Reconstituted cannabis material for aerosol generation

Abstract

The present disclosure provides an aerosol-generating material comprising reconstituted cannabis material. The reconstituted cannabis material comprises a combination of extracted cannabis fiber and web-building fibers (e.g., coniferous wood). The reconstituted cannabis material can produce an aerosol (e.g., smoke) that has a traditional cannabis taste and a reduced amount of irritants or harsh components. In one embodiment, the reconstituted cannabis material is formed from a plant that has a low content of cannabinoids, such as THC. By topically applying cannabinoids, such as THC and / or CBD, to the reconstituted plant material, the amount of cannabinoids in the aerosol generated from the reconstituted plant material can be controlled, as well as the cannabinoids can be delivered in a consistent and uniform amount.

Description

[Technical field]

[0001] (Related Applications) This application claims priority to U.S. Patent Application No. 62 / 803,883, filed February 11, 2019, the disclosures of both of which are incorporated herein by reference. [Background technology]

[0002] Cannabis or the cannabis plant refers to both marijuana, which is commonly used for recreational purposes, and cannabis, which is commonly used for industrial purposes. Cannabis is a green and / or brown mixture of dried and shredded leaves, stems, seeds, or flowers of the cannabis plant. Cannabis plant varieties include Cannabis sativa and Cannabis indica. Hemp (especially industrial hemp species) has a very similar appearance to marijuana, but unlike the cannabis plant species called marijuana, it generally contains only small amounts of tetrahydrocannabinol (THC). Both hemp and marijuana contain large amounts of cannabidiol (CBD). Both marijuana and hemp, which are cannabis, are known as painkillers, but because they generally have low THC content, only hemp and industrial hemp are used for food, paper, clothing, textiles, and CBD extracts. Recently, more than 25 states in the United States have legalized the use of cannabis for at least medical purposes. In addition, the use of cannabis for medical and recreational purposes is now legal in Canada as well. In light of these recent circumstances, the commercialization of cannabis has increased dramatically.

[0003] For example, cannabis has become increasingly popular as an alternative painkiller to traditional painkillers such as opioids. Opioids are powerful painkillers that act on the nervous system to suppress pain. Opioids are commonly used to relieve severe pain after surgery and also to relieve chronic pain. Unfortunately, however, opioids have many risks. For example, opioids are highly addictive, which has led to an epidemic of drug abuse. In fact, more than 11 million people abuse prescription opioids each year.

[0004] In light of the above drawbacks, more and more people in the medical community are considering cannabis as a legal alternative to opioid pain relief. Cannabis contains two drugs that relieve symptoms such as pain and nausea. Cannabis contains, for example, tetrahydrocannabinol (THC). THC acts on certain receptors in the brain to produce a euphoric and relaxed state. The highest concentrations of THC in cannabis are found in the dried flowers and buds. Cannabis is typically regulated based on the amount of THC it contains.

[0005] In addition to THC, cannabis also contains cannabidiol (CBD). CBD acts on pain receptors in the brain. However, CBD does not produce the euphoric sensation that THC produces. However, CBD exerts analgesic and anti-inflammatory effects. Cannabis, and especially CBD, is not addictive like many opioids.

[0006] Inhaling combusted cannabis is the most common, effective, and inexpensive way to get THC and CBD into the user's body. However, there are various problems with delivering cannabis to the patient or user via combustion. For example, the amount of THC and / or CBD delivered varies significantly depending on the particular plant and the particular part of the plant that is burned. Also, simply wrapping the cannabis material in rolling paper, for example, will result in significantly more inconsistent delivery based on various factors such as the paper used, the density of the packaging, the part of the plant used, and the method of preparing the plant. Also, the particular variety of cannabis used to make the product will result in more inconsistent delivery. In fact, different growing conditions for different plants will result in more inconsistent delivery even for the same variety. Furthermore, in addition to THC and CBD, cannabis contains over 60 cannabinoid compounds and over 400 other compounds that can give the product a bad taste and / or a harsh smoking experience.

[0007] In addition to controlling the amount delivered, problems also arise when producing smoking articles from cannabis plants using traditional cigarette making machines or machines that make sticks of heated tobacco products. Due to differences in texture, bulk density, etc., cannabis material can cause clogging and other interruptions when run on machines designed to process cured tobacco.

[0008] In view of the above, there is currently a need for improved aerosol-generating materials that can control the amount of delivery of bioactive compounds in the aerosol generated.In particular, there is a need for aerosol-generating materials that can control the amount of delivery of active compounds, such as THC and / or CBD, via aerosol.In addition, there is a need for aerosol-generating materials that can deliver active compounds in a uniform and consistent manner, as well as in a desired amount, and provide aerosols that do not contain harsh ingredients.In another aspect, there is a need for cannabis-based aerosol-generating filling materials that can be processed in conventional cigarette-making machines for producing cylindrical rods or machines that produce sticks for heated tobacco products. Summary of the Invention [Means for solving the problem]

[0009] In general, the present disclosure relates to aerosol-generating materials made from cannabis ingredients. The aerosol-generating materials may include reconstituted cannabis materials that generate aerosols when heated or burned. The reconstituted cannabis materials of the present disclosure are particularly suitable for treatment with active substances to control the amount of active substance delivered to the user. For example, in one embodiment, the reconstituted cannabis materials may be treated with controlled amounts of THC and / or CBD.

[0010] In one embodiment, for example, the disclosure relates to an aerosol-generating material comprising reconstituted cannabis material. The reconstituted cannabis material may comprise extracted cannabis fiber obtained from cannabis leaves, cannabis buds, cannabis stems, cannabis buds, cannabis flowers, cannabis seeds, or any combination thereof. In one aspect, the plant material used to form the reconstituted cannabis material may be subjected to two different extraction processes. For example, the reconstituted cannabis material may be formed from a biomass produced by a first extraction process that extracts select components from the plant material, such as cannabinoids, while leaving a significant amount of water-soluble components within the plant material. The biomass may then be subjected to a second extraction process that removes the water-soluble components, thereby producing the reconstituted cannabis material.

[0011] The extracted hemp fiber is combined with web-building fibers to produce a reconstituted hemp material. The web-building fibers may include, for example, delignified cellulose fibers, such as wood pulp fibers.

[0012] In one embodiment, the reconstituted cannabis material comprises extracted cannabis leaves in an amount of about 20% to about 50% by weight, extracted cannabis buds and / or flowers in an amount of about 20% to about 50% by weight, and delignified cellulose fibers in an amount of about 3% to about 20% by weight.

[0013] The web-building fibers included in the reconstituted cannabis material may include softwood fibers, hardwood fibers, flax fibers, hemp fibers, abaca fibers, bamboo fibers, coconut fibers, ramie fibers, jute fibers, or any combination thereof. The web-building fibers may be included in the reconstituted cannabis material in an amount greater than about 3% by weight, such as greater than about 5% by weight, or, for example, greater than about 8% by weight, and generally less than about 40% by weight.

[0014] In addition to extracted cannabis fibers and web-building fibers, in one embodiment, the reconstituted cannabis material may include a variety of other plant fibers. For example, in one embodiment, the reconstituted cannabis material may include extracted cocoa husk fibers.

[0015] In one embodiment, the reconstituted cannabis material may further comprise a humectant, such as glycerol, propylene glycol, or a combination thereof. In one embodiment, the humectant may be included in the reconstituted cannabis material in an amount of about 5% by weight or less. In another embodiment, the humectant may be included in the reconstituted cannabis material in an amount greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, or such as greater than about 20% by weight, and generally less than about 50% by weight.

[0016] In one embodiment, the reconstituted cannabis material may contain very small amounts of THC. For example, unprocessed reconstituted cannabis material may contain THC in an amount less than about 0.3% by weight, such as less than about 0.2% by weight, such as less than about 0.1% by weight. For example, the reconstituted cannabis material may be formed from industrial hemp. To regulate the amount of THC, the THC is applied topically to the reconstituted cannabis material, thereby controlling the amount of THC delivered to the user. This allows not only the amount of THC delivered to be controlled, but also allows a consistent and uniform amount of THC to be delivered via the aerosol-generating material.

[0017] In addition to THC, the reconstituted cannabis material of the present disclosure may be treated with various other aerosol delivery compositions containing an aerosol delivery substance. The aerosol delivery substance may, for example, include drugs or flavorings and may be in the form of oils or solids. Aerosol delivery substances that may be applied to the reconstituted cannabis material include other cannabinoids such as CBD in addition to THC. Further aerosol delivery substances that may be applied to the reconstituted cannabis material include nicotine, sugar, licorice extract, honey, coffee extract, maple syrup, tea extract, plant extract, tobacco extract, or fruit extract. In one embodiment, the aerosol delivery substance may include one or more terpenes. A terpene or blend of terpenes may be added to the reconstituted cannabis material to impart a unique aroma indicative of a high-quality cannabis product. Terpenes that may be added to the reconstituted cannabis material include pinene, humulene, b-caryophyllene, isopulegol, guaiol, neryl acetate, neomenthyl acetate, limonene, menthone, dihydrojasmone, terpinolene, menthol, phellandrene, terpinene, geranyl acetate, ocimene, myrcene, 1,4-cineole, 3-carene, linalool, menthofuran, perillyl alcohol, pinane, neomenthyl acetyl, and the like.

[0018] The aerosol delivery composition may be applied to the reconstituted cannabis material in an amount generally greater than about 0.1% by weight, such as greater than about 1% by weight, such as greater than about 3% by weight, such as greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, such as greater than about 20% by weight, such as greater than about 25% by weight, such as greater than about 30% by weight, such as greater than about 35% by weight, or such as greater than about 40% by weight, and generally less than about 50% by weight.

[0019] The reconstituted cannabis material may contain water soluble cannabis components, generally in an amount of less than about 50% by weight, such as less than about 20% by weight, such as less than about 10% by weight, or such as less than about 5% by weight. The water soluble cannabis components may be substantially removed from the reconstituted cannabis material or reapplied in any desired amount.

[0020] The reconstituted cannabis material may generally have a basis weight of about 40 gsm to about 120 gsm, for example about 55 gsm to about 85 gsm. The reconstituted cannabis material may be treated with a burn control or flame retardant. To form the filler material, the reconstituted cannabis material may be in the form of strips, pieces, or combinations thereof.

[0021] The reconstituted cannabis material of the present disclosure can be used for various types of applications. For example, the reconstituted cannabis material of the present disclosure can be used for non-combustion heat-based applications to generate aerosols. Alternatively, the reconstituted cannabis material of the present disclosure can be used to produce smoking articles. In yet another embodiment, the reconstituted cannabis material of the present disclosure can be used to produce smokeless blended products. When producing smokeless blended products, the web-building fibers may not be required or may be included in relatively small amounts, such as less than about 5% by weight, such as less than about 3% by weight. Alternatively, the smokeless blended product (or "snuff") may include web-building fibers in an amount between 5% and 50% by weight.

[0022] Other features and aspects of the present invention are described in detail below. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] definition

[0024] As used herein, "reconstituted plant material" refers to a material formed by a process of extracting a plant raw material, such as cocoa shells (the outer skins of cocoa beans), with a solvent to extract a soluble extract, such as a water-soluble extract, and an insoluble portion or residue (insoluble fibrous material) that includes fibrous material. The extracted insoluble fibrous material is then formed into a sheet by any suitable process. The soluble extract can be discarded or reapplied to the formed sheet. The soluble extract may be subjected to various processes to concentrate the extract or, optionally, to remove or add various ingredients before reapplying to the fibrous material. In the present disclosure, the reconstituted plant material is formed by combining the extracted cocoa husk fiber (insoluble fibrous material) with web-building fibers, such as cellulose fibers. The soluble extract obtained from the cocoa shells is optionally reapplied to a sheet.

