Methods for forming reconstituted tobacco

Abstract

A method for forming a final reconstituted tobacco sheet, the method comprising: receiving a tobacco input comprising a plurality of tobacco materials, the tobacco input comprising a first reconstituted tobacco material and at least one additional tobacco material; extracting the tobacco input (100) to form a tobacco extract and a tobacco pulp; separating the tobacco extract and the tobacco pulp (102); forming the tobacco pulp into a web (106); applying at least a portion of the tobacco extract to the web (108); and drying the web (110) to form a reconstituted tobacco output.

Description

[Technical Field]

[0001] This disclosure relates to products made or derived from tobacco, or incorporating tobacco, intended for human use and methods of making the same. Tobacco-derived products can be used in a variety of products, including smokeless oral products and smoking articles. [Background technology]

[0002] Paper is a cellulose pulp-derived material that can be used for many different products and applications. For each papermaking process, there is a correlation between the fibers used and the properties of the final paper product. See, for example, U.S. Pat. No. 5,582,681 to Back et al.; Sabharwal, H.S., Akhtar, M., Blanchette, R.A., and Young, R.A., Refiner Mechanical and Biomechanical Pulping of Jute, Holzforschung 49:537-544, 1995; and Mohta, D., Roy, D.N., and Whiting, P., Production of Refiner Mechanical Pulp From Kenaf for Newsprint in Developing Countries, TAPPI Journal Vol. 3(4), 2004, each of which is incorporated herein by reference in its entirety. The quality of the final paper product and the type of paper product produced also depend on the pulping, refining, and other common papermaking processes used.

[0003] Various methods for producing reconstituted tobacco use papermaking techniques. In a typical papermaking reconstituted tobacco process, tobacco is extracted with water, and the resulting water-soluble extract and water-insoluble pulp are separated from each other. The pulp portion can be refined to a desired consistency and formed into a mat or web, similar to wood pulp fibers in traditional papermaking processes. A water-soluble tobacco extract is applied to the insoluble pulp mat, and the resulting mixture is dried to produce a reconstituted tobacco sheet from which the tobacco component can be obtained. Tobacco stems are typically used in producing such reconstituted tobacco sheets, as their fibrous nature provides strength and structural integrity to the resulting sheet. See, for example, U.S. Pat. No. 3,398,754 to Tughan, U.S. Pat. No. 3,847,164 to Mattina, U.S. Pat. No. 4,131,117 to Kite, U.S. Pat. No. 4,182,349 to Selke, U.S. Pat. No. 4,270,552 to Jenkins, U.S. Pat. No. 4,308,877 to Mattina, U.S. Pat. No. 4,341,228 to Keritsis, U.S. Pat. No. 4,421,126 to Gellatly, U.S. Pat. No. 4,706,692 to Gellatly, U.S. Pat. No. 4,706,692 to Thom, all of which are incorporated herein by reference. See U.S. Pat. No. 4,962,774 to Asson, U.S. Pat. No. 4,941,484 to Clapp, U.S. Pat. No. 4,987,906 to Young, U.S. Pat. No. 5,056,537 to Brown, U.S. Pat. No. 5,143,097 to Sohn, U.S. Pat. No. 5,159,942 to Brinkley et al., U.S. Pat. No. 5,325,877 to Young, U.S. Pat. No. 5,445,169 to Brinkley, U.S. Pat. No. 5,501,237 to Young, and U.S. Pat. No. 5,533,530 to Young.

[0004] Paper-based materials and reconstituted tobacco materials are commonly associated with and / or incorporated into oral tobacco products and smoking articles, such as cigarettes and cigars, which burn tobacco during use to produce tobacco smoke. Certain alternatives to smoking articles also exist that release inhalable aerosols or vapors by heating, without combustion, a compound from a substrate material. These are sometimes referred to as non-combustion smoking articles, aerosol-generating assemblies, or non-combustion aerosol-delivery systems. One example of such a product is a heating device that releases a compound by heating, but not burning, a solid aerosolizable material. This solid aerosolizable material may, in some cases, include tobacco material. The heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products are sometimes referred to as non-combustion heating devices, tobacco heating devices, or tobacco heating products (THPs). A variety of different configurations for volatilizing at least one component of a solid aerosolizable material are known.

[0005] Another example is an e-cigarette / tobacco heating product hybrid device, also known as an e-cigarette hybrid device. These hybrid devices include a liquid source (which may or may not contain nicotine) that is vaporized by heating to produce an inhalable vapor or aerosol. These devices also include a solid aerosolizable material (which may or may not contain tobacco material), the components of which are mixed into the inhalable vapor or aerosol to produce the inhalation medium. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Patent No. 5,582,681 [Patent Document 2] U.S. Patent No. 3,398,754 [Patent Document 3] U.S. Patent No. 3,847,164 [Patent Document 4] U.S. Patent No. 4,131,117 [Patent Document 5] U.S. Patent No. 4,182,349 [Patent Document 6] U.S. Patent No. 4,270,552 [Patent Document 7] U.S. Patent No. 4,308,877 [Patent Document 8] U.S. Patent No. 4,341,228 [Patent Document 9] U.S. Patent No. 4,421,126 [Patent Document 10] U.S. Patent No. 4,706,692 [Patent Document 11] U.S. Patent No. 4,962,774 [Patent Document 12] U.S. Patent No. 4,941,484 [Patent Document 13] U.S. Patent No. 4,987,906 [Patent Document 14] U.S. Patent No. 5,056,537 [Patent Document 15] U.S. Patent No. 5,143,097 [Patent Document 16] U.S. Patent No. 5,159,942 [Patent Document 17] U.S. Patent No. 5,325,877 [Patent Document 18] U.S. Patent No. 5,445,169 [Patent Document 19] U.S. Patent No. 5,501,237 [Patent Document 20] U.S. Patent No. 5,533,530 [Non-patent literature]

[0007] [Non-Patent Document 1] Sabharwal, HS, Akhtar, M., Blanchette, RA, and Young, RA, Refiner Mechanical and Biomechanical Pulping of Jute, Holzforschung 49:537-544, 1995. [Non-patent document 2] Mohta, D., Roy, DN, and Whiting, P., Production of Refiner Mechanical Pulp From Kenaf for Newsprint in Developing Countries, TAPPI Journal Vol.3(4), 2004 Summary of the Invention [Means for solving the problem]

[0008] The present disclosure relates to methods for producing reconstituted tobacco, wherein at least a portion of a tobacco input used to produce the reconstituted tobacco sheet comprises reconstituted tobacco. In some aspects, the present disclosure provides methods for forming a reconstituted tobacco sheet. Such methods may include receiving a tobacco input comprising a plurality of tobacco materials, the tobacco input comprising a first reconstituted tobacco material and at least one additional tobacco material. In some embodiments, such methods further include extracting the tobacco input to form a tobacco extract and a tobacco pulp. In certain embodiments, such methods include separating the tobacco extract and the tobacco pulp and forming the tobacco pulp into a web. In some embodiments, such methods include applying at least a portion of the tobacco extract to the web and, optionally, drying the web to form a reconstituted tobacco output.

[0009] In some aspects of the disclosed methods, the first reconstituted tobacco material is in the form of shredded material. In some embodiments, the first reconstituted tobacco input comprises about 5 to about 50 weight percent tobacco input, based on the total weight of the tobacco input. In some embodiments, the at least one additional tobacco material comprises tobacco stems. In such embodiments, the tobacco stems may be present in an amount of about 15 to about 95 weight percent tobacco input, based on the total weight of the tobacco input. In certain embodiments, the at least one additional tobacco material comprises tobacco lamina. In such embodiments, the tobacco lamina is present in an amount of about 15 to about 95 weight percent tobacco input, based on the total weight of the tobacco input. In certain embodiments, the at least one additional tobacco material comprises a second reconstituted tobacco material. In such embodiments, the second reconstituted tobacco material comprises about 5 to about 50 weight percent tobacco input, based on the total weight of the tobacco input.

[0010] In yet other aspects of the disclosed methods, the tobacco input further comprises an active ingredient and / or a flavoring agent. In such embodiments, the active ingredient may be selected from the group consisting of a nicotine component, a botanical, a stimulant, a dietary supplement, an amino acid, a vitamin, a cannabinoid, a cannabimimetic, a terpene, and combinations thereof. Some embodiments of the disclosed methods further comprise adding the active ingredient and / or a flavoring agent to the tobacco pulp, a web formed from the tobacco pulp, and / or a tobacco extract applied to the web. In such embodiments, the active ingredient is selected from the group consisting of a nicotine component, a botanical, a stimulant, a dietary supplement, an amino acid, a vitamin, a cannabinoid, a cannabimimetic, a terpene, and combinations thereof. In some embodiments of the disclosed methods, the tobacco input may further comprise one or more ingredients selected from the group consisting of a flavoring agent, a filler, a binder, a pH adjuster, a buffer, a colorant, a disintegration aid, an antioxidant, a humectant, and a preservative.

[0011] In some embodiments, the disclosed method further comprises adding one or more ingredients selected from the group consisting of flavorings, fillers, binders, pH adjusters, buffers, colorants, disintegration aids, antioxidants, humectants, and preservatives to the tobacco pulp, the web formed from the tobacco pulp, and / or the tobacco extract applied to the web. In some embodiments, the step of extracting the tobacco input is carried out at a temperature of about 55°C to about 65°C for about 1.5 to 2 hours. In certain embodiments of the disclosed method, the tobacco input is extracted with water, and the weight ratio of water to tobacco input is in the range of about 4:1 to about 10:1. Some embodiments of the disclosed method further comprise refining the pulp to a consistency of about 10 to 30% prior to forming the web. In some embodiments, about 50% to about 100% of the tobacco extract is applied to the web. In some embodiments, the final reconstituted tobacco sheet has a moisture content of about 5 to about 15%, based on the total weight of the final reconstituted tobacco sheet. In some embodiments of the disclosed methods, extracting the tobacco input comprises separately extracting each of the plurality of tobacco materials, hi certain embodiments, extracting the tobacco input comprises blending the plurality of tobacco materials to form a blended material and extracting the blended material.

[0012] In some embodiments, methods provided by the present disclosure include receiving a second tobacco input, the second tobacco input including a reconstituted tobacco output and at least one additional tobacco material. Such methods may further include extracting the second tobacco input to form a second tobacco extract and a second tobacco pulp, separating the second tobacco extract and the second tobacco pulp, forming the second tobacco pulp into a second web, applying at least a portion of the second tobacco extract to the second web, and drying the second web to form a second reconstituted tobacco output.

[0013] In some other aspects, the present disclosure provides a final reconstituted tobacco sheet prepared according to any of the foregoing methods disclosed herein. In such embodiments, the final reconstituted tobacco sheet has a lower TSNA concentration compared to a reconstituted tobacco sheet formed from a control tobacco input substantially free of reconstituted tobacco. In yet other aspects, the present disclosure provides a substrate for use in an aerosol delivery device, the substrate comprising the final reconstituted tobacco sheet provided herein.

[0014] In a further aspect, the present disclosure provides a reconstituted tobacco material comprising tobacco pulp and a tobacco extract applied to the tobacco pulp. In some embodiments, at least a portion of the tobacco pulp comprises reconstituted tobacco pulp, and at least a portion of the tobacco extract comprises an extract from the reconstituted tobacco material. In some embodiments, the hot water soluble content is about 20 to about 60% by weight of the reconstituted tobacco material. In certain embodiments, the hot water soluble content is about 30 to about 50% by weight of the reconstituted tobacco material. In some embodiments, the reconstituted tobacco material may further comprise an aerosol-forming material in an amount of about 10 to about 50% by weight of the reconstituted tobacco material. In certain embodiments, the reconstituted tobacco material may further comprise an aerosol-forming material in an amount of about 10 to about 30% by weight of the reconstituted tobacco material.

[0015] In some aspects of the present disclosure, the aerosol-forming material comprises one or more polyols. In such embodiments, the one or more polyols are selected from the group consisting of glycerol, propylene glycol, and combinations thereof. In some embodiments, the reconstituted tobacco material has a moisture content of about 5% to about 25% (5-15%) by weight, based on the total weight of the reconstituted tobacco material. In some embodiments, the reconstituted tobacco material has a moisture content of about 5% to about 15% by weight, based on the total weight of the reconstituted tobacco material.

[0016] The present invention includes, but is not limited to, the following embodiments.

[0017] Embodiment 1: A method for forming a reconstituted tobacco sheet, the method comprising: receiving a tobacco input comprising a plurality of tobacco materials, the tobacco input comprising a first reconstituted tobacco material and at least one additional tobacco material; extracting the tobacco input to form a tobacco extract and a tobacco pulp; separating the tobacco extract and the tobacco pulp; forming the tobacco pulp into a web; applying at least a portion of the tobacco extract to the web; and drying the web to form a reconstituted tobacco output.

[0018] Embodiment 2: The method of embodiment 1, wherein the first reconstituted tobacco material is in the form of shredded material.

[0019] Embodiment 3: The method of any one of embodiments 1 or 2, wherein the first reconstituted tobacco input comprises about 5 to about 50 wt% tobacco input, based on the total weight of the tobacco input.

[0020] Embodiment 4: The method of any one of embodiments 1 to 3, wherein the at least one additional tobacco material comprises tobacco stem.

[0021] Embodiment 5: The method of any one of embodiments 1 to 4, wherein the tobacco stems are present in an amount of about 15 to about 95% by weight, based on the total weight of the tobacco input.

[0022] Embodiment 6: The method of any one of embodiments 1 to 5, wherein the at least one additional tobacco material comprises tobacco lamina.

[0023] Embodiment 7: The method of any one of embodiments 1 to 6, wherein the tobacco lamina is present in an amount of about 15 to about 95% by weight, based on the total weight of the tobacco input.

[0024] Embodiment 8: The method of any one of embodiments 1 to 7, wherein the at least one additional tobacco material comprises a second reconstituted tobacco material.

[0025] Embodiment 9: The method of any one of embodiments 1 to 8, wherein the second reconstituted tobacco material comprises about 5 to about 50 wt% tobacco input, based on the total weight of the tobacco input.

[0026] Embodiment 10: The method of any one of embodiments 1 to 9, wherein the tobacco input further comprises an active ingredient and / or a flavoring agent.

[0027] Embodiment 11: The method of any one of embodiments 1 to 10, wherein the active ingredient is selected from the group consisting of a nicotine component, a botanical, a stimulant, a dietary supplement, an amino acid, a vitamin, a cannabinoid, a cannabimimetic, a terpene, and combinations thereof.

[0028] Embodiment 12: The method of any one of embodiments 1 to 11, further comprising adding an active ingredient and / or flavoring agent to the tobacco pulp, the web formed from the tobacco pulp, and / or the tobacco extract applied to the web.

[0029] Embodiment 13: The method of any one of embodiments 1 to 12, wherein the active ingredient is selected from the group consisting of a nicotine component, a botanical, a stimulant, a dietary supplement, an amino acid, a vitamin, a cannabinoid, a cannabimimetic, a terpene, and combinations thereof.

[0030] Embodiment 14: The method of any one of embodiments 1 to 13, wherein the tobacco input further comprises one or more ingredients selected from the group consisting of flavorings, fillers, binders, pH adjusters, buffers, colorants, disintegration aids, antioxidants, humectants, and preservatives.

[0031] Embodiment 15: The method of any one of embodiments 1 to 14, further comprising adding one or more ingredients selected from the group consisting of flavoring agents, fillers, binders, pH adjusters, buffers, colorants, disintegration aids, antioxidants, humectants, and preservatives to the tobacco pulp, the web formed from the tobacco pulp, and / or the tobacco extract applied to the web.

[0032] Embodiment 16: The method of any one of embodiments 1 to 15, wherein extracting the tobacco input is carried out at a temperature of about 55°C to about 65°C for about 1.5 hours to 2 hours.

[0033] Embodiment 17: The method of any one of embodiments 1 to 16, wherein the tobacco charge is extracted with water, and the weight ratio of water to tobacco charge is within the range of about 4:1 to about 10:1.

[0034] Embodiment 18: The method of any one of embodiments 1 to 17, further comprising refining the pulp to a consistency of about 10-30% before forming the web.

[0035] Embodiment 19: The method of any one of embodiments 1 to 18, wherein about 50% to about 100% of the tobacco extract is applied to the web.

[0036] Embodiment 20: The method of any one of embodiments 1 to 19, wherein the final reconstituted tobacco sheet has a moisture content of about 5% to about 15%, based on the total weight of the final reconstituted tobacco sheet.

[0037] Embodiment 21: The method of any one of embodiments 1 to 20, wherein extracting the tobacco input comprises separately extracting each of the plurality of tobacco materials.

[0038] Embodiment 22: The method of any one of embodiments 1 to 21, wherein extracting the tobacco input comprises blending a plurality of tobacco materials to form a blended material, and extracting the blended material.

[0039] Embodiment 23: The method of any one of embodiments 1 to 22, further comprising receiving a second tobacco input, the second tobacco input comprising a reconstituted tobacco output and at least one additional tobacco material; extracting the second tobacco input to form a second tobacco extract and a second tobacco pulp; separating the second tobacco extract and the second tobacco pulp; forming the second tobacco pulp into a second web; applying at least a portion of the second tobacco extract to the second web; and drying the second web to form a second reconstituted tobacco output.

[0040] Embodiment 24: A final reconstituted tobacco sheet prepared according to the method of any one of embodiments 1 to 23.

[0041] Embodiment 25: The final reconstituted tobacco sheet of embodiment 24, wherein the final reconstituted tobacco sheet has a reduced concentration of TSNAs compared to a reconstituted tobacco sheet formed from a control tobacco input substantially free of reconstituted tobacco.

[0042] Embodiment 26: A substrate for use in an aerosol delivery device, the substrate comprising the final reconstituted tobacco sheet of embodiment 24 or 25.

[0043] Embodiment 27: A reconstituted tobacco material comprising tobacco pulp and a tobacco extract applied to the tobacco pulp, wherein at least a portion of the tobacco pulp comprises reconstituted tobacco pulp and at least a portion of the tobacco extract comprises an extract from the reconstituted tobacco material.

[0044] Embodiment 28: The reconstituted tobacco material of embodiment 28, wherein the hot water solubles content is about 20 to about 60% by weight of the reconstituted tobacco material.

[0045] Embodiment 29: The reconstituted tobacco material of any one of embodiments 27 or 28, wherein the hot water solubles content is about 30 to about 50% by weight of the reconstituted tobacco material.

[0046] Embodiment 30: The reconstituted tobacco material of any one of embodiments 27 to 29, further comprising an aerosol-forming material in an amount of about 10% to about 50% by weight of the reconstituted tobacco material.

[0047] Embodiment 31: The reconstituted tobacco material of any one of embodiments 27 to 30, further comprising an aerosol-forming material in an amount of about 10 to about 30% by weight of the reconstituted tobacco material.

[0048] Embodiment 32: The reconstituted tobacco material of any one of embodiments 27 to 31, wherein the aerosol-forming material comprises one or more polyols.

[0049] Embodiment 33: The reconstituted tobacco material of any one of embodiments 27 to 32, wherein the one or more polyols are selected from the group consisting of glycerol, propylene glycol, and combinations thereof.

[0050] Embodiment 34: The reconstituted tobacco material of any one of embodiments 27 to 33, wherein the moisture content of the reconstituted tobacco material is about 5% to about 25% by weight (5-15%), based on the total weight of the reconstituted tobacco material.

[0051] Embodiment 35: The reconstituted tobacco material of any one of embodiments 27 to 34, wherein the moisture content of the reconstituted tobacco material is from about 5% to about 15% by weight, based on the total weight of the reconstituted tobacco material.

[0052] Embodiment 36: An aerosol delivery device comprising: a reconstituted tobacco material according to any one of embodiments 27 to 35; a heat source configured to heat the substrate to form an aerosol; and an aerosol pathway extending from the substrate to the mouth end of the aerosol delivery device.

