WO2024069542A1

WO2024069542A1 - Method for forming reconstituted tobacco

Info

Publication number: WO2024069542A1
Application number: PCT/IB2023/059726
Authority: WO
Inventors: Scott KOCH; John Paul Mua
Original assignee: R. J. Reynolds Tobacco Company
Priority date: 2022-09-30
Filing date: 2023-09-28
Publication date: 2024-04-04

Abstract

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

Description

METHOD FOR FORMING RECONSTITUTED TOBACCO

FIELD OF THE DISCLOSURE

The present disclosure relates to products made or derived from tobacco, or that otherwise incorporate tobacco, and are intended for human use and methods for the production thereof. The tobacco-derived products can be employed in various products such as oral products in a smokeless form and in smoking articles.

BACKGROUND

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

Various methods for producing a reconstituted tobacco involve the use of paper-making techniques. In a typical paper-making reconstituted tobacco process, tobacco is extracted with water, and the resulting aqueous extract and water insoluble pulp are separated from one another. The pulp portion can be refined to a desired consistency, and formed into a mat or web, much like wood pulp fibers in a traditional paper making process. The aqueous tobacco extract is applied to the mat of insoluble pulp, and the overall resulting mixture is dried to provide a reconstituted tobacco sheet incorporating the tobacco components from which that sheet can be derived. Typically, tobacco stems are used in making such a reconstituted tobacco sheet, because the fibrous nature of those stems provides strength and structural integrity to the resulting sheet. See, for example, U.S. Pat. No. 3,398,754 to Tughan; U.S. Pat. No. 3,847,164 to Mattina; U.S. Pat. No. 4,131,117 to Kite; U.S. Pat. No. 4,182,349 to Selke; U.S. Pat. No. 4,270,552 to Jenkins; U.S. Pat. No. 4,308,877 to Mattina; U.S. Pat. No. 4,341,228 to Keritsis; U.S. Pat. No. 4,421,126 to Gellatly; U.S. Pat. No. 4,706,692 to Gellatly; U.S. Pat. No. 4,962,774 to Thomasson; U.S. Pat. No. 4,941,484 to Clapp; U.S. Pat. No. 4,987,906 to Young; U.S. Pat. No. 5,056,537 to Brown; U.S. Pat. No. 5,143,097 to Sohn; U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,325,877 to Young; U.S. Pat. No. 5,445,169 to Brinkley; U.S. Pat. No. 5,501,237 to Young; and U.S. Pat. No.

5,533,530 to Young, which are incorporated herein by reference.

Paper-based materials and reconstituted tobacco materials are commonly associated with and/or incorporated in oral tobacco products and smoking articles, such as cigarettes, cigars and the like that bum tobacco during use to create tobacco smoke. Certain alternatives to smoking articles also exist that release an inhalable aerosol or vapor by releasing compounds from a substrate material by heating without burning. These may be referred to as non-combustible smoking articles, aerosol generating assemblies or noncombustible aerosol provision systems. One example of such a product is a heating device which release compounds by heating, but not burning, a solid aerosolizable material. This solid aerosolizable material may, in some cases, contain a tobacco material. The heating volatilises at least one component of the material, typically forming an inhalable aerosol. These products may be referred to as heat-not-bum devices, tobacco heating devices, or tobacco heating products (THP). Various different arrangements for volatilizing at least one component of the solid aerosolizable material are known.

As another example, there are e-cigarette/tobacco heating product hybrid devices, also known as electronic tobacco hybrid devices. These hybrid devices contain a liquid source (which may or may not contain nicotine) which is vaporized by heating to produce an inhalable vapor or aerosol. These devices additionally contain a solid aerosolizable material (which may or may not contain a tobacco material) and components of this material are entrained in the inhalable vapor or aerosol to produce the inhaled medium.

BRIEF SUMMARY

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

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

In still other aspects of the disclosed methods, the tobacco input further comprises an active ingredient and/or a flavoring agent. In such embodiments, the active ingredient may be selected from the group consisting of a nicotine component, botanicals, stimulants, nutraceuticals, amino acids, vitamins, cannabinoids, cannabimimetics, terpenes, and combinations thereof. Some embodiments of the disclosed methods further comprise adding an active ingredient and/or a flavoring agent to the tobacco pulp, the web formed from the tobacco pulp, and/or the tobacco extract applied to the web. In such embodiments, the active ingredient is selected from the group consisting of a nicotine component, botanicals, stimulants, nutraceuticals, amino acids, vitamins, cannabinoids, cannabimimetics, terpenes, and combinations thereof. In some embodiments of the disclosed methods, the tobacco input can further comprise one or more components selected from the group consisting of flavorants, fillers, binders, pH adjusters, buffering agents, colorants, disintegration aids, antioxidants, humectants, and preservatives.

In some embodiments, the disclosed methods further comprise adding one or more components selected from the group consisting of flavorants, fillers, binders, pH adjusters, buffering agents, colorants, disintegration aids, antioxidants, humectants, and preservatives to the tobacco pulp, the web formed from the tobacco pulp, and/or the tobacco extract applied to the web. In some embodiments, the step of extracting the tobacco input is done at a temperature of about 55 °C to about 65 °C for approximately 1.5- 2 hours. In certain embodiments of the disclosed methods, the tobacco input is extracted with water, and wherein the weight ratio of water to tobacco input is in the range of approximately 4: 1 to about 10: 1. Some embodiments of the disclosed methods further comprise refining the pulp to about a 10-30% consistency before forming the web. In some embodiments, about 50% to about 100% of the tobacco extract is applied to the web. In some embodiments, the final reconstituted tobacco sheet has a moisture percentage of about 5 to about 15%, based on the total weight of the final reconstituted tobacco sheet. In some embodiments of the disclosed methods, extracting the tobacco input comprises extracting each of the multiple tobacco materials separately. In certain embodiments, extracting the tobacco input comprises blending the multiple tobacco materials to form a blended material and extracting the blended material.