[0025] As used herein, "aerosol-generating material" is meant to include both combustible materials that are combusted in smoking articles and aerosol-generating materials that are heated but not combusted to generate an inhalable aerosol. Combustible smoking articles include cigarettes, cigarillos, cigars, and the like. In cigarettes, the aerosol-generating material is wrapped by a wrapping material to form a smokable rod. Aerosol-generating devices for generating aerosol include devices that generate aerosol by heating the aerosol-generating material without burning it, for example, by electrical heating or by transfer of heat from a combustible fuel element or heat source, thereby releasing volatile compounds from the material. The volatile compounds released from the aerosol-generating material condense into an aerosol when cooled, which is inhaled by the smoker.

[0026] As used herein, "extracted cocoa husk fiber" refers to cocoa husk fiber that has undergone an extraction process in which the cocoa husk (cocoa shells) is contacted with an aqueous solution to remove water soluble components contained therein. This extraction process is distinct from the delignification and bleaching processes.

[0027] As used herein, "extracted by-product" refers to cannabis biomass that has been subjected to an extraction process to remove selected components, such as cannabinoids, without removing significant amounts of water-soluble components. Extracted by-products can also be referred to as biomass obtained by an extraction process in which the extractant is a solvent, such as ethanol, a supercritical fluid, such as carbon dioxide, a lipid, such as vegetable oil, or the like. According to the present disclosure, the extracted by-product may be subjected to a second extraction step to remove water-soluble components during the process of producing reconstituted cannabis material. Extracted by-products well suited for use in the present disclosure include those that contain water-soluble components in an amount greater than about 8% by weight, such as greater than about 12% by weight, such as greater than about 18% by weight, or such as greater than about 24% by weight.

[0028] As used herein, "delignified" cellulose fibers (e.g., pulp fibers) refer to fibers that have undergone a pulping or delignification process in which the cellulose fibers are separated from the plant material by chemical, mechanical, or a combination of chemical and mechanical means.

[0029] As used herein, the term "refining" is used to mean that the plant material has been subjected to a mechanical treatment that modifies the fibers of the plant material so that it is suitable for forming a fibrous sheet or substrate. Refining can be carried out using a cone refiner, a disc refiner, or a beater (e.g., a valley beater, etc.). The mechanical process grinds or beats the plant material and deforms or de-clusters the plant material. Refining is a process distinct from delignification and pulping.

[0030] As used herein, the term "stalk" is used to refer to the main structural part of the plant that remains after the leaves have been removed.

[0031] As used herein, the term "hurd" is used to refer to the structural part of a plant (e.g., a stem) that connects a leaf or leaf blade to the stalk, or to the veins or ribs that run through the leaf. The term "hurd" does not include the term "stalk" (and vice versa).

[0032] As used herein, "cannabis" refers to any type of cannabis plant, such as, for example, Cannabis sativa or Cannabis indica. More specifically, in this disclosure, the leaves, stems, seeds, flowers, or any other part of the cannabis plant are referred to as cannabis. Nevertheless, cannabis as referred to herein includes marijuana containing average or high levels of THC and / or CBD, hemp containing low or very low levels of THC, industrial hemp containing less than 0.3% THC, or any combination thereof.

[0033] Detailed Description

[0034] Those skilled in the art will appreciate that this disclosure is merely a description of exemplary embodiments and is not intended to limit the broader aspects of the disclosure.

[0035] The present disclosure generally relates to aerosol-generating materials made from cannabis ingredients. More specifically, the present disclosure relates to reconstituted cannabis materials that, when heated or burned, produce aerosols that have a milder cannabis odor and are less irritating when inhaled compared to conventional cannabis-filled materials. Particularly advantageously, the reconstituted cannabis materials of the present disclosure are suitable to act as carriers for active substances such as drugs and flavorings. In one embodiment, for example, the reconstituted cannabis materials may be treated with THC and / or CBD in such a way that the aerosols produced from the reconstituted cannabis materials can deliver a controlled, consistent, and uniform amount of THC and / or CBD to the user.

[0036] The reconstituted cannabis material of the present disclosure is suitable for combining with other smokable filler materials because it does not contain irritants and has a milder aerosol and taste. In addition, as mentioned above, the reconstituted cannabis material of the present disclosure has high absorbency, so it can be treated with various types of topical additives in addition to THC and CBD.

[0037] For example, the reconstituted cannabis material of the present disclosure can be combined with a tobacco material to form an aerosol-generating filler material having the taste and odor of tobacco and cannabis. In addition to tobacco materials, the reconstituted cannabis material of the present disclosure may also be combined with other aerosol-generating filler materials, such as herbal blends.

[0038] The reconstituted plant material of the present disclosure is generally formed from extracted cannabis components or fibers, optionally combined with web-building fibers. Cannabis is intended to encompass all varieties of the Cannabis sativa plant species, whether or not they contain detectable amounts of THC. For example, many species of cannabis contain THC. However, there are cannabis plant strains that have particularly low THC content, commonly referred to as industrial hemp. For example, industrial hemp may contain THC in an amount of less than about 1% by weight, such as less than about 0.5% by weight, such as less than about 0.3% by weight, such as less than about 0.2% by weight, or such as less than about 0.1% by weight. On the other hand, cannabis components used to produce medicinal or recreational drugs may contain THC in amounts of 3% to 20% by weight or more. Cannabis can be obtained from Cannabis indica or Cannabis sativa.

[0039] In one embodiment, the cannabis plant material, such as leaves, buds, flowers, seeds, cannabis residue, extraction by-products, and any combination thereof, is optionally cut or ground and then subjected to an extraction process to remove water-soluble components. The extracted cannabis fibers are then combined with web-building fibers and formed into a substrate, such as a reconstituted sheet. The substrate may optionally be treated with an extract obtained from cannabis. Alternatively, the extract obtained from cannabis may be discarded without being recombined with non-water-soluble fibers or other materials. The reconstituted plant material is then dried and formed into an aerosol-generating material, such as a smokable filler material. The aerosol-generating material may optionally be combined with various other ingredients. For example, the aerosol-generating material may be treated with various aerosol delivery substances. The aerosol-generating material may also be combined with various other aerosol or smoking filler materials, such as tobacco materials or other herbal filler materials.

[0040] The aerosol-generating material formed according to the present disclosure can be used in various types of consumer products. For example, in one embodiment, the aerosol-generating material can be incorporated into smoking articles such as cigarettes, cigarillos, cigars, etc. Particularly advantageously, the reconstituted cannabis material of the present disclosure is well suited for use in stick-making machines for traditional tobacco or heated tobacco products. Thus, aerosol-generating material rods, such as cigarettes, can be rapidly produced.

[0041] In one embodiment, the aerosol-generating materials of the present disclosure can be packaged and sold as loose filler material for use in pipes or to allow consumers to form their own cigarettes or other smoking articles. In another embodiment, the aerosol-generating materials of the present disclosure can be incorporated into devices that generate an aerosol that is inhaled by a user by heating the material rather than burning it (non-combustion heated devices). The aerosol-generating materials can be cut, shredded, or otherwise processed into the form most suitable for a particular application and product.

[0042] When forming the reconstituted plant material of the present disclosure, the cannabis component is first collected and optionally reduced in size. The cannabis component may include leaf, stem, bud, flower, and optionally stalk components. In one embodiment, the cannabis component is obtained from a cannabis plant with a relatively low THC content. For example, the THC content in the cannabis component may be less than about 1% by weight, such as less than about 0.3% by weight, such as less than about 0.2% by weight, or such as less than about 0.1% by weight. Using a cannabis component obtained from a cannabis plant with a low THC content can provide various advantages and benefits. For example, when THC is applied topically to the reconstituted cannabis material, producing a reconstituted cannabis material with a low THC content allows for better control of THC delivery. In addition, producing a reconstituted material without detectable amounts of THC allows the material to deliver other active substances such as CBD, flavors, nicotine, etc. It should be understood that in other embodiments, the reconstituted cannabis material can be produced from a THC-containing plant, such as Cannabis indica.

[0043] In one aspect, at least a portion of the cannabis components collected to produce the reconstituted cannabis material are cannabis extraction by-products. Cannabis extraction by-products include cannabis biomass that has already been subjected to a first extraction process to remove desired components from the plant, but without significant amounts of water-soluble components removed. For example, cannabis extraction by-products can be biomass remaining after extraction of one or more cannabinoids from cannabis plant material, such as THC and CBD. These types of extraction processes can use a variety of solvents and supercritical fluids. For example, in one embodiment, the extracted by-product is obtained by a cannabis extraction process in which cannabis material is crushed and mixed with a solvent. The solvent can be, for example, an alcohol, such as ethanol, an organic ester, a petroleum-derived hydrocarbon (e.g., toluene or trimethylpentane), or a lipid (e.g., vegetable oil). Vegetable oils include safflower oil and coconut oil. In another embodiment, the cannabis plant material may be contacted with a supercritical fluid, such as carbon dioxide, during the extraction process. Typically, the extraction process involves grinding or cutting the plant material to a desired size, followed by contacting the plant material with an extractant, such as a solvent or supercritical fluid. The plant material may be heated during contact with the solvent. For example, when contacting with a supercritical fluid, the temperature may be from about 31° C. to about 80° C., and the pressure may be from about 7.5 megapascals to about 50 megapascals (about 75 bar to about 500 bar).

[0044] The use of extracted by-products as part of the cannabis composition provides various advantages. For example, cannabis extraction by-products can produce milder aerosols and can be in a form that is easier to handle than the raw plant material. To produce reconstituted cannabis material, the cannabis extraction by-products can be subjected to a second extraction process that removes water-soluble components. For example, cannabis extraction by-products can contain water-soluble components in an amount greater than about 8% by weight, such as greater than about 12% by weight, such as greater than about 18% by weight, such as greater than about 24% by weight, or such as greater than about 28% by weight, and generally less than about 60% by weight, such as less than about 50% by weight.

[0045] After the cannabis components are recovered, they may be subjected to a grinding, milling or beating operation to reduce the size of the cannabis components or reduce them into individual fibers. For example, in one embodiment, the cannabis material may be fed into a hammer mill to beat the cannabis material against a screen to produce a fibrous material. It should be noted that size reduction of the cannabis components is not necessary when using cannabis extraction by-products that have already been subjected to a size-reducing extraction process.

[0046] After optionally reducing the size of the cannabis, the cannabis is subjected to an extraction process that removes water-soluble components. This extraction process has various advantages. For example, the extraction process can remove components from the cannabis that are irritating when inhaled via an aerosol. In this way, the extraction process can significantly and dramatically reduce various irritating properties from the aerosol generated from the aerosol-generating material. In addition, subjecting the cannabis to the extraction process can clean the cannabis and remove herbicides, pesticides, and / or microorganisms that may be present on the surface of the cannabis.

[0047] During the extraction process, the cannabis is contacted with a solvent to remove water-soluble components from the cannabis. In one embodiment, the solvent comprises only water. In another embodiment, various water-miscible solvents, such as alcohol (e.g., ethanol), may be combined with water to form an aqueous solvent. The water content of the aqueous solvent may be greater than 50% by weight of the solvent, in some instances, and especially greater than 90% by weight. Deionized water, distilled water, or tap water may be used. The amount of solvent in the suspension may range widely, but generally may be in an amount of about 50% to about 99% by weight of the suspension, in some embodiments about 60% to about 95% by weight, and in some embodiments about 75% to about 90% by weight. However, the amount of solvent may vary depending on the nature of the solvent, the temperature at which the extraction is performed, and the type of cocoa raw material.