[0053] Embodiment 37: The aerosol delivery device of embodiment 36, wherein the heat source comprises either an electric heating element or a combustible ignition source.

[0054] These and other features, aspects, and advantages of the present disclosure will become apparent from the following detailed description read in conjunction with the accompanying drawings, which are briefly described below. The present invention includes any combination of two, three, four, or more of the foregoing embodiments, as well as combinations of any two, three, four, or more features or elements described in this disclosure, regardless of whether such features or elements are explicitly combined in the description of a particular embodiment herein. The present disclosure, in any of its various aspects and embodiments, is intended to be read as a whole such that any separable features or elements of the disclosed invention are intended to be combinable unless the context clearly dictates otherwise.

[0055] Having thus described aspects of the present disclosure in general terms above, reference is now made to the accompanying drawings, which are not necessarily drawn to scale, and which are illustrative only and are not to be construed as limiting the disclosure. [Brief explanation of the drawings]

[0056] [Figure 1] FIG. 1 is a flow diagram illustrating the general steps of a method for producing reconstituted tobacco according to one embodiment of the present disclosure. [Figure 2] 1 is an exploded view of an exemplary embodiment of a smoking article, according to an exemplary embodiment of the present disclosure; FIG. [Figure 3]FIG. 1 shows a perspective view of an aerosol delivery device according to an exemplary embodiment of the present disclosure. [Figure 4] FIG. 4 shows a perspective view of the aerosol delivery device of FIG. 3 with the outer wrap removed, according to an embodiment of the present disclosure. [Figure 5] 1 shows a perspective view of an aerosol delivery device comprising a control body and an aerosol generation component, wherein the aerosol generation component and the control body are coupled to one another, according to an exemplary embodiment of the present disclosure. [Figure 6] FIG. 6 shows a perspective view of the aerosol delivery device of FIG. 5, in which the aerosol generation component and the control body are separated from each other, according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0057] The present invention will be described in more detail below. However, the present invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. As used in this specification and claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0058] One type of method for producing reconstituted tobacco involves the use of papermaking techniques. As used herein, the term "paper" is meant to include any sheet or board made from fiber or cellulosic materials, including paperboard. As used herein, the terms "paperboard" or "fiberboard" are used to refer to any solid support material made from fiber or cellulosic materials, such as cardboard or other paper products. Paperboard is generally a thicker form of paper. In various embodiments, the thickness (i.e., caliper) of paper is expressed in mils for paper and points for paperboard, however, both 1 mil and 1 point are equivalent to 0.001 inch. Density is expressed as mass per unit volume, and bulk is the reciprocal of density. The reconstituted tobacco products disclosed herein have a variety of potential applications in smokeless oral products and aerosol delivery devices; however, possible uses of reconstituted tobacco according to the present disclosure are not limited to the embodiments discussed herein.

[0059] The general steps for producing reconstituted tobacco sheets are known in the art, for example, U.S. Patent No. 3,398,754 to Tughan, U.S. Patent No. 3,847,164 to Mattina, U.S. Patent No. 4,131,117 to Kite, U.S. Patent No. 4,270,552 to Jenkins, U.S. Patent No. 4,308,877 to Mattina, U.S. Patent No. 4,341,228 to Keritsis, U.S. Patent No. 4,421,126 to Gellatly, U.S. Patent No. 4,706,692 to Gellatly, U.S. Patent No. 4,341,228 to Thomasson, U.S. Patent No. 4,421,126 to Gellatly, U.S. Patent No. 4,706,692 to Thomasson, U.S. Patent No. 4,341,228 to Thomasson, U.S. Patent No. 4,421,126 to Thomasson, U.S. Patent No. 4,706,692 to Thomasson, U.S. Patent No. 4,341,228 to Thomasson, U.S. Patent No. 4,341,228 to Thomasson, U.S. Patent No. 4,421,126 ...706,692 to Thomasson, U.S. Patent No. 4,341,228 to Thomasson, U.S. Patent No. 4,341,228 to Thomasson, U.S. Patent No. 4,341,228 to Thomas Nos. 5,962,774 to Clapp, 4,941,484 to Young, 4,987,906 to Brown, 5,056,537 to Sohn, 5,143,097 to Brinkley et al., 5,159,942 to Young, 5,325,877 to Young, 5,445,169 to Brinkley, 5,501,237 to Young, and 5,533,530 to Young. The method of the present disclosure includes incorporating a first reconstituted tobacco into a tobacco input for a method of producing a second reconstituted tobacco sheet.

[0060] For example, as shown in Figure 1, in a typical papermaking reconstituted tobacco process, a tobacco input is extracted with water (step 100), and the resulting water-soluble extract and water-insoluble pulp are separated from each other (step 102). The pulp portion can be refined to a desired consistency (step 104). As used herein, the term "consistency" is defined as the percentage of solids in a mixture. For example, the tobacco input can be extracted with water at a temperature of about 55°C to about 65°C for about 1.5 to 2 hours. The weight ratio of water to tobacco input can be about 7:1. The pulp and extract are separated, and the pulp can then be drained to a consistency of about 20%.

[0061] The pulp is then formed into a mat or web (step 106), similar to wood pulp fibers in a traditional papermaking process. A water-soluble tobacco extract is applied to the mat of insoluble pulp (step 108), and the resulting mixture is dried (step 110) to provide a reconstituted tobacco sheet incorporating the tobacco components from which the sheet can be obtained. Note that any amount of water-soluble extract can be reapplied to the mat / web formed from the water-insoluble pulp. For example, in some embodiments, about 0.1 to about 100% by weight of the water-soluble extract is applied to the mat / web formed from the water-insoluble pulp, or about 5 to about 90% by weight of the water-soluble extract, or about 5 to about 50% by weight of the water-soluble extract is applied to the mat / web formed from the water-insoluble pulp. In various embodiments, at least about 5% by weight, at least about 20% by weight, at least about 40% by weight, at least about 50% by weight, at least about 75% by weight, at least about 85% by weight, or at least about 90% by weight of the water-soluble extract is applied to the mat / web formed from the water-insoluble pulp. In certain embodiments, the water-soluble extract may be purified and / or filtered to remove certain undesirable components before being applied to a mat / web formed from the water-insoluble pulp.

[0062] As shown in step 112 of FIG. 1 , for example, after forming and / or receiving a first reconstituted tobacco sheet, the first reconstituted tobacco sheet is used as at least a portion of the tobacco input to produce a second reconstituted tobacco sheet. It should be noted that this process can be repeated any number of times. For example, the second reconstituted tobacco sheet can be used as at least a portion of the tobacco input to produce a third reconstituted tobacco sheet, which can be used as at least a portion of the tobacco input to produce a fourth reconstituted tobacco sheet, and so on. Furthermore, in certain embodiments, the tobacco input can include two or more separate reconstituted tobacco sheets (e.g., a first reconstituted tobacco sheet (as described above) and a second reconstituted tobacco sheet (as described above); or a first reconstituted tobacco sheet (as described above) and a third reconstituted tobacco sheet (as described above); or a second reconstituted tobacco sheet (as described above) and a third reconstituted tobacco sheet (as described above). Any number and / or combination of reconstituted tobacco sheets according to the present disclosure can be used as at least a portion of the tobacco input to produce a reconstituted tobacco sheet.

[0063] In various embodiments of the methods described herein, additional ingredients can be added / blended into the final reconstituted tobacco sheet being formed. Any number of additional ingredients, described in more detail below, can be blended into the reconstituted tobacco sheet at any time during the formation process. For example, in certain embodiments, one or more additional ingredients can be blended with the tobacco input prior to the extraction step (step 100 of FIG. 1 ). Thus, the additional ingredients are extracted along with the tobacco input. One or more additional ingredients can also be added to the extract and / or insoluble pulp after the extraction step. For example, additional liquid ingredients (e.g., flavorings, active ingredients, etc.) can be added to the water-soluble extract after separation from the water-insoluble pulp. In some embodiments, the water-insoluble pulp can be mixed with another type of pulp (e.g., wood pulp) before forming the web or mat (step 106 of FIG. 1 ). In some embodiments, one or more additional ingredients in liquid form can be applied to the insoluble pulp mat / web before, during, or after application of the water-soluble extract (step 108 of FIG. 1 ).

[0064] In some embodiments, cast sheet techniques can be used to create reconstituted tobacco substrates in the form of flat sheets. Cast sheets generally include a first reconstituted tobacco input, one or more fillers, one or more binders, optionally one or more aerosol-forming agents, and optionally an active ingredient, a flavoring, or both, each as described herein. For example, in some embodiments, the filler, at least a portion of the aerosol-forming materials disclosed herein, and the binder may be blended together to form a slurry, which may be cast onto a surface (e.g., a moving belt, etc.). The cast slurry may then undergo one or more drying and / or doctoring steps to result in a cast sheet of relatively uniform thickness. Other examples of casting and papermaking techniques are described in U.S. Pat. No. 4,674,519 to Keritsis et al., U.S. Pat. No. 4,941,484 to Clapp et al., U.S. Pat. No. 4,987,906 to Young et al., U.S. Pat. No. 4,972,854 to Kiernan et al., U.S. Pat. No. 5,099,864 to Young et al., U.S. Pat. No. 5,143,097 to Sohn et al., U.S. Pat. No. 5,159,942 to Brinkley et al., U.S. Pat. No. 5,322,076 to Brinkley et al., U.S. Pat. No. 5,339,838 to Young et al., U.S. Pat. No. 5,377,698 to Litzinger et al., U.S. Pat. No. 5,501,237 to Young et al., and U.S. Pat. No. 6,216,706 to Kumar, the disclosures of which are incorporated herein by reference in their entireties. In some embodiments, the flat sheet may be further reduced into cut lugs or strips for insertion into a substrate-containing segment of an aerosol delivery device. The cast sheet may also be gathered or rolled into a rod for insertion into a substrate-containing segment of an aerosol delivery device, as described in more detail below. The cast sheet may be glued or otherwise attached to a support.

[0065] The various components of the substrate (including the reconstituted tobacco input) can be contacted, combined, or mixed with one another using any mixing technique or equipment known in the art. Any mixing method that results in intimate contact of the substrate components can be used, such as a mixing device characterized by an impeller or other structure that allows for agitation. Examples of mixing equipment include casing drums, conditioning cylinders or drums, liquid spray devices, cone-type blenders, ribbon blenders, mixers available from Littleford Day, Inc. as FKM130, FKM600, FKM1200, FKM2000, and FKM3000, plowshare-type mixer cylinders, Hobart mixers, and the like. See also, for example, the types of processes described in U.S. Pat. No. 4,148,325 to Solomon et al., U.S. Pat. No. 6,510,855 to Korte et al., and U.S. Pat. No. 6,834,654 to Williams et al., each of which is incorporated herein by reference. The manner and methods for formulating the mixture will be apparent to those skilled in the art. See, for example, the types of methods described in U.S. Patent No. 4,148,325 to Solomon et al., U.S. Patent No. 6,510,855 to Korte et al., U.S. Patent No. 6,834,654 to Williams, U.S. Patent No. 4,725,440 to Ridgway et al., and U.S. Patent No. 6,077,524 to Bolder et al., each of which is incorporated herein by reference.

[0066] The sheet can optionally be dried to remove at least a portion of the liquid content (e.g., water). The final moisture content can be, for example, about 8 to about 21% on a wet basis. Additionally, flavorings, extracts, aerosol-forming materials, and the like can be added to the sheet after drying (as described in more detail below).

[0067] In various embodiments, loading the substrate with the aerosol-forming material is achieved by impregnating the substrate with the aerosol-forming material during preparation of the substrate material, after formation, or both. In some embodiments, the slurry used to prepare, for example, a cast sheet, contains the entire amount of aerosol-forming material. Alternatively, or additionally, a portion of the aerosol-forming material may be added to the substrate after formation (e.g., one or more aerosol-forming materials may be sprayed or otherwise disposed in or on a sheet-form substrate material). In some embodiments, additional aerosol-forming material may be impregnated into the substrate in the substrate-forming slurry or as a top dressing. Methods for loading aerosol-forming material into portions of a substrate are described in U.S. Publication No. 9,974,334 to Dooly et al., U.S. Patent Application Publication No. 2015 / 0313283 to Collett et al., and U.S. Patent Application Publication No. 2018 / 0279673 to Sebastian et al., the disclosures of which are incorporated herein by reference in their entireties. As will be appreciated by those skilled in the art, the method for loading a substrate with an aerosol-forming material is subject to multiple variations depending on the particular substrate material, configuration, etc. Accordingly, any such variations are contemplated herein.

[0068] Suitable aerosol-forming materials include, but are not limited to, water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extracts, and combinations thereof. In some embodiments, the aerosol-forming material may include water, polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, sugar alcohols, tobacco extracts, or any combination thereof. Each of the polyhydric alcohols, polysorbates, sorbitan esters, fatty acids, fatty acid esters, waxes, terpenes, and sugar alcohols is further described herein below.

[0069] The amount of aerosol-forming material present in the substrate material can vary. For example, in certain embodiments, a sufficient amount of aerosol-forming material is used to provide for the production of a visible mainstream aerosol that resembles in many respects the appearance of cigarette smoke. The amount of aerosol-forming material present can depend on factors such as the number of puffs desired per substrate component.

[0070] In some embodiments, the substrate material comprises at least about 1%, at least about 10%, at least about 15%, at least about 20%, at least about 25%, at least about 30%, at least about 35%, at least about 40%, at least about 45%, at least about 50%, at least about 55%, or at least about 60% by weight of aerosol-forming material, based on the total wet weight of the substrate. Exemplary ranges of total aerosol-forming material include from about 15% to about 60%, e.g., from about 15% to about 55%, or from about 15% to about 25%, by weight, based on the total wet weight of the substrate material.

[0071] In some embodiments, the substrate material comprises from about 1%, 5%, 10%, 12%, or 13% to about 18%, 20%, 25%, 30%, 35%, 45%, 55%, 65%, 75%, or 80% by weight of aerosol-forming material (all calculated on a dry weight basis). In some embodiments, the substrate material comprises from about 1-80%, 1-50%, 5-35%, 10-25%, 12-20%, or 13-18% by weight of aerosol-forming material (all calculated on a dry weight basis).

[0072] In some embodiments, the aerosol-forming material includes one or more polyhydric alcohols. Examples of polyhydric alcohols include glycerol, propylene glycol, and other glycols such as 1,3-propanediol, diethylene glycol, and triethylene glycol. In some embodiments, the polyhydric alcohol is selected from the group consisting of glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, triacetin, and combinations thereof.

[0073] In some embodiments, the polyhydric alcohol is a mixture of glycerol and propylene glycol. Glycerol and propylene glycol may be present in various ratios, with either component predominating depending on the intended use. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 3:1 to about 1:3. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 3:1, about 2:1, about 1:1, about 1:2, or about 1:3. In some embodiments, glycerol and propylene glycol are present in a weight ratio of about 1:1.

[0074] In some embodiments, the aerosol-forming material comprises one or more polysorbates. Examples of polysorbates include polysorbate 60 (polyoxyethylene (20) sorbitan monostearate, Tween 60) and polysorbate 80 (polyoxyethylene (20) sorbitan monooleate, Tween 80). The type of polysorbate used, or the combination of polysorbates used, depends on the desired intended effect, as different polysorbates provide different attributes due to their molecular size. For example, polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller polysorbate molecules may result in lower vapor production but deeper lung penetration. This may be desirable when users wish to avoid large "smoke" (i.e., vapor) puffs when in public. Conversely, larger polysorbate molecules can be used when a denser vapor capable of carrying the aromatic components of tobacco is desired. An additional benefit of using compounds of the polysorbate family is that polysorbates reduce the heat of vaporization of mixtures in which they are present.

[0075] In some embodiments, the aerosol-forming material comprises one or more sorbitan esters. Examples of sorbitan esters include sorbitan monolaurate, sorbitan monostearate (Span 60), sorbitan monooleate (Span 20), and sorbitan tristearate (Span 65).

[0076] In some embodiments, the aerosol-forming material comprises one or more fatty acids. The fatty acids can include short-chain, long-chain, saturated, unsaturated, straight-chain, or branched-chain carboxylic acids. Fatty acids generally range from C4 to C6 28 Non-limiting examples of short or long chain fatty acids include butyric acid, propionic acid, valeric acid, oleic acid, linoleic acid, stearic acid, myristic acid, and palmitic acid.

[0077] In some embodiments, the aerosol-forming material comprises one or more fatty acid esters, including alkyl esters, monoglycerides, diglycerides, triglycerides, and the like. Examples of monoglycerides include monolaurin and glycerol monostearate. Examples of triglycerides include triolein, tripalmitin, tristearate, glycerol tributyrate, and glycerol trihexanoate.

[0078] In some embodiments, the aerosol-forming material comprises one or more waxes, such as carnauba, beeswax, and candelilla, which are known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

[0079] In some embodiments, the aerosol-forming material comprises one or more terpenes. As used herein, the term "terpene" refers to a hydrocarbon compound produced by plants biosynthetically from isopentenyl pyrophosphate. Non-limiting examples of terpenes include limonene, pinene, farnesene, myrcene, geraniol, fennel, and cembrene.

[0080] In some embodiments, the aerosol-forming material comprises one or more sugar alcohols, including sorbitol, erythritol, mannitol, maltitol, isomalt, xylitol, etc. Sugar alcohols also serve as flavor enhancers for certain flavor compounds, such as menthol and other volatile substances, and generally improve the mouthfeel, texture, throat hit, and other sensory properties of the resulting aerosol.

[0081] In some embodiments, the aerosol-forming material comprises glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or any combination thereof. In some embodiments, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0082] As shown in Example 1 below, it has surprisingly been discovered that using reconstituted tobacco in a tobacco input to produce secondary reconstituted tobacco and / or reconstituted tobacco substrates in the form of flat sheets can beneficially affect the levels of different components within the reconstituted tobacco sheet without adversely affecting taste or other desirable properties. By using one or more reconstituted tobacco inputs in the methods described herein, the levels of various components can be tailored and controlled, including, but not limited to, nicotine, 4-(methylnitrosamino)-1-(3-pyridyl)-1-butanone (NNK), N-nitrosonornicotine (NNN), and tobacco-specific N-nitrosamines (TSNAs).

[0083] Tobacco Insert The present disclosure provides methods for producing reconstituted tobacco from a tobacco input. As described above, the tobacco input for the final reconstituted tobacco sheet produced according to the methods of the present disclosure comprises a first reconstituted tobacco input. In some embodiments, the tobacco input for producing the reconstituted tobacco sheet comprises at least about 5%, at least about 10%, at least about 15%, at least about 25%, at least about 50%, at least about 60%, or at least about 85% reconstituted tobacco by dry weight produced from a harvested plant of the Nicotiana species. As described above, the tobacco input can further comprise two or more different reconstituted tobacco inputs. It should be noted that when used in the tobacco input for the methods described herein, the reconstituted tobacco can be provided in the form of shredded or particulate material. The reconstituted tobacco sheet can be crushed, shredded, chipped, or shredded using equipment known in the art.

[0084] In some embodiments, the tobacco input for the final reconstituted tobacco can further include one or more components from a plant of Nicotiana species, including leaves, seeds, flowers, stalks, roots, and / or stems. Methods of the present disclosure can include harvesting a plant from Nicotiana species, and, in certain embodiments, separating certain components from the plant, such as the stems and / or roots, and physically processing these components.