In some aspects, the methods provided by the present disclosure further comprise receiving a second tobacco input, wherein the second tobacco input comprises the reconstituted tobacco output and at least one additional tobacco material. Such methods may further comprise extracting the second tobacco input to form a second tobacco extract and a second tobacco pulp, separating the second tobacco extract and the second tobacco pulp, forming the second tobacco pulp into a second web, applying at least a portion of the second tobacco extract to the second web, and drying the second web to form a second reconstituted tobacco output.

In some other aspects, the present disclosure provides a final reconstituted tobacco sheet prepared according to any of the aforementioned methods disclosed herein. In such embodiments, the final reconstituted tobacco sheet may exhibit lower TSNA concentration as compared to a reconstituted tobacco sheet formed from a control tobacco input that is substantially free of reconstituted tobacco. In still other aspects, the present disclosure provides a substrate for use in an aerosol delivery device, the substrate comprising a final reconstituted tobacco sheet as provided in the present disclosure.

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

In some aspects of the present disclosure, the aerosol forming material includes one or more polyols. In such embodiments, the one or more polyols is selected from the group consisting of glycerol, propylene glycol, and combinations thereof. In some embodiments, the reconstituted tobacco material has a moisture amount is about 5% to about 25% (5-15%) by weight, based on the total weight of the reconstituted tobacco material. In some embodiments, the reconstituted tobacco material has a moisture amount of about 5% to about 15% by weight, based on the total weight of the reconstituted tobacco material. The invention includes, without limitation, the following embodiments.

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

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

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

Embodiment 4: The method according to any one of embodiments 1-3, wherein the at least one additional tobacco material comprises tobacco stems.

Embodiment 5: The method according to any one of embodiments 1-4, wherein the tobacco stems are present in an about of about 15 to about 95 wt. %, based on the total weight of the tobacco input.

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

Embodiment 7: The method according to any one of embodiments 1-6, wherein the tobacco lamina is present in an about of about 15 to about 95 wt. %, based on the total weight of the tobacco input.

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

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

Embodiment 10: The method according to any one of embodiments 1-9, wherein the tobacco input further comprises an active ingredient and/or a flavoring agent. Embodiment 11: The method according to any one of embodiments 1-10, wherein the active ingredient is selected from the group consisting of a nicotine component, botanicals, stimulants, nutraceuticals, amino acids, vitamins, cannabinoids, cannabimimetics, terpenes, and combinations thereof.

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

Embodiment 13: The method according to any one of embodiments 1-12, wherein the active ingredient is selected from the group consisting of a nicotine component, botanicals, stimulants, nutraceuticals, amino acids, vitamins, cannabinoids, cannabimimetics, terpenes, and combinations thereof.

Embodiment 14: The method according to any one of embodiments 1-13, wherein the tobacco input further comprises one or more components selected from the group consisting of flavorants, fillers, binders, pH adjusters, buffering agents, colorants, disintegration aids, antioxidants, humectants, and preservatives.

Embodiment 15: The method according to any one of embodiments 1-14, further comprising adding one or more components selected from the group consisting of flavorants, fillers, binders, pH adjusters, buffering agents, colorants, disintegration aids, antioxidants, humectants, and preservatives to the tobacco pulp, the web formed from the tobacco pulp, and/or the tobacco extract applied to the web.

Embodiment 16: The method according to any one of embodiments 1-15, wherein the step of extracting the tobacco input is done at a temperature of about 55 °C to about 65 °C for approximately 1.5- 2 hours.

Embodiment 17: The method according to any one of embodiments 1-16, wherein the tobacco input is extracted with water, and wherein the weight ratio of water to tobacco input is in the range of approximately 4:1 to about 10:1.

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

Embodiment 19: The method according to any one of embodiments 1-18, wherein about 50% to about 100% of the tobacco extract is applied to the web. Embodiment 20: The method according to any one of embodiments 1-19, wherein the final reconstituted tobacco sheet has a moisture percentage of about 5 to about 15%, based on the total weight of the final reconstituted tobacco sheet.

Embodiment 21: The method according to any one of embodiments 1-20, wherein extracting the tobacco input comprises extracting each of the multiple tobacco materials separately.

Embodiment 22: The method according to any one of embodiments 1-21, wherein extracting the tobacco input comprises blending the multiple tobacco materials to form a blended material and extracting the blended material.

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

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

Embodiment 25 : The final reconstituted tobacco sheet of embodiment 24, wherein the final reconstituted tobacco sheet exhibits lower TSNA concentration as compared to a reconstituted tobacco sheet formed from a control tobacco input that is substantially free of reconstituted tobacco.

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

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

Embodiment 28: The reconstituted tobacco material of embodiment 28, wherein the hot water solubles amount is about 20 to about 60% by weight of reconstituted tobacco material. Embodiment 29: The reconstituted tobacco material according to any one of embodiments 27-28, wherein the hot water solubles amount is about 30 to about 50% by weight of reconstituted tobacco material.

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

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

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

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

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

Embodiment 35: The reconstituted tobacco material according to any one of embodiments 27-34, wherein the reconstituted tobacco material has a moisture amount of about 5% to about 15% by weight, based on the total weight of the reconstituted tobacco material.

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

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

These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The invention includes any combination of two, three, four, or more of the above-noted embodiments as well as combinations of any two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosed invention, in any of its various aspects and embodiments, should be viewed as intended to be combinable unless the context clearly dictates otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described aspects of the disclosure in the foregoing general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. The drawings are example only and should not be construed as limiting the disclosure.