[0048] In addition to aqueous solvents, non-aqueous solvents may be used. For example, the solvent may be an oil or grease. In one embodiment, a multi-phase solvent may be used, including a combination of water and an oil or grease.

[0049] After forming a mixture of the solvent and cannabis material, some or all of the soluble fraction of the mixture is separated from the mixture. The mixture of the solvent and cannabis material is agitated using stirring, shaking, or other mixing methods to increase the rate of solubilization. Typically, the process is carried out for about 30 minutes to about 6 hours. Process temperatures can range from about 10°C to about 100°C, such as from about 40°C to about 80°C.

[0050] After the cannabis material is soaked in the extractant, a press is used to mechanically separate the insoluble cannabis material from the cannabis liquid or extract. After the soluble fraction is separated from the cannabis feedstock or insoluble fraction, the soluble fraction is discarded or subjected to processing, such as concentration. The soluble fraction can be concentrated using any known type of concentrator, such as a vacuum evaporator. In one embodiment of the present disclosure, the soluble fraction can be highly concentrated. In one embodiment, for example, the cannabis soluble fraction is evaporated to have a final Brix of about 10% to about 60%, such as about 10% to about 50%, such as about 20% to about 50%, or such as about 15% to about 35%.

[0051] The concentrated cannabis soluble fraction obtained as described above may be used in another process or may later be coated onto the reconstituted plant material of the present disclosure, as described in more detail below.

[0052] The cannabis insoluble fraction obtained as described above is generally in an unrefined state. The cannabis material may include particles and fibers. In one embodiment, the extracted cannabis insoluble fraction is subjected to a refining process. For example, the extracted cannabis fiber can be fed into any suitable refining device, such as a cone refiner or a disc refiner. Other refining equipment that can be used includes beaters, such as a valley beater. Refining can be performed while the cannabis material is wet or after mixing the cannabis material with water. For example, in one embodiment, the cannabis material is refined when its consistency is less than about 10%, such as less than about 5%, such as less than about 3%.

[0053] According to the present disclosure, the extracted hemp fibers are combined with web-building fibers when forming a fibrous substrate, such as a reconstituted plant material. For example, the extracted hemp fibers are combined with water or an aqueous solution to form a pulp suspension (slurry). Web-building fibers, such as delignified cellulose fibers, may be combined with the hemp material during the formation of the slurry. The fiber slurry is then used to form a continuous reconstituted sheet. For example, in one embodiment, the fiber slurry is subjected to a papermaking process, which may include forming wires, gravity drains, suction drains, felt presses, and dryers (such as Yankee dryers and drum dryers). For example, in one embodiment, the fiber slurry is formed into a continuous sheet on a Fourdrinier table. One advantage of combining extracted hemp fibers with cellulose fibers is that the combined fibrous feedstock can be processed on conventional papermaking equipment.

[0054] In one embodiment, the fibrous slurry is placed on a porous forming surface and formed into a sheet. Excess water is removed by gravity drain and / or suction drain. In addition, various presses can be used to facilitate water removal. After the formed sheet is dried, it can be further processed.

[0055] The reconstituted material can also be formed using a variety of other methods. For example, in one embodiment, the reconstituted material can be formed by extruding the extracted hemp fibers and web-building fibers. In one embodiment, the reconstituted material can also be subjected to an expansion process. A gas, such as carbon dioxide, or a blowing agent can be used to form a foamed sheet. Suitable expansion media include starch, pullulan or other polysaccharides, solid blowing agents, inorganic salts and organic acids that provide a gaseous component in situ, organic gas agents, inorganic gas agents, and volatile liquid blowing agents. Extrusion also allows for the formation of rods and strands in addition to sheet materials.

[0056] In one aspect, the reconstituted plant material can be formed according to the cast leaf process. In the cast leaf process, the plant material is shredded and then mixed with other materials, such as a binder, to form a slurry. In the slurry, web building fibers are placed. The slurry is transferred to a sheet former to form a web material. The sheet former can be a continuous belt onto which the slurry is continuously distributed. The slurry is spread on the belt to form a sheet. The sheet is then dried, such as by heat. The sheet can be wound onto a bobbin, trimmed, slit, or otherwise manipulated to form a product.

[0057] Optionally, the formed packaging material may be treated with cannabis soluble parts, such as concentrated cannabis soluble parts separated from the insoluble fraction. The cannabis soluble parts can be applied to the web using various application methods, such as spraying, using a size press, saturating, etc. The amount of water-soluble cannabis extract applied to the reconstituted material depends on various factors and the expected end use. Generally, the water-soluble cannabis extract is applied to the reconstituted plant material in an amount that does not adversely affect the taste of the aerosol generated from the underlying material. For example, in one embodiment, the water-soluble cannabis extract is applied to the reconstituted material in an amount of about 60% by weight or less, such as an amount less than about 50%, such as an amount less than 40% by weight, such as an amount less than about 30% by weight, such as an amount less than about 20% by weight, such as an amount less than about 10% by weight, such as an amount less than about 5% by weight, or such as an amount less than about 3% by weight, and generally more than about 0.5% by weight. In one embodiment, the water-soluble cannabis extract is applied to the reconstituted material in an amount of about 10% to about 60% by weight, such as about 15% to about 40% by weight.

[0058] As mentioned above, the reconstituted cannabis material of the present disclosure can be produced from various parts of the cannabis plant, such as stems, leaves, buds, and flowers. These various parts of the cannabis plant can be combined in various ratios and amounts depending on the particular application and the desired results. The reconstituted cannabis material may be produced from only cannabis leaves and stems, or may be made from only cannabis buds and flowers. In one embodiment, the reconstituted cannabis material is produced from a combination of cannabis buds and / or cannabis flowers with cannabis leaves and / or cannabis stems. For example, in one embodiment, the weight ratio of cannabis leaves and / or cannabis stems to cannabis buds and / or cannabis flowers can be about 1:8 to about 8:1, such as about 1:5 to about 5:1, such as about 1:4 to about 4:1, or such as about 2:1 to about 1:2. In one embodiment, this ratio can be about 1:1.

[0059] In one embodiment, the reconstituted cannabis material may contain cannabis leaves and / or cannabis stems in an amount greater than about 10% by weight, such as greater than about 20% by weight, or such as greater than about 30% by weight, and generally less than about 70% by weight, such as less than about 60% by weight, such as less than about 50% by weight, or such as less than about 40% by weight. Similarly, the reconstituted cannabis material may contain cannabis buds and / or cannabis flowers in an amount greater than about 10% by weight, such as greater than about 20% by weight, such as greater than about 30% by weight, such as greater than about 40% by weight, such as greater than about 50% by weight, or such as greater than about 60% by weight, and generally less than about 80% by weight, such as less than about 70% by weight, such as less than about 60% by weight, or such as less than about 50% by weight.

[0060] In addition to varying the amount of cannabis stems, cannabis leaves, cannabis buds, and cannabis flowers, the reconstituted cannabis material of the present disclosure may be produced from only virgin cannabis plant material, only cannabis extraction by-products, or from a combination of virgin cannabis plant material and cannabis extraction by-products. For example, the cannabis plant part of the reconstituted cannabis material may contain cannabis extraction by-products or biomass in an amount greater than about 20% by weight, such as greater than about 40% by weight, such as greater than about 60% by weight, such as greater than about 80% by weight, or such as greater than about 95% by weight. Similarly, the cannabis part of the reconstituted cannabis material may contain virgin cannabis plant material in an amount greater than about 20% by weight, such as greater than about 40% by weight, such as greater than about 60% by weight, such as greater than about 80% by weight, or such as greater than about 90% by weight.

[0061] The hemp material can be combined with web-building fibers. The web-building fibers are incorporated into the reconstituted plant material or fiber substrate in an amount that can impart strength and integrity to the aerosol-generating material. The incorporation of web-building fibers into the reconstituted plant material can also allow the web-building fibers to hold the hemp fibers and other hemp components and prevent them from separating from the fiber substrate. In general, the incorporation of any suitable web-building fibers into the reconstituted plant material can improve one or more physical properties of the reconstituted material.

[0062] Various types of web-building fibers can be used. In one embodiment, the web-building fibers are delignified cellulose fibers. For example, the web-building fibers can include wood pulp fibers, such as softwood fibers and hardwood fibers. Other cellulose fibers that can be used include flax fibers, hemp fibers, abaca fibers, bamboo fibers, coconut fibers, cotton fibers, kapok fibers, ramie fibers, jute fibers, or any combination thereof. In one particular embodiment, the reconstituted plant material includes softwood fibers alone or in combination with other fibers, such as abaca fibers. In one embodiment, the web-building fibers can be hemp pulp fibers. In this way, the reconstituted cannabis material can be formed only from cannabis plant parts. The hemp pulp fibers can have an average fiber length of more than about 0.5 mm, such as more than about 1 mm, such as more than about 1.5 mm, or such as more than about 1.8 mm, and generally less than about 4 mm, such as less than about 3 mm, such as less than about 2.5 mm, or such as less than about 2.35 mm.

[0063] Typically, the web-building fibers are present in the reconstituted plant material in an amount greater than about 3% by weight, such as greater than about 5% by weight, such as greater than about 8% by weight, such as greater than about 10% by weight, such as greater than about 15% by weight, or such as greater than about 20% by weight, and typically, the web-building fibers are present in the reconstituted plant material in an amount less than about 50% by weight, such as less than about 30% by weight, such as less than about 20% by weight, or such as less than about 15% by weight.

[0064] In one embodiment, the web-building fibers incorporated in the reconstituted plant material include a combination of long and short fibers. The long fibers generally have an average length of more than about 1.5 mm, for example more than about 2 mm. Meanwhile, the short fibers generally have an average length of less than about 1.5 mm. The long fibers can be used to improve strength and integrity. Meanwhile, the short fibers can better retain the hemp fibers and other components in the fiber substrate. In one embodiment, for example, the short fibers can be included in the reconstituted plant material in an amount of more than about 3% by weight, for example more than about 5% by weight, and generally less than about 20% by weight. Meanwhile, the long fibers can be included in the reconstituted web material in an amount of more than about 2% by weight, for example more than about 5% by weight, and generally less than about 30% by weight, for example less than about 15% by weight. In one embodiment, the short fibers include hardwood fibers, and the long fibers include softwood fibers.

[0065] In addition to extracted hemp fibers and web-building fibers, the reconstituted hemp material of the present disclosure may also include various other plant fibers. In one embodiment, for example, the reconstituted hemp material may include extracted cocoa husk fibers. For example, extracted cocoa husk fibers have been found to produce a very neutral tasting aerosol. Combining extracted cocoa husk fibers with the reconstituted hemp material can further improve the overall taste of the product.

[0066] The cocoa material used in this disclosure is obtained from Theobroma cacao, also known as the cocoa tree. The cocoa tree is an evergreen tree native to the tropics. The cocoa tree produces a fruit called a cocoa pod. The cocoa pod is generally yellow to orange in color and weighs over a pound when ripe. The cocoa pod contains 10-80 cocoa beans that are used to make chocolate, juice, jelly, and the like. After the cocoa beans are removed from the cocoa pod, they are exposed to sunlight and / or UV light to dry-cure or ferment. The individual beans are covered with a husk or shell. The husk or shell is removed from the cocoa beans before the cocoa beans are used in food production. The reconstituted plant material of the present disclosure is formed from cocoa husks or shells, although other components of the cocoa pod may be used.

