is closed as depicted by motion D, and both stack 217 and cover 105 are placed in a container 103 as depicted by motion E. Container 103 is closed and sealed for freshness. Container 103 is preferably air-tight sealed and has substantially no oxygen. Air-sealed container 103 can contain nitrogen rather than oxygen or other gases to maintain freshness. Stack 217 is then removed and a number of the sheets 215 are separated and rolled to form a cigar, cigarette, or the like.

It should be appreciated that one of the unique features believed characteristic of the present application is that the loose-leaf sheets 215 are free of defects and stems so that the combustion is optimal.

In the preferred embodiment the sheets 215 are cut by a stamp or cutter 213. It is contemplated that a guide, mold, or the like could be used to facilitate the cut by hand with a knife, blade or scissors.

Referring now to FIG. 3, a method of producing rectangular loose-leaf sheets is depicted. Method 301 includes laying a tobacco leaf flat on a surface (step 303), positioning a rectangular cutter so that no part of the central stem or any other defect is within the area below the cutter (step 305), cutting a sheet from the tobacco leaf (step 307), repositioning the cutter as before but in a new position (step 309), and cutting sheets until no sheet can be cut that has no part of the central stem or other defects within it (step 311).

FIG. 4A is an isometric view of tobacco leaf 405, which includes a tear 410, a blotch 415, a disease 420, a central stem 401, and a primary vein 425. FIG. 4B depicts a similar embodiment, except a stamp 430 has been placed on the tobacco leaf 405. In a preferred embodiment, stamp 430 is configured to cut out a tobacco loose-leaf sheet (not shown) that is rectangular in shape. In a related embodiment, the tobacco loose-leaf sheet (not shown) is removed from a portion of a tobacco leaf 405 that does not have the central stem 401. In the depicted embodiment, the loose-leaf sheet (not shown) has the primary vein 431 running parallel to a length of the sheet. FIG. 4C depicts an alternative embodiment, where a tracer 440 is placed on tobacco leaf 405 and tracer knife 450 is configured to be traced about the tracer 440 to produce the tobacco loose-leaf sheet (not shown).

FIG. 4D depicts the removal of the tobacco loose-leaf sheet 470 from the cutting area 460 of tobacco leaf 405. In a preferred embodiment, the loose-leaf sheet 470 is removed from a portion of a tobacco leaf that does not have a defect. In related embodiments, a defect can be a hole, a tear, a blotch, a discoloration, a mark, a disease, or a mold. In a preferred embodiment, the tobacco loose-leaf sheet 470 is substantially flat, meaning it has substantially no curl and no predisposition for curling, even if moistened. In some embodiments, tobacco loose-leaf sheet 470 has at least one primary vein. In a preferred embodiment, the tracer 440 is rectangular. In a related embodiment, the loose-leaf sheet 470 has at least one secondary vein.

In a preferred embodiment, the removal of the tobacco loose-leaf sheet 470 from the cutting area 460 of tobacco leaf 405 includes selecting an area of the tobacco leaf that does not include a central stem via imaging the tobacco leaf with an imaging device. The imaging device can be an optical camera, a scanner, or an x-ray machine. In a related embodiment, the imaging device (not shown) captures and analyzes the captured image. In some embodiments, the analysis of the captured image includes using an image recognition algorithm to identify the central stem of the tobacco leaf and one or more defects.

FIG. 5A is an isometric view of a tobacco leaf 505, which includes a tear 510, a blotch 515, a disease 520, a primary vein 526, and a traced target area 525. FIG. 5B depicts a laser 530 lasing the traced target area 525 with laser beam 535 to produce loose-leaf sheet 540. In a preferred embodiment, a length of the loose-leaf sheet 540 is parallel to a primary vein 526. FIG. 5C depicts the loose-leaf sheet 540 removed from the tobacco leaf 505 after being lased by laser 530.