FIG. 1 is a flow diagram illustrating the general steps of a method for producing reconstituted tobacco according to an embodiment of the present disclosure;

FIG. 2 is an exploded view of an example embodiment of a smoking article, according to an example embodiment of the present disclosure;

FIG. 3 illustrates a perspective view of an aerosol delivery device, according to an example embodiment of the present disclosure;

FIG. 4 illustrates a perspective view of the aerosol delivery device of FIG. 3 with an outer wrap removed, according to one embodiment of the present disclosure;

FIG. 5 illustrates a perspective view of an aerosol delivery device comprising a control body and an aerosol generating component, wherein the aerosol generating component and the control body are coupled to one another, according to an example embodiment of the present disclosure; and

FIG. 6 illustrates a perspective view of the aerosol delivery device of FIG. 5, wherein the aerosol generating component and the control body are decoupled from one another, according to an example embodiment of the present disclosure.

DETAILED DESCRIPTION

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

One type of method for producing a reconstituted tobacco involves the use of paper-making techniques. As used herein, the term “paper” is meant to include any sheet or board made from a fibrous or cellulosic material and encompasses paperboard. As used herein, the term “paperboard” or “fiberboard” is used to refer to any solid, supportive material manufactured from a fibrous or cellulosic material such as, for example, cardboard or other paper product. Paperboard is generally a thicker form of paper. In various embodiments, the thickness of paper (i.e., caliper), is expressed in mils for paper and points for paperboard; however, both one mil and one point are equivalent to 0.001 inches. Density is expressed in mass per unit volume and bulk is the reciprocal of density. The reconstituted tobacco products disclosed herein have various potential uses in smokeless oral products and aerosol delivery devices; however, possible uses of reconstituted tobacco according to the present disclosure are not limited to the embodiments discussed herein.

The general steps for producing a reconstituted tobacco sheet are known in the art. See, for example, US Pat. Nos. 3,398,754 to Tughan; 3,847,164 to Mattina; 4,131,117 to Kite; 4,270,552 to Jenkins; 4,308,877 to Mattina; 4,341,228 to Keritsis; 4,421,126 to Gellatly; 4,706,692 to Gellatly; 4,962,774 to Thomasson; 4,941,484 to Clapp; 4,987,906 to Young; 5,056,537 to Brown; 5,143,097 to Sohn; 5,159,942 to Brinkley et al.; 5,325,877 to Young; 5,445,169 to Brinkley; 5,501,237 to Young; and 5,533,530 to Young, which are incorporated herein by reference. Methods of the present disclosure include incorporating a first reconstituted tobacco into the tobacco input for the method of producing a secondary reconstituted tobacco sheet.

As illustrated in FIG. 1 for example, in a typical paper-making reconstituted tobacco process, a tobacco input is extracted with water (operation 100), and the resulting aqueous extract and water insoluble pulp are separated from one another (operation 102). The pulp portion can be refined to a desired consistency (operation 104). As used herein, the term “consistency” is defined as the percentage of solids in a mixture. For example, the tobacco input can be extracted with water at a temperature of about 55 °C to about 65 °C for approximately 1.5-2 hours. The weight ratio of water to tobacco input can be approximately 7:1. The pulp and the extract can be separated and the pulp can then be drained to about a 20% consistency.

The pulp is then formed into a mat or web (operation 106), much like wood pulp fibers in a traditional paper making process. The aqueous tobacco extract is applied to the mat of insoluble pulp (operation 108), and the overall resulting mixture is dried (operation 110) to provide a reconstituted tobacco sheet incorporating the tobacco components from which that sheet can be derived. It is noted that any amount of the aqueous extract can be reapplied to the mat/web formed from the water insoluble pulp. For example, in some embodiments about 0.1 to about 100 wt. %, or about 5 to about 90 wt. %, or about 5 to about 50 wt. %, or about 50 to about 100 wt. % of the aqueous extract is applied to the mat/web formed from the water insoluble pulp. In various embodiments, at least about 5 wt. %, at least about 20 wt. %, at least about 40 wt. %, at least about 50 wt. %, at least about 75 wt. %, at least about 85 wt. %, or at least about 90 wt. % of the aqueous extract is applied to the mat/web formed from the water insoluble pulp. In certain embodiments, the aqueous extract can be refined and/or filtered to remove certain undesirable components before applying the aqueous extract to the mat/web formed from the water insoluble pulp.

As illustrated at operation 112 in FIG. 1, for example, after forming and/or receiving a first reconstituted tobacco sheet, the first reconstituted tobacco sheet is then used as at least a portion of the tobacco input for producing a second reconstituted tobacco sheet. It is noted that this process can be repeated any number of times. For example, the second reconstituted sheet can be used as at least a portion of the tobacco input for producing a third reconstituted tobacco sheet, the third reconstituted tobacco sheet can be used as at least a portion of the tobacco input for producing a fourth reconstituted tobacco sheet, etc. In addition, in certain embodiments, the tobacco input can include two or more separate reconstituted tobacco sheets (e.g., a first reconstituted tobacco sheet (as described above) and a second reconstituted tobacco sheet (as described above); or a first reconstituted tobacco sheet (as described above) and a third reconstituted tobacco sheet (as described above); or a second reconstituted tobacco sheet (as described above) and a third reconstituted tobacco sheet (as described above)). Any number and/or combination of reconstituted tobacco sheets according to the present disclosure can be used as at least a portion of the tobacco input for producing a reconstituted tobacco sheet.

In various embodiments of the methods described herein, additional components can be added/blended into the final reconstituted tobacco sheet that is formed. Any number of additional components, discussed in more detail below, can be blended into the reconstituted tobacco sheet at any point during the formation process. For example, in certain embodiments, one or more additional components can be blended with the tobacco input before the extraction step (operation 100 in Fig. 1). As such, the additional components would be extracted along with the tobacco input. One or more additional components can also be added to the extract and/or the insoluble pulp after the extraction step. For example, additional liquid components (e.g., flavorants, active ingredients, etc.) can be added to the aqueous extract after it has been separated from the water insoluble pulp. In some embodiments, the water insoluble pulp can be mixed with another type of pulp (e g., a wood pulp) before forming the web or mat (operation 106 in FIG. 1). In some embodiments, one or more additional components in liquid form can be applied to the mat/web of insoluble pulp before, during or after applying the aqueous extract (operation 108 in Fig. 1).