[0085] The selection of Nicotiana species plants (i.e., tobacco material) utilized in the products and processes of the present disclosure can vary. In particular, the tobacco or tobacco type can vary. Tobaccos that can be used include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi, and Yambol tobaccos), Maryland, dark, dark-fired, dark air-cured (e.g., Passanda, Cubano, Jatin, and Bezuki tobaccos), light air-cured (e.g., North Wisconsin and Galpao tobaccos), Indian air-cured, Red Russian, and Rustica tobaccos, as well as various other rare or specialty tobaccos. A description of various types of tobacco, cultivation methods, and harvesting methods can be found in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), incorporated herein by reference. Various representative types of plants from the Nicotiana species are described in Goodspeed, *The Genus Nicotiana* (Chonica Botanica) (1954), U.S. Pat. No. 4,660,577 to Sensabaugh, Jr. et al., U.S. Pat. No. 5,387,416 to White et al., U.S. Pat. No. 7,025,066 to Lawson et al., and U.S. Pat. No. 7,798,153 to Lawrence, Jr., each of which is incorporated herein by reference. Tobacco compositions containing thick air-cured tobacco are described in U.S. Pat. No. 8,186,360 to Marshall et al., which is incorporated herein by reference. Tobacco types are also described, for example, in U.S. Patent Application Publication No. 2011 / 0247640 to Beeson et al., which is incorporated herein by reference.

[0086] Specimens include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. ka wakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, Nx sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiph on,N.occidentalis,N.paniculata,N.plumbaginifolia,N.raimondii,N.rosulata,N.simulans,N.stocktonii,N.suaveolens,N. umbratica ,N.velutina ,N.wigandioides ,N.acaulis ,N.acuminata ,N.attenuata ,N.benthamiana ,N.cavicola ,N.clevelandii ,N .cordifolia, N. corymbosa, N. fragrans, N. goodspeed, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia;

[0087] Nicotiana species can be derived using genetic engineering or breeding techniques (e.g., tobacco plants can be genetically engineered or bred to increase or decrease the production of a component, characteristic, or trait). See, e.g., U.S. Patent No. 5,539,093 to Fitzmaurice et al., U.S. Patent No. 5,668,295 to Wahab et al., U.S. Patent No. 5,705,624 to Fitzmaurice et al., U.S. Patent No. 5,844,119 to Weigl, U.S. Patent No. 6,730,832 to Dominguez et al., U.S. Patent No. 7,173,170 to Liu et al., U.S. Patent No. 7,208,659 to Colliver et al., U.S. Patent No. 7,230,160 to Benning et al., U.S. Patent No. 7,230,160 to Conkli, and U.S. Patent No. 5,539,093 to Fitzmaurice et al., U.S. Patent No. 5,668,295 to Wahab et al., U.S. Patent No. 5,705,624 to Fitzmaurice et al., U.S. Patent No. 5,844,119 to Weigl, U.S. Patent No. 6,730,832 to Dominguez et al., U.S. Patent No. 7,173,170 to Liu et al., U.S. Patent No. 7,208,659 to Colliver et al., U.S. Patent No. 7,230,160 to Benning et al., U.S. Patent No. 5,539,093 to Fitzmaurice et al., U.S. Patent No. 5 See the types of genetic modifications of plants described in U.S. Patent Application Publication No. 2006 / 0236434 to Ng et al. and PCT Publication No. WO 2008 / 103935 to Nielsen et al., and also see the types of tobacco described in U.S. Patent No. 4,660,577 to Sensabaugh, Jr. et al., U.S. Patent No. 5,387,416 to White et al., and U.S. Patent No. 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

[0088] In some embodiments, Nicotiana species can be selected based on the content of various compounds present therein. For example, plants can be selected based on the fact that they produce relatively large amounts of one or more of the compounds desired to be isolated therefrom. In certain embodiments, Nicotiana species (e.g., Galpao commun tobacco) plants are specifically cultivated for their abundant leaf surface compounds. Tobacco plants can be grown in greenhouses, growth chambers, or outdoor fields, or grown hydroponically.

[0089] Various parts or regions of a Nicotiana species plant can be included within reconstituted tobacco as disclosed herein. For example, substantially the entire plant (e.g., the whole plant) can be harvested and used as is. Alternatively, various parts or fragments of the plant can be harvested or separated for further use after harvest. For example, flowers, leaves, stems, stalks, roots, seeds, and various combinations thereof can be isolated for further use or processing. In some embodiments, the tobacco material includes tobacco leaf (lamina). Reconstituted tobacco disclosed herein can include processed tobacco portions or pieces, cured and aged tobacco in essentially natural lamina and / or stem form, tobacco extract, extracted tobacco pulp (e.g., using water as a solvent), or mixtures of the foregoing (e.g., a tobacco input mixture combining extracted tobacco pulp with granulated dried and aged natural tobacco lamina).

[0090] Although the entire tobacco plant or any component thereof (e.g., leaves, flowers, stems, roots, stalks, etc.) can be used in the tobacco input, it may be advantageous to use the stem, stalk, and / or root of the tobacco plant. Typically, tobacco stems are used in producing such reconstituted tobacco sheets because the fibrous nature of these stems provides strength and structural integrity to the resulting reconstituted tobacco sheet. As used herein, the term "stems" refers to the parts of the plant that support the leaves and flowers. Tobacco lamina, tobacco shreds, and tobacco powder may also be useful in producing reconstituted tobacco sheets, including any waste tobacco material generated at any stage in the process of forming smoking articles such as cigarettes. The term "lamina" refers to the flat, thin structure of the leaf of a plant (i.e., the leaf blade) that contains the chloroplasts.

[0091] In certain embodiments, the tobacco input material comprises a solid tobacco material selected from the group consisting of lamina and stem. The tobacco used in the mixture most preferably comprises tobacco lamina or a mixture of tobacco lamina and stem (at least a portion of which has been smoke-treated). The tobacco portion of the tobacco input mixture can have a processed form, such as processed tobacco stems (e.g., cut roll stems, cut roll expanded stems, or cut puff stems) or volume-expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET)). See, for example, the tobacco growth processes described in U.S. Patent No. 4,340,073 to de la Burde et al., U.S. Patent No. 5,259,403 to Guy et al., U.S. Patent No. 5,908,032 to Poindexter et al., and U.S. Patent No. 7,556,047 to Poindexter et al., all of which are incorporated by reference. Additionally, the tobacco input may optionally incorporate fermented tobacco. See also the types of tobacco processing techniques described in Atchley et al., WO 2005 / 063060, which is incorporated herein by reference.

[0092] In some embodiments, the tobacco input material comprises at least about 10%, at least about 15%, at least about 25%, or at least about 40% by dry weight stem material of harvested plants of Nicotiana species. In some embodiments, the tobacco input for producing reconstituted tobacco sheet comprises at least about 40%, at least about 50%, at least about 60%, or at least about 85% by dry weight blade material of harvested plants of Nicotiana species.

[0093] In some embodiments, the tobacco input can include flue-cured tobacco stems, burley tobacco stems, and / or whole plant tobacco biomass (e.g., extracted green tobacco biomass). Tobacco stalks and / or roots can be separated into individual pieces (e.g., roots separated from the stem and / or root portions separated from each other, e.g., large roots, mid-roots, and small root portions), or the stalk and root can be combined. "Stalk" refers to the stalk remaining after the leaves (including the stem and leaf blades) have been removed. "Roots" and various specific root portions useful according to the present invention can be defined and classified as described, for example, in Mauseth, Botany: An Introduction to Plant Biology: Fourth Edition, Jones and Bartlett Publishers (2009) and Glimn-Lacy et al., Botany Illustrated, Second Edition, Springer (2006), both of which are incorporated herein by reference. Harvested stalks and / or roots are typically cleaned, crushed, and dried to produce material that can be described as particulate (i.e., shredded, crushed, ground, granulated, or powdered). As used herein, stalks and / or roots can also refer to stalks and / or roots that have undergone an extraction process to remove water-soluble materials. The cellulosic material (i.e., pulp) remaining after stalk and / or root material has undergone an extraction process can also be useful in the methods described herein.

[0094] Tobacco input materials (including reconstituted tobacco inputs) are typically used in a form that can be described as particulate (i.e., shredded, crushed, granulated, or powdered). The manner in which tobacco material is provided in finely divided or powdered form can vary. Preferably, plant parts or pieces are crushed, ground, or micronized using equipment and techniques for crushing, grinding, or the like. Most preferably, the plant material is in a relatively dry form during crushing or milling, using equipment such as a hammer mill, cutter head, or air-controlled mill. For example, tobacco parts or pieces may be crushed or milled when their moisture content is less than about 15% by weight or less than about 5% by weight. Most preferably, the tobacco material is used in the form of parts or pieces having an average particle size between 1.4 millimeters and 250 microns. In some instances, the tobacco particles can be sized to pass through a screen mesh to obtain the required particle size range. If desired, air classification equipment can be used to ensure collection of small tobacco particles of a desired size or size range. If desired, granular tobacco pieces of different sizes may be mixed together.

[0095] The method by which the reconstituted tobacco and optionally additional tobacco materials are provided in finely divided or powdered form can vary. Preferably, the reconstituted tobacco sheet and any additional tobacco portions or pieces are crushed, ground, or milled into a powder-type form using equipment and techniques for crushing, milling, etc. Most preferably, the tobacco input is relatively dry during crushing or milling, using equipment such as a hammer mill, cutter head, or air-controlled mill. For example, the reconstituted tobacco sheet and any tobacco portions or pieces may be crushed or milled when their moisture content is less than about 15% to about 5% by weight. For example, the reconstituted tobacco input and any additional tobacco input can be provided and processed separately or in combination. The tobacco plant or part thereof can be separated into individual parts or pieces (e.g., the leaves can be removed from the stems, and / or the stems and leaves can be removed from the stems). Harvested plants or individual parts or pieces can be further subdivided into parts or pieces (e.g., leaves can be chopped, cut, crushed, powdered, milled, or ground into pieces or pieces that can be characterized as filler-type pieces, granules, particulates, or fines). The plant or part thereof can be subjected to external force or pressure (e.g., by being subjected to a pressing or rolling treatment). When subjected to such treatment conditions, the plant or part thereof can have a moisture content that is close to its natural moisture content (e.g., the moisture content immediately after harvesting), a moisture content achieved by adding moisture to the plant or part thereof, or a moisture content resulting from drying the plant or part thereof. For example, powdered, powdered, ground, or milled pieces of a plant or part thereof can have a moisture content of less than about 25% by weight, often less than about 20% by weight, and often less than about 15% by weight.

[0096] For the preparation of oral products, harvested plants of Nicotiana species are typically subjected to a curing process. The tobacco materials incorporated into the mixtures for inclusion in the products disclosed herein are appropriately cured and / or aged. A description of various types of curing processes for various types of tobacco is provided in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). Examples of techniques and conditions for curing flue-cured tobacco are provided in Nestor et al., Beitrage Tabakforsch. Int., 20, 467-475 (2003), and U.S. Patent No. 6,895,974 to Peele, both of which are incorporated herein by reference. Representative techniques and conditions for air-curing tobacco are described in U.S. Patent No. 7,650,892 to Groves et al., U.S. Patent No. 7,650,892 to Roton et al., Beitrage Tabakforsch. Int., 21, 305-320 (2005), and Staaf et al., Beitrage Tabakforsch. Int., 21, 321-330 (2005), which are incorporated herein by reference. Certain types of tobacco can be subjected to alternative types of curing processes, such as fire-curing or sun-curing.

[0097] In certain embodiments, tobacco materials that can be used include flue-cured or Virginia (e.g., K326), Burley, sun-cured (e.g., Indian Kurnool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi, and Yambol tobaccos), Maryland, dark, dark-fired, dark air-cured (e.g., Madole, Passanda, Cubano, Jatin, and Bezuki tobaccos), light air-cured (e.g., North Wisconsin and Galpao tobaccos), Indian air-cured, Red Russian, and Rustica tobaccos, as well as various other rare or specialty tobaccos and various blends of any of the foregoing tobaccos.

[0098] Tobacco materials may also be in the form of so-called "blends." For example, tobacco materials may include a mixture of flue-cured burley (e.g., Malawi burley tobacco) and Oriental tobacco parts or fragments (e.g., tobacco composed of or derived from tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a typical blend may incorporate, on a dry weight basis, about 30 to about 70 parts burley tobacco (e.g., lamina, or lamina and stem) and about 30 to about 70 parts flue-cured tobacco (e.g., stem, lamina, or lamina and stem). Other exemplary tobacco blends may incorporate, on a dry weight basis, about 75 parts flue-cured tobacco, about 15 parts burley tobacco, and about 10 parts Oriental tobacco; about 65 parts flue-cured tobacco, about 25 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco, and about 25 parts Oriental tobacco. Another example tobacco blend incorporates, on a dry weight basis, from about 20 to about 30 parts Oriental tobacco and from about 70 to about 80 parts flue-cured tobacco.

[0099] The tobacco input material (including reconstituted tobacco input) used in the present disclosure can be subjected to processes such as, for example, fermentation, bleaching, etc. If desired, the tobacco material can be subjected to, for example, irradiation, pasteurization, or other controlled heat treatments. Such treatment processes are described in detail, for example, in U.S. Patent No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, the tobacco material can be treated with water and an additive selected from the group consisting of: water and an additive capable of inhibiting the reaction of asparagine to acrylamide upon heating of the tobacco material (e.g., lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating divalent and trivalent cations, asparaginase, certain non-reducing sugars, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functional group, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof. See, for example, the types of treatment processes described in U.S. Patent Applications Nos. 8,434,496, 8,944,072, and 8,991,403 to Chen et al., all of which are incorporated herein by reference. In certain embodiments, this type of treatment is useful when the original tobacco material is heat-treated using the aforementioned processes.

[0100] In some embodiments, the type of tobacco material is selected to initially be visually lighter in color (e.g., whitened or bleached) than other tobacco materials. In certain embodiments, the tobacco pulp can be whitened according to any means known in the art. For example, bleached tobacco materials produced by various bleaching methods using various bleaching agents, oxidizing agents, and oxidation catalysts can be used. Examples of oxidizing agents include peroxides (e.g., hydrogen peroxide), chlorites, chlorates, perchlorates, hypochlorites, ozone, ammonia, potassium permanganate, and combinations thereof. Examples of oxidation catalysts include titanium dioxide, manganese dioxide, and combinations thereof. Methods of treating tobacco with bleaching agents are described, for example, in U.S. Pat. No. 787,611 to Daniels, Jr., U.S. Pat. No. 1,086,306 to Oelenheinz, U.S. Pat. No. 1,437,095 to Delling, U.S. Pat. No. 1,757,477 to Rosenhoch, U.S. Pat. No. 2,122,421 to Hawkinson, U.S. Pat. No. 2,148,147 to Baier ... No. 2,170,107 to Baier, U.S. Pat. No. 2,274,649 to Pratz et al., U.S. Pat. No. 2,770,239 to Pratz et al., U.S. Pat. No. 3,612,065 to Rosen, U.S. Pat. No. 3,851,653 to Rosen, U.S. Pat. No. 3,889,689 to Rosen, U.S. Pat. No. 3,943,940 to Minami, U.S. Pat. No. 3,943,945 to Rosen, U.S. Pat. No. 4,143,666 to Rainer, U.S. Pat. No. 4,194,514 to Campbell, U.S. Pat. Nos. 4,366,823, 4,366,824, and 4,388,933 to Rainer et al., U.S. Pat. No. 4,641,667 to Schmekel et al., U.S. Pat. No. 5,713,376 to Berger, Byrd U.S. Patent No. 9,339,058 to Beeson et al., U.S. Patent No. 9,420,825 to Byrd Jr.No. 9,950,858 to Crooks et al., as well as U.S. Patent Application Publication No. 2012 / 0067361 to Bjorkholm et al., U.S. Patent Application Publication No. 2016 / 0073686 to Crooks, U.S. Patent Application Publication No. 2017 / 0020183 to Bjorkholm, U.S. Patent Application Publication No. 2017 / 0112183 to Bjorkholm, U.S. Patent Application Publication No. 2020 / 0196658 to McClanahan et al., and U.S. Patent Application Publication No. Zawadzki et al. No. 2021 / 0068445 to Zawadzki et al., U.S. Patent Application Publication No. 2021 / 0068448 to Sundvall et al., U.S. Patent Application Publication No. 2021 / 0076731 to Sundvall et al., and U.S. Patent Application Publication No. 2022 / 0071272 to Castelijn et al., and WO 1996 / 031255 to Giolvas and WO 2018 / 083114 to Bjorkholm, all of which are incorporated herein by reference.

[0101] In some embodiments, the whitened tobacco material can have an ISO brightness of at least about 50%, at least about 60%, at least about 65%, at least about 70%, at least about 75%, or at least about 80%. In some embodiments, the whitened tobacco material can have an ISO brightness ranging from about 50% to about 90%, from about 55% to about 75%, or from about 60% to about 70%. ISO brightness can be measured according to ISO 3688:1999 or ISO 2470-1:2016.

[0102] In some embodiments, whitened tobacco materials can be characterized as being lighter in color (e.g., "whitened") compared to untreated tobacco materials. White is typically defined with reference to the Commission Internationale de l'Eclairage (CIE) chromaticity diagram. Whitened tobacco materials, in certain embodiments, can be characterized as being closer to pure white on the chromaticity diagram than untreated tobacco materials.

[0103] In various embodiments, tobacco materials can be processed to extract soluble components of the tobacco material therefrom. As used herein, "tobacco extract" refers to a separated component of tobacco material extracted from solid tobacco pulp by a solvent contacted with the tobacco material in an extraction process. The tobacco extract can then be used in combination with reconstituted tobacco to form a secondary reconstituted tobacco according to the methods of the present disclosure. Various extraction techniques for tobacco materials can be used to provide the tobacco extract and tobacco solid material. See, for example, the extraction process described in U.S. Patent Application Publication No. 2011 / 0247640 to Beeson et al., incorporated herein by reference. Other exemplary techniques for extracting tobacco components are disclosed in U.S. Pat. No. 4,144,895 to Fiore, U.S. Pat. No. 4,150,677 to Osborne, Jr. et al., U.S. Pat. No. 4,267,847 to Reid, U.S. Pat. No. 4,289,147 to Wildman et al., U.S. Pat. No. 4,351,346 to Brummer et al., U.S. Pat. No. 4,359,059 to Brummer et al., U.S. Pat. No. 4,506,682 to Muller, U.S. Pat. No. 4,589,428 to Keritsis, U.S. Pat. No. 4,605,016 to Soga et al., U.S. Pat. No. 4,716,911 to Poulose et al., and U.S. Pat. No. 4,716,911 to Niven, Jr.No. 4,727,889 to Bernasek et al., U.S. Pat. No. 4,887,618 to Bernasek et al., U.S. Pat. No. 4,941,484 to Clapp et al., U.S. Pat. No. 4,967,771 to Fagg et al., U.S. Pat. No. 4,986,286 to Roberts et al., U.S. Pat. No. 5,005,593 to Fagg et al., U.S. Pat. No. 5,018,540 to Grubbs et al., U.S. Pat. No. 5,060, No. 669, U.S. Patent No. 5,065,775 to Fagg, U.S. Patent No. 5,074,319 to White et al., U.S. Patent No. 5,099,862 to White et al., U.S. Patent No. 5,121,757 to White et al., U.S. Patent No. 5,131,414 to Fagg, U.S. Patent No. 5,131,415 to Munoz et al., U.S. Patent No. 5,148,819 to Fagg, U.S. Patent No. 5,199 to Kramer ... No. 7,494 to Smith et al., U.S. Pat. No. 5,230,354 to Smith, U.S. Pat. No. 5,234,008 to Fagg, U.S. Pat. No. 5,243,999 to Smith, U.S. Pat. No. 5,301,694 to Raymond et al., U.S. Pat. No. 5,318,050 to Gonzalez-Parra et al., U.S. Pat. No. 5,343,879 to Teague, U.S. Pat. No. 5,360,022 to Newton No. 5,435,325 to Clapp et al., U.S. Pat. No. 5,445,169 to Brinkley et al., U.S. Pat. No. 6,131,584 to Lauterbach, U.S. Pat. No. 6,298,859 to Kierulff et al., U.S. Pat. No. 6,772,767 to Mua et al., and U.S. Pat. No. 7,337,782 to Thompson, all of which are incorporated herein by reference.

