SMOKABLE SHELLS WITH PREFERABLY ORIENTED LEAVES AND METHODS FOR THEIR PREPARATION

TECHNICAL FIELD

Various embodiments and variations of the present disclosure are related to smokable products and methods of preparing smokable products with preferably oriented leaves.

BACKGROUND

A growing demand exists for more natural cigars and smokable products. The legalization of cannabis will add to this growing market. But, current technologies, processes, and products have failed to address the needs of this growing consumer base. For example, cannabis leaves when used as a shell for cigars and as prepared according to current processes are not tasteless, do not burn properly, and can develop mold during storage. These issues impair the function of a smokable product, which in turn reduces the enjoyment or satisfaction that one may derive from the smokable product. Further, conventional curing techniques are generally inapplicable to leaves such as cannabis leaves since the resulting effect is usually the disintegration of the leaves.

Furthermore, it would be desirable to have a smokable product having even burning characteristics with a relatively hard, open tip filter on which the smoker can bite down without deteriorating the filter.

The present disclosure addresses these among other shortcomings.

SUMMARY

Various embodiments and variations of the present disclosure are related to smokable products and methods of preparing smokable products.

It has been surprisingly and unexpectedly discovered that the disclosed methods were able to overcome the shortcomings of other leaf preparing techniques to allow for the preparation of leaves such as cannabis leaves for use as part of a smokable shell without disintegration. It has also been surprisingly and unexpectedly discovered that the disclosed shells had significantly improved burning characteristics over other types of smokable shells.

In various embodiments smokable products are disclosed including: a plurality of treated leaves arranged in a longitudinal orientation to form an elongate tubular smokable shell. At least some of the treated leaves of various embodiments have a chlorophyll content that is less than a chlorophyll content of an untreated leaf. A smokable shell of various embodiments defines a cavity capable of receiving a smokable fill material.

In variations methods of preparing a smokable product are disclosed, including the steps of: freezing leaves at a temperature effective for forming ice nuclei or ice crystals for a predetermined time; and arranging at least some of the leaves in an overlapping longitudinal orientation to form a smokable shell, the smokable shell defining a cavity capable of receiving a smokable fill material. The temperature of variations is 0° C. or less.

BRIEF DESCRIPTION OF THE DRAWINGS

For a further understanding of the nature, objects, and advantages of the present invention, reference should be had to the following detailed description, read in conjunction with the following drawings, wherein like reference numerals denote like elements and wherein:

FIG. 1 shows a side view of one embodiment of a smokable product in which one constituent leaf is oriented longitudinally. For simplicity, overlapping leaves also oriented longitudinally are not shown.

FIG. 2A shows a side view of the smokable product of FIG. 1, in which the smokable product is rotated approximately 90 degrees about the axis A-A of FIG. 1. In this Figure, two overlapping leaves are shown.

FIG. 2B depicts a smokable product in which there are two layers of an outer wall of the smokable shell. A proximal end is on the right hand side includes a filter. A distal end that can be lit is on the left hand side.

FIG. 3 shows an openable closed distal end of a smokable shell, where the openable closed end is in a closed position.

FIG. 4 is a perspective view of the proximal end of a smokable shell, where the proximal end is in an open position to reveal a filter.

FIG. 5 shows the proximal end of a smokable shell, where the proximal end opens into a cavity beyond the filter that is capable of receiving a smokable fill material.

FIG. 6 shows a longitudinal sectional view of a smokable product including a smokable shell and smokable fill material within the cavity of the smokable shell.

FIG. 7 shows one arrangement of selected whole leaves in which the primary veins are oriented substantially in parallel.

FIG. 8 shows a sheet of leaves prepared from an arrangement of leaves that is used to form the smokable shell.

FIG. 9 shows a perspective view of a lit or ignited smokable product, where the smokable shell delivers an increased amount of air or oxygen to a combustion zone located at or near the distal end.

FIG. 10 depicts one illustrative sequence of igniting a smokable product, where white ash is formed during or after the combustion of a portion of the smokable shell.

FIGS. 11 and 12 show the formation of white ash during or after the combustion of a portion of a smokable shell.

FIG. 13 shows a smokable shell with representative indicia.

FIG. 14 shows a smokable shell with a smokable end cover and representative indicia.

FIG. 15 shows a smokable shell with a smokable cover and representative indicia.

FIGS. 16, 17, and 18 show smokable shells or smokable products that are packaged for sale, where the packaging includes representative indicia.

FIGS. 19 and 20 are flow charts outlining representative methods of preparing leaves and smokable shells.

FIG. 21 is a flow chart outlining some methods of arranging leaves into smokable shells.

FIG. 22 is a flow chart outlining methods of arranging leaves into smokable products and packaging the smokable products for sale.

FIG. 23 shows steps of freezing leaves for a predetermined time.

FIG. 24 shows steps of extracting components from the leaves for a predetermined time.

FIGS. 25-34 show steps of arranging the leaves to form a shell so that their primary veins are substantially oriented in a mutually parallel relationship.

FIGS. 35-38 show steps of preparing an end cover and applying an end cover to a shell.

DETAILED DESCRIPTION

As required, detailed embodiments and variations of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments and variations are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

Except in the examples, or where otherwise expressly indicated, all numerical quantities in this description indicating amounts of material or conditions of reaction and/or use are to be understood as modified by the word “about”. The first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation; and, unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property. Ranges are also understood to be inclusive.

Unless indicated otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the present disclosure belongs.

It is also to be understood that this disclosure is not limited to the specific embodiments and variations and methods described below, as specific components or conditions may, of course, vary. Furthermore, the terminology used herein is used only for describing particular embodiments and variations and is not intended to be limiting in any way.

It must also be noted that, as used in the specification and the appended claims, the singular form “a,” “an,” and “the” comprise plural referents unless the context clearly indicates otherwise. For example, reference to a component in the singular is intended to comprise a plurality of components.

The term “or” is be understood to mean “at least one of”. The term “and” is also be understood to mean “at least one of” or “all”.

The term “comprising” is synonymous with “including,” “having,” “containing,” or “characterized by.” These terms are inclusive and open-ended and do not exclude additional, unrecited elements or method steps.

The phrase “consisting of” excludes any element, step, or ingredient not specified in the claim. When this phrase appears in a clause of the body of a claim, rather than immediately following the preamble, it limits only the element set forth in that clause; other elements are not excluded from the claim as a whole.

The phrase “consisting essentially of” limits the scope of a claim to the specified materials or steps, plus those that do not materially affect the basic and novel characteristic(s) of the claimed subject matter.

The terms “comprising”, “consisting of”, and “consisting essentially of” can be alternatively used. When one of these three terms is used, the presently disclosed and claimed subject matter can include the use of either of the other two terms.

The term “some of” is understood to include “at least one of”, “part of”, “all of”, or “the entirety of”.

The term “proximal” is understood to mean “near” or “at”.

The term “smokable product” refers interchangeably to a smokable shell, a smokable product including a smokable shell and a smokable fill material within a cavity of the smokable shell, or a kit/packaging/container including a smokable shell or a smokable shell and smokable fill material.

The terms “leaf” or “leaves” refers a leaf or portions of a leaf that include at least some of the apex, midvein or primary vein, secondary vein(s), lamina, or margin of the leaf. A leaf or leaves can also include a leaf or leaves that are treated or modified to remove a portion of the components from the leaf such as cells, chlorophyll, chloroplasts, sugars, starches, nutrients, water, terpenes, flavonoids, or terpenoids. The term “leaf”, “leaves”, or “leaflet(s)” is also used interchangeably. Leaflets are a leaflike structures that make up a leaf and can be arranged to form the smokable shell of various embodiments.

The term “treated leaf” or “treated leaves” is understood to mean an untreated leaf or untreated leaves modified or treated to be different from untreated leaves, which can include different properties or characteristics. For example, a treated leaf can be treated to include at least some of the apex, midvein or primary vein, secondary vein(s), lamina, or margin of an untreated leaf. In another example, a treated leaf can be treated to remove at least some of a component from an untreated leaf such that the treated leaf has a content of the component that is less than a content of the component of the untreated leaf In other examples, a treated leaf can be treated to add a component or increase a content of a component in an untreated leaf.

The term “vein structure” is understood to mean at least some of the veins from an untreated leaf or a treated leaf. A vein structure also includes: at least some of a secondary vein or secondary veins from a leaf; or at least some of a primary vein from a leaf.