[0067] The cocoa husk or shells contain fibers that are well suited for making substrates and web materials. In one embodiment, the cocoa husk is optionally cut or ground and then subjected to an extraction process to remove water-soluble components. The extraction process for the cocoa husk may be carried out separately from the cannabis material, or the cocoa husk material may be combined with the cannabis material and subjected to the same extraction process.

[0068] The amount of extracted cocoa husk fiber included in the reconstituted plant material may depend on the particular application and the desired results. The extracted cocoa husk fiber may, for example, be included in the reconstituted plant material in an amount of 1% to about 80% by weight, such as about 5% to about 50% by weight. For example, the extracted cocoa husk fiber may be included in the reconstituted plant material in an amount of more than about 10% by weight, such as more than about 20% by weight, or such as more than about 30% by weight, and generally less than about 60% by weight, such as less than about 50% by weight, or such as less than about 40% by weight.

[0069] In one embodiment, the reconstituted web material can further include a humectant. The humectant can be incorporated into the reconstituted plant material for various reasons to provide various benefits and advantages. For example, in one embodiment, the humectant is incorporated into the reconstituted plant material to improve the processability and handling of the reconstituted fiber substrate. In another embodiment, the humectant can be added in large amounts to the reconstituted plant material to make it well suited for non-combustion heating applications to generate inhalable aerosols.

[0070] Various humectants can be incorporated into the reconstituted plant material.Humectants include, for example, glycerol, propylene glycol, or a combination thereof.Other humectants that can be used include sorbitol, triethylene glycol, lactic acid, glyceryl diacetate, glyceryl triacetate, triethyl citrate, isopropyl myristate, or any combination thereof, including in combination with glycerol and / or propylene glycol.

[0071] As mentioned above, the amount of humectant included in the reconstituted plant material may depend on various factors. In one embodiment, for example, the humectant is included in the reconstituted plant material in an amount of less than about 5% by weight, such as less than about 3% by weight, and generally more than about 0.5% by weight, such as more than about 1% by weight. In another embodiment, the humectant is included in the reconstituted plant material in an amount of more than about 5% by weight, such as more than about 10% by weight, such as more than about 15% by weight, or such as more than about 20% by weight, and generally less than about 50% by weight, such as less than about 40% by weight, such as less than about 30% by weight, or such as less than about 25% by weight. When added to the reconstituted plant material in an amount of about 10-40% by weight, such as about 12-30% by weight, or such as about 15-25% by weight, the humectant acts as an aerosol generating agent to promote the generation of aerosols when the reconstituted plant material is heated without burning.

[0072] The reconstituted plant material of the present disclosure can also include a variety of other optional ingredients. For example, in one embodiment, the reconstituted plant material may be optionally treated with a burn control agent. The burn control agent can function as an ash conditioner to control the burn rate of the material or to improve the coherence and / or color of the ash produced upon combustion of the material.

[0073] The burn control agent may include, for example, a salt of a carboxylic acid. For example, the burn control agent may include an alkali metal salt of a carboxylic acid, an alkaline earth metal salt of a carboxylic acid, or any combination thereof. Examples of burn control agents that can be used include salts of acetic acid, citric acid, malic acid, lactic acid, tartaric acid, carbonic acid, formic acid, propionic acid, glycolic acid, fumaric acid, oxalic acid, malonic acid, succinic acid, nitric acid, phosphoric acid, or any combination thereof. Specific burn control agents that can be used include potassium citrate, sodium citrate, potassium succinate, sodium succinate, or any combination thereof. When present, the burn control agent can be applied to the reconstituted plant material in an amount generally greater than about 0.1% by weight, such as greater than about 0.5% by weight, or such as greater than about 1% by weight, and generally less than about 5% by weight, such as less than about 4% by weight, such as less than about 3% by weight, or such as less than about 2% by weight.

[0074] The above-mentioned burn control agents can accelerate the burn rate of the reconstituted plant material depending on the amount applied to the material. However, it has been found that the reconstituted cannabis material of the present disclosure has very good burn characteristics without the addition of burn control agents. In fact, in one embodiment, a flame retardant may be optionally applied to the reconstituted plant material. Flame retardants include, for example, film-forming polymers such as alginates, guar gum, pectin, polyvinyl alcohol, cellulose derivatives, starch, starch derivatives, etc. Other flame retardants include ammonium aluminum sulfate, diammonium hydrogen orthophosphate, ammonium dihydrogen orthophosphate, sodium dihydrogen orthophosphate, boric acid, aluminum borate, calcium borate, ammonium bromide, lithium bromide, magnesium bromide, ammonium chloride, magnesium chloride, zinc chloride, aluminum phosphate, calcium phosphate, potassium silicate, aluminum sulfate, calcium sulfate, magnesium sulfate, sodium carbonate, and any combination thereof. When present, the flame retardant may be applied to the reconstituted plant material in an amount greater than about 0.1% by weight, such as greater than about 0.3% by weight, and generally less than about 2% by weight, such as less than about 1% by weight.

[0075] The reconstituted plant material of the present disclosure may optionally include a filler material. The filler material may include particles incorporated into the reconstituted web material for any desired purpose, such as to facilitate the formation of the reconstituted plant material and / or to affect the appearance of the reconstituted plant material. The filler material particles that can be incorporated into the reconstituted web material can be made of calcium carbonate, magnesium oxide, kaolin clay, bentonite, or any combination thereof. The filler material particles can optionally be incorporated into the reconstituted web material in an amount greater than about 1% by weight, such as greater than about 5% by weight, or such as greater than about 10% by weight, and generally less than about 30% by weight, such as less than about 25% by weight, less than about 20% by weight, or such as less than about 15% by weight.

[0076] Once the reconstituted plant material has been formed into a fibrous substrate as described above, the fibrous substrate can be used as an aerosol-generating material for use in any suitable smoking article or non-combustion heating device. In one embodiment, the reconstituted plant material is first formed into loose filler material by subjecting it to a chopping or cutting process. For example, the loose filler material can be in the form of strips, pieces, or combinations thereof. The loose filler material is then loaded into any suitable aerosol-generating device or smoking article.

[0077] The reconstituted plant material of the present disclosure produces an aerosol or smoke that has the characteristic cannabis taste and odor and is free of harsh ingredients or irritants.

[0078] The reconstituted plant material may be used alone to generate the aerosol-generating material or may be combined with other aerosol-generating filler materials. In one embodiment, for example, the reconstituted plant material of the present disclosure may be combined with tobacco material. The tobacco material blended with the reconstituted plant material of the present disclosure may include, for example, cut tobacco, reconstituted tobacco material, or a combination thereof. In one embodiment, the reconstituted plant material of the present disclosure may be in the form of a loose filler material that is homogenously blended with the tobacco material to form an aerosol-generating material that is low in nicotine and has a desired taste and odor. For example, the aerosol-generating material may include the reconstituted plant material of the present disclosure in an amount greater than about 5% by weight, such as greater than about 10% by weight, such as greater than about 20% by weight, such as greater than about 30% by weight, such as greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 60% by weight, such as greater than about 70% by weight, or such as greater than about 80% by weight. The reconstituted plant material of the present disclosure may be combined with tobacco material such that the resulting aerosol-generating material contains the reconstituted plant material in an amount of less than about 90% by weight, such as less than about 80% by weight, such as less than about 70% by weight, such as less than about 60% by weight, such as less than about 50% by weight, such as less than about 40% by weight, or such as less than about 30% by weight. For example, in one embodiment, the aerosol-generating material may contain the reconstituted plant material of the present disclosure in an amount of about 5% to about 30% by weight, such as about 10% to about 20% by weight. In another embodiment, a greater amount of reconstituted plant material may be incorporated into the aerosol-generating material. In this embodiment, the reconstituted plant material may be included in the aerosol-generating material in an amount of about 30% to about 80% by weight, such as about 40% to about 60% by weight. The weight percentages above are based on the total weight of the aerosol-generating material. The remaining portion of the aerosol-generating material may contain only tobacco filler material.

[0079] In another embodiment, the reconstituted plant material of the present disclosure may be combined with other cannabis filling materials. For example, the reconstituted material of the present disclosure may take the form of a loose filling material that is homogenously mixed with other cannabis filling materials. The other cannabis filling materials may include, for example, dried flowers, dried buds, dried seeds, dried leaves, dried stems, or any combination thereof. The other cannabis materials may include, for example, materials that have not undergone an extraction process. The aerosol-generating material may include the reconstituted cannabis material of the present disclosure in an amount generally greater than about 20% by weight, such as greater than about 30% by weight, such as greater than about 40% by weight, such as greater than about 50% by weight, such as greater than about 60% by weight, and generally less than about 90% by weight, such as less than about 80% by weight, less than 70% by weight, such as less than about 60% by weight, such as less than 50% by weight, or such as less than about 40% by weight. The remaining portion of the aerosol-generating material may be comprised of the reconstituted cocoa husk material of the present disclosure.

[0080] In addition to or instead of being combined with tobacco materials, the reconstituted cannabis material of the present disclosure may be combined with various herbal filling materials. For example, the reconstituted cannabis material may be homogenously blended with various types of herbal filling materials. The weight ratio of the reconstituted cannabis material to the herbal filling materials may generally be about 1:8 to about 8:1, such as about 1:5 to about 5:1, or such as about 2:1 to about 1:2.

[0081] For example, the reconstituted plant material of the present disclosure may be combined with an aerosol-generating fill material formed from other plant material, such as herbs, plants, or trees, such as, for example, cacao trees, coffee trees or beans, tea trees or leaves, vines, ginger, ginkgo, chamomile, tomato, ivy, yerba mate, rooibos, cucumber, mint, grains (such as wheat, barley, rye), other trees (such as broadleaf trees, resinous trees), or any combination thereof.

[0082] The reconstituted cannabis material of the present disclosure is also well suited to hold a variety of different topical additives. In this regard, the reconstituted cannabis material of the present disclosure can act as a carrier to deliver active substances in the aerosol generated from the material. For example, the reconstituted plant material is highly absorbent and can contain up to 50% by weight of topical additives.

[0083] In this regard, the reconstituted cannabis material of the present disclosure may be treated with various aerosol delivery compositions containing one or more aerosol delivery substances. Aerosol delivery compositions that can be applied to the reconstituted plant material of the present disclosure include solutions, suspensions, oils, and the like. For example, solutions and suspensions can be applied to the reconstituted plant material and then dried, leaving a solid residue within the fiber substrate.

[0084] In one embodiment, the aerosol delivery composition can be obtained by extracting plant matter from a plant for application to the reconstituted plant material. Additionally or alternatively, the present disclosure may include isolating at least one compound from the plant matter, concentrating the plant matter, or purifying or removing compounds from the plant matter to obtain the modified plant matter to be applied to the reconstituted material. Optionally, such a process can convert the original raw plant matter into modified plant matter, whether in the form of a dry extract, liquid extract, liquid, or isolated material, based on the desired final properties of the plant matter to be applied to the reconstituted material. Of course, the plant matter may be the original plant matter or modified plant matter, but in one embodiment, the plant matter is applied to the reconstituted plant material without further processing after extraction. Additionally, although the aerosol delivery composition is described as being extracted from a plant, it should be understood that synthetic or naturally derived aerosol delivery compositions (i.e., not necessarily extracted) may also be used.