[0104] Typical inclusion ranges of tobacco material beyond the reconstituted tobacco input can vary depending on the nature and type of tobacco material and the intended effect on the final reconstituted tobacco, with exemplary ranges being up to about 91% by weight (or up to about 85% by weight, or up to about 60% by weight, or up to about 40% by weight, or up to about 25% by weight, or up to about 15% by weight, or up to about 5% by weight) of the total weight of the final reconstituted tobacco (e.g., from about 0.1 to about 85% by weight).

[0105] Added ingredients Flavoring agents As used herein, a "flavoring agent" or "flavorant" is any flavorful or aromatic substance that can alter the sensory characteristics associated with reconstituted tobacco. Examples of sensory characteristics that can be altered by a flavoring agent include taste, mouthfeel, moistness, coolness / heat, and / or aroma / aroma. Flavoring agents may be natural or synthetic, and the flavor characteristics imparted thereby may be described as, but are not limited to, fresh, sweet, herbal, confectionery, floral, fruity, or spicy. Specific types of flavorings include, but are not limited to, vanilla, coffee, chocolate / cocoa, cream, mint, spearmint, menthol, peppermint, wintergreen, eucalyptus, lavender, cardamom, nutmeg, cinnamon, clove, cascarilla, sandalwood, honey, jasmine, ginger, anise, sage, licorice, lemon, orange, apple, peach, lime, cherry, strawberry, trigeminal sensates, melatonin, terpenes, and any combination thereof. See also Leffingwell et al., "Tobacco Flavoring for Smoking Products," R.J. Reynolds Tobacco Company (1972), incorporated herein by reference. Flavoring agents may also include ingredients considered humectants, coolants, or smoothing agents, such as eucalyptus. These flavors may be provided neat (i.e., alone) or in composites, and may be used as concentrates or flavor packages (e.g., spearmint and menthol, orange and cinnamon; lime, pineapple, etc.). Representative types of ingredients are also described in U.S. Patent No. 5,387,416 to White et al., U.S. Patent Application Publication No. 2005 / 0244521 to Strickland et al., and WO 05 / 041699 to Quinter et al., each of which is incorporated herein by reference. In some cases, the flavors may be provided in spray-dried or liquid form.

[0106] Flavoring agents generally include at least one volatile flavor component. As used herein, "volatile" refers to a chemical that readily generates vapor at ambient temperatures (i.e., a chemical that has a higher vapor pressure at a given temperature compared to non-volatile substances). Typically, volatile flavor components have a molecular weight of less than about 400 Da and often contain at least one carbon-carbon double bond, a carbon-oxygen double bond, or both. In one embodiment, the at least one volatile flavor component includes one or more alcohols, aldehydes, aromatic hydrocarbons, ketones, esters, terpenes, terpenoids, or combinations thereof. Non-limiting examples of aldehydes include vanillin, ethyl vanillin, p-anisaldehyde, hexanal, furfural, isovaleraldehyde, cuminaldehyde, benzaldehyde, and citronellal. Non-limiting examples of ketones include 1-hydroxy-2-propanone and 2-hydroxy-3-methyl-2-cyclopentenon-1-one. Non-limiting examples of esters include allyl hexanoate, ethyl heptanoate, ethyl hexanoate, isoamyl acetate, and 3-methylbutyl acetate. Non-limiting examples of terpenes include sabinene, limonene, gamma-terpinene, beta-farnesene, nerolidol, thujone, myrcene, geraniol, nerol, citronellol, linalool, and eucalyptol. In one embodiment, the at least one volatile flavor component comprises one or more of ethyl vanillin, cinnamaldehyde, sabinene, limonene, gamma-terpinene, beta-farnesene, or citral. In one embodiment, the at least one volatile flavor component comprises ethyl vanillin.

[0107] The amount of flavoring agent utilized in the reconstituted tobacco can vary, but is typically up to about 10% by weight, with certain embodiments characterized by a flavoring agent content of at least about 0.1% by weight, e.g., from about 0.5 to about 10% by weight, from about 1 to about 6% by weight, or from about 2 to about 5% by weight, based on the total weight of the final dried reconstituted tobacco sheet.

[0108] salt In some embodiments, the reconstituted tobacco may further comprise a commonly used salt (e.g., an alkali metal salt) in an amount sufficient to provide the reconstituted tobacco with desired sensory attributes. Non-limiting examples of suitable salts include sodium chloride, potassium chloride, ammonium chloride, flour salt, and the like. When present, a representative amount of salt is about 0.5% by weight or more, about 1.0% by weight or more, or about 1.5% by weight or more, but typically comprises about 10% by weight or less, or about 7.5% by weight or less, or about 5% by weight or less (e.g., about 0.5 to about 5% by weight) of the total weight of the reconstituted tobacco.

[0109] sweetener The reconstituted tobacco can further include one or more sweeteners. The sweetener can be any sweetener or combination of sweeteners, in natural or artificial form, or a combination of natural and artificial sweeteners. Natural sweeteners include, for example, isomaltulose, fructose, sucrose, glucose, maltose, mannose, galactose, lactose, stevia, honey, etc. Artificial sweeteners include sucralose, maltodextrin, saccharin, aspartame, acesulfame K, neotame, etc. In some embodiments, the sweetener comprises one or more sugar alcohols. Sugar alcohols are polyols derived from mono- or disaccharides, which may be partially or fully hydrogenated. Sugar alcohols, for example, have from about 4 to about 20 carbon atoms and include erythritol, arabitol, ribitol, isomalt, maltitol, dulcitol, iditol, mannitol, xylitol, lactitol, sorbitol, and combinations thereof (e.g., hydrogenated starch hydrolysates). When a sweetener is present, a representative amount of sweetener may comprise from about 0.1 to about 20% or more of the mixture by weight, for example, from about 0.1 to about 1%, from about 1 to about 5%, from about 5 to about 10%, or from about 10 to about 20% of the mixture by weight, based on the total weight of the reconstituted tobacco.

[0110] Binder A binder (or combination of binders) may be used in certain embodiments in an amount sufficient to provide the mixture with desired physical attributes and physical integrity. Binders often also function as thickeners or gelling agents. Typical binders may be organic or inorganic, or a combination thereof. Representative binders include modified cellulose, povidone, sodium alginate, starch-based binders, pectin, carrageenan, pullulan, zein, and the like, and combinations thereof. In some embodiments, the binder comprises pectin or carrageenan, or a combination thereof.

[0111] Binders may be used in amounts sufficient to provide the reconstituted tobacco with the desired physical attributes and physical integrity. The amount of binder utilized in the reconstituted tobacco may vary, but is typically up to about 30% by weight, with particular embodiments characterized by a binder content of at least about 0.1% by weight, e.g., from about 1 to about 30% by weight, or from about 5 to about 10% by weight, based on the total weight of the reconstituted tobacco.

[0112] In certain embodiments, the binder comprises a gum, such as a natural gum. As used herein, natural gum refers to a naturally occurring polysaccharide material that has binding properties and is also useful as a thickening or gelling agent. Representative natural gums, typically derived from plants and having some water solubility, include xanthan gum, guar gum, gum arabic, gum ghatti, gum tragacanth, gum karaya, locust bean gum, gellan gum, and combinations thereof. When present, natural gum binder materials are typically present in an amount of up to about 5% by weight, e.g., about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9, or about 1% to about 2, about 3, about 4, or about 5% by weight, based on the total weight of the reconstituted tobacco.

[0113] buffer In certain embodiments, the reconstituted tobacco of the present disclosure can include a pH adjuster or buffer. Examples of pH adjusters and buffers that can be used include, but are not limited to, metal hydroxides (e.g., alkali metal hydroxides such as sodium hydroxide and potassium hydroxide), and other alkali metal buffers such as metal carbonates (e.g., potassium carbonate or sodium carbonate), or metal bicarbonates such as sodium bicarbonate. When present, buffers are typically present in an amount less than about 5% by weight of the reconstituted tobacco, e.g., about 0.5% to about 5% by weight, e.g., about 0.75% to about 4%, about 0.75% to about 3%, or about 1% to about 2% by weight, based on the total weight of the reconstituted tobacco. Non-limiting examples of suitable buffers include alkali metal acetates, glycinates, phosphates, glycerophosphates, citrates, carbonates, bicarbonates, borates, or mixtures thereof.

[0114] coloring agent Colorants may be used in amounts sufficient to provide the reconstituted tobacco with desired physical attributes. Colorants include various dyes and pigments, such as caramel color, titanium dioxide, etc. The amount of colorant utilized in the mixture may vary, but, when present, is typically up to about 3% by weight, e.g., about 0.1%, about 0.5%, or about 1% to about 3% by weight, based on the total weight of the reconstituted tobacco.

[0115] Active ingredient The reconstituted tobacco disclosed herein can include one or more active ingredients. As used herein, "active ingredient" refers to one or more substances belonging to any of the following categories: APIs (active pharmaceutical ingredients), food additives, natural medicines, and naturally occurring substances capable of exerting a beneficial effect on humans. Exemplary active ingredients include any ingredient known to affect one or more biological functions in the body, such as ingredients that provide pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or that affect the structure or any function of the human body (e.g., providing a stimulating effect on the central nervous system, providing an energy-enhancing effect, antipyretic or analgesic effect, or other beneficial effect on the body). In some embodiments, the active ingredient may be of the type commonly referred to as a dietary supplement, nutraceutical, "phytochemical," or "functional food." These types of additives are sometimes defined in the art to encompass substances commonly available from natural sources (e.g., botanical materials) that provide one or more beneficial biological effects (e.g., health-promoting, disease-preventing, or other medicinal properties) but that are not classified or regulated as drugs.

[0116] Non-limiting examples of active ingredients include those falling into the categories of botanical-derived ingredients, stimulants, amino acids, nicotine components, and / or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, such as A, B3, B6, B12, and C, and / or cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD)). Each of these categories is further described herein below. The specific selection of active ingredients will depend on the desired flavor, texture, and desired characteristics of the particular reconstituted tobacco product. Additionally, any of the aforementioned types of active ingredients can be encapsulated in the composition, the final product, or both to avoid chemical degradation of these actives, including, but not limited to, caffeine, vitamin A, and iron (Fe), or to reduce strong tastes. Furthermore, these encapsulated actives may need to be combined with excipients in the composition to enhance their solubility and / or bioavailability. Non-limiting examples of these excipients include beta-carotene, lycopene, vitamin D, vitamin E, coenzyme Q10, vitamin K, and curcumin.

[0117] In certain embodiments, the active ingredient is selected from the group consisting of caffeine, taurine, GABA, theanine, tryptophan, vitamin B6, vitamin B12, vitamin C, lemon balm extract, ginseng, citicoline, sunflower lecithin, and combinations thereof. For example, the active ingredient may include a combination of caffeine, theanine, and optionally ginseng. In another embodiment, the active ingredient includes a combination of theanine, gamma-aminobutyric acid (GABA), and optionally lemon balm extract. In further embodiments, the active ingredient includes one or more of theanine, theanine and tryptophan, theanine and the B vitamins B6 and B12, or tryptophan, theanine and the B vitamins B6 and B12. In yet further embodiments, the active ingredient includes a combination of caffeine, taurine, and vitamin C, optionally further including one or more B vitamins (e.g., vitamin B6 or B12). A magnesium salt (eg, magnesium gluconate) can be added to any of the above combinations, particularly those that also include theanine.

[0118] In some embodiments, the active ingredients described herein may be susceptible to degradation (e.g., oxidation, photolysis, thermal degradation, evaporation) during processing or storage of oral products. In such embodiments, the active ingredient (e.g., caffeine, vitamin A, iron (Fe), etc.) may be encapsulated or otherwise matrix-modified with fillers, binders, etc. to provide enhanced stability to the active ingredient. For example, binders such as functionalized cellulose (e.g., cellulose ethers, including but not limited to hydroxypropyl cellulose) can be used to enhance the stability of such actives against degradation. Furthermore, encapsulated actives may need to be combined with excipients in compositions to enhance their solubility and / or bioavailability. Non-limiting examples of suitable excipients include β-carotene, lycopene, vitamin D, vitamin E, coenzyme Q10, vitamin K, and curcumin.

[0119] The specific percentage of active ingredients present will vary depending on the desired characteristics of a particular product. The active ingredients or combinations thereof can be present at a total concentration of at least about 0.001% by weight of the reconstituted tobacco, e.g., in the range of about 0.001% to about 20%. In some embodiments, the active ingredient or combination of active ingredients is present at a concentration of about 0.1% w / w to about 10% by weight, e.g., about 0.5% w / w to about 10% by weight, about 1% to about 10%, or about 1% to about 5% by weight, based on the total weight of the reconstituted tobacco. In some embodiments, the active ingredient or combination of active ingredients is present in an amount by weight of about 0.001%, about 0.01%, about 0.1%, or about 1%, up to about 20%, e.g., about 0.001%, about 0.002%, about 0.003%, about 0.004%, about 0.005%, about 0.006%, about 0.007%, about 0.008%, about 0.009%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.08%, about 0.09%, about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09 ... The active ingredient may be present in a concentration of from about 5%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, about 15%, about 16%, about 17%, about 18%, about 19%, or about 20%. Further suitable ranges for particular active ingredients are provided herein below.

[0120] vegetable In some embodiments, the active ingredient comprises a botanical ingredient. As used herein, the term "botanical ingredient" or "botanical" refers to any plant or fungal-derived material, including plant material in its natural form and plant material derived from natural plant material, such as extracts or isolates from plant material processed from natural plant material (e.g., plant material that has been subjected to heat treatment, fermentation, bleaching, or other treatment processes that can alter the physical and / or chemical properties of the material). For purposes of this disclosure, "botanical" includes, but is not limited to, "herbal materials," which refer to seed-producing plants that do not develop persistent woody tissue and are often valued for their medicinal or sensory properties (e.g., tea or tisane). Reference to plant material as "non-tobacco" is intended to exclude tobacco material (i.e., not including Nicotiana species). In some embodiments, the tobacco input disclosed herein can be characterized as being free of tobacco material beyond the reconstituted tobacco input (e.g., any embodiment as disclosed herein can be completely or substantially free of any additional tobacco material beyond the reconstituted tobacco input). By "substantially free," it is meant that no additional tobacco material has been intentionally added. For example, certain embodiments of the tobacco input can be characterized as having less than 0.001%, or less than 0.0001%, or even 0%, by weight of tobacco other than in the form of reconstituted tobacco.

[0121] When present, the botanicals are typically present at a concentration of about 0.01% w / w to about 10% by weight, e.g., about 0.01% w / w, about 0.05%, about 0.1%, or about 0.5% to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, about 11%, about 12%, about 13%, about 14%, or about 15% by weight, based on the total weight of the reconstituted tobacco. In some embodiments, the non-tobacco plant material is in particulate form and is present in the substrate in an amount of about 15 to about 60% by weight, or about 15 to about 25% by weight, based on the total weight of the reconstituted tobacco.

[0122] Botanical materials useful in the present disclosure can include any of the compounds and sources described herein, including, but not limited to, mixtures thereof. Certain botanical materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytochemicals," or "functional foods." Certain botanicals, either as plant materials or extracts thereof, are used in traditional herbal medicines and are further described herein. Non-limiting examples of botanical materials include, but are not limited to, acai berry (Euterpe oleracea martius), acerola (Malpighia glabra), alfalfa, allspice, angelica root, anise (e.g., star anise), annatto seed, apple (Malus domestica), apricot oil, ashwagandha, bacopa monniera, baobab, basil (Ocimum basilicum), mitsuba, beet root, bergamot, blackberry (Mollus nigra), black cohosh, black pepper, black tea, blueberry, borage (Peumus boldus), borage, white clover, cacao, calamus root, and cam (Myrcaria dubia). dubia, cannabis / hemp, caraway seeds, catnip, catuaba, cayenne pepper, centella asiatica, chaga mushroom, chai, chamomile, cherry, chervil, chlorophyll, chocolate, cinnamon (Cinnamomum cassia), citrus, citrongrass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), cocoa, coffee, comfrey leaves and root, cordyceps, coriander seeds, cranberry, curcumin, damiana, dandelion, Dorstenia arifolia, Dorstenia odorata, echinacea, elderberry, elderflower, endorphins (Anethum graveolens, evening primrose, essential oils, eucalyptus, fennel, feverfew, garlic, Galphimia glauca, gingerofficinale, Ginkgo biloba, Ginseng, Goji berry, Goldenshrimp, Grape seed, Grapefruit, Grapefruit rosé (Citrus paradisi), Graviola (Annona muricata), Green tea, Griffonia simplicifolia, Guarana, Guts kola, Hawthorn, Hemp, Hops, Hibiscus flower (Hibiscus sabdariffa), Honeybush, Jiaogulan, Kava, Champagne (Spilanthes oleraceae), Jasmine (Jasminum officinale), Juniper berry (Juniperus communis), Kaempferia parviflora (Thai ginseng), Kava, Lavender, Lemon (Citrus limon), Lemon balm, Lemongrass, Lilac, Lion's mane, Lutein, Maca (Lepidium meyenii), Macaca, Marjoram, Milk thistle, Mint (menthe), Nardostachys chinesis), violet oil extract, oolong tea, orange (Citrus sinensis), oregano, papaya, pennyroyal, peppermint (Mentha piperita), potato peel, quercetin, quince, red clover, resveratrol, Rhizoma gastrodiae, Rhodiola, rooibo (red or green), rosehips (Rosa canina), rose essential oil, rosemary, sage, St. John's wort, salvia (Salvia officinalis), savory, saw palmetto, sceletium tortuasum, schisandra, milk thistle, elm bark, skullcap, high tannins in sorghum bran, high tannins in sorghum grain, spearmint (Mentha spicata, Spikenard, Spirulina, Sumac bran, Terpenes, Thyme, Tisanes, Turmeric, Uva Ursi (Turnera aphrodisiaca), Uva Ursi (uvaursi, valerian, vanilla, white mulberry, wild yam root, wintergreen, Withania somnifera, yacon root, yellow dock, yerba mate, and Santa tea. In some embodiments, the botanical material is in an encapsulated form.

[0123] In some embodiments, the active ingredient comprises lemon balm. Lemon balm (Melissa officinalis) is a mild lemon-scented herb in the same family as mint (Lamiaceae). The herb is native to Europe, North Africa, and Western Asia. Lemon balm tea, as well as essential oils and extracts, are used in traditional and alternative medicine. In some embodiments, the active ingredient comprises lemon balm extract. In some embodiments, the lemon balm extract is present in an amount of about 1 to about 4% by weight, based on the total weight of the reconstituted tobacco.

[0124] In some embodiments, the active ingredient comprises ginseng. Ginseng is the root of a plant in the Panax genus and is characterized by the presence of unique steroidal saponin phytochemicals (ginsenosides) and gintonin. Ginseng finds use in nutritional beverages or herbal teas and as a dietary supplement in traditional medicine. Cultivated species include Korean ginseng (P. ginseng), Southern Chinese ginseng (P. notoginseng), and American ginseng (P. quinquefolius). American and Korean ginseng differ in the types and amounts of various ginsenosides present. In some embodiments, the ginseng is American ginseng or Korean ginseng. In particular embodiments, the active ingredient comprises Korean ginseng. In some embodiments, the ginseng is present in an amount of about 0.4 to about 0.6% by weight, based on the total weight of the reconstituted tobacco.

[0125] In some embodiments, the non-tobacco plant material is present in particulate form. The particulate non-tobacco plant material can have a variety of particle sizes. For example, in some embodiments, the non-tobacco plant material has a particle size of about 0.05 mm to about 1 mm. In some examples, the non-tobacco plant material particles can be sized to pass through a screen mesh to achieve the desired particle size range. In some embodiments, the particulate non-tobacco plant material includes eucalyptus, rooibo, star anise, fennel, or a combination thereof.