The term “component” is understood to mean a component within an untreated leaf or a treated leaf. Examples of components includes cells, chlorophyll, chloroplasts, sugars, starches, nutrients, water, terpenes, flavonoids, or terpenoids.

The term “content” is understood to mean weight, moles, moles per surface area, or relative percentages such as weight percent, mole percent, percentage of moles per surface area. For example, content can include weight percent or mole percent. In other examples, content can include moles per surface area such as micromole or micromolar (μM) per micron squared (μM²). Measurements of content can be taken by various devices as well. Examples of devices that can measure content such as chlorophyll include chlorophyll meters. Examples of chlorophyll meters are disclosed in U.S. Pat. No. 9,733,179, which is incorporated in its entirety by reference. Differences or changes in content can be expressed as percentages.

Various embodiments and variations of the present disclosure are related to smokable products and methods of preparing smokable products in which the primary veins of at least partially overlapping leaves are oriented substantially in parallel along the length of the smokable shell. For orientation and reference herein the longitudinal axis of a shell is denoted by the line A-A in FIG. 1. Thus, the primary veins in preferred embodiments are substantially aligned with the longitudinal axis A-A.

In various embodiments smokable products are disclosed including: a plurality of treated partially overlapping leaves arranged with their primary veins extending in parallel with the longitudinal axis of the smokable shell , where at least some of the treated leaves have a chlorophyll content that is less than a chlorophyll content of an untreated leaf; wherein the smokable shell defines a cavity capable of receiving a smokable fill material.

In various embodiments smokable products prepared by processes are disclosed, including the steps of: freezing leaves at a temperature effective for forming ice nuclei or ice crystals for a predetermined time; extracting at least some chlorophyll from the leaves; and arranging at least some of the leaves so that their primary veins extend substantially longitudinally and in parallel with each other to form the smokable shell. The temperature effective for forming ice nuclei or ice crystals of various embodiments or steps is 0° C. or less.

The smokable product of various embodiments can include a filter medium positioned within the cavity of the smokable shell. Preferably the filter is relatively hard so that the smoker can if desired bite down on the filter without harming the filter even after repeated bites or chews. The filter medium can include materials suitable for smoking and capable of filtering materials or particulates from smoke. Examples of materials for the filter medium include fibrous material such as cardboard, natural fibrous materials such as corn husk, biodegradable materials, adsorbent materials, activated materials, filter paper, cellulosic fibers such as alpha cellulose or cotton, cellulose ester fibers such as cellulose acetate and cellulose acetate butyrate, viscose rayon, polypyrrolidone fibers, nanofibers, crepe paper, or combinations thereof.

The smokable product of various embodiments can include a smokable fill material. Examples of smokable fill materials include: tobacco-containing material such as tobacco, tobacco derivatives, reconstituted tobacco, tobacco extract, homogenized tobacco, or tobacco substitutes; or non-tobacco-containing material such as cannabis, cannabis extract, mint, vanilla, peppermint, anise, basil, bay leaves, cardamom, cinnamon, coriander, cumin, ginger, nutmeg, oregano, paprika, rosemary, saffron, sage, thyme, vanilla, lavender, licorice, coffee, tea, eucalyptus, clove, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, rose, bergamot and orange blossom; or combinations thereof.

FIGS. 1, 2A, 2B, and 3-5 show smokable products 10, 10′ of various embodiments including a smokable shell 100 and filter 300. The shell 100 includes treated leaves 201 arranged so that their primary veins (only one shown in FIG. 1) are oriented longitudinally to form a generally cylindrical wall 110, 110′, where the wall 110, 110′ defines a cavity 130. Preferably a smokable shell has a number of overlapping leaves, so that secondary veins of adjacent leaves overlap. In a preferred embodiment 2-3 leaves may at least partially overlap. This contrasts with other products in which for example 5-10 leaves may overlap and their primary veins are oriented perpendicularly to the longitudinal axis A-A (FIG. 1).

The smokable shell 100 has an openable closed proximal end 140, 140′ and an open distal end 150. The tubular filter 300 is positioned within the cavity 130 adjacent to the openable closed proximal end 140, 140′. FIG. 6 shows a smokable product 10′ further including a smokable fill material 400 within the cavity 130.

FIG. 2A further shows the wall 110 having a single layer and FIG. 2B shows the wall 110′ having more than one layer—in this case, two layers. The wall 110 or a layer of the wall 110′ has a thickness 111 that is effective for combustion or smoking. The wall of various embodiments can have at least a substantially uniform thickness. A number of overlapping leaves with longitudinally aligned primary veins define a wall.

In several embodiments, a variation in the thickness of the wall ranges from 0% to 30%. In various embodiments, the thickness of the wall can vary by 0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, or 30% from a base thickness. In various embodiments, the variation in thickness of the wall can be a range between any two variations listed above.

In various embodiments, a thickness or base thickness of the wall ranges from 3000 microns (μm) or less or 3 millimeter (mm) or less. In various embodiments, a thickness or base thickness of the wall is 0.1 μm, 0.2 μm, 0.3 μm, 0.4 μm, 0.5 μm, 0.6 μm, 0.7 μm, 0.8 μm, 0.9 μm, 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 7 μm, 8 μm, 9 μm, 10 μm, 20 μm, 30 μm, 40 μm, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 600 μm, 700 μm, 800 μm, 900 μm, 1000 μm, 1500 μm, 2000 μm, 2500 μm, or 3000 μm . In various embodiments, the thickness or base thickness of the wall is a range between any two thicknesses listed above.

In various embodiments, at least some of the treated leaves have a secondary vein extending from a primary vein to a position proximal to a leaf margin and the at least some of the treated leaves are arranged such that the primary veins on different treated leaves substantially align longitudinally to extend along a wall of the smokable shell. FIGS. 1, 2A, and 2B show the secondary veins 230 of adjacent leaves 201 arranged in a pattern 180 that extends at an angle across the axis A-A along the wall 110, 110′ of the smokable shell 100. The pattern 180 can extend along the wall 110, 110′ of the smokable shell 100 such that the pattern extends in a spiraling or helical manner along a length of the wall 110, 110′. For example, pattern 180 can include different alignments of secondary veins 230 such that one alignment spirals across a length of the wall 110, 110′ or multiple alignments together extend helically across a length of the wall 110, 110′.

FIGS. 3 and 4 show an openable closed proximal end 140, 140′ of the smokable shell 100. A user draws from the openable closed end 140, 140′ to receive smoke from a combustion zone 500. FIG. 3 shows the openable closed end 140, 140′ in a closed position 141 where the leaves 201 when arranged to form the wall 110, 110′ are closed over to form the openable closed end 140, 140′ in the closed position 141. Forming the openable closed end 140, 140′ in the closed position 141 can also be an element for packaging the smokable product 10, 10′ for sale. FIG. 4 shows the openable closed end 140, 140′ in an open position 142. Before use, a user can transition the openable closed end 140, 140′ from the closed position 141 to the open position 142. With the openable closed end 140, 140′ in an open position 142, a user can draw smoke from the combustion zone 500 as shown in FIG. 9. During the draw, smoke travels through the cavity 130 and the filter 300.

FIG. 5 shows an open end 150 of the smokable shell 100. The open end 150 is connected to the cavity 130 such that a user can access the open end 150 to fill the cavity 130 with a smokable fill material 400. FIG. 6 shows a smokable product 10 including a smokable shell 100 and filter 300, where smokable fill material 400 has been positioned within the cavity 130. The smokable fill material 400 can be added to the cavity 130 with the open end 150.

As previously disclosed, the wall or openable closed end of the smokable shell are formed from the arrangement of treated leaves. At least some of the treated leaves of various embodiments are fan leaves. In other examples, at least some of the treated leaves of various embodiments are selected from different types of leaves outlined in the Hickey system that can include: Pinnate, Parallelodromous, Campylodromous, Acrodromous, or Palinactodromous types. In other examples, at least some of the treated leaves of various embodiments are selected from leaves as described by the divisions of the blade of the leaves that can include: Palmately compound, Pinnately compound, Odd pinnate, Even pinnate, Bipinnately compound, Trifoliate (or trifoliolate), or Pinnatifid. For example, as disclosed in FIGS. 1-6, the leaves are Palmately compound leaves, where the leaves have the leaflets radiating from the end of the petiole.