In some embodiments, cast sheet technology may be used to make a reconstituted tobacco substrate in the form of a flat sheet. The cast sheet generally comprises a first reconstituted tobacco input, one or more fillers, one or more binders, optionally one or more aerosol formers, and optionally an active ingredient, a flavorant, or both, each as described herein. For example, in some embodiments the filler, at least a portion of the aerosol forming material as disclosed herein, and a binder may be blended together to form a slurry, which may be cast onto a surface (such as, for example, a moving belt). The cast slurry may then experience one or more drying and/or doctoring steps such that the result is a relatively consistent thickness cast sheet. Other examples of casting and paper-making techniques are set forth in U.S. Pat. No. 4,674,519 to Keritsis et al.; U.S. Pat. No. 4,941,484 to Clapp et al.; U.S. Pat. No. 4,987,906 to Young et al.; U.S. Pat. No. 4,972,854 to Kiernan et al.; U.S. Pat. No. 5,099,864 to Young et al.; U.S. Pat. No. 5,143,097 to Sohn et al.; U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No. 5,322,076 to Brinkley et al.; U.S. Pat. No. 5,339,838 to Young et al.; U.S. Pat. No. 5,377,698 to Litzinger et al.; U.S. Pat. No. 5,501,237 to Young; and U.S. Pat. No. 6,216,706 to Kumar; the disclosures of which is incorporated herein by reference in their entireties. In some embodiments, the flat sheet may further be reduced into cut rag or strips for inserting into the substrate-containing segment of an aerosol delivery device. The cast sheet may also be gathered or rolled into rod for insertion into the substrate-containing segment of an aerosol delivery device, as described in more detail below. The cast sheet may be adhered or otherwise attached to a support.

The various components of the substrate (which include a reconstituted tobacco input) may be contacted, combined, or mixed together using any mixing technique or equipment known in the art. Any mixing method that brings the substrate ingredients into intimate contact can be used, such as a mixing apparatus featuring an impeller or other structure capable of agitation. Examples of mixing equipment include casing drums, conditioning cylinders or drums, liquid spray apparatus, conical-type blenders, ribbon blenders, mixers available as FKM130, FKM600, FKM1200, FKM2000 and FKM3000 from Littleford Day, Inc., Plough Share types of mixer cylinders, Hobart mixers, and the like. See also, for example, the types of methodologies set forth in US Pat. Nos. 4,148,325 to Solomon et al.; 6,510,855 to Korte et al.; and 6,834,654 to Williams, each of which is incorporated herein by reference. Manners and methods for formulating mixtures will be apparent to those skilled in the art. See, for example, the types of methodologies set forth in US Pat. No. 4,148,325 to Solomon et al.; US Pat. No. 6,510,855 to Korte et al.; and US Pat. No. 6,834,654 to Williams, US Pat. Nos. 4,725,440 to Ridgway et al., and 6,077,524 to Bolder et al., each of which is incorporated herein by reference.

The sheets may optionally be dried to remove at least a portion of the liquid content (e.g., water). The final moisture content may be, for example, from about 8 to about 21% moisture by weight on a wet basis. Additionally, flavorants, extracts, aerosol forming materials, and the like (as discussed in more detail below) can be added to the sheets after drying.

In various embodiments, loading of the substrate with the aerosol forming materials is achieved by impregnating the substrate with the aerosol forming materials during preparation of the substrate material, after formation, or both. In some embodiments, the slurry used e.g., in preparation of a cast sheet, includes the entire quantity of aerosol forming material. Alternatively, or in addition, a portion of the aerosol forming material may be added to the substrate post-formation (e.g., one or more aerosol forming materials may be sprayed or otherwise disposed in or on the substrate material in sheet form). In some embodiments, further aerosol forming materials may be impregnated in the substrate, either to the substrate forming slurry, or as a top dressing. Methods for loading aerosol forming materials onto substrate portions are described in U.S. Pat. No. 9,974,334 to Dooly et al., and U.S. Pub. Pat. App. Nos. 2015/0313283 to Collett et al. and 2018/0279673 to Sebastian et al., the disclosures of which are incorporated by reference herein in their entirety. As one of skill will recognize, multiple permutations of methods for loading the substrate with the aerosol forming materials is possible, depending on the specific substrate material, form, and the like. Accordingly, any such modifications are contemplated herein.

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

The amount of aerosol forming material that is present in the substrate material may vary. For example, in certain embodiments, sufficient amounts of aerosol forming material are employed in order to provide for the generation of a visible mainstream aerosol that in many regards resembles the appearance of tobacco smoke. The amount of aerosol forming materials present may be dependent upon factors such as the number of puffs desired per substrate component. In some embodiments, the substrate material comprises the aerosol forming material in an amount of at least about 1% by weight, at least about 10% by weight, of at least about 15% by weight, at least about 20% by weight, at least about 25% by weight, at least about 30% by weight, at least about 35% by weight, at least about 40% by weight, at least about 45% by weight, at least about 50% by weight, at least about 55% by weight, or at least about 60% by weight, based on a total wet weight of the substrate. Example ranges of total aerosol forming materials include about 15% to about 60% by weight, such as about 15% to about 55%, or about 15% to about 25%, based on the total wet weight of the substrate material.