[0126] In some embodiments, the non-tobacco plant material is present in the form of an extract. As used herein, "botanical extract" refers to an isolated component of a plant material extracted from a solid plant material by contacting the solid plant material with a solvent (e.g., water, alcohol, etc.) in an extraction process. Various extraction techniques for solid plant material can be used to provide a plant material extract. In some embodiments, the botanical extract is an extract of Angelica root, caraway seed, cinnamon, clove, coriander seed, elderberry, elderflower, ginger, jasmine, lavender, lilac, peppermint (Mentha piperita), quince, or a combination thereof.

[0127] stimulants In some embodiments, the active ingredient comprises one or more stimulants. As used herein, the term "stimulant" refers to a substance that increases central nervous system and / or physical activity, such as a substance that enhances focus, cognitive function, energy, mood, alertness, etc. Non-limiting examples of stimulants include caffeine, theacrine, theobromine, and theophylline. Theacrine (1,3,7,9-tetramethyluric acid) is a purine alkaloid structurally related to caffeine and has stimulating, analgesic, and anti-inflammatory properties. The stimulant may be natural, naturally derived, or completely synthetic. For example, certain plant materials (such as guarana, tea, coffee, and cocoa) can have a stimulating effect due to the presence of caffeine or related alkaloids, and are therefore "natural" stimulants. "Naturally derived" means that the stimulant (e.g., caffeine, theacrine) is in a purified form that has been separated from its natural (e.g., plant) matrix. For example, caffeine can be obtained by extraction and purification from plant sources (e.g., tea). "Totally synthetic" means that the stimulant is obtained by chemical synthesis.

[0128] In some embodiments, the active ingredient comprises caffeine. In some embodiments, the active ingredient comprises theacrine. In some embodiments, the active ingredient comprises a combination of caffeine and theacrine. In some embodiments, the active ingredient is caffeine. In some embodiments, the caffeine is present in encapsulated form. An example of encapsulated caffeine is Vitashure®, available from Balchem ​​Corp., 52 Sunrise Park Road, New Hampton, NY 10958.

[0129] When present, the stimulant or combination of stimulants (e.g., caffeine, theacrine, and combinations thereof) is typically present in a concentration of about 0.1% w / w to about 15% by weight, for example, from about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% by weight, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, or about 15% by weight, based on the total weight of the composition. In some embodiments, the composition comprises caffeine in an amount of about 1.5 to about 6% by weight, based on the total weight of the reconstituted tobacco.

[0130] amino acid In some embodiments, the active ingredient comprises an amino acid. As used herein, the term "amino acid" refers to an organic compound containing an amino group (-NH2) and a carboxyl group (-COOH) or sulfonic acid group (SO3H) functional group, along with a side chain (R group) specific to each amino acid. Amino acids can be proteinogenic or non-proteinogenic. "Proteinogenic" means that the amino acid is one of the 20 naturally occurring amino acids found in proteins. Proteinogenic amino acids include alanine, arginine, asparagine, aspartic acid, cysteine, glutamine, glutamic acid, glycine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tryptophan, tyrosine, and valine. "Non-proteinogenic" means that the amino acid is not naturally found in proteins or is not directly produced by cellular machinery (e.g., is a product of post-translational modification). Non-limiting examples of non-proteinogenic amino acids include gamma-aminobutyric acid (GABA), taurine (2-aminoethanesulfonic acid), theanine (L-gamma-glutamylethylamide), hydroxyproline, and beta-alanine. In some embodiments, the active ingredient includes theanine. In some embodiments, the active ingredient includes GABA. In some embodiments, the active ingredient includes a combination of theanine and GABA. In some embodiments, the active ingredient is a combination of theanine, GABA, and lemon balm. In some embodiments, the active ingredient is a combination of caffeine, theanine, and ginseng. In some embodiments, the active ingredient includes taurine. In some embodiments, the active ingredient is a combination of caffeine and taurine.

[0131] When present, the amino acid or combination of amino acids (e.g., theanine, GABA, and combinations thereof) is typically present at a concentration of about 0.1% w / w to about 15% by weight, for example, from about 0.1% w / w, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9% by weight, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 11%, about 12%, about 13%, about 14%, or about 15% by weight, based on the total weight of the reconstituted tobacco.

[0132] vitamin In some embodiments, the active ingredient comprises a vitamin or a combination of vitamins. As used herein, the term "vitamin" refers to an organic molecule (or set of related molecules) that is an essential micronutrient required for the proper functioning of mammalian metabolism. There are 13 vitamins required for human metabolism: vitamin A (as all-trans retinol, all-trans retinyl esters, and all-trans beta-carotene and other provitamin A carotenoids), vitamin B1 (thiamine), vitamin B2 (riboflavin), vitamin B3 (niacin), vitamin B5 (pantothenic acid), vitamin B6 (pyridoxine), vitamin B7 (biotin), vitamin B9 (folic acid or folate), vitamin B12 (cobalamin), vitamin C (ascorbic acid), vitamin D (calciferol), vitamin E (tocopherols and tocotrienols), and vitamin K (quinones). In some embodiments, the active ingredient comprises vitamin C. In some embodiments, the active ingredient is a combination of vitamin C, caffeine, and taurine.

[0133] If present, the vitamin or combination of vitamins (e.g., vitamin B6, vitamin B12, vitamin E, vitamin C, or a combination thereof) is typically present at a concentration of about 0.01% w / w to about 6% by weight, based on the total weight of the reconstituted tobacco, for example, from about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, or about 0.1% w / w to about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, about 0.9%, about 1%, about 2%, about 3%, about 4%, about 5%, or about 6% by weight.

[0134] antioxidants In some embodiments, the active ingredient comprises one or more antioxidants. As used herein, the term "antioxidant" refers to a substance that can prevent or inhibit oxidation by terminating free radical reactions, slowing or preventing certain cell damage. Antioxidants can be naturally occurring or synthetic. Naturally occurring antioxidants include those found in foods and plant materials. Non-limiting examples of antioxidants include certain plant materials, vitamins, polyphenols, and phenol derivatives.

[0135] Examples of botanical materials associated with antioxidant properties include, but are not limited to, acai berry, alfalfa, allspice, anatomy, apricot oil, basil, bee balm, wild bergamot, black pepper, blueberry, borage seed oil, bugleweed, cacao, mustard root, canip, catuaba, cayenne pepper, chaga mushroom, chervil, cinnamon, dark chocolate, potato peel, grape seed, ginseng, ginkgo biloba, Saint John's ort, yarrow, green tea, black tea, black cohosh, cayenne, chamomile, cloves, cocoa powder, cranberry, dandelion, grapefruit, honeybush, echinacea, garlic, evening primrose, feverfew, ginger, cordenseal, hawthorn, and hibiscus. Flowers, Jiaogulan, Birkat, Lavender, Licorice, Marjoram, Milk Thistle, Mint, Oolong Tea, Beetroot, Orange, Oregano, Papaya, Pennyroyal, Peppermint, Red Clover, Rooibos Tea (Red or Green), Rosehips, Rosemary, Sage, Clary Sage, Savory, Spearmint, Spirulina, Elm Bark, Sorghum Bran (High Tannins), Sorghum Grain (High Tannins), Sumac Bran, Comfrey Leaf and Root, Goji Berry, Gutukola, Thyme, Turmeric, Uva Ursi, Valerian, Wild Yam Root, Wintergreen, Yacon Root, Yellow Dock, Yerba Mate, Bacopa Monniera, Withania Somnifera, Lion's Mane, Silybum Marianum. Such plant materials may be provided in fresh or dried form, in essential oil form, or in the form of extracts. Plant materials (and their extracts) often contain various classes of compounds known to provide antioxidant benefits, such as minerals, vitamins, isoflavones, phytosterols, allyl sulfides, dithiolthiones, isothiocyanates, indoles, lignans, flavonoids, polyphenols, and carotenoids. Examples of compounds found in plant extracts or oils include ascorbic acid, peanut endocarb, resveratrol, sulforaphane, beta-carotene, lycopene, lutein, coenzyme Q, carnitine, quercetin, kaempferol, and the like.See, for example, Santhosh et al., Phytomedicine, 12 (2005) 216-220, which is incorporated herein by reference.

[0136] Non-limiting examples of other suitable antioxidants include citric acid, vitamin E or a derivative thereof, tocopherol, epicatechol, epigallocatechol, epigallocatechol gallate, erythorbic acid, sodium erythorbate, 4-hexylresorcinol, theaflavin, theaflavin monogallate A or B, theaflavin digallate, phenolic acids, glycosides, quercitrin, isoquercitrin, hyposides, polyphenols, catechol, resveratrol, oleuropein, butylated hydroxyanisole (BHA), butylated hydroxytoluene (BHT), tertiary butylhydroquinone (TBHQ), and combinations thereof.

[0137] When present, antioxidants are typically present at a concentration of about 0.001% w / w to about 10% by weight, e.g., about 0.001%, about 0.005%, about 0.01% w / w, about 0.05%, about 0.1%, or about 0.5%, up to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, based on the total weight of the composition.

[0138] Nicotine content In certain embodiments, the reconstituted tobacco of the present disclosure can include a nicotine compound. Various nicotinic compounds and their administration methods are described in U.S. Patent Application Publication No. 2011 / 0274628 to Borschke, which is incorporated herein by reference. As used herein, "nicotine compound" or "nicotine source" often refers to a natural or synthetic nicotine compound isolated from plant material, meaning that the compound is at least partially purified and not contained within a plant structure such as tobacco leaves. Most preferably, the nicotine is naturally occurring and obtained as an extract from Nicotiana species (e.g., tobacco). The nicotine can have the enantiomeric forms S(-)-nicotine, R(+)-nicotine, or a mixture of S(-)-nicotine and R(+)-nicotine. Most preferably, the nicotine is in the form of S(-)-nicotine (e.g., in a form that is substantially all S(-)-nicotine) or a racemic mixture composed primarily of S(-)-nicotine (e.g., a mixture composed of about 95 parts by weight of S(-)-nicotine and about 5 parts by weight of R(+)-nicotine). Most preferably, the nicotine is used in a substantially pure form or in an essentially pure form. Highly preferred nicotine used has a purity of greater than about 95%, more preferably greater than about 98%, and most preferably greater than about 99% by weight.

[0139] In certain embodiments, the nicotine component may be included in the mixture in free base form, salt form, complex form, or solvate form. By "nicotine component" is meant nicotine in any suitable form (e.g., free base or free salt) for providing oral absorption of at least a portion of the nicotine present. Typically, the nicotine component is selected from the group consisting of nicotine free base and nicotine salts. In some embodiments, nicotine is in its free base form, which can be readily adsorbed onto, for example, a microcrystalline cellulose material to form a microcrystalline cellulose-nicotine carrier complex. See, for example, the discussion of nicotine in free base form in U.S. Patent Application Publication No. 2004 / 0191322 to Hansson, incorporated herein by reference.

[0140] In some embodiments, at least a portion of the nicotine may be used in the form of a salt. Nicotine salts can be provided using ingredients and techniques of the type described in U.S. Patent No. 2,033,909 to Cox et al. and Perfetti, Beitrage Tabakforschung Int., 12:43-54 (1983), which are incorporated herein by reference. Furthermore, nicotine salts are available from sources such as Pfaltz and Bauer, Inc. and K&K Laboratories, Division of ICN Biochemicals, Inc. Typically, the nicotine component is selected from the group consisting of nicotine free base, hydrochloride, dihydrochloride, monotartrate, bitartrate, sulfate, salicylate, and nicotine zinc chloride. In some embodiments, the nicotine component or a portion thereof is a nicotine salt with one or more organic acids.

[0141] In some embodiments, at least a portion of the nicotine may be in the form of a nicotine resin complex, in which the nicotine is bound to an ion exchange resin such as nicotine polacrilex, which is nicotine bound to a polymethacrylic acid such as Amberlite IRP64, Purolite C115HMR, or Doxion P551. See, for example, U.S. Patent No. 3,901,248 to Lichtneckert et al., incorporated herein by reference. Another example is a nicotine-polyacrylcarbomer complex, including Carbopol 974P. In some embodiments, the nicotine may be present in the form of a nicotine-polyacryl complex.

[0142] Typically, the nicotine component (calculated as the free base), if present, is at a concentration of at least about 0.001%, e.g., in the range of about 0.001% to about 10%, by weight of the reconstituted tobacco. In some embodiments, the nicotine component is present in a concentration of about 0.1% w / w to about 10% by weight, e.g., about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, calculated as the free base, based on the total weight of the reconstituted tobacco. In some embodiments, the nicotine component is present in a concentration of about 0.1% w / w to about 3% by weight, calculated as the free base, based on the total weight of the reconstituted tobacco, e.g., about 0.1% w / w to about 2.5% by weight, about 0.1% to about 2.0%, about 0.1% to about 1.5%, or about 0.1% to about 1% by weight. These ranges may also apply to other active ingredients described herein.

[0143] In some embodiments, reconstituted tobaccos of the present disclosure can be characterized as being free of nicotine components (e.g., any embodiment disclosed herein can be completely or substantially free of nicotine components). By "substantially free," it is meant that nicotine has not been intentionally added beyond trace amounts that may be naturally present, for example, in plant material. For example, certain embodiments can be characterized as having less than 0.001% nicotine by weight, calculated as the free base, or less than 0.0001%, or even 0% nicotine by weight.

[0144] cannabinoids In some embodiments, the active ingredient comprises one or more cannabinoids. As used herein, the term "cannabinoid" refers to a diverse class of chemical compounds that act on cannabinoid receptors, also known as the endocannabinoid system, in cells to alter neurotransmitter release in the brain. Ligands for these receptor proteins include endocannabinoids naturally produced in animals, phytocannabinoids found in cannabis, and artificially produced synthetic cannabinoids. Cannabinoids found in cannabis include, but are not limited to, cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabinol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A). In certain embodiments, the cannabinoid is selected from tetrahydrocannabinol (THC), the primary psychoactive compound in cannabis, and cannabidiol (CBD), another major component of the plant that lacks psychoactive properties. All of the above compounds can be used in isolated or synthetically derived form from plant material.

[0145] In some embodiments, the cannabinoid is selected from the group consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabiditriol (CBO), tetrahydrocannabimolic acid (THCA), tetrahydrocannabivaric acid (THCV A), and mixtures thereof. In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. The choice of cannabinoid and the specific proportions thereof that may be present in the disclosed oral products will vary depending on the desired flavor, texture, and other characteristics of the oral product.

[0146] Alternatively, the active ingredient may be a cannabimimetic, a class of compounds derived from plants other than cannabis that have similar biological effects on the endocannabinoid system as cannabinoids. Examples include yangonin, α-amyrin or β-amyrin (also classified as terpenes), cyanidin, curcumin (tumeric), catechin, quercetin, salvinorin A, N-acylethanolamine, and N-alkylamide lipids. Such compounds can be used in the same amounts and ratios as those described herein for cannabinoids.

[0147] If present, the cannabinoid (e.g., CBD) or cannabimimetic is typically at a concentration of at least about 0.1% by weight of reconstituted tobacco based on the total weight of the composition, for example, from about 0.1% to about 30% by weight, such as about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, about 10%, about 15%, about 20%, or about 30%.

[0148] terpenes Active ingredients suitable for use in the present disclosure can also be classified as terpenes, many of which are associated with biological effects such as sedative effects. Terpenes are understood to have the general formula (C5H8)n and include monoterpenes, sesquiterpenes, and diterpenes. Terpenes can be acyclic, monocyclic, or bicyclic in structure. Some terpenes provide enhancer effects when used in combination with cannabinoids or cannabimimetics. Examples include beta-caryophyllene, linalool, limonene, beta-citronellol, linalyl acetate, pinene (alpha or beta), geraniol, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, and germacrene, which can be used alone or in combination.

[0149] In some embodiments, the terpene is derived from a cannabinoid-producing plant, e.g., a variety of Cannabis sativa, such as hemp. Suitable terpenes in this regard include so-called "C10" terpenes, which are terpenes containing 10 carbon atoms, and so-called "C15" terpenes, which are terpenes containing 15 carbon atoms. In some embodiments, the active ingredient comprises two or more terpenes. For example, the active ingredient may comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more terpenes, as defined herein. In some embodiments, the terpene is selected from pinene (alpha and beta), geraniol, linalool, limonene, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, germacrene, and mixtures thereof.

[0150] Pharmaceutical ingredients In some embodiments, the active ingredient comprises an active pharmaceutical ingredient (API). The API can be any known agent adapted for therapeutic, prophylactic, or diagnostic use. These can include, for example, synthetic organic compounds, proteins and peptides, polysaccharides and other sugars, lipids, phospholipids, inorganic compounds (e.g., magnesium, selenium, zinc, nitrates), neurotransmitters or their precursors (e.g., serotonin, 5-hydroxytryptophan, oxitriptan, acetylcholine, dopamine, melatonin), and nucleic acid sequences with therapeutic, prophylactic, or diagnostic activity. Non-limiting examples of APIs include analgesics and antipyretics (e.g., acetylsalicylic acid, acetaminophen, 3-(4-isobutylphenyl)propanoic acid), phosphatidylserine, myo-inositol, docosahexaenoic acid (DHA, omega-3), arachidonic acid (AA, omega-6), S-adenosylmethionine (SAM), β-hydroxy-β-methylbutyrate (HMB), citicoline (cytidine-5'-diphosphate-choline), and cotinine. In some embodiments, the active ingredient comprises citicoline. In some embodiments, the active ingredient is a combination of citicoline, caffeine, theanine, and ginseng. In some embodiments, the active ingredient comprises sunflower lecithin. In some embodiments, the active ingredient is a combination of sunflower lecithin, caffeine, theanine, and ginseng.

[0151] The amount of API can vary. For example, if present, the API is typically present at a concentration of about 0.001% w / w to about 10% by weight, e.g., about 0.01%, about 0.02%, about 0.03%, about 0.04%, about 0.05%, about 0.06%, about 0.07%, about 0.08%, about 0.09%, about 0.1% w / w, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, about 0.9%, or about 1%, to about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight, based on the total weight of the reconstituted tobacco.

[0152] In some embodiments, the composition is substantially free of any API. By "substantially free of API," it is meant that the composition does not contain, and specifically excludes the presence of, any API, as defined herein, such as any Food and Drug Administration (FDA)-approved therapeutic agent intended to treat any medical condition.

[0153] In certain embodiments, the active ingredient is selected from the group consisting of caffeine, taurine, GABA, theanine, tryptophan, vitamin B6, vitamin B12, vitamin C, lemon balm extract, ginseng, citicoline, sunflower lecithin, and combinations thereof. For example, the active ingredient may include a combination of caffeine, theanine, and optionally ginseng. In another embodiment, the active ingredient includes a combination of theanine, gamma-aminobutyric acid (GABA), and optionally lemon balm extract. In further embodiments, the active ingredient includes theanine, theanine and tryptophan, theanine and one or more of the B vitamins B6 and B12, or tryptophan, theanine and the B vitamins B6 and B12. In yet further embodiments, the active ingredient includes a combination of caffeine, taurine, and vitamin C, and optionally further includes one or more B vitamins (e.g., vitamin B6 or B12). A magnesium salt (eg, magnesium gluconate) can be added to any of the above combinations, particularly those that also include theanine.

[0154] In some embodiments, the active ingredients described herein may be susceptible to degradation (e.g., oxidative, photolytic, thermal, evaporative) during processing or storage of oral products. In such embodiments, the active ingredients may be encapsulated (e.g., caffeine, vitamin A, iron (Fe), etc.) or otherwise matrix-modified with fillers, binders, etc. to provide enhanced stability to the active ingredients. For example, binders such as functionalized cellulose (e.g., cellulose ethers, including, but not limited to, hydroxypropyl cellulose) can be used to enhance the stability of such actives against degradation. Furthermore, these encapsulated actives may need to be combined with excipients in the composition to enhance their solubility and / or bioavailability. Non-limiting examples of these excipients include β-carotene, lycopene, vitamin D, vitamin E, coenzyme Q10, vitamin K, and curcumin.