At least some of the treated leaves of various embodiments include leaves from different plant varieties such as open-pollinated, heirloom, cultivars, or hybrids. In one example, leaves from hybrid plants can have thicknesses that are suitable for incorporation into a smokable shell.

At least some of the treated leaves of various embodiments include leaves from different plant varieties such as plants of a Cannabaceae family, Cannabis genus, or Arecaceae family or different types of leaves such as bay leaves, bamboo leaves, coconut leaves, or tobacco leaves. Examples of plants from the Cannabaceae family or Cannabis genus can include Sativa, Indicia, Ruderalis strains/subspecies, hybrids of the strains/subspecies, cultivars of the strains/subspecies, or combinations thereof. Examples from the Arecaceae family can include king palms.

At least some of the treated leaves of various embodiments are selected from untreated leaves preferably having a primary vein or primary vein and ten or more secondary veins extending from a primary vein to a position adjacent to an edge of a leaf. FIG. 7 shows an arrangement 160 of selected whole leaves 202. Selected whole leaves 202 include untreated leaves or treated leaves, where the treated leaves have a content of a component that is either greater or less than a content of a component of untreated leaves or an additional component. As shown in FIG. 7, selected whole leaves 202, which are eventually modified into treated leaves 201, have a primary vein or primary vein 240 extending from a point adjacent to one end 242 to a point adjacent to a second end 243 of the leaf 202. Secondary veins 230 extend from the primary vein 240 to a point proximal to a margin 220 of a blade 210 of the leaf 202. In various embodiments, at least some of the treated leaves or selected whole leaves have 10 to 50 secondary veins. In various embodiments, at least some of the treated leaves or selected whole leaves have 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50 secondary veins. In various embodiments, at least some of the treated leaves or selected whole leaves have a number of secondary veins ranging between any two numbers of secondary veins disclosed above. In various embodiments, at least some of the secondary veins extend from a primary vein to a position proximal to a margin of the treated leaves or selected whole leaves. The arrangement of the secondary veins on the treated leaves or selected whole leaves can be symmetrical or asymmetrical.

For example, in various embodiments, at least some of the selected whole leaves 202 or at least some of the blades 210 of the selected whole leaves 202 has a length 202a ranging from 0.5 inches (in) (1.27 centimeter (cm)) to 10 in (25.4 cm). In various embodiments, at least some of the selected whole leaves 202 or at least some of the blades 210 of the selected whole leaves 202 has a length 202a of 0.5 inches (in) (1.27 centimeter (cm)), 0.6 in (1.524 cm), 0.7 in (1.778 cm), 0.8 in (2.032 cm), 0.9 in (2.286 cm), 1 in (2.54 cm), 1.1 in (2.794 cm), 1.2 in (3.048 cm), 1.3 in (3.302 cm), 1.4 in (3.556 cm), 1.5 in (3.81 cm), 1.6 in (4.064 cm), 1.7 in (4.318 cm), 1.8 in (4.572 cm), 1.9 in (4.826 cm), 2 in (5.08 cm), 2.5 in (6.35 cm), 3 in (7.62 cm), 3.5 in (8.89 cm), 4 in (10.16 cm), 4.5 in (11.43 cm), 5 in (12.7 cm), 5.5 in (13.97 cm), 6 in (15.24 cm), 6.5 in (16.51 cm), 7 in (17.78 cm), 7.5 in (19.05 cm), 8 in (20.32 cm), 8.5 in (21.59 cm), 9 in (22.86 cm), 9.5 in (24.13 cm), or 10 in (25.4 cm). In various embodiments, the length 202a of at least some of the selected whole leaves 202 or at least some of the blades 210 of the selected whole leaves 202 is a range between any two lengths listed above.

For example, in various embodiments, at least some of the selected whole leaves 202 or at least some of the blades 210 of the selected whole leaves 202 has a width 202b ranging from 0.5 in (1.27 cm) to 10 in (25.4 cm). In various embodiments, at least some of the selected whole leaves 202 or at least some of the blades 210 of the selected whole leaves 202 has a width 202b of 0.5 in (1.27 cm), 0.6 in (1.524 cm), 0.7 in (1.778 cm), 0.8 in (2.032 cm), 0.9 in (2.286 cm), 1 in (2.54 cm), 1.1 in (2.794 cm), 1.2 in (3.048 cm), 1.3 in (3.302 cm), 1.4 in (3.556 cm), 1.5 in (3.81 cm), 1.6 in (4.064 cm), 1.7 in (4.318 cm), 1.8 in (4.572 cm), 1.9 in (4.826 cm), 2 in (5.08 cm), 2.5 in (6.35 cm), 3 in (7.62 cm), 3.5 in (8.89 cm), 4 in (10.16 cm), 4.5 in (11.43 cm), 5 in (12.7 cm), 5.5 in (13.97 cm), 6 in (15.24 cm), 6.5 in (16.51 cm), 7 in (17.78 cm), 7.5 in (19.05 cm), 8 in (20.32 cm), 8.5 in (21.59 cm), 9 in (22.86 cm), 9.5 in (24.13 cm), or 10 in (25.4 cm). In various embodiments, the width 201b of at least some of the selected whole leaves 202 or at least some of the blades 210 of the selected whole leaves 202 is a range between any two widths listed above. In one example, a whole leaf had a width of 1.22 cm (3.1 cm).

In various embodiments, at least some of the treated leaves include at least some of the lamina and vein structure of the untreated leaf.

In various embodiments, at least one of the treated leaves include at least some of the margin of the untreated leaf.

At least some of the treated leaves of various embodiments has at least 20% of the lamina, vein structure, margin, or apex of the untreated leaf. In various embodiments, at least some of the treated leaves have 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% the lamina, vein structure, margin, or apex of the untreated leaf. In various embodiments, the percentage of the lamina, vein structure, margin, or apex of the untreated leaf that at least some of the treated leaves have is a range between any two percentages listed above. The percentage of the lamina, vein structure, margin, or apex of the untreated leaf that at least some of the treated leaves have is understood to percentages relative to area, surface area, or weight.

At least some of the treated leaves of various embodiments have a content of a component that is no more than 80% of a content of a component of an untreated leaf. In various embodiments, at least some of the treated leaves have a content of a component that is 0%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80% of a content of a component of an untreated leaf. In various embodiments, the content of a component of at least some of the treated leaves is a range between any two percentages of a content of a component of an untreated leaf. In one example, the component is chlorophyll. In other examples, the component can include other cellular components such as various cellular components, cells, chlorophyll, chloroplasts, sugars, starches, nutrients, water, terpenes, flavonoids, terpenoids, or combinations thereof.

At least some of the treated leaves of various embodiments have a chlorophyll content of a component that is no more than 80% of a chlorophyll content of a component of an untreated leaf. In various embodiments, at least some of the treated leaves have a chlorophyll content that is 0%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80% of a chlorophyll content of an untreated leaf. In various embodiments, the chlorophyll content of at least some of the treated leaves is a range between any two percentages of a content of a chlorophyll of an untreated leaf.

In various embodiments, at least some of the treated leaves have a content of terpenes, flavonoids, or terpenoids that is less than a content of terpenes, flavonoids, or terpenoids of an untreated leaf. In various embodiments, at least some of the treated leaves have a content of terpenes, flavonoids, or terpenoids that is 0%, 10%, 20%, 30%, 40%, 50%, 60%, 70%, or 80% of a content of terpenes, flavonoids, or terpenoids of an untreated leaf. In various embodiments, the content of terpenes, flavonoids, or terpenoids of at least some of the treated leaves is a range between any two percentages of a content of terpenes, flavonoids, or terpenoids of an untreated leaf.

The removal of the components reduces the flavor intensity of the smokable shell. In various embodiments, at least some of the treated leaves are leaves imparting a flavor intensity to a user that is 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% lower than a flavor intensity of an untreated leaf. In various embodiments, the lower flavor intensity is a range between any two percentages listed above.

The removal of the components can also influence the color of the leaves or the shell. In various embodiments, at least some of the treated leaves have at least one of the following colors: green (495-570 nm wavelength), red (620-750 nm wavelength), yellow (570-590 nm wavelength), purple or violet (380-450 nm wavelength), black, white, orange (590-620 nm), pink, magenta, blue (450-495 nm wavelength), brown, burgundy, pale green, translucent, transparent, or variations/combinations of colors. In various embodiments, the treated leaves have a plurality of colors listed above.