[0085] Examples of aerosol delivery substances that may be included in the aerosol delivery composition (in addition to nicotine) include sugars, licorice extracts, menthol, honey, coffee, maple syrup, tobacco, herbal extracts, plant extracts, tea, fruit extracts, flavors (such as clove, anise, cinnamon, sandalwood, geranium, rose oil, vanilla, caramel, cocoa, lemon oil, cassia, spearmint, fennel, ginger, etc.), flavors and aromas (such as cocoa, vanilla, caramel, etc.), artificial flavors and flavors (such as vanillin), or any combination thereof. The extracts applied to the reconstituted plant material may be water-soluble or oil-soluble. Thus, a variety of carrier liquids may be used to apply the aerosol delivery substance to the reconstituted plant material.

[0086] In one embodiment, the reconstituted plant material of the present disclosure can be used as a carrier for cannabis components, such as cannabinoids. Cannabis contains various cannabinoids that can be used, for example, for pain relief. Topical application of cannabinoids to the reconstituted plant material allows for uniform and consistent delivery of the cannabinoids contained in the aerosol generated from the reconstituted plant material. Thus, in one embodiment, the reconstituted cannabis material of the present disclosure can be produced from plant material that contains no cannabinoids or only very small amounts of cannabinoids. Cannabinoids extracted from the cannabis plant can then be applied to the reconstituted plant material of the present disclosure. In this way, the amount of cannabinoids in the aerosol-generating material can be carefully controlled. Also, the aerosol generated from the aerosol generation can deliver the cannabinoids in a consistent manner that does not change from inhalation to inhalation.

[0087] Cannabinoids that can be incorporated into the reconstituted plant material of the present disclosure include cannabidiol (CBD) and tetrahydrocannabinol (THC). THC, found in cannabis, acts on certain receptors in the brain, resulting in a euphoric and relaxed state. CBD, on the other hand, also acts on pain receptors in the brain, but does not produce the euphoric sensation that THC produces. According to the present disclosure, in one embodiment, THC can be applied to the reconstituted plant material of the present disclosure, CBD can be applied to the reconstituted plant material, or both THC and CBD can be applied to the reconstituted plant material.

[0088] In addition to THC and CBD, various other cannabinoids can also be incorporated into reconstituted plant material according to the present disclosure.For example, other cannabinoids contained in cannabis include cannabichromene, cannabinol, cannabigerol, tetrahydrocannabivarin, cannabidivarin, cannabidiolic acid, other cannabidiol derivatives, and other tetrahydrocannabinol derivatives.The above cannabinoids may be used alone or in any combination.

[0089] The cannabinoids can be applied to the reconstituted plant material using various methods. For example, in one embodiment, the cannabinoids, such as CBD, can be formulated into a powder that can be applied to the reconstituted plant material as an aqueous suspension. Alternatively, a cannabis oil extract can be obtained from a raw cannabis plant. The oil extract can include THC alone, CBD alone, or a combination of THC and CBD. The oil extract can be applied to the reconstituted plant material such that the aerosol generated from the reconstituted plant material contains a controlled amount of cannabinoids.

[0090] Other ingredients that can be added to the reconstituted cannabis material are various flavorings, particularly terpenes. For example, a terpene or blend of terpenes can be used to produce a desirable aroma and indicate the quality of the product to the user. Also, one or more terpenes can improve the sensory response when inhaling the aerosol produced from the reconstituted material.

[0091] Various terpenes can be applied to the reconstituted plant material, including, but not limited to, pinene, humulene, b-caryophyllene, isopulegol, guaiol, neryl acetate, neomenthyl acetate, limonene, menthone, dihydrojasmone, terpinolene, menthol, phellandrene, terpinene, geranyl acetate, ocimene, myrcene, 1,4-cineole, 3-carene, linalool, menthofuran, perillyl alcohol, pinane, neomenthyl acetyl, α-bisabolol, borneol, camphene, camphor, caryophyllene oxide, α-cedrene, β-eudesmol, fenchol, geraniol, isoborneol, nerol, sabinene, α-terpineol, or any combination thereof.

[0092] In one embodiment, various types of terpenes can be blended to mimic the ratio of terpenes found in natural cannabis plants. For example, about 2 to about 12 types of terpenes can be blended and applied to the reconstituted plant material. Each terpene can be applied to the reconstituted plant material in an amount greater than about 0.001% by weight and generally less than about 5% by weight. For example, each terpene can be applied in an amount of about 0.01% to about 1.5% by weight. Alternatively, for example, each terpene can be applied in an amount of about 0.1% to about 1.1% by weight.

[0093] Exemplary blends of terpenes include α-pinene, β-caryophyllene, and β-pinene; α-humulene, α-pinene, β-caryophyllene, β-pinene, and guaiol; β-caryophyllene, β-pinene, and d-limonene; β-caryophyllene, β-pinene, and nerolidol; β-caryophyllene, β-pinene, d-limonene, and terpinolene; α-bisabolol, α-pinene, β-caryophyllene, β-myrcene, β-pinena, and d-limonene. β-caryophyllene, β-pinena, and p-cymene; α-humulene, β-caryophyllene, β-pinene, d-limonene, linalool, and nerolidol; β-caryophyllene and β-pinene; β-caryophyllene, β-myrcene, and terpinolene; α-pinene, β-caryophyllene, β-pinene, and d-limonene; α-humulene, α-pinene, β-caryophyllene, β-myrcene, β-pinena, d-limonene, and guaiol.

[0094] The aerosol delivery composition comprising one or more aerosol delivery agents as described above can be applied to the reconstituted plant material using any suitable method or technique. For example, the aerosol delivery composition can be sprayed or coated onto the fiber substrate in any suitable manner.

[0095] The reconstituted plant material produced according to the present disclosure has excellent mechanical properties and a highly desirable aesthetic appearance.Generally, the reconstituted plant material has a basis weight of more than about 40 gsm, such as more than about 45 gsm, or such as more than about 55 gsm.The basis weight of the reconstituted plant material is generally less than about 120 gsm, such as less than about 100 gsm, or such as less than about 85 gsm.

[0096] In one embodiment, the reconstituted plant material of the present disclosure can be formed into loose filler material using various methods, such as extrusion, or cutting and / or chopping the reconstituted material. Filler material made according to the present disclosure can be approximately 4 cm 3 / g, e.g., about 5 cm 3 / g or, for example, about 6 cm 3 / g and generally about 10 cm3 / g, e.g., about 8 cm 3 The reconstituted plant material has a filling force of less than about 1 / g. The reconstituted plant material has excellent burn properties. For example, the reconstituted plant material has a static burn rate of more than about 4 mm / mm, such as more than about 5 mm / mm, and generally has a static burn rate of less than about 8 mm / mm, such as less than about 7 mm / mm.

[0097] Aerosol-generating materials incorporating the reconstituted plant material of the present disclosure can be used in various types of aerosol-generating products. In one embodiment, for example, the aerosol-generating materials of the present disclosure can be formed into a smokable rod and wrapped in a wrapping material. The smoking article or cigarette can include a filter located at one end thereof.

[0098] In one embodiment, the reconstituted plant material is formed into the form of a sheet in a paper former. The sheet is then cut into strips and fed into a drum that is rotated or agitated. In the drum, the reconstituted plant material is mixed with one or more humectants and a casing. The casing may include various flavorings or mainstream smoke enhancing elements. For example, the casing may include licorice, corn syrup, and / or sugars. After processing in the drum, the reconstituted plant material is subjected to a cutting or shredding process to obtain a desired particle size. The cut reconstituted plant material is also referred to as cut rag. After cutting to the desired size, various aerosol delivery substances or flavorings may be applied to the reconstituted plant material. For example, one or more terpenes and / or one or more cannabinoids (e.g., CBD and / or THC) may be applied to the reconstituted plant material. After the aerosol delivery substances are applied to the reconstituted plant material, the reconstituted plant material is packaged and shipped for use in any suitable form. In one aspect, the reconstituted plant material may be fed into a cigarette making machine to form the reconstituted plant material into rod-like elements. Alternatively, the reconstituted plant material may be packaged in loose form for use as a roll-your-own tobacco product, a non-combustible heat-not-burn product, or as snuff.

[0099] In addition to cigarettes, aerosol-forming materials made in accordance with the present disclosure may also include cigars and cigarillos.

[0100] As mentioned above, the reconstituted plant material of the present disclosure can also be used to produce smokeless blended products, which may be dry products or may contain a significant amount of moisture.

[0101] When making a smokeless blended product, the product may be made from only the reconstituted plant material of the present disclosure, or may be made by blending the reconstituted plant material of the present disclosure with other filler materials. When making a smokeless blended product using the reconstituted plant material of the present disclosure, the amount of web-building fibers in the product may be reduced. For example, the amount of web-building fibers may be less than about 5% by weight, such as less than about 3% by weight. In one aspect, the reconstituted plant material may be free of web-building fibers. In another embodiment, the reconstituted plant material may include about 5% to about 40% by weight of web-building fibers.

[0102] To produce smokeless blended products, the reconstituted plant material of the present disclosure is ground or cut to a desired size. For example, the particle size can be relatively small or striped depending on the end use. In one embodiment, for example, the reconstituted plant material is cut or ground to an average particle size of more than about 50 μm, for example more than about 100 μm, and generally less than about 3 mm, for example less than about 2 mm. Alternatively, the reconstituted plant material can be ground to a powder or granular material with an average particle size of less than about 100 μm.

[0103] If desired, the reconstituted plant material may be heat treated. Heat treatment may provide texture and color to the reconstituted plant material and enhance natural flavors. After the optional heat treatment step, additives such as pH adjusters and flavorings may be added to the reconstituted plant material. When producing a moist smokeless blended product, water is added to the smokeless blended product such that the moisture content is greater than about 10% by weight, such as greater than about 20% by weight, such as greater than about 30% by weight, or such as greater than about 40% by weight, and generally less than about 60% by weight, such as less than about 50% by weight. If desired, one or more humectants may be added to the smokeless blended product to increase the wetness of the smokeless blended product. In one embodiment, for example, sodium chloride and / or sodium carbonate may be added to the reconstituted plant material.

[0104] The reconstituted plant material may also be used to produce dried snuff, such as dried oral snuff, by grinding the reconstituted plant material into a powder to which other ingredients, such as flavourings, are added.

[0105] In one aspect, the smokeless reconstituted cannabis material can be placed in an oral pouch intended for use in the oral cavity, for example, between the upper and lower gums of the lips or cheeks. The oral pouch can have a rectangular shape, such as a rectangle. The total weight of the oral pouch can generally range from about 0.1 g to about 2.5 g, for example, from about 0.2 g to about 0.8 g. The oral pouch can be formed from any suitable saliva-permeable pouch material, such as a nonwoven fabric. The pouch material may also include a binder to facilitate sealing of the pouch material by ultrasonic bonding. The binder may be, for example, an acrylate polymer. In one aspect, the pouch material can be formed from a nonwoven material including regenerated cellulose fibers, such as viscose rayon staple fibers, and a binder. If desired, the pouch material may include additional flavorings and / or colorants.