[0155] In other embodiments, the initial amount of active ingredient can be increased to compensate for gradual degradation losses in order to provide a desired concentration of active ingredient by weight. Thus, initial amounts greater than those disclosed herein are contemplated by the present disclosure.

[0156] Other additives The disclosed reconstituted tobaccos can include other additives. For example, the mixture can be processed, blended, compounded, combined, and / or mixed with other materials or ingredients. The additives can be artificial or obtained or derived from herbal or biological sources. Examples of additional types of additives include thickeners or gelling agents (e.g., fish gelatin), emulsifiers, oral care additives (e.g., thyme oil, eucalyptus oil, and zinc), preservatives (e.g., potassium sorbate, etc.), zinc or magnesium salts selected for their relative water solubility (e.g., magnesium gluconate or zinc gluconate) for compositions that are more water soluble, or for their relative water insolubility (e.g., magnesium oxide or zinc oxide) for compositions that are less water soluble, disintegration aids, or combinations thereof. See, for example, U.S. Patent No. 9,237,769 to Mua et al., U.S. Patent No. 7,861,728 to Holton, Jr. et al., U.S. Patent Application Publication No. 2010 / 0291245 to Gao et al., and U.S. Patent Application Publication No. 2007 / 0062549 to Holton, Jr. et al., each of which is incorporated herein by reference, for descriptions of representative ingredients, combinations of ingredients, relative amounts of ingredients, and embodiments and methods for using the ingredients. Typical inclusion ranges of such additional additives may vary depending on the nature and function of the additive and its intended effect on the final reconstituted tobacco, with exemplary ranges being up to about 10% by weight (e.g., about 0.1 to about 5% by weight) based on the total weight of the reconstituted tobacco. The aforementioned additives can be used together (e.g., as an additive blend) or separately (e.g., individual additive components can be added at different stages in the preparation of the final reconstituted tobacco).

[0157] In some embodiments, any one or more of the reconstituted tobacco sheet, active ingredient, tobacco material, optional additive ingredients, and overall input material for the reconstituted tobacco described herein can be described as a particulate material. As used herein, the term "particulate" refers to material in the form of a plurality of individual particles, some of which may be in the form of agglomerates of a plurality of particles, the particles having an average length-to-width ratio of less than 2:1, e.g., less than 1.5:1, e.g., about 1:1. In various embodiments, the particles of the particulate material can be described as substantially spherical or granular.

[0158] The particle size of particulate matter can be measured by sieve analysis. As those skilled in the art will readily understand, sieve analysis (otherwise known as gradient testing) is a method used to measure the particle size distribution of particulate materials. Typically, sieve analysis involves a nested column of sieves, preferably in the form of a wire mesh fabric. A pre-weighed sample can be introduced into the top or uppermost sieve of the column, which has the largest sieve opening or mesh size (i.e., the largest pore size of the sieve). Each subsequent sieve in the column has an increasingly smaller sieve opening or mesh size than the sieve above it. Typically, the base of the sieve column has a receiving section for collecting any particles having a particle size smaller than the sieve opening or mesh size of the bottom or lowest sieve of the column (which has the smallest sieve opening or mesh size).

[0159] In some embodiments, the sieve column can be placed on or within a mechanical agitator. The agitator causes vibration of each sieve within the column. The mechanical agitator can be activated for a predetermined period of time to ensure all particles are collected on the correct sieve. In some embodiments, the sieve column is agitated for a period of 0.5 to 10 minutes, e.g., 1 to 10 minutes, e.g., 1 to 5 minutes, e.g., about 3 minutes. Once agitation of the sieves within the column is complete, the material collected on each sieve is weighed. The weight of each sample on each sieve can then be divided by the total weight to obtain the percentage of mass retained on each sieve. As one skilled in the art would readily understand, the sieve opening size or mesh size of each sieve in a column used in sieve analysis can be selected based on the particle size of the sample being analyzed or the known maximum / minimum particle size. In some embodiments, a sieve column can be used for sieve analysis, and the column can include 2 to 20 sieves, e.g., 5 to 15 sieves. In some embodiments, the sieve analysis can use a column of sieves, the column comprising 10 sieves. In some embodiments, the maximum sieve opening or mesh size of the sieve used in the sieve analysis can be 1000 μm, such as 500 μm, such as 400 μm, such as 300 μm.

[0160] In some embodiments, any particulate material referred to herein (e.g., tobacco material, active ingredient, further ingredient, and input material as a whole) can be characterized as having at least 50% by weight of particles having a particle size as measured by sieve analysis of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less. In some embodiments, at least 60% by weight of the particles of any particulate material referred to herein have a particle size as measured by sieve analysis of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less. In some embodiments, at least 70% by weight of the particles of any particulate material referred to herein have a particle size of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less, as measured by sieve analysis. In some embodiments, at least 80% by weight of the particles of any particulate material referred to herein have a particle size of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less, as measured by sieve analysis. In some embodiments, at least 90% by weight of the particles of any particulate material referred to herein have a particle size of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less, as measured by sieve analysis. In some embodiments, at least 95% by weight of the particles of any particulate material referred to herein have a particle size of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less, as measured by sieve analysis. In some embodiments, at least 99% by weight of the particles of any particulate material referred to herein have a particle size of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less, as measured by sieve analysis.In some embodiments, about 100% by weight of the particles of any particulate material referred to herein have a particle size of about 1000 μm or less, such as about 500 μm or less, for example about 400 μm or less, such as about 350 μm or less, for example about 300 μm or less, as measured by sieve analysis.

[0161] In some embodiments, at least 50% by weight, such as at least 60% by weight, for example at least 70% by weight, such as at least 80% by weight, for example at least 90% by weight, for example at least 95% by weight, for example at least 99% by weight of the particles of any particulate material referred to herein have a particle size of from about 0.01 μm to about 1000 μm, such as from about 0.05 μm to about 750 μm, for example from about 0.1 μm to about 500 μm, such as from about 0.25 μm to about 500 μm, as measured by sieve analysis. In some embodiments, at least 50% by weight, such as at least 60% by weight, for example at least 70% by weight, such as at least 80% by weight, for example at least 90% by weight, for example at least 95% by weight, for example at least 99% by weight of the particles of any particulate material referred to herein have a particle size of from about 10 μm to about 400 μm, such as from about 50 μm to about 350 μm, for example from about 100 μm to about 350 μm, such as from about 200 μm to about 300 μm, as measured by sieve analysis.

[0162] Products incorporating reconstituted tobacco Reconstituted tobacco produced according to the methods of the present disclosure can be used in a variety of products and processes. For example, the reconstituted tobacco formed from the first reconstituted tobacco input can be used as an input in the production of other cellulosic materials, such as, but not limited to, microcrystalline cellulose (MCC), regenerated cellulose, and the like.

[0163] Alternatively, the reconstituted tobacco material can be used as part of an article (also referred to herein as a consumable). A consumable is an article intended to be consumed, in part or in whole, by a user during use. The consumable may comprise or consist of the reconstituted tobacco material described herein. The consumable may also include one or more other elements, such as a filter or an aerosol modifier. The consumable may also include a heating element that emits heat to generate an aerosol in the reconstituted tobacco material during use. The heating element may, for example, comprise a combustible material or may include a susceptor that can be heated by penetration of a changing magnetic field.

[0164] The susceptor is a material that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The heating material can be an electrically conductive material, such that penetration by the varying magnetic field causes induction heating of the heating material. The heating material can be a magnetic material, such that penetration by the varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material can be both electrically conductive and magnetic, such that the heating material can be heated by both heating mechanisms.

[0165] Induction heating is a process of heating a conductive object by penetrating it with a changing magnetic field. This process is described by Faraday's induction and Ohm's law. An induction heater can include an electromagnet and a device for passing a variable current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are properly positioned relative to one another so that the resulting changing magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are generated in the object, the flow of the eddy currents against the object's electrical resistance heats the object. This process is called Joule heating, ohmic heating, or resistive heating.

[0166] In some embodiments, the susceptor is in the form of a closed circuit. It has been found that when the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet during use is enhanced, thereby resulting in increased or improved Joule heating.

[0167] Magnetic hysteresis heating is the process of heating an object made of a magnetic material by passing a changing magnetic field through it. Magnetic materials can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field passes through such a material, the magnetic dipoles align in the direction of the magnetic field. Thus, when a changing magnetic field, such as an alternating magnetic field generated by an electromagnet, passes through a magnetic material, the orientation of the magnetic dipoles changes with the applied changing magnetic field. This magnetic dipole reorientation generates heat in the magnetic material.

[0168] If an object is both conductive and magnetic, penetrating it with a changing magnetic field can cause both Joule heating and magnetic hysteresis heating within the object. Furthermore, the use of magnetic materials can enhance the magnetic field, which can enhance Joule heating.

[0169] Because each of the above processes generates heat within the object itself, rather than from an external heat source via thermal conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selecting the appropriate object material and geometry, and by using an appropriate varying magnetic field magnitude and orientation relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the object, allowing for greater freedom and control in the design of the heating profile and potentially lower costs.

[0170] The delivery systems described herein can be implemented as combustible aerosol delivery systems or non-combustible aerosol delivery systems. For example, reconstituted tobacco sheets produced according to the methods of the present disclosure can be useful as paper materials in the manufacture of combustible smoking articles (e.g., filters, tipping papers, plug wraps, etc.). Traditional cigarette filter materials include cellulose acetate tow, cellulose acetate web, polypropylene tow, cellulose acetate web, paper, reconstituted tobacco strands, etc. In certain embodiments, reconstituted tobacco produced according to the present disclosure can be useful as a filler material in compositions comprising at least one active ingredient and / or flavorant. Reconstituted tobacco produced according to the methods disclosed herein can also be useful as a substrate in the form of a flat or cast sheet.

[0171] For example, filter materials, filter elements, and filter rods for various aerosol delivery devices containing reconstituted tobacco manufactured according to the present disclosure can be used to provide multi-segment filter rods. Such multi-segment filter rods can be used to manufacture filter cigarettes having multi-segment filter elements. The manufacture of multi-segment filter rods can be carried out using a rod-forming unit of the type used to provide multi-segment cigarette filter components. Multi-segment cigarette filter rods can be manufactured using a cigarette filter rod manufacturing device available under the trade name Mulfi from Hauni-Werke Körber & Co. KG in Hamburg, Germany. Filter element components or segments for filter elements for multi-segment filtered cigarettes are typically provided from filter rods manufactured using conventional rod-forming units, such as those available from Hauni-Werke Körber & Co. KG as KDF-2 and KDF-3E. Typically, a tow processing unit is used to provide filter materials such as filter tow (i.e., esterified pulp). An exemplary tow processing unit is commercially available as E-60, supplied by Arjay Equipment Corp., Winston-Salem, NC. Other exemplary tow processing units are commercially available as AF-2, AF-3, and AF-4 from Hauni-Werke Körber & Co. KG. Further, exemplary embodiments and methods for operating filter material supply units and filter making units are described in U.S. Pat. No. 4,281,671 to Byrne, U.S. Pat. No. 4,862,905 to Green, Jr. et al., U.S. Pat. No. 5,060,664 to Siems et al., U.S. Pat. No. 5,387,285 to Rivers, and U.S. Pat. No. 7,074,170 to Lanier, Jr. et al.Other types of techniques for feeding filter material to a rod-forming unit are described in U.S. Patent No. 4,807,809 to Pryor et al. and U.S. Patent No. 5,025,814 to Raker et al., both of which are incorporated herein by reference.

[0172] Aerosol delivery devices incorporating filter elements incorporating reconstituted tobacco produced in accordance with the present disclosure can be manufactured using conventional cigarette manufacturing techniques. For example, so-called "6-up," "4-up," and "2-up" filter rods of the common types and configurations conventionally used in the manufacture of filtered cigarettes can be handled using conventional or appropriately modified cigarette rod handling devices, such as tipping devices available as Lab MAX, MAX, MAX S, or MAX 80 from Hauni-Werke Körber & Co. KG. See, for example, the types of devices described in U.S. Patent No. 3,308,600 to Erdmann et al., U.S. Patent No. 4,281,670 to Heitmann et al., U.S. Patent No. 4,280,187 to Reuland et al., U.S. Patent No. 6,229,115 to Vos et al., U.S. Patent No. 7,296,578 to Read, Jr., and U.S. Patent No. 7,434,585 to Holmes, each of which is incorporated herein by reference. The operation of these types of devices will be readily apparent to those skilled in the art of automated cigarette manufacturing.

[0173] Although the disclosed filter materials and filter elements are generally described herein with respect to embodiments related to aerosol delivery devices, it should be understood that the features, components, and characteristics of such aerosol delivery devices may be embodied in many different forms and / or associated with various aerosol delivery devices, as will be understood by those skilled in the art. For example, the filter materials and filter elements provided herein may be used with embodiments such as traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), non-combustion heated cigarettes, electronic aerosol delivery devices, etc. Accordingly, the use of various filter materials and filter elements, including reconstituted tobacco according to the present disclosure, with the aerosol delivery devices described herein below is described with respect to embodiments related to aerosol delivery devices by way of example only, and it should be understood that such filter materials and filter elements may be embodied and used in a variety of other products and devices.

[0174] FIG. 2 shows an exploded view of a smoking article in the form of a cigarette 200 that can include reconstituted tobacco material of the present disclosure. The cigarette 200 includes a generally cylindrical rod 202 that includes a filler or roll of smokable filler material contained in a surrounding wrapping material 204. The rod 202 is conventionally referred to as a "tobacco rod." The ends of the tobacco rod 202 are open to expose the smokable filler material. Reconstituted tobacco produced in accordance with the present disclosure can be used in the manufacture of wrapping material and / or as at least a portion of the tobacco material within the tobacco rod. The cigarette 200 is shown as having one optional band 206 (e.g., a printed coating including a film-forming agent such as starch, ethyl cellulose, or sodium alginate) applied to the wrapping material 204, the band circumscribing the cigarette rod 202 in a direction transverse to the longitudinal axis of the cigarette 200. That is, the band 206 provides a transverse region relative to the longitudinal axis of the cigarette 200. The band 206 may be printed on the inner surface of the wrapping material 204 (i.e., facing the smokable filler material) or, less preferably, on the outer surface of the wrapping material. Although a cigarette may have a wrapping material with one optional band, the cigarette may also have a wrapping material with two, three, or more further optional spaced bands bearing numbering specifications.

[0175] The tobacco rod 200 has a lighting end 208 at one end and a filter element 212 (e.g., comprising one or more segments of filter material as disclosed herein) disposed at the mouth end 210. The filter element 212 can be manufactured according to methods known in the art. The filter element generally comprises a cellulosic material, which may include reconstituted tobacco produced in accordance with the present disclosure. The filter element 212 can have a generally cylindrical shape, and its diameter can be essentially equal to the diameter of the tobacco rod 202. The filter element 212 is circumscribed along its outer or longitudinal periphery by a layer of outer plug wrap 214 to form the filter element. It should be noted that any of the paper-like materials used to form smoking articles (e.g., plug wrap, tipping material, etc.) can include reconstituted tobacco produced in accordance with the present disclosure. The filter element is positioned adjacent to one end of the tobacco rod 202 so that the filter element and the tobacco rod are axially aligned in an end-to-end relationship and preferably abut one another. The ends of the filter element allow the passage of air and smoke.

[0176] The smoking article may further include an outer tipping material 220 surrounding the tobacco rod 202, the wrapping material 204, the filter element 212, and the plug wrap 214. A ventilated or air-diluted smoking article may be provided with an optional air dilution means, such as a series of perforations 222 each extending through the tipping material 220 and the plug wrap 214. The optional perforations 222 may be made by various techniques known to those skilled in the art, such as laser perforation techniques. Alternatively, so-called offline air dilution techniques may be used (e.g., through the use of porous paper plug wrap and pre-perforated gradient material). For air-diluted or ventilated cigarettes, the amount or degree of air dilution or ventilation may vary. Often, the amount of air dilution in an air-diluted cigarette is greater than about 10%, commonly greater than about 20%, often greater than about 30%, and sometimes greater than about 40%. Typically, the upper level of air dilution in an air-diluted cigarette is less than about 80%, and often less than about 70%. As used herein, the term "air dilution" is the ratio (expressed as a percentage) of the volume of air drawn through the air dilution means to the total volume of air and smoke drawn through the cigarette and exiting the cigarette's end-most section. The filter element 212 may be attached to the tobacco rod 202 using a tipping material 220 (e.g., an essentially air-impermeable graded material) that surrounds both the entire length of the filter element and the adjacent region of the tobacco rod 202. The inner surface of the tipping material 220 is fixedly joined, using a suitable adhesive, to the outer surface of the plug wrap 214 and the outer surface of the wrapping material 204 of the tobacco rod 202, thus connecting the filter element and the tobacco rod to form the cigarette 200.

[0177] FIG. 3 shows a perspective view of an aerosol delivery device according to another exemplary embodiment of the present disclosure, and FIG. 4 shows a perspective view of the aerosol delivery device of FIG. 3 with the outer wrap removed. In particular, FIG. 3 shows an aerosol delivery device 300 including an outer wrap 302 and a heat source 304. In the embodiment shown in FIG. 3, for example, the aerosol delivery device 300 has a lighting end 303 disposed proximate the heat source 304 and a mouth end 301 disposed at the opposite end of the aerosol delivery device. FIG. 4 shows the aerosol delivery device 300 with the outer wrap 302 removed to reveal other internal components of the aerosol delivery device 300. In the embodiment shown in FIG. 4, for example, the aerosol delivery device 300 includes the heat source 304, a tobacco rod or substrate portion 310, an intermediate component 308, and a filter element 312. Similar to the tobacco rod of a smoking article, the substrate portion of the non-combustion heating device can include reconstituted tobacco produced in accordance with the present disclosure. In the illustrated embodiment, the intermediate component 308 and the filter element 312 together comprise a mouthpiece 314 .

[0178] In various embodiments, the heat source 304 may be configured to generate heat upon ignition. In the illustrated embodiment, the heat source 304 has a generally cylindrical shape and includes a combustible fuel element incorporating a combustible carbonaceous material. In other embodiments, the heat source 304 may have a different shape, for example, a prismatic shape with a triangular, cubic, or hexagonal cross section. Carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials may be primarily composed of carbon and / or may typically have a carbon content of greater than about 60%, generally greater than about 70%, often greater than about 80%, and often greater than about 90% on a dry weight basis.

[0179] In some cases, the heat source 304 can incorporate elements other than combustible carbonaceous material (e.g., tobacco components such as powdered tobacco or tobacco extract; flavoring agents; salts such as sodium chloride, potassium chloride, and sodium carbonate; heat-stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources such as ammonia salts; and / or binders, e.g., guar gum, ammonium alginate, and sodium alginate). While the specific dimensions of the applicable heat source can vary, in some embodiments, the heat source 304 can have a length in the inclusive range of about 7 mm to about 20 mm, and in some embodiments, about 17 mm, and an overall diameter in the inclusive range of about 3 mm to about 8 mm, and in some embodiments, about 4.8 mm (and in some embodiments, about 7 mm). While the heat source can be constructed in various ways in other embodiments, in the illustrated embodiment, the heat source 304 is extruded or composited using crushed or powdered carbonaceous material, forming a mass of about 0.5 g / cm on a dry weight basis. 3 often exceeding about 0.7 g / cm 3 often exceeding about 1 g / cm 3has a density greater than. For example, refer to the fuel source components, formulations, and types of designs described in U.S. Patent No. 5,551,451 to Riggs et al. and U.S. Patent No. 7,836,897 to Borschke et al., which are hereby incorporated by reference in their entirety. In various embodiments, the heat source may have various forms, such as, for example, a substantially solid cylindrical or hollow cylindrical shape (e.g., a tube), but the heat source 304 of the illustrated embodiment is generally cylindrical and includes an extruded monolithic carbonaceous material having a plurality of grooves 316 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the aerosol delivery device, particularly the heat source, may include a heat transfer component. In various embodiments, the heat transfer component may be proximate to the heat source, and in some embodiments, the heat transfer component may be within or disposed within the heat source. Some examples of heat transfer components are described in U.S. Patent Application No. 15 / 923,735, filed Mar. 16, 2018, entitled "Smoking Article with Heat Transfer Component", which is hereby incorporated by reference in its entirety.