FIG. 6A is an isometric view of tobacco leaf processing assembly 600, which includes upper press 610, tobacco leaf 620A, and lower press 630. The tobacco leaf 620A is disposed between the upper press 610 and lower press 630. In the depicted embodiment, the upper press 610 and lower press 630 of tobacco leaf processing assembly 600 are distanced from one another in an open position. In a preferred embodiment, the tobacco leaf 620A is crumpled. FIG. 6B depicts the tobacco leaf 620B disposed between upper press 610 and lower press 630. In the depicted embodiment, the tobacco leaf 620B is the same as tobacco leaf 620A, except it has been flattened out. For example, the leaf can be moistened, stretched, and flattened by hand. Tobacco leaf 620A could also be flattened out by a vacuum surface on lower press 630 or by using clamps. FIG. 6C depicts the upper press 610 and lower press 630 pressed together in a closed position to further flatten the tobacco leaf 620B (not shown). FIG. 6D is similar to FIG. 6A, except tobacco leaf 620C is substantially flat. In a preferred embodiment, the upper press 610 and lower press 630 comprise flat surfaces.

FIG. 7A is an isometric view of tobacco leaf processing assembly 700 which includes processing table 705, table vacuum area 710, repositioning tool 720, cutter 715, and roller table 730. Roller table 730 includes a leading roller 725 with a web of roller material 740 positioned along the length of table 730 and leading into wrapping roller 735. Roller material 740 includes flow-thru apertures 745, and tobacco loose-leaves 760 and 765. In a preferred embodiment, the repositioning tool 720 includes a robotic arm and a vacuum surface.

FIG. 7B depicts a tobacco leaf 750 positioned over table vacuum area 710 (not shown), where cutter 715 is in an inactive position. In a preferred embodiment, tobacco leaf 750 is moistened and stretched atop processing table 705. FIG. 7C depicts cutter 715 in an active position, cutting tobacco leaf 750 at the table vacuum area 710 (not shown). FIG. 7D depicts cutter 715 retracted to an inactive position from target 710, which produced loose-leaf sheet 755. FIG. 7E depicts the repositioning tool 720 lowering down along the direction of travel denoted by the arrow to the loose-leaf sheet 755. FIG. 7F depicts the repositioning tool 720 over table vacuum area 710 (not shown) and beginning to remove the loose-leaf sheet 755 (not shown) from tobacco leaf 750 using its vacuum surface. The vacuum surface of reposition tool 720 overcomes the vacuum surface of table vacuum area 710. It is also contemplated that the vacuum surface of table vacuum area 710 can be momentarily turned off to allow the vacuum surface of repositioning tool 720 to grab sheet 755.

FIG. 7G depicts the repositioning tool 720 moving the loose-leaf sheet 755 across the processing table 705 away from table vacuum area 710 toward roller table 730, while the roller material 740 advances into wrapping roller 735. In a preferred embodiment, the vacuum surface of repositioning tool 720 provides greater suction than the table vacuum area 710 of the processing table 705. FIG. 7H depicts the repositioning tool 720 placing the loose-leaf sheet 755 onto roller material 740. In a preferred embodiment, the placing of the loose-leaf sheet 755 onto roller material 740 comprises turning off the vacuum surface of repositioning tool 720. In a preferred embodiment, table 730 produces a negative pressure along its surface via flow-thru apertures 745, vacuuming loose-leaf sheet 755 to roller material 740. In a related embodiment, the negative pressure produced by table vacuum area 710 is configured to be less than that produced by table 730. In a preferred embodiment, the negative pressure produced by table 730 is exhibited opposite the side of the roller material 740 tobacco loose-leaves 760 and 765. In a related embodiment, as roller material 740 advances along table 730, loose-leaf sheet 755 is wrapped along into the wrapping roller 735.