FIG. 8 shows a sheet 170 of treated leaves 201 prepared from an arrangement 160 of selected whole leaves 202 that is used to form the smokable shell 100 of various embodiments. As shown in FIGS. 7 and 8, top portions 250 and bottom portion 260 of the selected whole leaves 202 in the arrangement 160 are removed to form edges 171, 172 of the sheet 170. Eleven leaves appear in FIG. 8. In use, a preferred number of at least partially overlapping leaves is between about 2-3. This contrasts with other approaches in which there may be 5-10 overlapping leaves that are oriented transversely across the longitudinal axis of the smokable product.

Among the benefits of a reduced number of leaves and their orientation area more even burn from the distal to the proximal end. This probably stems from the fact that a progressive line of combustion has fewer areas of discontinuity to cross because there is only one primary vein as the burn advances. In contrast, if the primary veins of for example 10 leaves are oriented transversely, more barriers to burning are presented by the overlapping secondary veins.

For the arrangement 160 or sheet 170, the distance 231 between secondary veins 230 of at least some of the treated leaves 202 of various embodiments ranges between 0.01 in (0.0254 cm) and 3 in (7.62 cm). In various embodiments, the distance 231 between secondary veins 230 of at least some of the treated leaves 202 is 0.01 in (0.0254 cm), 0.05 in (0.127 cm), 0.1 in (0.254 cm), 0.2 in (0.508 cm), 0.3 in (0.762 cm), 0.4 in (1.016 cm), 0.5 in (1.27 cm), 0.6 in (1.524 cm), 0.7 in (1.778 cm), 0.8 in (2.032 cm), 0.9 in (2.286 cm), 1 in (2.54 cm), 1.1 in (2.794 cm), 1.2 in (3.048 cm), 1.3 in (3.302 cm), 1.4 in (3.556 cm), 1.5 in (3.81 cm), 1.6 in (4.064 cm), 1.7 in (4.318 cm), 1.8 in (4.572 cm), 1.9 in (4.826 cm), 2 in (5.08 cm), 2.1 in (5.334 cm), 2.2 in (5.588 cm), 2.3 in (5.842 cm), 2.4 in (6.096 cm), 2.5 in (6.35 cm), 2.6 in (6.604 cm), 2.7 in (6.858 cm), 2.8 in (7.112 cm), 2.9 in (7.366 cm), or 3 in (7.62 cm). In various embodiments, the distance 231 is a range between any two distances listed above. In one example, the distance 231 is 0.32 in (0.8128 cm).

For the arrangement 160 or sheet 170, the distance 241 between primary veins 240 of at least some adjacent treated leaves 201 or selected whole leaves 202 ranges from 0.01 in (0.0254 cm) to 3 in (7.62 cm). In various embodiments, the distance 241 between primary veins 240 of at least some adjacent treated leaves 201 or selected whole leaves 202 is 0.01 in (0.0254 cm), 0.05 in (0.127 cm), 0.1 in (0.254 cm), 0.2 in (0.508 cm), 0.3 in (0.762 cm), 0.4 in (1.016 cm), 0.5 in (1.27 cm), 0.6 in (1.524 cm), 0.7 in (1.778 cm), 0.8 in (2.032 cm), 0.9 in (2.286 cm), 1 in (2.54 cm), 1.1 in (2.794 cm), 1.2 in (3.048 cm), 1.3 in (3.302 cm), 1.4 in (3.556 cm), 1.5 in (3.81 cm), 1.6 in (4.064 cm), 1.7 in (4.318 cm), 1.8 in (4.572 cm), 1.9 in (4.826 cm), 2 in (5.08 cm), 2.1 in (5.334 cm), 2.2 in (5.588 cm), 2.3 in (5.842 cm), 2.4 in (6.096 cm), 2.5 in (6.35 cm), 2.6 in (6.604 cm), 2.7 in (6.858 cm), 2.8 in (7.112 cm), 2.9 in (7.366 cm), or 3 in (7.62 cm). In various embodiments, the distance 241 is a range between any two distances listed above. In one example, the distance 231 is 0.51 in (1.2954 cm).

In various embodiments, the width 173 or length 174 of the sheet 170 ranges from 0.5 in (1.27 cm) to 10 in (25.4 cm). In various embodiments, the width 173 or length 174 of the sheet 170 is 0.5 in (1.27 cm), 0.6 in (1.524 cm), 0.7 in (1.778 cm), 0.8 in (2.032 cm), 0.9 in (2.286 cm), 1 in (2.54 cm), 1.1 in (2.794 cm), 1.2 in (3.048 cm), 1.3 in (3.302 cm), 1.4 in (3.556 cm), 1.5 in (3.81 cm), 1.6 in (4.064 cm), 1.7 in (4.318 cm), 1.8 in (4.572 cm), 1.9 in (4.826 cm), 2 in (5.08 cm), 2.5 in (6.35 cm), 3 in (7.62 cm), 3.5 in (8.89 cm), 4 in (10.16 cm), 4.5 in (11.43 cm), 5 in (12.7 cm), 5.5 in (13.97 cm), 6 in (15.24 cm), 6.5 in (16.51 cm), 7 in (17.78 cm), 7.5 in (19.05 cm), 8 in (20.32 cm), 8.5 in (21.59 cm), 9 in (22.86 cm), 9.5 in (24.13 cm), or 10 in (25.4 cm). In various embodiments, the width 173 or length 174 of the sheet 170 is a range between any two widths or lengths listed above. In one example, the width 173 of the sheet is 3.28 in (8.3312 cm).

In various embodiments, the distance 175 between an edge 171, 172 and a point where a side vein 230 closest to the edge 171, 172 connects with a primary vein 240 ranges from 0.01 in (0.0254 cm) to 3 in (7.62 cm). In various embodiments, the distance 175 between an edge 171, 172 and a point where a side vein 230 closest to the edge 171, 172 connects with a primary vein 240 is 0.01 in (0.0254 cm), 0.05 in (0.127 cm), 0.1 in (0.254 cm), 0.2 in (0.508 cm), 0.3 in (0.762 cm), 0.4 in (1.016 cm), 0.5 in (1.27 cm), 0.6 in (1.524 cm), 0.7 in (1.778 cm), 0.8 in (2.032 cm), 0.9 in (2.286 cm), 1 in (2.54 cm), 1.1 in (2.794 cm), 1.2 in (3.048 cm), 1.3 in (3.302 cm), 1.4 in (3.556 cm), 1.5 in (3.81 cm), 1.6 in (4.064 cm), 1.7 in (4.318 cm), 1.8 in (4.572 cm), 1.9 in (4.826 cm), 2 in (5.08 cm), 2.1 in (5.334 cm), 2.2 in (5.588 cm), 2.3 in (5.842 cm), 2.4 in (6.096 cm), 2.5 in (6.35 cm), 2.6 in (6.604 cm), 2.7 in (6.858 cm), 2.8 in (7.112 cm), 2.9 in (7.366 cm), or 3 in (7.62 cm). In various embodiments, the distance 175 is a range between any two distances listed above. In one example, the distance 175 is 0.28 in (0.7112 cm).

The smokable product of various embodiments can include an adhesive for attaching adjacent leaves, the adhesive including a thickener and a compound capable of forming a polymer matrix. Examples of a thickener includes starches, vegetable gums, pectin, alginin, guar gum, locust bean gum, or xanthan gum. Examples of compounds capable of forming a polymer matrix include gelatin, agar, or carrageen. In various embodiments, a ratio of the weight (e.g. weight %) or volume (e.g. volume %) of thickener to compound capable of forming a polymer matrix ranges from 10:1 to 1:10. In various embodiments, a ratio of the weight (e.g. weight %) or volume (e.g. volume %) of thickener to compound capable of forming a polymer matrix is 10:1, 9:1, 8:1, 7:1, 6:1, 5:1, 4:1, 3:1, 2:1, 1:1, 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, or 1:10. In various embodiments, the ratio is a range between any two ratios listed above. In different examples, a ratio of the weight % or volume % of thickener to compound capable of forming a polymer matrix is 1:1.

FIG. 9 shows a perspective view of an ignited smokable product 10′ of various embodiments. When ignited at or adjacent to the distal open end 150, a combustion zone 500 forms on the smokable product 10′ and can move towards the proximal openable closed end 140. A user can also draw air 510 to move the combustion zone 500 towards the proximal openable closed end 140. The smokable shell 100 includes treated leaves 201 treated to remove components and having 10 secondary veins 230 or more extending from primary longitudinally-oriented veins 240.