[0180] In the illustrated embodiment, the grooves 316 in the heat source 304 are substantially equal in width and depth and substantially equally distributed around the circumference of the heat source 304; however, other embodiments may include as few as two grooves, and still other embodiments may include as few as one groove. Still other embodiments may not include any grooves at all. Further embodiments may include multiple grooves that may be of unequal width and / or depth and unevenly spaced around the circumference of the heat source. In still other embodiments, the heat source may include grooves and / or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to its opposite second end. In some embodiments, the heat source may include a foamed carbon monolith formed by a foaming process of the type disclosed in U.S. Pat. No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. Accordingly, some embodiments may provide advantages in terms of reducing the time it takes to ignite the heat source. In some other embodiments, the heat source may be co-extruded with an insulating layer (not shown), thereby reducing manufacturing time and costs. Other embodiments of the fuel element include carbon filters of the type described in U.S. Pat. No. 4,922,901 to Brooks et al., or other heat source embodiments such as those disclosed in U.S. Patent Application Publication No. 2009 / 0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

[0181] Generally, the heat source is positioned in sufficient proximity to the tobacco rod or substrate portion 310 (e.g., containing reconstituted tobacco produced in accordance with the present disclosure and one or more aerosolizable components therein) such that an aerosol formed / volatilized by the application of heat from the heat source to the aerosolizable components (as well as any flavorings, agents, etc. similarly provided for delivery to the user) is deliverable to the user via the mouthpiece. That is, when the heat source heats the tobacco rod or substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. Note that the foregoing terms mean that references to release, releasing, releases, or released are interchangeable to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol, or a mixture thereof.

[0182] As shown in FIG. 4 , the aerosol delivery device 304 of the illustrated embodiment also includes an intermediate component 308 and at least one filter element 312. Note that in various embodiments, the intermediate component 308 or the filter element 312, individually or together, may be considered the mouthpiece 314 of the aerosol delivery device 300. In one or more embodiments, the intermediate component may be omitted; for example, some examples of aerosol delivery devices according to the present disclosure may include only the heat source 304, the tobacco rod or substrate material 310, and the filter element 312. While in various embodiments, an intermediate component need not be included, in the illustrated embodiment, the intermediate component 308 comprises a substantially rigid member that is substantially inflexible along its longitudinal axis. In the illustrated embodiment, the intermediate component 308 comprises a hollow tubular structure and is included to add structural integrity to the aerosol delivery device 300 and to cool the generated aerosol. In some embodiments, the intermediate component 308 may be used as a container for collecting the aerosol. In various embodiments, such components may be constructed from any of a variety of materials and may include reconstituted tobacco prepared according to the present disclosure and one or more adhesives. Exemplary materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and / or composite materials. For example, in some embodiments, the intermediate component may comprise a hollow cylindrical element constructed from a paper or plastic material (e.g., ethyl vinyl acetate (EVA) or other polymeric materials such as polyethylene, polyester, silicone, or ceramics (e.g., silicon carbide, alumina, etc.), or other acetate fibers, etc.).

[0183] As previously described, in some embodiments, the mouthpiece 314 may include a filter element 312 configured to accommodate an aerosol in response to suction applied to the mouthpiece 314. In various embodiments, the filter element 312 is provided as a rod-shaped element radially and / or longitudinally disposed proximate the second end of the intermediate component 308. In particular, the filter element 312 may include one or more segments of filter material as previously described herein. In this manner, upon drawing on the mouthpiece 314, the filter element 312 accommodates the aerosol flowing through the intermediate component 308 of the aerosol delivery device 300. In some embodiments, the filter element 312 may include individual segments, e.g., including one or more individual segments of filter material prepared according to the methods provided herein.

[0184] In various embodiments, the size and shape of intermediate component 308 and / or filter element 312 may vary, for example, the length of intermediate component 308 may be in the inclusive range of about 10 mm to about 30 mm, the diameter of intermediate component 308 may be in the inclusive range of about 3 mm to about 8 mm, the length of filter 312 may be in the inclusive range of about 10 mm to about 20 mm, and the diameter of filter element 312 may be in the inclusive range of about 3 mm to about 8 mm. In the illustrated embodiment, intermediate component 308 has a length of about 20 mm and a diameter of about 4.8 mm (or in some embodiments, about 7 mm), and filter 312 has a length of about 15 mm and a diameter of about 4.8 mm (or in some embodiments, about 7 mm).

[0185] The types and configurations of aerosol delivery devices according to the present disclosure may vary and are not intended to be limited by the figures and / or descriptions provided herein for illustrative purposes only. For example, FIG. 5 illustrates another exemplary embodiment of an aerosol delivery device 400 according to the present disclosure. The aerosol delivery device 400 may include a control body 402 and an aerosol generating component 404, which may contain reconstituted tobacco prepared according to the present disclosure. In some embodiments, the aerosol generating component is configured for use with an electrically conductive and / or inductive heat source to heat the substrate material to form an aerosol. In various embodiments, the electrically conductive heat source may include a heating assembly including a resistive heating element. The resistive heating element may be configured to generate heat when an electric current is passed through it. Conductive materials useful as resistive heating elements may have low mass, low density, and moderate resistivity, and may be thermally stable at temperatures experienced during use. Useful heating elements heat and cool rapidly, thus providing efficient use of energy. Rapid heating of the element may be beneficial to provide nearly instantaneous volatilization of the aerosol-forming material in close proximity thereto. Rapid cooling prevents substantial volatilization (and thus waste) of the aerosol-forming material during periods when aerosol formation is undesirable. Such heating elements can also allow for relatively precise control of the temperature range experienced by the aerosol-forming material, particularly when time-based current control is used. Useful conductive materials are typically chemically non-reactive with the materials being heated (e.g., the aerosol-forming material and other inhalable materials) so as not to adversely affect the flavor or content of the aerosol or vapor produced. Some example, non-limiting materials that can be used as conductive materials include carbon, graphite, carbon / graphite composites, metals, ceramics such as metal and non-metal carbides, nitrides, oxides, silicides, intermetallic compounds, cermets, metal alloys, and metal foils. High-temperature resistant materials can be particularly useful. Various different materials can be blended to achieve desired properties of resistivity, mass, and thermal conductivity. In certain embodiments, metals that can be utilized include, for example, nickel, chromium, alloys of nickel and chromium (e.g., nichrome), and steel.Materials that may be useful for providing resistive heating are described in U.S. Pat. No. 5,060,671 to Counts et al., U.S. Pat. No. 5,093,894 to Deevi et al., U.S. Pat. No. 5,224,498 to Deevi et al., and Sprinkel et al., the disclosures of which are incorporated herein by reference in their entireties. No. 5,322,075 to Deevi et al., U.S. Pat. No. 5,353,813 to Deevi et al., U.S. Pat. No. 5,468,936 to Deevi et al., U.S. Pat. No. 5,498,850 to Das, U.S. Pat. No. 5,659,656 to Das, U.S. Pat. No. 5,498,855 to Deevi et al., U.S. Pat. No. 5,530,225 to Hajaligol, U.S. Pat. No. 5,665,262 to Hajaligol, U.S. Pat. No. 5,573,692 to Das et al., and U.S. Pat. No. 5,591,368 to Fleischhauer et al.

[0186] In various embodiments, the heating element may be provided in various forms, such as in the form of a foil, foam, mesh, hollow ball, half-ball, disk, spiral, fiber, wire, film, thread, strip, ribbon, or cylinder. Such heating elements often comprise a metallic material and are configured to generate heat as a result of electrical resistance associated with the passage of an electric current. Such resistive heating elements may be positioned in close proximity to and / or in direct contact with the substrate portion. For example, in one embodiment, the heating element may comprise a cylinder or other heating device disposed within the control body 402, the cylinder being composed of one or more electrically conductive materials, including, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, carbon (e.g., graphite), or any combination thereof. In various embodiments, the heating element may also be coated with any of these or other electrically conductive materials. The heating element may be positioned in close proximity to the engagement end of the control body 402 and configured to substantially surround a portion of the heating end 406 of the aerosol generating component 404, including the substrate portion 410. In this manner, the heating element may be positioned proximate to the substrate portion 410 of the aerosol-generating component 404 when the aerosol-generating component 404 is inserted into the control body 402. In other examples, at least a portion of the heating element may penetrate at least a portion of the aerosol-generating component (e.g., one or more prongs and / or spikes that penetrate the aerosol-generating component) when the aerosol-generating component is inserted into the control body. Note that while in some embodiments the heating element may comprise a cylinder, in other embodiments the heating element can take various forms and in some embodiments may directly contact and / or penetrate the substrate portion.

[0187] In addition to being configured for use with an electrically conductive heat source, as described above, the aerosol generation component of the present disclosure may also be configured for use with an inductive heat source to heat a substrate portion to form an aerosol. In various embodiments, the inductive heat source may comprise a resonant transformer, which may include a resonant transmitter and a resonant receiver (e.g., a susceptor). In some embodiments, the resonant transmitter and resonant receiver may be disposed within the control body 402. In other embodiments, the resonant receiver, or a portion thereof, may be disposed within the aerosol generation component 404. For example, in some embodiments, the control body 402 may include a resonant transmitter, which may include, for example, a foil material, a coil, a cylinder, or other structure configured to generate an oscillating magnetic field, and a resonant receiver, which may include one or more prongs extending into or surrounded by the substrate portion. In some embodiments, the aerosol generation component is in intimate contact with the resonant receiver. Exemplary resonant transformer components, including a resonant transmitter and a resonant receiver, are described in U.S. Patent Application Publication No. 2019 / 0124979 to Sebastian et al., incorporated herein by reference in its entirety.

[0188] In various embodiments, the aerosol generation component 404 and the control body 402 may be permanently or removably disposed in functional relationship. In this regard, Figure 5 illustrates the aerosol delivery device 400 in a coupled configuration, and Figure 6 illustrates the aerosol delivery device 400 in a separated configuration. Various mechanisms may connect the aerosol generation component 404 to the control body 402, providing a threaded engagement, a press-fit engagement, an interference fit, a sliding fit, a magnetic engagement, etc.

[0189] In various embodiments, the aerosol delivery device 400 according to exemplary embodiments of the present disclosure may have a variety of overall shapes, including, but not limited to, overall shapes that may be defined as substantially rod-shaped, substantially tubular, or substantially cylindrical. In the embodiment of FIGS. 5-6, the device 400 has a substantially circular cross-section. However, other cross-sectional shapes (e.g., oval, square, triangular, etc.) are also encompassed by the present disclosure. For example, in some embodiments, one or both of the control body 402 or the aerosol generation component 404 (and / or any subcomponents) may have a substantially rectangular shape, such as a substantially rectangular cuboid shape (e.g., similar to a USB flash drive). In other embodiments, one or both of the control body 402 or the aerosol generation component 404 (and / or any subcomponents) may have other handheld shapes. For example, in some embodiments, the control body 402 may have a small box shape, various podmod shapes, or a fob shape. Thus, such language describing the physical form of the article may also apply to its individual components, including the control body 402 and the aerosol-generating component 404.

[0190] The arrangement of components within the aerosol delivery device of the present disclosure may vary across various embodiments. In some embodiments, the substrate portion may be positioned in close proximity to the heat source to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heat source may be positioned sufficiently close to the substrate portion so that heat from the heat source can volatilize the substrate portion (e.g., the aerosol-forming material therein) and form an aerosol for delivery to the user. When the heat source heats the substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by the consumer. It should be noted that the foregoing terms, references to release, releasing, releases, or released, are meant to be interchangeable to include form or generate, forming or generating, forms or generates, and formed or generated. Specifically, the inhalable substance is released in the form of a vapor or an aerosol or a mixture thereof, although such terms are also used interchangeably herein unless specifically stated otherwise.

[0191] As previously mentioned, various embodiments of the aerosol delivery device 400 can incorporate a battery and / or other power source to provide sufficient current to provide various functions to the aerosol delivery device, such as powering the heat source, powering the control system, and powering the indicators. As described in more detail below, the power source can take various forms. The power source can provide sufficient power to rapidly activate the heat source to provide aerosol formation and can be used for a desired duration to power the aerosol delivery device. In some embodiments, the power source is sized to fit comfortably within the aerosol delivery device so that the aerosol delivery device can be easily handled. Examples of useful power sources typically include rechargeable lithium-ion batteries (e.g., rechargeable lithium-manganese dioxide batteries). In particular, lithium polymer batteries can be used, as such batteries can provide increased safety. Other types of batteries, such as N50-AAA CADNICA nickel-cadmium batteries, can also be used. Furthermore, the exemplary power source is lightweight enough not to impair the desired smoking experience. Some examples of possible power sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al. and U.S. Patent Application Publication No. 2017 / 0112191 to Sur et al., the disclosures of which are incorporated herein by reference in their entireties.

[0192] In certain embodiments, one or both of the control body 402 and the aerosol generating component 404 may be referred to as disposable or reusable. For example, the control body 402 may have a replaceable or rechargeable battery, a solid-state battery, a thin-film solid-state battery, a rechargeable supercapacitor, etc., and thus may be combined with any type of charging technology, including connection to a wall charger, a car charger (i.e., cigarette lighter socket), a computer via a universal serial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), etc., a photovoltaic cell (sometimes called a solar cell) or solar panel, a wireless charger such as a charger using inductive wireless charging (e.g., including wireless charging according to the Qi wireless charging standard from the Wireless Power Consortium (WPC)), or a radio frequency (RF)-based charger. An example of an inductive wireless charging system is described in U.S. Patent Application Publication No. 2017 / 0112196 to Sur et al., which is incorporated herein by reference in its entirety. Additionally, in some embodiments, the aerosol generating component 404 may comprise a disposable device. Disposable components for use with control bodies are disclosed in U.S. Patent No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

[0193] In further embodiments, the power source may comprise a capacitor. The capacitor can discharge more quickly than a battery and can be charged between puffs, allowing the battery to discharge into the capacitor at a slower rate than if it were used to directly power the heat source. For example, a supercapacitor, such as an electric double layer capacitor (EDLC), can be used separately from or in combination with the battery. When used alone, the supercapacitor may be recharged before each use of the article. Thus, the device may also include a charger component that can be attached to the smoking article during use to replenish the supercapacitor.

[0194] Additional components may be utilized in the aerosol delivery device of the present disclosure. For example, the aerosol delivery device may include a flow sensor that is sensitive to either pressure or airflow changes when a consumer inhales on the article (e.g., a puff-activated switch). Other possible current activation / deactivation mechanisms may include a temperature-activated on / off switch or a lip-pressure-activated switch. An exemplary mechanism that can provide such puff activation capability includes the Model 163PC01D36 silicon sensor manufactured by the MicroSwitch division of Honeywell, Inc. of Freeport, Illinois. Representative flow sensors, current regulation components, and other current control components, including various microcontrollers, sensors, and switches, for aerosol delivery devices are described in U.S. Patent No. 4,735,217 to Gerth et al., U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al., U.S. Patent No. 5,372,148 to McCafferty et al., U.S. Patent No. 6,040,560 to Fleischhauer et al., U.S. Patent No. 7,040,314 to Nguyen et al., and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated by reference in their entireties. See also the control scheme described in U.S. Patent No. 9,423,152 to Ampolini et al., all of which are incorporated by reference in their entireties.

[0195] In another example, the aerosol delivery device may include a first conductive surface configured to contact a first body part of a user holding the device, and a second conductive surface conductively insulated from the first conductive surface and configured to contact a second body part of the user. Thus, when the aerosol delivery device detects a change in conductivity between the first and second conductive surfaces, the vaporizer is activated to vaporize the substance, resulting in vapor that can be inhaled by the user-held unit. The first and second body parts may be the lips or a portion of the hand. The two conductive surfaces may also be used to charge a battery included in the personal vaporizer unit. The two conductive surfaces may also form or be part of a connector that can be used to output data stored in the memory. See U.S. Pat. No. 9,861,773 to Terry et al., incorporated herein by reference in its entirety.

[0196] Further, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor associated with the mouth end of the device that can detect a user's lip activity associated with inhalation and subsequently trigger heating of a heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow to a heat load array in response to a pressure drop across a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a receptacle in a smoking device that includes an identifier that detects non-uniformity in infrared transmittance of an inserted component and a controller that executes a detection routine when a component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle having multiple differential phases; and U.S. Pat. No. 5,930,649 to Watkins et al. No. 4,289 to Counts et al. discloses photonic optoelectronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for modifying the resistance of draw through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses particular battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interface means for facilitating charging of a smoking device and enabling computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses a smoking device identification system; and PCT Patent Application WO 2010 / 003480 to Flick discloses a fluid flow detection system for indicating puffs in an aerosol generating system, all of the foregoing disclosures are incorporated herein by reference in their entireties.

[0197] Further examples of components related to electronic aerosol delivery articles and disclosing materials or components that may be used in the devices include U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. No. 5,249,586 to Morgan et al., U.S. Pat. No. 5,666,977 to Higgins et al., U.S. Pat. No. 6,053,176 to Adams et al., U.S. Pat. No. 6,164,287 to White, U.S. Pat. No. 6,196,218 to Voges, U.S. Pat. No. 6,810,883 to Felter et al., U.S. Pat. No. 6,854,461 to Nichols, U.S. Pat. No. 7,832,410 to Hon, U.S. Pat. No. 7,513,253 to Kobayashi, U.S. Pat. No. 7,896,006 to Hamano, U.S. Pat. No. 6,772,756 to Shayan, U.S. Pat. No. 8,832,410 to Hon, U.S. Pat. No. 8,832,410 to Hon, U.S. Pat. No. 8,832,410 to Hon, U.S. Pat. No. 8,513,253 to Kobayashi, U.S. Pat. No. 8,896,006 to Hamano, U.S. Pat. No. 8,896,006 to Hon ... Nos. 8,156,944 and 8,375,957 to Thorens et al., U.S. Pat. No. 8,794,231 to Thorens et al., U.S. Pat. No. 8,851,083 to Oglesby et al., U.S. Pat. Nos. 8,915,254 and 8,925,555 to Monsee et al., U.S. Pat. No. 9,220,302 to DePiano et al., U.S. Patent Application Publication No. 2006 / 0196518 to Hon, and U.S. Patent Application Publication No. 2009 / 0188490 to Oglesby et al., U.S. Patent Application Publication No. 2010 / 0024834 to Wang, U.S. Patent Application Publication No. 2010 / 0307518 to Wang, PCT Patent Application Publication No. WO 2010 / 091593 to Hon, and PCT Patent Application Publication No. WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. Additionally, U.S. Patent Application Publication No. 2017 / 0099877 to Worm et al., which is incorporated herein by reference in its entirety, discloses an aerosol delivery device and a capsule that can be included in a fob-shaped configuration for the aerosol delivery device. The various materials disclosed by the aforementioned documents may be incorporated into the device in various embodiments, and all of the foregoing disclosures are incorporated herein by reference in their entirety.