In a preferred embodiment, the loose-leaf sheet 755 and roller material 740 are tightly wound onto the wrapping roller 735. In a related embodiment the elasticity of the roller material 740 provides tension against the loose-leaf sheet 755 when the sheet and the material are tightly wound onto the wrapping roller 735. In some embodiments, the loose-leaf sheet 755 and the roller material 740 are stored on the wrapping roller 735 for a period of time. A period of time could be 30 minutes, 1 hour, an 8 hour shift, the next day, or any other suitable period. In other embodiments, the diameter of wrapping roller 735 is big enough to not introduce a significant curl onto loose-leaf sheet 755. In related embodiments, after being wound, the roller material 740 and the loose-leaf sheet 755 can be unwound from wrapping roller 735.

The loose-leaf sheet 755 can also be placed in a container (not shown). In a preferred embodiment, the oxygen is removed from the container and the loose-leaf sheet 755 is air-sealed inside the container (not shown). In a related embodiment, the air in the container (not shown) is replaced with nitrogen and the loose-leaf sheet 755 is air-sealed inside the nitrogen-filled container (not shown).

In preferred embodiments, roller material 740 is moist, breathable, and elastic. In a related embodiment, roller material 740 has a friction surface to grab the loose-leaf sheet 755. In a similar embodiment, roller material 740 is a web. In a related embodiment, the roller material 740 is disposed on a conveyor belt (not shown) that has a vacuum surface between the leading roller 725 and the wrapping roller 735. The conveyor belt (not shown) is configured to assist in advancing the web from the leading roller 725 and the wrapping roller 735. In a preferred embodiment, the vacuum surface of the conveyor belt (not shown) holds the loose-leaf sheet 755 against the roller material 740.

FIG. 8A depicts a tobacco leaf 810 with a traced cutting area 820. In the depicted embodiment, traced cutting area 820 is configured to produce a loose-leaf sheet in an ovoid shape. FIG. 8B depicts a similar embodiment, where traced cutting area 820 is configured to produce a loose-leaf sheet in a rectangular shape. FIG. 8C depicts a similar embodiment to FIG. 8B, where traced cutting area 820 is configured to produce a loose-leaf sheet in a slanted shape. In a preferred embodiment, traced cutting area 820 includes a primary vein.

FIG. 8D depicts a tobacco leaf 810 with a traced cutting area 820 having no primary vein. In the depicted embodiment, the traced cutting area 820 is oriented parallel to primary veins of tobacco leaf 810. FIG. 8E depicts a similar embodiment to FIG. 8D, except the traced cutting area 820 is not oriented parallel to primary veins of tobacco leaf 810. FIG. 8F depicts a tobacco leaf 810 with a traced cutting area 820 configured to produce a loose-leaf sheet with a primary vein starting on a long edge and ending on a short edge. In a preferred embodiment, the length of the primary vein extends primarily longitudinally along shape of the loose-leaf sheet. FIG. 8G depicts a similar embodiment, where traced cutting area 820 is configured to produce a loose-leaf sheet in a trapezoidal shape.

FIG. 9 is a functional block diagram illustrating the steps for manufacturing a rectangular and substantially flat loose-leaf wrapper. The method comprises flattening the tobacco leaf (step 910), selecting an area of the tobacco leaf that does not include a central stem (step 920), and cutting a sheet from the tobacco leaf either by using (i) a cutter (steps 930 and 960) (ii) a tracer and cutter (steps 940 and 970), or (iii) a laser (step 950).

As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.

The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value with a range is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.

It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

1. A rectangular loose-leaf wrapper comprising: a tobacco loose-leaf sheet that is substantially rectangular in shape and substantially flat; andwherein the tobacco loose-leaf sheet is removed from a portion of a tobacco leaf that does not have a central stem.

2. The rectangular loose-leaf wrapper of claim 1, the tobacco loose-leaf sheet is removed from a portion of a tobacco leaf that does not have a primary vein.

3. The rectangular loose-leaf wrapper of claim 1, the tobacco loose-leaf sheet is removed from a portion of a tobacco leaf that has a primary vein that extends longitudinally along a length of the sheet.