It has been surprisingly and unexpectedly discovered that the disclosed shells had significantly improved burn qualities over other types of smokable shells that lack longitudinally-oriented primary veins in the leaves. Without being limited by theory, the veins 230, 240 mimic a pattern and may burn like a wick that delivers a greater amount of air or oxygen 520 to the combustion zone 500. By delivering greater amount of air or oxygen 520 to the combustion zone 500, the temperature of the combustion zone 500 and the degree of carbonization of organic materials increases. Higher combustion zone temperatures and increased carbonization highlight improvement in burning quality of the smokable shell 100, which is evidenced by the whiteness of the resulting ash. To this extent, increased whiteness of the resulting ash is understood to be improved burning quality. FIG. 10 shows a sequence of igniting a smokable product of various embodiments, where white ash is formed during or after the combustion of the smokable shell. During ignition (I) as shown in FIG. 10, a combustion zone 500 forms on the smokable product 10′. Progressing from (I)-(VI) of FIG. 10, a white ash replaces the smokable shell 100 has the combustion zone continues to burn 601, 602, 603, 604, 605. FIGS. 11 and 12 further highlight white ash replacing the smokable shell 100, which indicates improved burning qualities for the smokable shell 100.

Whiteness is a measurement of light reflectance across all wavelengths of light comprising the full visible spectrum. Thus, reflectance can be used to measure the whiteness of the white ash. Commission of Illumination (CIE) Whiteness is a commonly used whiteness index. In various embodiments, the ash from the combustion of the shell has a CIE Whiteness measurement of at least 50. In various embodiments, the ash from the combustion of the shell has a CIE Whiteness measurement of 50, 60, 70, 80, 90, or 100. In various embodiments, the CIE Whiteness from the ash is a range between any two measurements.

The smokable product of various embodiments can include representative indicia. The representative indicia of various embodiments can, for example, identify the source of the smokable product or be decorative. The representative indicia of various embodiments can be associated with a smokable shell or be a part of the smokable shell. FIGS. 13, 14, and 15 shows a smokable product 10, 10′ having indicia 711.

The smokable product of various embodiments can include an end cover 720. The end cover of various embodiments can include materials that are visually pleasing or have tastes and smells that can be tasted or smelled by a user when used in combination with the smokable shell. Examples of materials that can be used include petals from flowers, foil such as gold leaf, gold, platinum, platinum gold, white gold, silver, or rose gold. FIG. 14 shows an end cover 720 positioned on a portion of an outer surface of the wall 110, 110′ and the 140, 140′ openable closed end in the closed position 141 of the smokable product 10, 10′.

The smokable product of various embodiments can include a smokable cover, where the smokable cover covers at least a portion of an outer surface of the wall of the smokable product or smokable shell. The smokable end cover can include materials that are visually pleasing or have tastes and smells that can be tasted or smelled by a user when used in combination with the smokable shell. The material is also combustible such that the addition of the material does not substantially impede the function of the smokable shell. Examples of materials that can be used include foil such as gold leaf, gold, platinum, platinum gold, white gold, silver, or rose gold. The cover can cover at least a portion of an outer surface of the wall of the smokable shell. FIG. 15 shows a smokable cover 730 positioned on an outer surface of the wall 110, 110′ and the 140, 140′ openable closed end in the closed position 141 of the smokable product 10, 10′.

In various embodiments, the smokable product is included as a finished product packaged for sale, where the smokable shell or smokable product may be contained within or covered with a packaging or container. The packaging or container may be configured to or may include at least one material configured to substantially prevent light or air from reaching the smokable shell or smokable product, the temperature of the smokable shell or smokable product from increasing, or both. FIG. 16 shows a finished product packaged for sale including the smokable product 10 or smokable shell 100 within a container 801. FIG. 17 shows a finished product packaged for sale including the smokable product 10 or smokable shell 100 within a first container 802 and FIG. 18 shows first containers 802 packed within a second container 803. FIGS. 17 and 18 also show the containers 801, 802, 803 having indicia 712, 713, 714.

In various embodiments kits are disclosed including a smokable shell and a smokable fill material. The smokable shell and smokable fill material can be packaged separately within the kit of various embodiments. The kit of various embodiments can also include packaging or a container containing the smokable product and smokable fill material.

Various methods of preparing a smokable product are disclosed, including the steps of:

freezing leaves at a temperature effective for forming ice nuclei or ice crystals for a predetermined time; and

arranging at least some of the leaves so that their primary veins are oriented in parallel and longitudinally to form a smokable shell, the smokable shell defining a cavity capable of receiving a smokable fill material.

The temperature is preferably about 0° C. or less. The methods of variations can also include the step of adding the smokable fill material to the cavity of the smokable shell.

FIGS. 19 and 20 are flow charts outlining methods of preparing leaves and smokable shells 1000, 1000′ of variations.

In step 2000, selected whole leaves 202′″ are selected and acquired for arrangement into a smokable shell. The selection 2000 of the selected whole leaves 202′″ of variations can be conducted when the stomates of the leaves are open. Stoma or stomates are pores found on the epidermis of the leaves that allows for gas exchange. Without being limited by theory, freezing the leaves when the stomates are open can increase the extent of the freeze damage. Also, stomates of the selected whole leaves 202′″ are open during ambient humidity (e.g. 50% to 60% humidity) or during the day. In variations, the whole leaves 202′″ are acquired at a humidity ranging from 30% to 100%. In variations, the whole leaves 202′″ are acquired at 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% humidity. In variations, the humidity is a range between any two humidities listed above. The selection 2000 of the selected whole leaves 202′″ of variations can also include steps of inducing the stomates of the leaves to open. This can include placing plants from which the leaves are acquired in artificial conditions such as environments with humidities as discussed above or with light intensities that stimulate the stomates to open. In variations, at least some of the selected whole leaves have a percentage of stomates open ranging from 30% to 100%. In variations, at least some of the selected whole leaves have 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% of stomates open prior to the freezing. In variations, the percentage of stomates that are open is a range between any two percentages listed above.

Step 3000 discloses freezing at a temperature effective for forming ice nuclei or ice crystals. Alternatively, step 3000 discloses freezing leaves at 0° C. or less for a predetermined time. In variations, the leaves are frozen at 0° C., −10° C., −20° C., −30° C., −40° C., −50° C., −60° C., −70° C., −80° C., −90° C., −100° C., −110° C., −120° C., −130° C., −140° C., −150° C., −160° C., −170° C., −180° C., −190° C., −200° C., or −210° C. In variations, the temperature is a range between any two temperatures listed above. The predetermined time of variations is 24 hours or more. In variations, the predetermined time is 1 day, 1.25 days, 1.5 days, 1.75 days, 2 days, 2.25 days, 2.5 days, 2.75 days, 3 days, 3.25 days, 3.5 days, 3.75 days, 4 days, 4.25 days, 4.5 days, 4.75 days, 5 days, 5.25 days, 5.5 days, 5.75 days, 6 days, 6.5 days, 1 week, 1.5 weeks, 2 weeks, 2.5 weeks, 3 weeks, 3.5 weeks, 4 weeks, 4.5 weeks, 5 weeks, 5.5 weeks, 6 weeks, 6.5 weeks, 7 weeks, 7.5 weeks, 8 weeks, 8.5 weeks, 9 weeks, 9.5 weeks, or 10 weeks. In variations, the predetermined time is a range between any two times listed above.

As shown in FIG. 23, the leaves 202″, 202′″ in step 3000 can be placed in a container 3010 and placed in a freezer or a freezing medium for a predetermined time 3020 to freeze 3030 the leaves 202″, 202′″. The freezing 3000, 3030 of the leaves 202″, 202′″ of variations can be conducted when the stomates of the leaves 202″, 202′″ are open. As previously discussed, curing techniques were inapplicable to leaves such as cannabis leaves since the resulting effect was the disintegration of the leaves in that the curing techniques caused the leaves to disintegrate. Freezing overcomes these limitations by inducing freeze damage to the leaves. Without being limited by theory, freezing places environmental stress on the leaves in that the formation of stable ice nucleus or nuclei forms on or within the leaves. For example, stable ice nuclei can form on or within the open stomates of the leaves. As the temperature continues to fall over time, the stable ice nucleus grows on, within, or throughout the leaves that can cause components of the leaves to freeze. The result of the freezing includes freezing-induced cellular dehydration, cell death from super cooling, or damage to organs of the leaves from, for example, large ice masses affecting tissue or organ structure, embolisms in the xylem, frost-burn, or ice-encasement that can cause hypoxic stress. For example, the freeze damage can include fractures in the cellular walls of the leaves.