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

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

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

In some embodiments, the aerosol forming material comprises one or more polysorbates. Examples of polysorbates include Polysorbate 60 (polyoxyethylene (20) sorbitan monostearate, Tween 60) and Polysorbate 80 (polyoxyethylene (20) sorbitan monooleate, Tween 80). The type of polysorbate used or the combination of polysorbates used depends on the intended effect desired, as the different polysorbates offer different attributes due to molecular sizes. For example, the polysorbate molecules increase in size from polysorbate 20 to polysorbate 80. Using smaller size polysorbate molecules creates less vapor quantity, but permits deeper lung penetration. This may be desirable when the user is in public where he would not want to create a large plume of "smoke" (i.e. vapors). Conversely, if a dense vapor is desired, which can convey the aromatic constituents of tobacco, larger polysorbate molecules can be employed. An additional benefit of using the polysorbate family of compounds is that the polysorbates lower the heat of vaporization of mixtures in which they are present.

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

In some embodiments, the aerosol forming material comprises one or more fatty acids. Fatty acids may include short-chain, long-chain, saturated, unsaturated, straight chain, or branched chain carboxylic acids. Fatty acids generally include C4 to C28 aliphatic carboxylic acids. Non-limiting examples of short- or long-chain fatty acids include butyric, propionic, valeric, oleic, linoleic, stearic, myristic, and palmitic acids.

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

In some embodiments, the aerosol forming material comprises one or more waxes. Examples of waxes include carnauba, beeswax, candellila, which are known known to stabilize aerosol particles, improve palatability, or reduce throat irritation.

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

In some embodiments, the aerosol forming material comprises one or more sugar alcohols. Examples of sugar alcohols include sorbitol, erythritol, mannitol, maltitol, isomalt, and xylitol. Sugar alcohols may also serve as flavor enhancers to certain flavor compounds, e.g. menthol and other volatiles, and generally improve on mouthfeel, tactile sensation, throat impact, and other sensory properties, of the resulting aerosol.

In some embodiments, the aerosol forming material comprises glycerol, propylene glycol, 1,3- propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, propylene carbonate, or a combination of any thereof. In some embodiments, the aerosol forming material comprises, consists essentially of, or consists of glycerol. As illustrated in Example 1 below, it was surprisingly discovered that using reconstituted tobacco in the tobacco input for producing a secondary reconstituted tobacco and/or a reconstituted tobacco substrate in the form of a flat sheet can beneficially impact the levels of different components within the reconstituted tobacco sheet without negatively affecting taste or other desirable properties. By using one or more reconstituted tobacco inputs in the methods described herein, the levels of various components, such as, but not limited to, nicotine, 4-(m ethylnitrosamino)-! -(3 -pyridyl)- 1-butanone (NNK), N- nitrosonomicotine (NNN), and tobacco-specific N-nitrosamines (TSNAs) can be adjusted and controlled.

Tobacco Input

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

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

The selection of the plant from the Nicotiana species (i.e., tobacco material) utilized in the products and processes of the disclosure can vary; and in particular, the types of tobacco or tobaccos may vary. Tobaccos that can be employed include flue-cured or Virginia (e.g., K326), burley, sun-cured (e.g., Indian Kumool and Oriental tobaccos, including Katerini, Prelip, Komotini, Xanthi and Yambol tobaccos), Maryland, dark, dark-fired, dark air cured (e.g., Passanda, Cubano, Jatin and Bezuki tobaccos), light air cured (e.g., North Wisconsin and Galpao tobaccos), Indian air cured, Red Russian and Rustica tobaccos, as well as various other rare or specialty tobaccos. Descriptions of various types of tobaccos, growing practices and harvesting practices are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999), which is incorporated herein by reference. Various representative types of plants from the Nicotiana species are set forth in Goodspeed, The Genus Nicotiana, (Chonica Botanica) (1954); US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; 7,025,066 to Lawson et al.; and 7,798,153 to Lawrence, Jr.; each of which is incorporated herein by reference.

Tobacco compositions including dark air cured tobacco are set forth in US Patent No. 8,186,360 to Marshall et al., which is incorporated herein by reference. See also, types of tobacco as set forth, for example, in US Patent Appl. Pub. No. 2011/0247640 to Beeson et al., which is incorporated herein by reference.

Exemplary Nicotiana species include N. tabacum, N. rustica, N. alata, N. arentsii, N. excelsior, N. forgetiana, N. glauca, N. glutinosa, N. gossei, N. kawakamii, N. knightiana, N. langsdorffi, N. otophora, N. setchelli, N. sylvestris, N. tomentosa, N. tomentosiformis, N. undulata, N. x sanderae, N. africana, N. amplexicaulis, N. benavidesii, N. bonariensis, N. debneyi, N. longiflora, N. maritina, N. megalosiphon, N. occidentalis, N. paniculata, N. plumbaginifolia, N. raimondii, N. rosulata, N. simulans, N. stocktonii, N. suaveolens, N. umbratica, N. velutina, N. wigandioides, N. acaulis, N. acuminata, N. attenuata, N. benthamiana, N. cavicola, N. clevelandii, N. cordifolia, N. corymbosa, N. fragrans, N. goodspeedii, N. linearis, N. miersii, N. nudicaulis, N. obtusifolia, N. occidentalis subsp. Hersperis, N. pauciflora, N. petunioides, N. quadrivalvis, N. repanda, N. rotundifolia, N. solanifolia and N. spegazzinii.

Nicotiana species can be derived using genetic-modification or crossbreeding techniques (e.g., tobacco plants can be genetically engineered or crossbred to increase or decrease production of components, characteristics or attributes). See, for example, the types of genetic modifications of plants set forth in US Pat. Nos. 5,539,093 to Fitzmaurice et al.; 5,668,295 to Wahab et al.; 5,705,624 to Fitzmaurice et al.; 5,844,119 to Weigl; 6,730,832 to Dominguez et al.; 7,173,170 to Liu et al.; 7,208,659 to Colliver et al. and 7,230,160 to Benning et al.; US Patent Appl. Pub. No. 2006/0236434 to Conkling et al.; and PCT WO 2008/103935 to Nielsen et al. See, also, the types of tobaccos that are set forth in US Pat. Nos. 4,660,577 to Sensabaugh, Jr. et al.; 5,387,416 to White et al.; and 6,730,832 to Dominguez et al., each of which is incorporated herein by reference.