[0106] In one embodiment, the smoking article manufactured according to the present disclosure has low flame spread. For example, the wrapping material of the smoking article includes a plurality of separate low flame spread areas spaced apart along the axial direction of the smoking article. For example, in one embodiment, the separate low flame spread areas can be in the form of a circular band. The circular band can have a width such that, when the smoking article is left in a static burning state, oxygen is restricted to the burning coal for a length or period of time sufficient for oxygen to extinguish the coal. For example, the circular band can have a width of more than about 3 mm, such as more than about 4 mm, such as more than about 5 mm, and generally less than about 10 mm, such as less than about 8 mm, such as less than about 7 mm.

[0107] The spacing between the low flame spread areas can vary depending on a variety of factors. The spacing should not be so large that the tobacco burns for a sufficient length of time to ignite the substrate before the coal burns into the low flame spread area. The spacing also affects the thermal inertia of the coal during burning, i.e., the ability of the coal to burn through the low flame spread area without self-extinguishing. In general, the spacing between the annular zones should be greater than about 5 mm, such as greater than about 10 mm, such as greater than about 15 mm, and generally less than about 50 mm, such as less than about 40 mm, or such as less than about 30 mm. Each smoking article can include about 1 to about 3 annular zones.

[0108] Generally, any suitable flame retardant composition can be applied to the packaging material of the smoking article.In one embodiment, for example, the flame retardant composition comprises a film-forming material.For example, the film-forming material that can be used according to the present invention includes alginate, guar gum, pectin, polyvinyl alcohol, polyvinyl acetate, cellulose derivatives (e.g., ethyl cellulose, methyl cellulose, carboxymethyl cellulose), starch, starch derivatives, etc.

[0109] In a particular embodiment, the film-forming material may comprise alginate alone or in combination with starch.Generally, alginate is a derivative of an acidic polysaccharide or gum that exists in brown seaweed as an insoluble mixed salt of calcium, sodium, potassium and magnesium.Generally speaking, these derivatives are calcium, sodium, potassium and / or magnesium salts of high molecular weight polysaccharides composed of various proportions of D-mannuronic acid and L-guluronic acid.Examples of salts or derivatives of alginic acid include ammonium alginate, potassium alginate, sodium alginate, propylene glycol alginate, or any combination thereof.

[0110] In one embodiment, an alginate having a relatively low molecular weight may be used. For example, the alginate has a viscosity of less than about 500 cP when contained in a 3 wt% aqueous solution at 25°C. More specifically, the alginate may have a viscosity of less than 250 cP, particularly less than 100 cP, and in one embodiment, a viscosity of about 20 to 60 cP, under the above conditions. As used herein, viscosity is measured by a Brookfield LVF viscometer equipped with an appropriate spindle depending on the viscosity. At the above low viscosity levels, the alginate composition has a high solids content, but can still be formed with a solution viscosity low enough to apply the composition to paper packaging materials using conventional techniques. For example, the solids content of the alginate solution prepared according to the present invention may be greater than about 6 wt%, particularly greater than about 10 wt%, and more specifically, in the range of about 10 wt% to about 20 wt%.

[0111] At the above solids content, the alginate composition used according to the present invention can have a solution viscosity of more than about 250 cP, particularly more than about 500 cP, especially more than about 800 cP, and in one embodiment, a viscosity of more than about 1,000 cP at 25°C. In general, the solution viscosity of the alginate film-forming composition can be adjusted according to the method of applying the film-forming composition to the packaging material. For example, the solution viscosity of the film-forming composition can be adjusted according to whether the composition is sprayed or printed on the packaging material.

[0112] It should also be appreciated that in other embodiments, alginates having a relatively high molecular weight may be used depending on the application. For example, the alginate may have a viscosity of greater than about 500 cP when contained in a 3 wt % aqueous solution at 25° C.

[0113] In addition to the film-forming material, the low flame spread composition applied to the packaging material may include various other components. For example, in one embodiment, the low flame spread composition may include a filler material. Examples of filler materials include, for example, calcium carbonate, calcium chloride, calcium lactate, calcium gluconate, etc. In addition to calcium compounds, magnesium compounds such as magnesium oxide and various other particles such as clay particles may be used.

[0114] The low-flame-spread composition may be aqueous in one embodiment. In particular, the low-flame-spread composition may comprise an aqueous dispersion or an aqueous solution. Alternatively, the low-flame-spread composition may comprise a non-aqueous solution or dispersion before being applied to the paper packaging material. In this embodiment, for example, the low-flame-spread composition may comprise an alcohol for application to the packaging material.

[0115] Also, unlike the film-forming composition, the low flame spread composition may include a cellulose slurry (a type of dispersion). As used herein, a slurry containing paper-making materials is not a film-forming composition. The cellulose slurry applied to the paper substrate may include fibrous cellulose, one or more filler materials, and / or cellulose particles. As used herein, cellulose fibers and cellulose particles should be distinguished from derivatized cellulose, such as carboxymethyl cellulose. For example, cellulose fibers and cellulose particles are not water-soluble. In one embodiment, the cellulose slurry applied to the packaging material may include microcrystalline cellulose.

[0116] The formed low-flame spread composition is applied to a discrete area of ​​the packaging material. There are various methods for applying the low-flame spread composition to the packaging material. For example, the low-flame spread composition is sprayed, brushed, applied with a movable orifice, or printed onto the packaging material. To form the treated area, the low-flame spread composition can be applied in a single pass or multiple pass operation. For example, the low-flame spread composition can be applied to the packaging material in successive steps to form a low-flame spread area on the packaging material having low flame spread properties. Generally, in a multiple pass process, the treated area can be formed by applying the low-flame spread composition in about 2 to about 8 passes.

[0117] The amount of the low flame spread composition applied to the packaging material can vary. For example, the low flame spread composition is applied to the packaging material in an amount of less than about 15% by weight, such as less than about 10% by weight, or such as less than about 8% by weight. Generally, the low flame spread composition is applied in an amount of more than 1% by weight based on the weight of the low flame spread composition contained in the low flame spread region.

[0118] As used herein, the weight percentages above are based on the area treated with the chemical components. In other words, the weight percentages above for the low flame spread composition are the amount applied within the treated area, not the total amount applied to the entire surface of the packaging material.

[0119] The methods of the present disclosure can produce low flame spread regions that have relatively high permeability and relatively low diffusivity, for example, smoking articles that have a permeability greater than 10 CORESTA, yet still pass the ASTM E2187-09 test at least 75% of the time.

[0120] Generally, the low flame spread region has a relatively low diffusivity. The diffusivity is measured at room temperature (23°C). Generally, the diffusivity of the low flame spread region at 23°C may be less than about 0.5 cm / s, such as less than 0.4 cm / s, or such as less than 0.3 cm / s. In an embodiment, the low flame spread region may have a diffusivity of more than about 0.05 cm / s, such as more than about 0.15 cm / s, such as more than 0.16 cm / s, or such as more than 0.17 cm / s, while still having the desired low flame spread. The diffusivity is measured using a Sodim CO2 diffusivity tester.

[0121] In addition to being incorporated into smoking articles, the aerosol-forming materials of the present disclosure can also be packaged in a variety of other forms and sold to consumers. For example, in one embodiment, the aerosol-forming materials can be packaged and sold as filler material in the form of strips or pieces. The filler material can be used as a filler material for pipes or hand-rolled cigarettes, or can be used in non-combustion heated aerosol generating devices.

[0122] The present disclosure may be better understood with reference to the following examples.

[0123] Working Example

[0124] The following test methods were used to define various parameters as well as to obtain the results of the examples that follow.

[0125] Tests and Methods

[0126] Packing force and equilibrium moisture content (EMC)

[0127] Samples of the filler material were conditioned (22°C ± 1°C, 60% ± 3% RH, minimum 48 h) according to ISO 3402. After conditioning, the filler material was spread (if necessary) and cut into cut lugs (instrument: BUROMA disc cutter; width: 0.7 mm).

[0128] To perform the packing force analysis, 14 g of cut packing material (accuracy: ±0.01 g) was placed in a Borgwaldt cylinder (model DM4625; diameter = 5.98 cm, height = 10.8 cm). A weight of 2 kg was applied for 60 seconds. When the piston was released, the height of the filler column was displayed and recorded (H, in cm).

[0129] The packing force of the sample (unit: cc / g) was calculated as 2×H.

[0130] The equilibrium moisture content was measured according to the following method: The weight of an empty pan (made of glass) was measured and recorded (T) with an accuracy of ±1 mg.

[0131] The loaf was then filled with the cut filling material (5-7 g) and the weight of the loaf with the cut filling material was recorded (W1, accuracy: ±1 mg).

[0132] The loaves with cut filling material were then dried in a Hearson oven (Mark V) at 100°C for 3 hours (± 5 minutes).

[0133] After drying, the pan was cooled in a desiccator for 15 min and weighed (W2, accuracy: ±1 mg). The moisture content (%) of the sample was calculated as follows:

[0134]

number

[0135] Water-soluble component content

[0136] Samples of the filler material were ground to a powder (using an IKA or RETSCHE-MUHLE grinder; mesh size: 1 mm).

[0137] A glass fiber filter (DURIEUX filter Nr28, diameter = 55 mm) was placed in a stainless steel pan. The pan + filter was then weighed (T, accuracy: ±1 mg). A 5000 mg (±200 mg) sample of the ground filler material was placed in the pan and weighed accurately (W1, accuracy: ±1 mg).

[0138] The ground packing material was gently sprayed with water and the pan was attached to a laboratory percolator (RENEKA LC). Extractions were performed three times according to the predefined percolation settings. After percolation, the samples were carefully washed with water and the pan was placed in an electric oven to dry at 100°C for 16 hours.

[0139] After washing, the pan was cooled in a desiccator for 15 min and weighed (W3, accuracy: ±1 mg).

[0140] The dry weight (W2) of the ground sample used in the test for measuring the content of water-soluble components was calculated as W2 = W1 × (100-H) / 100.

[0141] Finally, the percentage of water soluble components in the dried final product was calculated as follows:

[0142]

number

[0143] Cigarette making

[0144] The filler material samples were conditioned according to ISO 3402 (22°C ± 1°C, 60% ± 3% RH, minimum 48 hours). After conditioning, the filler material sheets were cut into strips (instrument: BUROMA disc cutter, width: 0.7 mm). The cut filler material was sieved through a laboratory sieve (mesh size: 1 mm).

[0145] Next, the empty cigarette tube was filled with the cut filler material to 100% using a PRIVILEG hand-rolling machine. The weight of the cut filler material was adjusted so that the pressure drop was 100±5 mmWG.

[0146] The empty cigarette tubes had the following characteristics: Tube weight = 200±5mg, Total length = 84mm, diameter = 8.1±0.1mm, tip length = 25mm Acetate filter (denier = 3.0Y / 35000HK, length = 15±0.5mm, pressure loss = 43±3mmWG), Porosity of cigarette paper = 50CU, No filter venting.

[0147] The cigarettes were then sorted using a SODIMAT instrument. The cigarette lots selected for smoke analysis had the following characteristics: filler weight: mean target weight ± 10 mg, pressure drop (PD): mean target PD ± 3.5 mmWG.

[0148] Prior to smoke analysis, cigarettes were conditioned according to ISO 3402 (22°C ± 1°C, 60% ± 3% RH, minimum 48 hours).

[0149] Combustion Power Analysis

[0150] The ten cigarettes were placed in a FILTRONA static burn rate measuring apparatus, which is equipped with ten cigarette holders and ten individual chronometers.

[0151] Two cotton threads were placed 40 mm apart above the 10 cigarettes. A chronometer was attached to each cotton thread.