4. The rectangular loose-leaf wrapper of claim 1, wherein the loose-leaf sheet is removed from a portion of a tobacco leaf that does not have a defect.

5. The rectangular loose-leaf wrapper of claim 4, wherein the defect is a hole, a tear, a blotch, a discoloration, a mark, a disease, or a mold.

6. The rectangular loose-leaf wrapper of claim 1, wherein the loose-leaf sheet has at least one secondary vein.

7. The rectangular loose-leaf wrapper of claim 1, wherein the tobacco loose-leaf sheet is stored in an air-sealed container that has substantially no oxygen.

8. The rectangular loose-leaf wrapper of claim 7, wherein the air-sealed container contains nitrogen.

9. The rectangular loose-leaf wrapper of claim 7, wherein the air-sealed container contains a plurality of substantially flat tobacco loose-leaf sheets.

10. The rectangular loose-leaf wrapper of claim 9, wherein the plurality of substantially flat tobacco loose-leaf sheets are stacked.

11. A method of making a loose-leaf wrapper that is substantially flat comprising: moistening and stretching a tobacco leaf,selecting an area of the tobacco leaf that does not include a central stem;placing the area onto a first vacuum surface of a work table;cutting the area with a cutter to form a tobacco loose-leaf sheet;grabbing and removing the sheet from the tobacco leaf using a repositioning tool having a second vacuum surface;placing the sheet onto a web coupled with a first roller and a second roller using the repositioning tool; androlling the sheet onto the second roller.

12. The method of claim 11, wherein the web is disposed on a conveyor belt that has a third vacuum surface between the first roller and the second roller.

13. The method of claim 12, wherein the conveyor belt is configured to assist in advancing the web from the first roller to the second roller.

14. The method of claim 13, wherein the third vacuum surface holds the sheet against the web.

15. The method of claim 14, wherein the repositioning tool comprises a robotic arm coupled with the second vacuum surface.

16. The method of claim 15, wherein the second vacuum surface of the repositioning tool provides greater suction than the first vacuum surface of the work table.

17. The method of claim 16, wherein the step of placing the sheet onto the web using the grabbing tool comprises turning off the second vacuum.

18. The method of claim 11, wherein the web is moist, breathable, and elastic.

19. The method of claim 18, wherein the step of rolling the sheet onto the second roller comprises tightly winding the sheet and the web onto the second roller.

20. The method of claim 19, wherein the elasticity of the web provides tension against the sheet when the sheet and the web are tightly wound onto the second roller.

21. The method of claim 20, further comprising the step of storing the sheet and the web on the second roller for a period of time.

22. The method of claim 21, further comprising the step of unwinding the sheet and the web from second roller.

23. The method of claim 22, further comprising the step of placing the sheet in a container.

24. The method of claim 23, further comprising the steps of (i) removing oxygen from the container and (ii) air-sealing the sheet inside the container.

25. The method of claim 23, further comprising the steps of (i) replacing air in the container with nitrogen and (ii) air-sealing the sheet inside the nitrogen-filled container.

26. The method of claim 11, wherein the step of cutting the area with a cutter to form a tobacco loose-leaf sheet comprising tracing, lasing, or stamping a peripheral boundary of the area.

27. The method of claim 11, wherein the step of selecting an area of the tobacco leaf that does not include a central stem comprises imaging the tobacco leaf with an imaging device.

28. The method of claim 27, wherein the imaging device is an optical camera, a scanner, or an x-ray machine.

29. The method of claim 28, further comprising the step of analyzing an image from the imaging device.

30. The method of claim 29, wherein the step of analyzing the image comprises using an image recognition algorithm to identify the central stem of the tobacco leaf and one or more defects.

31. A method of making a loose-leaf wrapper that is substantially flat comprising: moistening and stretching a tobacco leaf,selecting an area of the tobacco leaf that does not include a central stem;cutting the area with a cutter to form a tobacco loose-leaf sheet; andpressing the sheet between a first flat surface and a second flat surface.