The Nicotiana species can, in some embodiments, be selected for the content of various compounds that are present therein. For example, plants can be selected on the basis that those plants produce relatively high quantities of one or more of the compounds desired to be isolated therefrom. In certain embodiments, plants of the Nicotiana species (e.g., Galpao commun tobacco) are specifically grown for their abundance of leaf surface compounds. Tobacco plants can be grown in greenhouses, growth chambers, or outdoors in fields, or grown hydroponically. Various parts or portions of the plant of the Nicotiana species can be included within a reconstituted tobacco as disclosed herein. For example, virtually all of the plant (e.g., the whole plant) can be harvested, and employed as such. Alternatively, various parts or pieces of the plant can be harvested or separated for further use after harvest. For example, the flower, leaves, stem, stalk, roots, seeds, and various combinations thereof, can be isolated for further use or treatment. In some embodiments, the tobacco material comprises tobacco leaf (lamina). The reconstituted tobacco disclosed herein can include processed tobacco parts or pieces, cured and aged tobacco in essentially natural lamina and/or stem form, a tobacco extract, extracted tobacco pulp (e.g., using water as a solvent), or a mixture of the foregoing (e.g., a tobacco input mixture that combines extracted tobacco pulp with granulated cured and aged natural tobacco lamina).

Although whole tobacco plants or any component thereof (e.g., leaves, flowers, stems, roots, stalks, and the like) could be used in the tobacco input, it can be advantageous to use stems, stalks and/or roots of the tobacco plant. Typically, tobacco stems are used in making such a reconstituted tobacco sheet, because the fibrous nature of those stems provides strength and structural integrity to the resulting reconstituted tobacco sheet. As used herein, the term “stem” refers to the part of the plant that supports leaves and flowers. Tobacco lamina, tobacco scrap, and tobacco fines can also be useful in producing reconstituted tobacco sheets, including any waste tobacco materials formed during any part of the process of forming smoking articles such as cigarettes. The term “lamina” refers to a flat thin structure of the leaf of a plant (z. e. , leaf blade) that contains chloroplast.

In certain embodiments, the tobacco input material comprises solid tobacco material selected from the group consisting of lamina and stems. The tobacco that is used for the mixture most preferably includes tobacco lamina, or a tobacco lamina and stem mixture (of which at least a portion is smoke- treated). Portions of the tobaccos within the tobacco input mixture may have processed forms, such as processed tobacco stems (e.g., cut-rolled stems, cut-rolled-expanded stems or cut-puffed stems), or volume expanded tobacco (e.g., puffed tobacco, such as dry ice expanded tobacco (DIET)). See, for example, the tobacco expansion processes set forth in US Pat. Nos. 4,340,073 to de la Burde et al.; 5,259,403 to Guy et al.; and 5,908,032 to Poindexter, et al.; and 7,556,047 to Poindexter, et al., all of which are incorporated by reference. In addition, the tobacco input optionally may incorporate tobacco that has been fermented. See, also, the types of tobacco processing techniques set forth in PCT W02005/063060 to Atchley et al., which is incorporated herein by reference.

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

In some embodiments the tobacco input can comprise flue-cured tobacco stalks, burley tobacco stalks, and/or whole-plant tobacco biomass (e.g., extracted green tobacco biomass). The tobacco stalks and/or roots can be separated into individual pieces (e.g., roots separated from stalks, and/or root parts separated from each other, such as big root, mid root, and small root parts) or the stalks and roots may be combined. By “stalk” is meant the stalk that is left after the leaf (including stem and lamina) has been removed. “Root” and various specific root parts useful according to the present invention may be defined and classified as described, for example, in Mauseth, Botany: An Introduction to Plant Biology: Fourth Edition, Jones and Bartlett Publishers (2009) and Glimn-Lacy et al., Botany Illustrated, Second Edition, Springer (2006), which are incorporated herein by reference. The harvested stalks and/or roots are typically cleaned, ground, and dried to produce a material that can be described as particulate (i.e., shredded, pulverized, ground, granulated, or powdered). As used herein, stalks and/or roots can also refer to stalks and/or roots that have undergone an extraction process to remove water soluble materials. The cellulosic material (i.e., pulp) remaining after stalks and/or root materials undergo an extraction process can also be useful in the methods described herein.

The tobacco input material (including the reconstituted tobacco input) is typically used in a form that can be described as particulate (i.e., shredded, ground, granulated, or powder form). The manner by which the tobacco material is provided in a finely divided or powder type of form may vary. Preferably, plant parts or pieces are comminuted, ground or pulverized into a particulate form using equipment and techniques for grinding, milling, or the like. Most preferably, the plant material is relatively dry in form during grinding or milling, using equipment such as hammer mills, cutter heads, air control mills, or the like. For example, tobacco parts or pieces may be ground or milled when the moisture content thereof is less than about 15 weight percent or less than about 5 weight percent. Most preferably, the tobacco material is employed in the form of parts or pieces that have an average particle size between 1.4 millimeters and 250 microns. In some instances, the tobacco particles may be sized to pass through a screen mesh to obtain the particle size range required. If desired, air classification equipment may be used to ensure that small sized tobacco particles of the desired sizes, or range of sizes, may be collected. If desired, differently sized pieces of granulated tobacco may be mixed together.