[0152] Each cigarette was lit in sequence. For each cigarette, a chronometer was automatically started when the burn cone cut the first cotton thread. When the char line reached the second cotton thread, the chronometer was automatically stopped, thus measuring the time required to burn a 40 mm rod of filler material.

[0153] The average time (in seconds) was calculated from the 10 chronometer readings.

[0154] The average burning power (mm / min) was calculated as follows:

[0155]

number

[0156] Analysis of tar, nicotine, water, and CO in smoke

[0157] Two sets of 20 cigarettes were smoked in a Borgwaldt RM20 kit machine according to ISO standards (ISO 3308).

[0158] Nicotine and water in the smoke (mg / cig) were measured by gas chromatography according to the ISO 10315 and ISO 10362-1 standards.

[0159] Tar in the smoke (mg / cig) was measured according to the ISO 4387 standard.

[0160] CO (mg / cig) in the smoke was measured using a non-dispersive infrared (NDIR) method according to the ISO 8454 standard.

[0161] Example 1

[0162] A hemp filler material according to the present disclosure comprising fibers derived from hemp (Cannabis sativa) plants was produced according to the following method: hemp leaves and hemp flowers in a 50% / 50% ratio were ground in a knife mill to particles of about 1 mm size. The ground hemp material was then mixed with water at 70° C. for 45 minutes in a hemp:water ratio of 1:10. The mixture was then pressed to separate the soluble portion (hemp liquid) from the insoluble portion (hemp fiber). The fiber fraction was refined using a disc refiner. After purification, delignified fiber from resin trees (softwood fiber) was added to the refined fiber fraction in a ratio of 15%:85% delignified fiber:fiber according to the present disclosure derived from hemp plants (hemp filler material) to produce hemp filler material sheets. The hemp filler material sheets were dried. The aqueous portion derived from the hemp plant (the so-called "extract") was concentrated in an evaporator to a solids concentration of 50% and then coated in various amounts onto a reconstituted sheet using a size press, after which it was dried. Sample E: The above hemp filling material without the addition of hemp extract. Sample A: Sample E coated with 3% vegetable glycerin and 29% cannabis extract, which are soluble components of the traditional hemp plant used as starting material. Sample B: 15% vegetable glycerin and 25% hemp extract coated onto sample E.

[0163] Smoking rating: Sample E was evaluated as a conventional cigarette. The smoke yield was very good. The burn / free burn ratio was good. There was a slight bitterness and a slight tingling on the tongue. It was somewhat neutral. Sample A was evaluated with a conventional cigarette. The amount of smoke was very good. The cannabis taste was very good and strong. There was no harshness. The addition of hemp extract and a small amount of vegetable glycerin improved the taste, reduced the harshness, and improved the smoking experience. Sample B was evaluated in a non-combustion heat device (PAX3 device). Smoke yield was very good. Burn was good and had a nice cannabis smell. Had a nice herbal taste. A bit on the bitter side. Taste was long-lasting.

[0164] Example 2

[0165] Hemp filler material according to the present disclosure, including fibers derived from hemp (Cannabis sativa) plants, was produced according to the following method: hemp leaves were ground in a knife mill to particles of about 1 mm in size. The ground hemp material was then mixed with water at 70° C. for 45 minutes, in a ratio of hemp:water of 1:10. The mixture was then pressed to separate the soluble portion (hemp liquid) from the insoluble portion (hemp fiber). The fiber fraction was refined using a disc refiner. After refining, delignified fiber from resin trees was added to the refined fiber fraction in a ratio of delignified fiber:fiber according to the present disclosure derived from hemp plants of 15%:85% to produce hemp filler material sheets. The hemp filler material sheets were dried. They were then coated in various amounts onto reconstituted sheets using a size press, and then dried. Sample A: The above hemp filling material without the addition of hemp extract. Sample B: Sample A coated with 3% vegetable glycerin and 29% cannabis extract, which are soluble components of the traditional hemp plant used as the starting material. Sample C: Sample A coated with 15% vegetable glycerin and 25% hemp extract.

[0166] Example 3

[0167] A hemp filling material according to the present disclosure, comprising fibers derived from hemp (Cannabis sativa) plants, was produced according to the following method: hemp leaves were ground in a knife mill to particles of about 1 mm in size. The ground hemp material was then mixed with water at 70° C. for 45 minutes, in a ratio of 1:10 hemp:water. The mixture was then pressed to separate the soluble portion (hemp liquid) from the insoluble portion (hemp fiber). The fiber fraction was refined using a disc refiner. After purification, delignified fiber from the resin tree was added to the refined fiber fraction in a ratio of 15%:85% delignified fiber:fiber according to the present disclosure derived from hemp plants to produce hemp filling material sheets. The hemp filling material sheets were dried. The aqueous portion (so-called “extract”) derived from the hemp plants was concentrated in an evaporator to a solid concentration of 50%, then coated on a reconstituted sheet in a ratio of 26% using a size press, and then dried.

[0168] Various other substances were then added to the hemp filler material sheets by coating and / or spraying. Substances that can be applied to the hemp filler sheets include aromas, CBD, THC, etc.

[0169] Example 4

[0170] A hemp filler material according to the present disclosure comprising fibers derived from hemp (Cannabis sativa) plants was produced according to the following method: hemp leaves were ground in a knife mill to particles of about 1 mm in size. The ground hemp material was then mixed with water at 70° C. for 45 minutes in a ratio of hemp:water of 1:10. The mixture was then pressed to separate the soluble portion (hemp liquid) from the insoluble portion (hemp fiber). The fiber fraction was refined using a disc refiner. After purification, delignified fiber from resin trees was added to the refined fiber fraction in a ratio of delignified fiber:fiber according to the present disclosure derived from hemp plants of 15%:85% to produce a hemp filler material sheet. The hemp filler material sheet was dried.

[0171] In parallel, the aqueous portion (tobacco liquid) derived from the tobacco plant, also called tobacco "extract", prepared as above, was concentrated in an evaporator to a solid concentration of 50%, and then coated on a hemp filler material sheet by coating in a size press, and then dried. Also, for demonstration purposes, some reconstituted tobacco materials were produced by the same method.

[0172] The following samples were prepared:

[0173] [Table 1]

[0174] Example 5

[0175] A hemp tobacco filler material according to the present disclosure, comprising fiber derived from a hemp (Cannabis sativa) plant and fiber derived from a tobacco (Nicotiana tabacum) plant, was produced according to the following method: hemp leaves and tobacco leaves were ground in a knife mill to particles of about 1 mm in size. The ground hemp tobacco material was then mixed in a 50%:50% ratio and then mixed with water at 70°C for 45 minutes to achieve a hemp tobacco material:water ratio of 1:10. The mixture was then pressed to separate the soluble portion (a mixture of hemp liquid and tobacco liquid) from the insoluble portion (a mixture of hemp fiber and tobacco fiber). The fiber fraction was refined using a disc refiner. After purification, the delignified fiber from the resin tree and the mixture of tobacco and hemp fibers prepared as above were added to the purified fiber fraction in a ratio of delignified fiber:mixture of fibers according to the present disclosure derived from tobacco and hemp plants of 15%:85% to produce hemp-tobacco filler material sheets. The hemp-tobacco filler material sheets were then dried. The aqueous portion derived from the hemp and tobacco plants, also called "extract", was concentrated in an evaporator to a solid concentration of 50%, then coated in the desired ratio using a size press and then dried. The following samples were made:

[0176] [Table 2]

[0177] Example 6

[0178] In order to make the reconstituted plant material according to the present disclosure, various raw materials were collected. The cannabis sample obtained initially was in a virgin state. In addition, two different raw materials of cannabis extraction by-products were collected to make the sample. The samples used in this example are as follows: Sample No. 1: A cannabis extraction by-product having a very fine particle size and a very uniform morphology. This cannabis extraction by-product was the product of an extraction process using supercritical carbon dioxide. The amount of hot water solubles in this sample was determined to be 37% by weight. Sample No. 2: A mixture of cannabis leaves, stems, seed husks, hurds, and flowers that had not been previously extracted. The amount of hot water solubles was determined to be 14% by weight. Sample No. 3: Cannabis extract by-product containing small leaves, flowers, and small stems. The cannabis extract by-product was pre-extracted with ethanol. The amount of hot water solubles was determined to be 27% by weight.

[0179] Each of the above samples was combined with 30% hemp pulp by weight.

[0180] The raw material was extracted according to the following parameters: 250g of raw materials. · One extraction at 70°C (158°F) for 20 minutes. · The pulp is pressed to obtain thick extract (SEL). · Extract once at 70°C for 10 minutes. The pulp is pressed to obtain a thin extract.

[0181] The extraction was carried out using a casserole and a hot plate, the temperature of which was controlled by a temperature sensor and set by a converter on the hot plate.

[0182] A cider press was used to separate the fibre and liquid.

[0183] It was refined using a PFI mill.

[0184] The standard procedure for preparing the samples is as follows. (1) Weigh out the appropriate amount of air-dried fiber (usually 24 g of air-dried fiber corresponds to 22.5 g of dry fiber). (2) Adjust to the appropriate concentration with 200 ml of H2O (usually about 10%). (3) The hydrated pulp was added to a laboratory blender and the volume was brought to 32 ounces (approximately 950 ml). (4) The blender was run for 2 minutes at a Powerstat setting of 50%. (5) The water was dewatered using a Buchner funnel and filter screen. The sample was placed on the wire of a handsheet former and the pulp was manually pressed. (6) The dehydrated sample was placed in a container of appropriate size with a known mass and water was added to bring the mass to 225 ± 1 g. (7) Additional water was added to the sample and mixed.

[0185] Samples #2 and #3 were then placed in a PFI bowl and rotated 7000 times.

[0186] The refined hemp pulp and raw materials were mixed using a blender. Ten handsheets of each sample were made.

[0187] The extract from each sample was concentrated. Concentration of the liquid was done using a vacuum rotary evaporator (Rotavap). The vapor was condensed into water at approximately 20°C (68°F). The heat bath was set at 60°C (140°F). The liquid was concentrated to approximately 24% Brix.

[0188] After concentration, the extract was applied to each sample of the reconstituted material. Additionally, 1.5% by weight of glycerol (a humectant) was added to each sample.

[0189] For sample number 1, the extractive was applied in an amount of 30.15% by weight. For sample number 2, the extractive was applied in an amount of 18.2% by weight. For sample number 3, the extractive was applied in an amount of 25.7% by weight. The extractive was applied to each sample using a manual size press. The base sheet for each sample was cut into four pieces, coated, and dried at 110°C for 4 minutes.

[0190] The treated samples were then cut using conventional shredding equipment. The resulting cannabis reconstituted material filler was fed into a laboratory-scale cigarette making machine. It was observed that each sample was successfully transported on the cigarette making machine and produced cannabis cigarettes of excellent quality, including wrapping materials and filters.

[0191] As mentioned above, various different embodiments can be created according to the present disclosure. Furthermore, each embodiment can be combined to create new embodiments. In one embodiment, for example, the present disclosure relates to an aerosol-generating material comprising a combination of reconstituted cannabis material and web-constructed fibers. The reconstituted cannabis material can include extracted cannabis fibers. The extracted cannabis fibers can be obtained from various sources, such as cannabis leaves, cannabis stems, cannabis buds, cannabis flowers, or any combination thereof. The reconstituted cannabis material can also include extracted cannabis stalks, cannabis seeds, and / or cannabis residues. The reconstituted cannabis material can be formed from only raw materials, from cannabis extraction by-products that have been subjected to additional water-soluble extraction, or from a combination of both. The reconstituted cannabis material can also be formed from cannabis plant material that contains less than 0.3% by weight of tetrahydrocannabinol, from cannabis plant material that contains more than 0.3% by weight of tetrahydrocannabinol, or from a combination of both.