[0198] Referring to FIG. 6 , in the illustrated embodiment, the aerosol-generating component 404 includes a heating end 406 configured to be inserted into the control body 402 and a mouth end 408 at which a user draws to generate an aerosol. At least a portion of the heating end 406 includes a substrate portion 410. In some embodiments, the substrate portions 410 each include a substrate comprising an aerosol-forming material as disclosed herein. In various embodiments, the aerosol-generating component 404, or a portion thereof, may be wrapped in an outer overwrap material 412. In various embodiments, the mouth end 408 of the aerosol-generating component 404 may include a filter 414, which may be made of, for example, a cellulose acetate or polypropylene material. The filter 414 may additionally or alternatively include strands of tobacco-containing material, such as those described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various embodiments, the filter 414 may enhance the structural integrity of the mouth end of the aerosol-generating component 404 and / or provide filtering capabilities as needed and / or resistance to suction. In some embodiments, the filter can include individual segments. For example, some embodiments can include segments that provide filtering, segments that provide draw resistance, hollow segments that provide space for the aerosol to cool, segments that provide increased structural integrity, other filter segments, and any one or any combination of the above.

[0199] In some embodiments, the material of the outer overwrap 412 can include a material that prevents heat transfer, which can include paper or other fibrous materials, such as cellulose materials. The outer overwrap material can also include at least one filler material embedded or dispersed within the fibrous material. In various embodiments, the filler material can have the form of water-insoluble particles. Additionally, the filler material can incorporate inorganic components. In various embodiments, the outer overwrap can be formed from multiple layers, such as an underlying bulk layer and an overlying layer, such as a typical cigarette wrapper. Such materials can include, for example, lightweight "rag fibers" such as flax, hemp, sisal, rice straw, and / or esparto. The outer overwrap can also include materials commonly used in filter elements of conventional cigarettes, such as cellulose acetate. Additionally, the extra length of the external overlap at the mouth end 408 of the aerosol-generating component may function to simply separate the substrate portion 410 from the consumer's mouth, or to provide space for placement of a filter material, to affect inhalation of the article, or to affect the flow characteristics of vapor or aerosol exiting the device during inhalation, as described below. Further discussion regarding configurations for external overlap materials that can be used with the present disclosure can be found in U.S. Patent No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

[0200] In some embodiments, the aerosol generating component and control body may be provided together, typically as a finished aerosol delivery article, although the components may be provided separately. For example, the present disclosure also encompasses disposable units for use with reusable smoking articles or reusable medication delivery articles. In certain embodiments, such disposable units (which may be aerosol generating components as shown in the accompanying figures) may comprise a substantially tubular body having a heating end configured to engage a reusable aerosol delivery article, an opposing mouth end configured to allow passage of an inhalable substance to a consumer, and a wall having an outer surface and an inner surface defining an interior space. Various embodiments of aerosol generating components (or cartridges) are described in U.S. Pat. No. 9,078,473 to Worm et al., the entire contents of which are incorporated herein by reference.

[0201] While some figures described herein depict the control body and aerosol generation components in operative relationship, it is understood that the control body and aerosol generation components may exist as individual devices. Accordingly, descriptions provided elsewhere herein relating to combined components should also be understood as applying to the control body and aerosol generation components as separate, distinct components. It should be noted that the types of aerosol delivery devices described herein and illustrated in the above-referenced embodiments are not intended to limit the present disclosure. In particular, the filter materials and / or filter elements of the present disclosure may be incorporated into a variety of different aerosol delivery devices, including, but not limited to, conventional cigarettes, non-combustion heating devices, tobacco heating products, electronic aerosol delivery devices, and the like. Some examples of aerosol delivery devices suitable for use with the filter materials and filter elements described herein include U.S. Pat. No. 4,756,318 to Clearman et al., U.S. Pat. No. 4,714,082 to Banerjee et al., U.S. Pat. No. 4,771,795 to White et al., U.S. Pat. No. 4,793,365 to Sensabaugh et al., U.S. Pat. No. 4,989,619 to Clearman et al., U.S. Pat. No. 4,917,128 to Clearman et al., U.S. Pat. No. 4,961,438 to Korte, U.S. Pat. No. 4,966,171 to Serrano et al., and U.S. Pat. No. 4,969 to Bale et al., which are incorporated herein by reference. ,476, U.S. Pat. No. 4,991,606 to Serrano et al., U.S. Pat. No. 5,020,548 to Farrier et al., U.S. Pat. No. 5,027,836 to Shannon et al., U.S. Pat. No. 5,033,483 to Clearman et al., U.S. Pat. No. 5,040,551 to Schlatter et al., U.S. Pat. No. 5,050,621 to Creighton et al., U.S. Pat. No. 5,052,413 to Baker et al., U.S. Pat. No. 5,065,776 to Lawson, U.S. Pat. No. 5,076,296 to Nystrom et al., U.S. Pat. No. 5,076,297 to Farrier et al., U.S. Pat. No. 5,099,No. 861, U.S. Pat. No. 5,105,835 to Drewett et al., U.S. Pat. No. 5,105,837 to Barnes et al., U.S. Pat. No. 5,115,820 to Hauser et al., U.S. Pat. No. 5,148,821 to Best et al., U.S. Pat. No. 5,159,940 to Hayward et al., U.S. Pat. No. 5,178,167 to Riggs et al., U.S. Pat. No. 5,183,062 to Clearman et al., U.S. Pat. No. 5,211,684 to Shannon et al., U.S. Pat. No. 5,240,014 to Deevi et al., U.S. Pat. No. 5,240,014 to Nichols et al. No. 240,016 to Clearman et al., U.S. Patent No. 5,345,955 to Clearman et al., U.S. Patent No. 5,396,911 to Casey, III et al., U.S. Patent No. 5,551,451 to Riggs et al., U.S. Patent No. 5,595,577 to Bensalem et al., U.S. Patent No. 5,727,571 to Meiring et al., U.S. Patent No. 5,819,751 to Barnes et al., U.S. Patent No. 6,089,857 to Matsuura et al., U.S. Patent No. 6,095,152 to Beven et al., and U.S. Patent No. 6,578,584 to Beven. Additionally, the filter elements of the present invention can be incorporated into aerosol delivery devices of the type sold by R.J. Reynolds Tobacco Company under the trade names "Premier" and "Eclipse." See, for example, those types of aerosol delivery devices described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco, RJ Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, pp. 1-58 (2000), which are incorporated herein by reference.

[0202] The dimensions of representative smoking articles and / or aerosol delivery devices incorporating reconstituted tobacco produced in accordance with the present disclosure may vary. In some embodiments, smoking articles and / or aerosol delivery devices according to the present disclosure may be rod-shaped and have a diameter of about 7.5 mm (e.g., a circumference of about 20 mm to about 27 mm, often about 22.5 mm to about 25 mm), and an overall length of about 70 mm to about 120 mm, often about 80 mm to about 100 mm. However, the length of the smoking article and / or aerosol delivery device may vary. In some embodiments, for example, smoking articles and / or aerosol delivery devices incorporating reconstituted tobacco produced in accordance with the present disclosure may have an overall length of about 100 mm or less, about 80 mm or less, about 60 mm or less, or about 40 mm or less. The length of the filter element may also vary. A typical filter element may have an overall length of about 15 mm to about 40 mm, often about 20 mm to about 35 mm.

[0203] Certain filter elements, smoking articles, and aerosol delivery devices incorporating reconstituted tobacco prepared according to the methods of the present disclosure may exhibit desirable resistance to aspiration. For example, exemplary smoking articles and / or aerosol delivery devices including filter elements prepared according to the methods described herein exhibit a pressure drop of about 40 mmWG to about 400 mmWG. In certain embodiments, smoking articles and / or aerosol delivery devices including filter elements prepared according to the methods described herein may exhibit a pressure drop value of about 100 mmWG to about 350 mmWG, about 150 mmWG to about 325 mmWG, or about 200 mmWG to about 300 mmWG. Typically, the pressure drop value of an aerosol delivery device is measured using a Filtrona Quality Test Module (QTM series) available from Filtrona Instruments and Automation Ltd.

[0204] Filter elements incorporating reconstituted tobacco formed according to the present disclosure typically exhibit comparable or even increased hardness compared to filter elements made from conventional cellulose acetate tow. The amount of plasticizer added to the filter rod and the denier per filament of the filter tow can significantly affect filter hardness. Filter hardness is a measure of the compressibility of the filter material. A test instrument that can be used for the harness test is the D61 Automatic Hardness Tester available from Sodim SAS. This instrument applies a constant load (e.g., 300 g) to the sample for a set period of time (e.g., 3-5 seconds) and digitally displays the compression value as a percentage difference in the average diameter of the filter element. In certain embodiments, filter elements incorporating reconstituted tobacco prepared according to the present disclosure can exhibit hardness ranging from about 70% to about 99%. In some embodiments, filter elements incorporating reconstituted tobacco prepared according to the present disclosure can exhibit hardness of about 75% or greater, about 80% or greater, about 85% or greater, or about 90% or greater. Test procedures for cigarette filter hardness are described, for example, in US Pat. No. 3,955,406 to Strydom and US Pat. No. 4,232,130 to Baxter et al., both of which are incorporated herein by reference.

[0205] Example A control reconstituted tobacco sheet using only traditional tobacco material as the tobacco input was prepared according to the following procedure. To improve extraction efficiency, flue-cured tobacco stem and lamina components were hammer-milled to particles less than 5 mm. The ground stems and lamina were then mixed to obtain a ratio of 15% tobacco stems and 85% tobacco lamina. The ground flue-cured tobacco stems and lamina were then mixed with 10-11 times their weight of water in an extraction vessel to form a slurry. The slurry was heated to 70-75°C and held at 70-75°C for 12 hours with constant stirring. The slurry was then separated into its solid / fiber and weak extract (WEL) components by mechanical means (centrifugation and / or filtration).

[0206] The fibers were further mixed with 8-9% by weight cellulose fiber / wood pulp, and then water was added to dilute the mixture to a 2-5% (w / v) slurry. The slurry was then refined into a pulp using a rotary disc refiner and then further diluted to a 1% (w / v) pulp. This pulp was drained on a Fourdrinier wire to form a base web or base sheet.

[0207] Separately, the WEL was vacuum evaporated at 60-65°C and 55 psi to obtain a concentrated extract (CEL) with a solids content of 25-30% (w / v). The CEL was then mixed with glycerol at a weight ratio of approximately 3-20% based on the weight of the original raw material. The CEL was then coated or sprayed back onto the base web to obtain a hot-water solubles content of 40-45% in the final sheet. As used herein, the term "hot-water solubles" generally refers to the amount of tobacco material extract contained in the final sheet, which typically includes sugars, proteins, amino acids, organic acids, polyphenols, flavonoids, waxes, TSNAs, nitrates, nitrites, trace metals, heavy metals, and added glycerol. The final sheet was then tunnel-dried at 300-325°C for approximately 5-10 minutes. Control reconstituted tobacco sheets were tested for nicotine, NNK, NNN, and TSNA levels. The test results are shown in Table 1 below.

[0208] Reconstituted tobacco sheet A was prepared using the same procedure as the control sample, but contained 15% ground flue-cured tobacco stems and 85% ground flue-cured tobacco lamina. No extract was added to the base sheet. Reconstituted tobacco sheet A was tested for nicotine, NNK, NNN, and TSNA levels. The test results are shown in Table 1 below.

[0209] Reconstituted tobacco sheet B was prepared using a procedure similar to the control sample, except that 8.1% of the ground material was replaced with sheet A, and the remaining 91.9% contained the hot-air-dried leaf blend. The CEL extract was then re-added to the base sheet to achieve a hot-water solubles content of 40-45% in the final sheet, which was then tunnel-dried at 300-325°C for 5-10 minutes. Reconstituted tobacco sheet B was tested for nicotine, NNK, NNN, and TSNA levels. The test results are shown in Table 1 below.

[0210] Reconstituted tobacco sheet C was prepared using the same procedure as the control sample, except that the ground material was replaced with a combination of 60% ground burley stalk and 40% flue-dried stalk. No extract was added to the base sheet. Reconstituted tobacco sheet C was tested for nicotine, NNK, NNN, and TSNA levels. The test results are shown in Table 1 below.

[0211] Reconstituted tobacco sheet D was prepared using a procedure similar to that of the control sample, except that 20.0% of the ground material was replaced with sheet C, and the remaining 80% contained the hot-air-dried leaf blade blend. The CEL extract was then re-added to the base sheet to achieve a hot-water solubles content of 40-45% in the final sheet, which was then tunnel-dried at 300-325°C for 5-10 minutes. Reconstituted tobacco sheet D was tested for nicotine, NNK, NNN, and TSNA levels. The test results are shown in Table 1 below.

[0212] [Table 1]

[0213] As shown in Table 1 above, using reconstituted tobacco as part of the tobacco input to form reconstituted tobacco sheet B reduced the total TSNAs present in the reconstituted tobacco sheet compared to the control reconstituted tobacco sheet. Furthermore, it was surprisingly discovered that the nicotine content of reconstituted tobacco sheet B was at least equivalent, and in some cases slightly higher, than the control reconstituted tobacco sheet. As shown in Table 1 above, using reconstituted tobacco as part of the tobacco input to form reconstituted tobacco sheet D reduced the total TSNAs present in the reconstituted tobacco sheet compared to the control reconstituted tobacco sheet. Furthermore, it was surprisingly discovered that the nicotine content of reconstituted tobacco sheet D was at least equivalent, and in some cases slightly higher, than the control reconstituted tobacco sheet. Visual inspection of the control reconstituted tobacco sheet and reconstituted tobacco sheets A-D revealed that the use of reconstituted tobacco in the tobacco input did not affect the overall appearance and / or structure of the final reconstituted tobacco sheet.

[0214] Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing description. It is to be understood, therefore, that the invention is not to be limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. A method for forming a reconstituted tobacco sheet, comprising: receiving a tobacco input comprising a plurality of tobacco materials, the tobacco input comprising a first reconstituted tobacco material and at least one additional tobacco material; extracting the tobacco input to form a tobacco extract and a tobacco pulp; separating the tobacco extract from the tobacco pulp; forming tobacco pulp into a web; applying at least a portion of a tobacco extract to the web; drying the web to form a reconstituted tobacco output; and A method comprising:

2. 10. The method of claim 1, wherein the first reconstituted tobacco material is in the form of shredded material.

3. 10. The method of claim 1, wherein the first reconstituted tobacco charge comprises about 5 to about 50 weight percent tobacco charge, based on the total weight of the tobacco charge.

4. The method of claim 1 , wherein the at least one additional tobacco material comprises tobacco stem.

5. 5. The method of claim 4, wherein the tobacco stems are present in an amount of from about 15 to about 95 weight percent, based on the total weight of the tobacco charge.

6. The method of claim 1 , wherein the at least one additional tobacco material comprises tobacco lamina.

7. 7. The method of claim 6, wherein the tobacco blade is present in an amount of from about 15 to about 95 weight percent, based on the total weight of the tobacco input.

8. 8. The method of any one of claims 1 to 7, wherein the at least one additional tobacco material comprises a second reconstituted tobacco material.

9. 10. The method of claim 8, wherein the second reconstituted tobacco material comprises about 5 to about 50 weight percent tobacco input, based on the total weight of the tobacco input.

10. 8. The method of any one of claims 1 to 7, wherein the tobacco input further comprises an active ingredient and / or a flavoring agent.

11. 11. The method of claim 10, wherein the active ingredient is selected from the group consisting of nicotine components, botanicals, stimulants, dietary supplements, amino acids, vitamins, cannabinoids, cannabimimetics, terpenes, and combinations thereof.

12. 8. The method of claim 1, further comprising adding active ingredients and / or flavoring agents to the tobacco pulp, the web formed from the tobacco pulp, and / or the tobacco extract applied to the web.

13. 13. The method of claim 12, wherein the active ingredient is selected from the group consisting of nicotine components, botanicals, stimulants, dietary supplements, amino acids, vitamins, cannabinoids, cannabimimetics, terpenes, and combinations thereof.

14. 8. The method of any one of claims 1 to 7, wherein the tobacco input further comprises one or more ingredients selected from the group consisting of flavorings, fillers, binders, pH adjusters, buffers, colorants, disintegration aids, antioxidants, humectants, and preservatives.

15. 8. The method of claim 1, further comprising adding one or more ingredients selected from the group consisting of flavoring agents, fillers, binders, pH adjusters, buffers, colorants, disintegration aids, antioxidants, humectants, and preservatives to the tobacco pulp, the web formed from the tobacco pulp, and / or the tobacco extract applied to the web.

16. 8. The method of any one of claims 1 to 7, wherein extracting the tobacco input is carried out at a temperature of about 55°C to about 65°C for about 0.5 hours to 2 hours.

17. 8. The method of any one of claims 1 to 7, wherein the tobacco charge is extracted with water, the weight ratio of water to tobacco charge being in the range of about 4:1 to about 10:

1.

18. The method of any one of claims 1 to 7, further comprising refining the pulp to a consistency of about 10 to 30% before forming the web.

19. The method of any one of claims 1 to 7, wherein about 50% to about 100% of the tobacco extract is applied to the web.

20. 8. The method of claim 1, wherein the final reconstituted tobacco sheet has a moisture content of about 5% to about 15%, based on the total weight of the final reconstituted tobacco sheet.

21. 8. The method of claim 1, wherein extracting the tobacco input comprises separately extracting each of the plurality of tobacco materials.

22. 8. The method of claim 1, wherein extracting the tobacco input comprises blending a plurality of tobacco materials to form a blended material, and extracting the blended material.

23. receiving a second tobacco input, the second tobacco input comprising the reconstituted tobacco output and at least one additional tobacco material; extracting the second tobacco input to form a second tobacco extract and a second tobacco pulp; separating the second tobacco extract from the second tobacco pulp; forming the second tobacco pulp into a second web; applying at least a portion of a second tobacco extract to a second web; drying the second web to form a second reconstituted tobacco output; and The method of claim 1 , further comprising:

24. A final reconstituted tobacco sheet prepared according to the method of any one of claims 1 to 7.

25. 25. The final reconstituted tobacco sheet of claim 24, wherein the final reconstituted tobacco sheet has a reduced concentration of TSNAs compared to a reconstituted tobacco sheet formed from a control tobacco input substantially free of reconstituted tobacco.

26. 25. A substrate for use in an aerosol delivery device, the substrate comprising the final reconstituted tobacco sheet of claim 24.

27. A reconstituted tobacco material comprising tobacco pulp and a tobacco extract applied to the tobacco pulp, wherein at least a portion of the tobacco pulp comprises reconstituted tobacco pulp and at least a portion of the tobacco extract comprises an extract from the reconstituted tobacco material.

28. 28. The reconstituted tobacco material of claim 27, wherein the hot water solubles content is from about 20 to about 60% by weight of the reconstituted tobacco material.

29. 28. The reconstituted tobacco material of claim 27, wherein the hot water solubles content is from about 30 to about 50% by weight of the reconstituted tobacco material.

30. 30. The reconstituted tobacco material of any one of claims 27-29, further comprising an aerosol-forming material in an amount of about 10 to about 50% by weight of the reconstituted tobacco material.

31. 31. The reconstituted tobacco material of claim 30, further comprising an aerosol-forming material in an amount of about 10 to about 30% by weight of the reconstituted tobacco material.

32. 31. The reconstituted tobacco material of claim 30, wherein the aerosol-forming material comprises one or more polyols.

33. 33. The reconstituted tobacco material of claim 32, wherein the one or more polyols are selected from the group consisting of glycerol, propylene glycol, and combinations thereof.

34. 30. The reconstituted tobacco material of any one of claims 27 to 29, wherein the moisture content of the reconstituted tobacco material is from about 5% to about 25% by weight (5-15%), based on the total weight of the reconstituted tobacco material.

35. 30. The reconstituted tobacco material of any one of claims 27-29, wherein the moisture content of the reconstituted tobacco material is from about 5% to about 15% by weight, based on the total weight of the reconstituted tobacco material.

36. 1. An aerosol delivery device comprising:

30. A reconstituted tobacco material according to any one of claims 27 to 29; a heat source configured to heat the substrate to form an aerosol; an aerosol pathway extending from the substrate to the mouth end of the aerosol delivery device; An aerosol delivery device comprising:

37. 37. The aerosol delivery device of claim 36, wherein the heat source comprises either an electric heating element or a combustible ignition source.

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