In variations, the freezing step can further include freezing the leaves at 30% humidity or more. In variations, the freezing step can further include freezing the leaves at 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 100% humidity. In variations, the humidity of the freezing step is a range between any two humidities listed above. Freezing at humidities such as ambient humidities or more can increase the amount of ice nucleation on or within the leaves. The freezing step can also include combining the leaves with materials having specific heat capacities effective for increasing the number of ice nuclei or size of ice crystals, which can induce a greater level of freeze damage to the leaves relative to leaves frozen without the materials. Examples of the materials can include ice nucleators such as inorganic crystalline solids and silver iodide, amino acid crystals, monolayers of long chain alcohols, and organic compounds such as phloroglucinol and metaldehyde.

In variations, the freezing step includes freezing leaves at 0° C. or less for predetermined times. As shown in FIG. 19, the freezing step 3000 can be repeated 3001 multiple times. In variations, the freezing of leaves at a temperature effective for forming ice nuclei or ice crystals for a predetermined time is repeated 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 times. In variations, the number of times the freezing step is repeated is a range between any two number of times listed above. The temperature or predetermine time for the repeated step(s) 3001 can be the same or vary from the first freezing step 3000.

As shown in FIG. 19, step 4000 discloses extracting components from the leaves. Examples of components can include as cellular components, cells, chlorophyll, chloroplasts, sugars, starches, nutrients, water, terpenes, flavonoids, or terpenoids. The extracting step 4000 can be repeated 4001 a plurality of time. In variations, the extracting step 4000 is repeated 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 times. In variations, the number of times the extracting step 4000 is repeated 4001 is a range between any two number of times listed above.

In variations, the extracting step includes combining the leaves with a solvent for a predetermined time. As shown in the method 1000′ outlined in FIG. 20, the extracting step 4000 includes combining the leaves with a solvent 4100 for a predetermined time. The solvent extracting step 4100 as shown in FIG. 24 includes combining the leaves 202″ with a solvent 4120 in a container 3010, 4100 for a predetermined time 4130, 4140. Examples of solvents include ethanol, fruit infused ethanol, grape ethanol, anionic surfactants such as sodium lauryl sulfate, ionic surfactants such as polyethylene glycol, isopropyl alcohol, or Everclear (e.g. 75.5% to 95% ethanol or 151 to 190 proof ethanol). As the time 4130 progresses from (I) to (II) of FIG. 24, a concentration 4151 of components 4150 are extracted from the leaves 202′ and into the solvent 4120. The longer the leaves 202′, 202″ are combined with the solvent, the greater the concentration 4151, 4152 of the components 4150 in the solvent 4120. As the predetermined time 4130, 4140 is reached, a concentration 4152 of the components 4150 is extracted from the leaves 202 and into the solvent as shown in (III) of FIG. 24. Without being limited by theory, the removal of components such as chlorophyll or chloroplasts from the leaves can change the color of the leaves similar to the color change in leaves during the autumn season where colors from the carotenoids, anthocyanins, and cell wall are visible after removal of components. To this end, a user can vary the conditions of the extraction (e.g. solvent, predetermined time, plant strain, etc.) to achieve a desired color for the leaves.

In other variations, the extracting step can include other methods of extraction such as decellularization of the leaves by perfusing a solvent through the leaves. The other methods of extraction of variations can be done with or without freezing the leaves. Examples of decellularization are disclosed in: Ott, Harald C., et al. “Perfusion-decellularized matrix: using nature's platform to engineer a bioartificial heart.” Nature medicine 14.2 (2008): 213; Gershlak, Joshua R., et al. “Mesenchymal stem cells ability to generate traction stress in response to substrate stiffness is modulated by the changing extracellular matrix composition of the heart during development.” Biochemical and biophysical research communications 439.2 (2013): 161-166; and Guyette, Jacques P., et al. “Bioengineering human myocardium on native extracellular matrix.” Circulation research 118.1 (2016): 56-72. Each of these papers is incorporated in their entirety by reference.

In one example, a volume of the solvent is provided such that the selected whole leaves are capable of being submerged within the volume of the solvent. In variations, at least some of the selected whole leaves are combined with the solvent at ratio of weight (grams) of the selected whole leaves to a volume (milliliter) or weight of the solvent of 1:1, 1:10, 1:50, 1:100, 1:500, 1:1000, 1:5000; 1:10000; 1:50000; 1:100000; 1:500000; 1:1000000; 1:5000000. In variations, the ratio is a range between any two ratios listed above.

The predetermined time for the extracting 4000 or solvent extracting 4100 of variations is 24 hours or more. In variations, the predetermined time is 1 day, 1.25 days, 1.5 days, 1.75 days, 2 days, 2.25 days, 2.5 days, 2.75 days, 3 days, 3.25 days, 3.5 days, 3.75 days, 4 days, 4.25 days, 4.5 days, 4.75 days, 5 days, 5.25 days, 5.5 days, 5.75 days, 6 days, 6.5 days, 1 week, 1.5 weeks, 2 weeks, 2.5 weeks, 3 weeks, 3.5 weeks, 4 weeks, 4.5 weeks, 5 weeks, 5.5 weeks, 6 weeks, 6.5 weeks, 7 weeks, 7.5 weeks, 8 weeks, 8.5 weeks, 9 weeks, 9.5 weeks, or 10 weeks. In variations, the predetermined time is a range between any two times listed above.

In variations, the extracting step includes combining the leaves with a solvent for predetermined times. As shown in FIG. 20, the solvent extracting step 4100 can be repeated 4101 a plurality of times. In variations, the solvent extracting step 4100 is repeated 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 times. In variations, the number of times the solvent extracting step 4100 is repeated 4101 is a range between any two number of times listed above.

As shown in FIG. 20, the extracting step can also include a washing step 4200 where the selected whole leaves 202 are combined with a medium to remove excess solvent 4120 from the leaves 202. Also as shown in FIG. 20, the solvent extracting step 4100 (or the extracting step 4000) can be combined as a cycle 4201 which is repeated 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 times. In variations, the number of times the cycle 4201 is repeated is a range between any two number of times listed above.

The methods 1000, 1000′ of variations also includes the step of arranging the leaves into a shell 5000. As shown in FIGS. 21 and 22, the arranging step can include the steps of drying the leaves 5010 or flattening the leaves 5015. The drying step 5010 can include wiping the surface of the leaves to remove excess moisture to an extent where the leaves are still flexible for rolling. The flattening of the leaves 5015 can include applying a weighted object or a force to the leaves such that the thickness of the leaves is reduced to a desired thickness.

In variations, the arranging step further includes arranging a portion of the leaves such that primary veins on different leaves align to extend longitudinally along a wall of the smokable shell. As shown in FIGS. 21 and 22, the arranging step 5000 can include the steps of applying an adhesive to a blade of a leaf 5020, positioning another leaf on the leaf with the adhesive 5030, repeating 5031 the applying 5020 and positioning 5030 steps to attain desired dimensions, and modifying the arrangement of the leaves to form a sheet of treated leaves 5040.

Step 5020 is shown in FIG. 25, where an adhesive 900 is placed on a blade 2010 of a first leaf 202. Step 5030 is shown in FIG. 26, where a second leaf 202 is positioned and attached on the first leaf 202 via the adhesive 900 on the blade. As shown in FIG. 26, the leaves 202 are positioned relative to each other such that primary veins 230 align. In step 5031, the applying 5020 and positioning 5030 steps to form an arrangement 160 as shown in FIG. 7. Step 5040 is shown in FIG. 27, where the top and bottom edges of the arrangement 160 of leaves 202 are removed 5045 to form a sheet 170 of treated leaves 201 as shown in FIG. 8.