The manner by which the reconstituted tobacco and optionally the additional tobacco material is provided in a finely divided or powder type of form may vary. Preferably, the reconstituted tobacco sheets and any additional tobacco parts or pieces are comminuted, ground or pulverized into a powder type of form using equipment and techniques for grinding, milling, or the like. Most preferably, the tobacco input is relatively dry in form during grinding or milling, using equipment such as hammer mills, cutter heads, air control mills, or the like. For example, reconstituted tobacco sheets and any tobacco parts or pieces may be ground or milled when the moisture content thereof is less than about 15 weight percent to less than about 5 weight percent. For example, the reconstituted tobacco input and any additional tobacco input can be provided and processed separately or in combination. The tobacco plant or portion thereof can be separated into individual parts or pieces (e.g., the leaves can be removed from the stems, and/or the stems and leaves can be removed from the stalk). The harvested plant or individual parts or pieces can be further subdivided into parts or pieces (e.g., the leaves can be shredded, cut, comminuted, pulverized, milled or ground into pieces or parts that can be characterized as filler-type pieces, granules, particulates or fine powders). The plant, or parts thereof, can be subjected to external forces or pressure (e.g., by being pressed or subjected to roll treatment). When carrying out such processing conditions, the plant or portion thereof can have a moisture content that approximates its natural moisture content (e.g., its moisture content immediately upon harvest), a moisture content achieved by adding moisture to the plant or portion thereof, or a moisture content that results from the drying of the plant or portion thereof. For example, powdered, pulverized, ground or milled pieces of plants or portions thereof can have moisture contents of less than about 25 weight percent, often less than about 20 weight percent, and frequently less than about 15 weight percent.

For the preparation of oral products, it is typical for a harvested plant of the Nicotiana species to be subjected to a curing process. The tobacco materials incorporated within the mixture for inclusion within products as disclosed herein are those that have been appropriately cured and/or aged. Descriptions of various types of curing processes for various types of tobaccos are set forth in Tobacco Production, Chemistry and Technology, Davis et al. (Eds.) (1999). Examples of techniques and conditions for curing flue-cured tobacco are set forth in Nestor et al., Beitrage Tabakforsch. Int., 20, 467-475 (2003) and US Pat. No. 6,895,974 to Peele, which are incorporated herein by reference. Representative techniques and conditions for air curing tobacco are set forth in US Pat. No. 7,650,892 to Groves et al.; Roton et al., Beitrage Tabakforsch. Int., 21, 305-320 (2005) and Staaf et al., Beitrage Tabakforsch. Int., 21, 321-330 (2005), which are incorporated herein by reference. Certain types of tobaccos can be subjected to alternative types of curing processes, such as fire curing or sun curing.

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

The tobacco material may also have a so-called "blended" form. For example, the tobacco material may include a mixture of parts or pieces of Hue-cured, burley (e.g., Malawi burley tobacco) and Oriental tobaccos (e.g., as tobacco composed of, or derived from, tobacco lamina, or a mixture of tobacco lamina and tobacco stem). For example, a representative blend may incorporate about 30 to about 70 parts burley tobacco (e.g., lamina, or lamina and stem), and about 30 to about 70 parts flue cured tobacco (e.g., stem, lamina, or lamina and stem) on a dry weight basis. Other example tobacco blends incorporate about 75 parts flue-cured tobacco, about 15 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 25 parts burley tobacco, and about 10 parts Oriental tobacco; or about 65 parts flue-cured tobacco, about 10 parts burley tobacco, and about 25 parts Oriental tobacco; on a dry weight basis. Other example tobacco blends incorporate about 20 to about 30 parts Oriental tobacco and about 70 to about 80 parts flue-cured tobacco on a dry weight basis.

Tobacco input materials (including the reconstituted tobacco input) used in the present disclosure can be subjected to, for example, fermentation, bleaching, and the like. If desired, the tobacco materials can be, for example, irradiated, pasteurized, or otherwise subjected to controlled heat treatment. Such treatment processes are detailed, for example, in US Pat. No. 8,061,362 to Mua et al., which is incorporated herein by reference. In certain embodiments, tobacco materials can be treated with water and an additive capable of inhibiting reaction of asparagine to form acrylamide upon heating of the tobacco material (e.g., an additive selected from the group consisting of lysine, glycine, histidine, alanine, methionine, cysteine, glutamic acid, aspartic acid, proline, phenylalanine, valine, arginine, compositions incorporating di- and trivalent cations, asparaginase, certain non-reducing saccharides, certain reducing agents, phenolic compounds, certain compounds having at least one free thiol group or functionality, oxidizing agents, oxidation catalysts, natural plant extracts (e.g., rosemary extract), and combinations thereof. See, for example, the types of treatment processes described in US Pat. Pub. Nos. 8,434,496, 8,944,072, and 8,991,403 to Chen et al., which are all incorporated herein by reference. In certain embodiments, this type of treatment is useful where the original tobacco material is subjected to heat in the processes previously described.

In some embodiments, the type of tobacco material is selected such that it is initially visually lighter in color than other tobacco materials to some degree (e.g., whitened or bleached). Tobacco pulp can be whitened in certain embodiments according to any means known in the art. For example, bleached tobacco material produced by various whitening methods using various bleaching or oxidizing agents and oxidation catalysts can be used. Example oxidizing agents include peroxides (e.g., hydrogen peroxide), chlorite salts, chlorate salts, perchlorate salts, hypochlorite salts, ozone, ammonia, potassium permanganate, and combinations thereof. Example oxidation catalysts are titanium dioxide, manganese dioxide, and combinations thereof. Processes for treating tobacco with bleaching agents are discussed, for example, in US Patent Nos. 787,611 to Daniels, Jr.; 1,086,306 to Oelenheinz; 1,437,095 to Delling; 1,757,477 to Rosenhoch; 2,122,421 to Hawkinson; 2,148,147 to Baier; 2,170,107 to Baier; 2,274,649 to Baier; 2,770,239 to Prats et al.; 3,612,065 to Rosen; 3,851,653 to Rosen; 3,889,689 to Rosen; 3,943,940 to Minami; 3,943,945 to Rosen; 4,143,666 to Rainer; 4,194,514 to Campbell; 4,366,823, 4,366,824, and 4,388,933 to Rainer et al.; 4,641,667 to Schmekel et al.; 5,713,376 to Berger; 9,339,058 to Byrd Jr. et al.; 9,420,825 to Beeson et al.; and 9,950,858 to Byrd Jr. et al.; as well as in US Pat. App. Pub. Nos.