[0192] In one embodiment, the reconstituted cannabis material comprises extracted cannabis leaves in an amount of about 20% to about 50% by weight, extracted cannabis buds and / or flowers in an amount of about 20% to about 50% by weight, and delignified cellulose fibers in an amount of about 3% to about 20% by weight.

[0193] In any of the embodiments described above, the reconstituted cannabis material may be treated with water soluble cannabis components. The water soluble cannabis components may be obtained by extracting cannabis fiber. If desired, the water soluble cannabis components may be concentrated and then reapplied to the reconstituted cannabis material. In one embodiment, the reconstituted cannabis material may contain water soluble cannabis components in an amount of less than about 10% by weight, such as less than about 5% by weight. In another embodiment, the reconstituted cannabis material may contain water soluble cannabis components in an amount of about 10% to about 60% by weight.

[0194] In any of the above-described embodiments, the web-constructing fibers combined with the reconstituted cannabis material can vary. In one embodiment, the web-constructing fibers include wood pulp fibers, such as softwood fibers, hardwood fibers, or a combination thereof. In one embodiment, the web-constructing fibers include softwood fibers and hardwood fibers in a ratio of 1:2 to 2:1. In one embodiment, the web-constructing fibers include flax fibers. In one embodiment, the web-constructing fibers include abaca fibers. In one embodiment, the web-constructing fibers include bamboo fibers. In one embodiment, the web-constructing fibers include coconut fibers. In one embodiment, the web-constructing fibers include ramie fibers. In one embodiment, the web-constructing fibers include jute fibers. In one embodiment, the web-constructing fibers include hemp pulp fibers. The hemp pulp fibers may be used alone or in combination with wood pulp fibers (e.g., softwood fibers, hardwood fibers, or a combination thereof). In one embodiment, the web-constructing fibers are included in the aerosol-generating material in an amount greater than about 5% by weight. In one embodiment, the web constructing fibers are present in the aerosol-generating material in an amount greater than about 8% by weight. In one embodiment, the web constructing fibers are present in the aerosol-generating material in an amount greater than about 15% by weight. In one embodiment, the web constructing fibers are present in the aerosol-generating material in an amount greater than about 20% by weight. In one embodiment, the web constructing fibers are present in the aerosol-generating material in an amount greater than about 25% by weight. In one embodiment, the web constructing fibers are present in the aerosol-generating material in an amount less than about 50% by weight, for example less than about 40% by weight.

[0195] In any of the above-mentioned embodiments, various other ingredients may be added to the aerosol-generating material. For example, the aerosol-generating material may further include extracted cocoa husk fiber, the reconstituted cannabis material including a combination of extracted cannabis fiber and web-building fiber. The extracted cocoa husk fiber may be included in the reconstituted cannabis material in an amount of more than about 10% by weight, such as more than about 20% by weight, and generally less than 80% by weight, such as less than about 40% by weight.

[0196] In one embodiment, the reconstituted cannabis material may be combined with dried cannabis material that has not been subjected to the extraction process.

[0197] In one embodiment, the aerosol generating material of the present disclosure may include an aerosol delivery composition applied to the reconstituted plant material. The aerosol delivery composition includes an aerosol delivery substance. In one embodiment, the aerosol delivery substance includes a medicament or flavoring. In any embodiment described herein, the aerosol delivery composition may be an oil, an aqueous solution, an aqueous dispersion, or a solid. In one embodiment, the aerosol delivery substance includes nicotine. In one embodiment, the aerosol delivery substance includes a cannabinoid. In one embodiment, the aerosol delivery substance includes tetrahydrocannabinol. In one embodiment, the aerosol delivery substance includes cannabidiol. In one embodiment, the aerosol delivery substance includes a combination of tetrahydrocannabinol and cannabidiol. The nicotine or cannabinoid may be combined with other aerosol delivery substances. In one embodiment, the other aerosol delivery substance includes a sugar. In one embodiment, the other aerosol delivery substance includes honey. In one embodiment, the other aerosol delivery substance includes coffee. In one embodiment, the other aerosol delivery substance includes maple syrup. In one embodiment, the other aerosol delivery material comprises a plant extract, such as a tea extract, or an extract of a herb. In one embodiment, the other aerosol delivery material comprises a tobacco extract. In one embodiment, the other aerosol delivery material comprises only a tobacco extract. In one embodiment, the other aerosol delivery material comprises a terpene or a blend of terpenes. The terpene or a blend of terpenes can be used with any of the above aerosol delivery materials that include nicotine or cannabinoids.

[0198] The aerosol delivery composition comprising one or more aerosol delivery substances may be included in the reconstituted cannabis material in an amount greater than about 1% by weight. In one embodiment, the one or more aerosol delivery substances may be included in the reconstituted cannabis material in an amount greater than about 3% by weight, such as greater than about 5% by weight. The one or more aerosol delivery substances may also be included in the reconstituted cannabis material in an amount less than about 50% by weight, such as less than about 25% by weight.

[0199] In any of the above-described embodiments, the reconstituted cannabis material may have a basis weight of about 40 gsm to about 120 gsm. Whether flue-cured, reconstituted, or both, the aerosol-generating material may be tobacco-free or may include tobacco.

[0200] In one embodiment, the aerosol-forming material may include a humectant. In any of the above-described embodiments, a humectant may be applied to the reconstituted plant material. The humectant may be glycerol, propylene glycol, or a combination of glycerol and propylene glycol. In one embodiment, the humectant may be present in an amount of about 5% by weight or less. In one embodiment, the humectant may be present in an amount of about 10% by weight or more and about 50% by weight or less.

[0201] In any of the above embodiments, the reconstituted material may include a burn control agent. The burn control agent may include a salt of a carboxylic acid, such as citric acid or succinic acid. In any of the above embodiments, the reconstituted material may be treated with a flame retardant alone or in combination with a burn control agent.

[0202] In any of the above-mentioned embodiments, the aerosol-generating material may be in the form of a filler material consisting of strips, pieces, or a combination thereof. In any of the above-mentioned embodiments, the filler material may have a static burn rate of greater than 4 mm / min or greater than 5 mm / min. Also, in any of the above-mentioned embodiments, the filler material may have a static burn rate of greater than 4 cm 3 / g, e.g. 5cm 3 / g or, for example, 6 cm 3 The filler may have a packing strength of more than 1000 g / g.

[0203] In any of the above-described embodiments, the aerosol-generating material can be used in a variety of products. In any of the above-described embodiments, the aerosol-generating material can be formed into a smokable rod and wrapped with a wrapping material to create a smoking article. The smoking article can optionally include a filter at one end thereof. Optionally, the wrapping material can include a plurality of discrete low-flame-spread regions.

[0204] In any of the above-described embodiments, the aerosol-forming materials described above may be used in a non-combustion heated device.

[0205] In any of the above described embodiments, the aerosol forming material may be used as a snuff product.

[0206] Those skilled in the art will appreciate that the present invention can be modified or altered in various ways without departing from the spirit of the invention. In addition, it should be understood that aspects of the various embodiments can be interchanged in whole or in part. Furthermore, those skilled in the art will appreciate that the above detailed description and examples are for illustrative purposes only and are not intended to limit in any way the scope of the invention as set forth in the appended claims.

Claims

1. A method of producing an aerosol-forming material comprising reconstituted cannabis material, comprising: (1) preparing extracted cannabis fibre that has been subjected to an extraction step in which cannabis is contacted with an aqueous solution to remove water-soluble components contained in cannabis; and combining the (1) extracted cannabis fiber with (2) web-building fibers to form a reconstituted cannabis material; The extracted cannabis fiber comprises cannabis leaves, cannabis stems, cannabis buds, cannabis flowers, or any combination thereof; The method, wherein the web construction fibers include flax fibers, hemp fibers, abaca fibers, softwood fibers, hardwood fibers, bamboo fibers, coconut fibers, ramie fibers, jute fibers, or any combination thereof.

2. 2. The method of claim 1 , the reconstituted cannabis material has been treated with a humectant; The method of claim 1, wherein the humectant comprises glycerol, propylene glycol, or a combination thereof.

3. 3. The method of claim 2, The method, wherein the humectant is present in the reconstituted cannabis material in an amount less than 5% by weight, or in an amount greater than 5% by weight and less than 50% by weight.

4. The method according to any one of claims 1 to 3, 20%-50% by weight of extracted cannabis leaves, 20%-50% by weight of extracted cannabis buds and / or flowers, and 3%-20% by weight of the web building fibers.

5. The method according to any one of claims 1 to 4, 4. A method according to claim 3, wherein said reconstituted cannabis material is formed from cannabis plant material containing tetrahydrocannabinol in an amount of less than 0.3% by weight.

6. The method according to any one of claims 1 to 5, The method, wherein the reconstituted cannabis material further comprises extracted cannabis stems, seeds, and / or cannabis residue.

7. The method according to any one of claims 1 to 6, Further comprising an aerosol delivery composition applied to the reconstituted cannabis material, The aerosol delivery composition comprises an aerosol delivery agent, The aerosol delivery agent comprises nicotine, a cannabinoid, tetrahydrocannabinol, cannabidiol, or a combination of cannabidiol and tetrahydrocannabinol.

8. 8. The method of claim 7, The reconstituted cannabis material is formed from cannabis plant material containing tetrahydrocannabinol in an amount of less than 0.3% by weight; The method, wherein the aerosol delivery material comprises an extract obtained from Cannabis indica plant material.

9. 9. The method according to claim 7 or 8, A method wherein the aerosol delivery composition is included in the reconstituted cannabis material in an amount greater than 1% by weight, greater than 3% by weight, greater than 5% by weight, greater than 10% by weight, greater than 15% by weight, greater than 20% by weight, greater than 25% by weight, greater than 30% by weight, greater than 35% by weight, or greater than 40% by weight, and less than 50% by weight.

10. A method according to any one of claims 1 to 9, comprising: A method wherein the reconstituted cannabis material comprises water soluble cannabis components in an amount of less than 10% by weight, or less than 5% by weight, or in an amount of 10% to 60% by weight.

11. A method according to any one of claims 1 to 10, comprising: The method, wherein the web building fibers are present in the reconstituted cannabis material in an amount greater than 3% by weight, greater than 5% by weight, or greater than 8% by weight, and less than 40% by weight.

12. A method according to any one of claims 1 to 11, comprising: The method, wherein the reconstituted cannabis material has a basis weight of from 40 gsm to 120 gsm, or from 55 gsm to 85 gsm.

13. A method for producing a smoking article comprising a smokable rod and a packaging material for packaging the rod, comprising: Providing a smokable rod comprising an aerosol-forming material produced by the method of any one of claims 1 to 12; and wrapping the smokable rod in a wrapping material to form a smoking article.

14. A method for manufacturing an aerosol generating device including a heating device and a chamber, comprising: Providing a chamber containing an aerosol-forming material produced by the method of any one of claims 1 to 12; and combining the chamber and a heating device to form an aerosol generating device, The method, wherein the heating device is arranged to generate an inhalable aerosol by heating the aerosol-forming material without combustion.

15. 1. A method for producing a smokeless blend product, comprising: Providing an aerosol-forming material produced by a method according to any one of claims 1 to 12; The method includes producing a smokeless blended product using the aerosol-forming material.

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