To form a shell 100 from the sheet 170, an adhesive 900 is applied 5050 to a portion of the sheet 170 adjacent to an edge 171, 172. A mold or mandrel 5051, 5052 is placed on a portion of the sheet 170 adjacent to an edge 171, 172 opposite the edge 171, 172 where the adhesive 900 is adjacent. In variations, the mold includes a material or component that prevents the mold from sticking to the shell. In one example, the mold is a plastic tube rolled in parchment paper to prevent the sheets from sticking to the tubes. Alternatively, the mold can be made of a non-stick material or have a coating preventing sticking of the sheet to the mold. As shown in FIG. 30, the mold 5051 can be made up of a plurality of molding elements 5052. The diameter of the mold can be selected based on the desired ring gauge and length for the smokable shell. As shown in FIG. 29, the sheet 170 is rolled 5060 around the mold 5051 with the primary veins arranged longitudinally to a point where the adhesive 900 contacts the shell 170 at a second point. In different examples, the rolling is accomplished in a manner such that the sheet is rolled to a predetermined thickness effective for combustion. For example, the rolling can be accomplished such that the sheet is rolled around at least once or at most twice around the mold.

In variations, the methods can include drying at least some of the treated leaves after the arranging step to remove a residual the moisture from the treated leaves and the treated leaves after removal are combustible. The methods of variations can include drying the leaves after the arranging step to remove 50% or more of the moisture from at least some of the leaves. In variations, the drying removes 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100% of the moisture. In variations, the drying removes a percentage of the moisture that is a range between any two percentages listed above. As highlighted in FIGS. 21, 22, and 31, the rolled sheet 170 after the rolling is dried 5070 and the mold 5051 is removed 5080, 5081 after the drying 5070. The rolled sheet 170 can be further trimmed 5090 after removal 5080, 5081 of the mold 5051, 5052 as shown in FIG. 32. Prior to the drying 5070, an end cover 720 or smokable cover 730 can be prepared and added 6000, 7000 to the shell 170.

To reduce a likelihood of warping or cracking, a second mold or mandrel 5102 can be inserted 5100,5101 into cavity 130 of the rolled sheet 170 as shown in FIG. 33. The second mold 5102 can be the same or different from the previously used mold 5051. After insertion 5100, 5101 of the second mold 5102, the rolled sheet 170 can be dried 5110. After drying 5110, the second mold 5102 can be removed and a filter 300 can be placed in the cavity 130 of the rolled sheet 170 to form the smokable product 10 as shown in FIG. 34. Indicia 711, 712 can be placed 8000 on the smokable product 10 and the smokable product 10 can be packaged for sale 9000 by placement into a container 801, 802, 803.

FIGS. 35, 36, 37, and 38 show steps of preparing an end cover and applying an end cover to a shell. As shown in FIG. 35, adhesive 900 is applied 6100 to components 721 forming the end cover 720. The components can be visually pleasing or have tastes and smells that can be tasted or smelled by a user when used in combination with the smokable shell. Examples of materials that can be used include petals from flowers, foil such as gold leaf, gold, platinum, platinum gold, white gold, silver, or rose gold. The components can also be prepared in a same manner 1000, 1000′ as the treated leaves. As shown in FIG. 36, the components 721 are repeatedly attached together 6200 to form a sheet 722. The sheet 722 as shown in FIG. 37 is attached the openable closed end 140, 140′ of the rolled sheet 170 and dried 5070 to form the end cover as shown in FIG. 38.

For the attachment 7000 of smokable cover 730, the second mold 5102 as shown in FIG. 30 is inserted in the cavity 130 of the rolled sheet 170. The smokable end cover can include materials that are visually pleasing or have tastes and smells that can be tasted or smelled by a user when used in combination with the smokable shell. The material is also combustible such that the addition of the material does not substantially impede the function of the smokable shell. Examples of materials that can be used include foil such as gold leaf, gold, platinum, platinum gold, white gold, silver, or rose gold. The materials can also be prepared in a same manner 1000, 1000′ as the treated leaves. Adhesive 900 is applied to a portion of the outer surface of the wall 110, 110′ or end 140, 140′, 150 of the rolled sheet 170. A smokable cover 730 is then attached to and manipulated to cover the outer surface of the wall 110, 110′ or end 140, 140′, 150 of the rolled sheet 170. After attachment, the smokable cover 730 and rolled sheet 170 are dried 5070 together.

The following examples illustrate some variations in the present disclosure. Those skilled in the art will recognize many variations that are within the spirit of the present disclosure and scope of the claims.

Preparation of Leaves

Leaves from a vegetative or flowering plant are removed from the plant. An example of the type of leave that are selected are fan leaves. The size of the leaves can include any or all different sizes or, in one example, be of a size similar to a size of a hand of an average human male. The thickness of the leaves can include any or leaf thicknesses. For example, leaves from hybrid plants such as hybrids derived various cannabis strains, species, or subspecies can have thicknesses that allow for a tight assembly when being arranged to form a smokable shell or molds.

The leaves are sorted relative to size and thickness such that each leaf when arranged will burn evenly. Sorting the leaves allows for selection of leaves that have a substantially uniform density or thickness or does not have a substantial variation in thickness. Substantial variations in thickness also could negatively impact function of the mold as a smokable product.

After sorting, the leaves are placed in container(s). The number of leaves placed in each container can give an approximation of how many molds or smokable products that can be prepared.

The container(s) are placed in a freezer, where the ambient temperature is reduced to and stored at 0° C. or less for a predetermined time. The predetermined time can be a time sufficient for freeze damage to occur to the leaves. Without being limited by theory, the freeze damage can cause the leaf wall or cell walls to crack or shatter. This can allow for easier or greater extraction of cellular components such as chlorophyll from the leaves. The predetermined time can also be relative to the thickness of the leaves as well. For example, the leaves can be stored at 0° C. or less for a predetermined time of 1 to 2 weeks.

After storage for a predetermined time, the leaves are solvent extracted for a predetermined time to remove cellular components of the leaves such as chlorophyll, starches, sugars and nutrients from the leaves. Examples of solvents that can be used include ethanol, fruit infused ethanol, grape ethanol, isopropyl alcohol, or Everclear (e.g. 75.5% to 95% ethanol or 151 to 190 proof ethanol). An example of the solvent extraction process includes combining leaves with a solvent for a period of time, which can also be accomplished by submerging the leaves in a volume of solvent. Without being limited by theory, the solvent diffuses more thoroughly through the freeze damaged leaves as compared to non-damaged leaves and is capable of solubilizing a greater concentration of cellular components as compared to non-damaged leaves when combined with a solvent. When solubilized, the cellular components diffuse from the leaves. In different examples, the leaves can be combined with a solvent for one, two, or three weeks. In other examples, the solvent extraction process can include multiple solvent extractions steps or cycles where the leaves are combined with solvent for predetermined periods of time. In these examples, a cycle can include: combining the leaves with solvent; removing the solvent; and combining the leaves with solvent. The cycle can also be repeated two, three, or four times in different examples. The solvent extraction process can be also undertaken to achieve a desired color for the leaves.

After removing the leaves from the solvent, the remaining solvent has a green color from the components extracted from the leaves. This solvent can be placed into a distiller to reclaim the solvent. After reclamation of the solvent, the left-over components can be utilized to form other products. For example, a green sticky hash oil chlorophyll extract can be utilized in cannabis edibles or making a pressed cannabis chlorophyll pill.

After solvent extraction, the leaves can be washed to remove additional solvent or cellular components from the leaves. Examples of mediums that can be used for washing the leaves include water, distilled water, mineral water, filtered water. An example of the wash process includes submerging the leaves in a medium for a predetermined time such as 1 hour. The wash process can be also undertaken to achieve a desired color for the leaves.

The solvent extraction process and the wash process can also be undertaken sequentially as a cycle such that the leaves can prepared with multiple cycles of solvent extraction and wash processes. For example, the leaves can be prepared with one, two, three, or four cycles of solvent extraction and wash processes.

Preparation of Adhesive

An adhesive for attaching adjacent leaves of the smokable product. The adhesive can include a thickener and a compound capable of forming a polymer matrix and an example of preparing the adhesive is provided below. In one example, the adhesive includes pectin as the thickener and gelatin as a compound capable of forming a polymer matrix. The pectin and gelatin can be combined a 1:1 ratio. For example, the ratio of pectin to gelatin can be 1 fluid ounce of pectin to 1 fluid ounce gelatin. In an example preparation of the adhesive, a desired amount of gelatin is combined with boiling water (˜100° C.) to soften the gelatin. After solubilization of the gelatin in water, the gelatin can be kept at a temperature between room temperature (>25° C.) and boiling (<100° C.). A desired amount of pectin is mixed with the gelatin. The adhesive can have a viscosity such that it is capable of being applied to a leaf and a stickiness for arranging of the leaves. The adhesive can also be colorless, odorless, or tasteless.

Arranging of Leaves to Form Smokable Shells

After the solvent extraction or wash steps, the surfaces of the leaves are also wiped dry.

In arranging the leaves, a leaf is placed on a surface with a side of the leaf having the primary vein and secondary veins extending longitudinally. A thin layer of the adhesive is applied to a blade or lamina of the leaf After application of the adhesive, a second leaf is placed on the adhesive such that the leaves are attached together after the adhesive has dried. When positioning the second leaf on the adhesive layer, the secondary veins of the second leaf are placed over the secondary veins of the first leaf such that the secondary veins from the first leaf appear to continue to extend to the secondary veins of the second leaf.

A thin layer of the adhesive is then applied to an opposite blade or lamina of the second leaf. After application of the adhesive, a third leaf is placed on the adhesive such that the third leaf is attached to the second leave after the adhesive has dried. When positioning the third leaf on the adhesive layer, the secondary veins of the third leaf are placed over the secondary veins of the second leaf such that the secondary veins from the second leaf appear to continue to extend to the secondary veins of the third leaf and some of the secondary veins from the first leaf appear to continue to extend to some of the secondary veins of the third leaf.

The combining of the leaves forms a sheet to which the application of the adhesive and the positioning of subsequent leaves are repeated until a desired length for the sheet is reached. At this point, the leaves are arranged such that there appears to be semi-continuous or continuous lines on the sheet. This pattern allows for the smokable shell to burn evenly. The veins of the leaf mimic a pattern and burn like a wick, thus creating an even burn when a user draws from the smokable shell during smoking. As the combustion zone travels down the smokable shell, the veins spiral in a circular form around the shell product. When the sheet is at the desired length, the bottom and top tips of the leaves are removed.

After the sheets are formed, a cylindrical mold is used in the rolling process. In one example, the mold is a custom plastic tubes. The diameter of the mold can be selected based on the desired ring gauge and length for the smokable shell. The plastic tube is rolled in parchment paper to prevent the sheets from sticking to the tubes. Alternatively, the mold can be made of a non-stick material or have a coating preventing sticking of the sheet to the mold.

During the rolling, adhesive is placed on an end of the sheet. The tube is placed on the other end of the sheet and the sheet is rolled around the tube to a point where the adhesive contacts a portion of the sheet that is rolled on to the tube. Once the sheet has been rolled on to the tube, one end of the sheet is collapsed to for a closed end. In different examples, the rolling is accomplished in a manner such that sheet is rolled to a predetermined thickness effective for combustion. For example, the rolling can be accomplished such that sheet is rolled around at least once or at most twice around the tube. In other word, the complete smokable shell in different examples can have one or two layers.

The rolled sheet is slowly dried for at least 24 hours at 75° F. (23.89° C.) at a humidity ranging from 0% to 65% humidity. After drying, the plastic tube and parchment paper are removed. After removal of the tube and sheet, the tube is reinserted into the cavity of the rolled sheet and the rolled sheet is slowly again dried for at least 24 hours at 75° F. (23.89° C.) at a humidity ranging from 0% to 65% humidity to prevent warping and misshaping.

After the second drying step, the plastic tube is removed from the rolled sheet and a filter is positioned within the cavity adjacent to the proximal end. At this point, rolled sheet is a smokable shell. An example of a filter includes a corn husk spliff filters. The filters are prepared by 3-D printing or striping the husk into strips and rolling them to the desired size for the smokable shell. The filters allow the right balance of airflow as a person takes a draw from the smokable product. The corn husk filter is made from natural corn husk. As a result of the filter, the user's fingers are isolated from the leaves of the smokable shell.

After placement of the filter and gluing the filter to the leaves, the smokable shell is labelled and packaged. The shells are then inspected for cracks ensuring the finished product is completed.

Preparing a Smokable Product Using Thai-Stick Method

A smokable product can be prepared by a method similar to a thai-stick method. Using a mold, a fill material or smokable material can be pressed onto a stick or rod. In this example, cannabis buds are attached to a rod. The buds and rod can be placed within a mold or wrapped with a conforming element such as a rope or hemp wick and stored for 24 hours at a temperature ranging from 55° F. to 75° F. (12.78° C. to 23.89° C.) at 62% humidity. The mold or wrap can compress the fill material (e.g. cannabis bud) to size and shape for being received in the cavity of the smokable shell After storage, the compress fill material can be inserted into the cavity of the smokable shell.

Alternatively after the cannabis buds are attached to the rod, the buds and rod can be placed within smokable shell and stored for a time period of 24 hours, months, or years at a temperature ranging from 55° F. to 75° F. (12.78° C. to 23.89° C.) at 62% humidity.

Preparing Smokable Shell With an End Having a Smokable End Cover

The smokable shell can be prepared with a smokable end cover. The smokable end cover can include materials that are visually pleasing or have tastes and smells that can be tasted or smelled by a user when used in combination with the smokable shell. Examples of materials that can be used include petals from flowers, foil such as gold leaf, gold, platinum, platinum gold, white gold, silver, or rose gold. The following is an example of the preparation of a smokable end cover with the smokable shell, where the end cover includes petals from a rose plant or plants from the genus Rosa.

Petals from a rose plant are removed from a rose plant and prepared in a manner similar to the preparation of the leaves for the smokable shell of any embodiment. In one example, the leaves are: stored at 0° C. or less for a predetermined time; solvent extracted for a predetermined time; or washed to remove excess solvent from the petals.

The prepared petals are arranged to cover an end of the smokable shell such as an end where a user can draw smoke from. The petals are arranged similar to the arrangement of the leaves for the smokable shell of any embodiment. For example, a thin layer of the adhesive is applied to a portion of a first petal and a second petal placed on the portion such that the second petal is attached to the first petal. The petals are arranged to form a sheet having a surface area that can cover an end of the smokable shell and a portion of an outer surface of a wall of the smokable shell.

After forming the sheet, a thin layer of adhesive is applied the sheet. The sheet is positioned on the smokable shell such that the adhesive attaches the sheet to the smokable shell. During the attachment, the sheet is manipulated to generally conform to the shape of the end and a portion of the smokable shell and dried for 48 hours at a temperature ranging from 60° F. to 80° F. (15.56° C. to 26.67° C.) at a humidity ranging from 0% to 62%.

Preparing a Smokable Shell Having a Cover

The smokable shell can be prepared with a smokable end cover. The smokable end cover can include materials that are visually pleasing or have tastes and smells that can be tasted or smelled by a user when used in combination with the smokable shell. The material is also combustible such that the addition of the material does not substantially impede the function of the smokable shell. Examples of materials that can be used include foil such as gold leaf, gold, platinum, platinum gold, white gold, silver, or rose gold. The cover can cover at least a portion of an outer surface of the wall of the smokable shell. The following is an example of the preparation of a smokable cover with the smokable shell, where the cover includes gold leaf or 24 karat gold leaf, where the cover generally covers the outer surfaces of the wall and ends of the smokable shell.

Prior to adding the gold leaf cover, a mold or a plurality of molds is inserted into the cavity of the smokable shell to prevent the shell from warping. The molds include or be made resiliently deformable materials such as plastics, wood, or straws. In the example, the plurality of molds are hollow flexible cylinders (e.g. straws) having bore diameters smaller than the diameter of the cavity of the smokable shell.

A thin layer of the adhesive is applied to a portion of the outer surface of the wall or end of the smokable shell. A sheet of gold leaf is then attached to and manipulated to cover the outer surface of the wall and ends of the smokable shell. After attachment of the sheet, the smokable shell is dried for 1 minute a temperature ranging from 50° F. to 75° F. (10° C. to 23.89° C.) at 62% humidity and the plurality of molds are removed.

Among the benefits conferred by the disclosed product and method of manufacture are: lower manufacturing cost and less leaking because there are fewer leaves per smokable product; improved shell smoothness, less cracking and enhanced evenness in burning because there are fewer material discontinuities;

While exemplary embodiments and variations are described above, it is not intended that these embodiments and variations describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments and variations may be combined to form further embodiments and variations of the invention.

	Number	Date	Country
Parent	16148745	Oct 2018	US
Child	16871374		US

SMOKABLE SHELLS WITH PREFERABLY ORIENTED LEAVES AND METHODS FOR THEIR PREPARATION

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CROSS REFERENCE TO RELATED APPLICATION

Continuation in Parts (1)