2012/0067361 to Bjorkholm et al.; 2016/0073686 to Crooks; 2017/0020183 to Bjorkholm; 2017/0112183 to Bjorkholm; and 2020/0196658 to McClanahan et al.; 2021/0068445 to Zawadzki et al.; 2021/0068448 to Zawadzki et al.; 2021/0076731 to Sundvall et al.; and 2022/0071272 to Castelijn et al., and in PCT Publ. Appl. Nos. WO1996/031255 to Giolvas and WO2018/083114 to Bjorkholm, all of which are incorporated herein by reference.

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

In some embodiments, the whitened tobacco material can be characterized as lightened in color (e.g., "whitened") in comparison to an untreated tobacco material. White colors are often defined with reference to the International Commission on Illumination's (CIE's) chromaticity diagram. The whitened tobacco material can, in certain embodiments, be characterized as closer on the chromaticity diagram to pure white than an untreated tobacco material.

In various embodiments, the tobacco material can be treated to extract a soluble component of the tobacco material therefrom. "Tobacco extract" as used herein refers to the isolated components of a tobacco material that are extracted from solid tobacco pulp by a solvent that is brought into contact with the tobacco material in an extraction process. A tobacco extract can then be used in combination with a reconstituted tobacco to form a secondary reconstituted tobacco according to methods of the present disclosure. Various extraction techniques of tobacco materials can be used to provide a tobacco extract and tobacco solid material. See, for example, the extraction processes described in US Pat. Appl. Pub. No. 2011/0247640 to Beeson et al., which is incorporated herein by reference. Other example techniques for extracting components of tobacco are described in US Pat. Nos. 4,144,895 to Fiore; 4,150,677 to Osborne, Jr. et al.; 4,267,847 to Reid; 4,289,147 to Wildman et al.; 4,351,346 to Brummer et al.; 4,359,059 to Brummer et al.; 4,506,682 to Muller; 4,589,428 to Keritsis; 4,605,016 to Soga et al.; 4,716,911 to Poulose et al.; 4,727,889 to Niven, Jr. et al.; 4,887,618 to Bemasek et al.; 4,941,484 to Clapp et al.; 4,967,771 to Fagg et al.; 4,986,286 to Roberts et al.; 5,005,593 to Fagg et al.; 5,018,540 to Grubbs et al.; 5,060,669 to White et al.; 5,065,775 to Fagg; 5,074,319 to White et al.; 5,099,862 to White et al.; 5,121,757 to White et al.; 5,131,414 to Fagg; 5,131,415 to Munoz et al.; 5,148,819 to Fagg; 5,197,494 to Kramer; 5,230,354 to Smith et al.; 5,234,008 to Fagg; 5,243,999 to Smith; 5,301,694 to Raymond et al.; 5,318,050 to Gonzalez-Parra et al.; 5,343,879 to Teague; 5,360,022 to Newton; 5,435,325 to Clapp et al.; 5,445,169 to Brinkley et al.; 6,131,584 to Lauterbach; 6,298,859 to Kierulff et al.; 6,772,767 to Mua et al.; and 7,337,782 to Thompson, all of which are incorporated by reference herein.

Typical inclusion ranges for tobacco materials beyond the reconstituted tobacco input can vary depending on the nature and type of the tobacco material, and the intended effect on the final reconstituted tobacco, with an example range of up to about 91% by weight (or up to about 85% by weight, or up to about 60% by weight, or up to about 40% by weight, or up to about 25% by weight, or up to about 15% by weight, or up to about 5% by weight), based on total weight of the final reconstituted tobacco (e.g., about 0.1 to about 85% by weight).

Additional Components

Flavoring agent

As used herein, a "flavoring agent" or "flavorant" is any flavorful or aromatic substance capable of altering the sensory characteristics associated with the reconstituted tobacco. Examples of sensory characteristics that can be modified by the flavoring agent include taste, mouthfeel, moistness, coolness/heat, and/or fragrance/aroma. Flavoring agents may be natural or synthetic, and the character of the flavors imparted thereby may be described, without limitation, as fresh, sweet, herbal, confectionary, floral, fruity, or spicy. Specific types of flavors include, but are not limited to, vanilla, coffee, chocolate/cocoa, cream, mint, spearmint, menthol, peppermint, wintergreen, eucalyptus, lavender, cardamon, nutmeg, cinnamon, clove, cascarilla, sandalwood, honey, jasmine, ginger, anise, sage, licorice, lemon, orange, apple, peach, lime, cherry, strawberry, trigeminal sensates, melatonin, terpenes, and any combinations thereof. See also, Leffingwell et al., Tobacco Flavoring for Smoking Products, R. J. Reynolds Tobacco Company (1972), which is incorporated herein by reference. Flavorings also may include components that are considered moistening, cooling or smoothening agents, such as eucalyptus. These flavors may be provided neat (i.e., alone) or in a composite, and may be employed as concentrates or flavor packages (e.g., spearmint and menthol, orange and cinnamon; lime, pineapple, and the like). Representative types of components also are set forth in US Pat. No. 5,387,416 to White et al.; US Pat. App. Pub. No. 2005/0244521 to Strickland et al.; and PCT Application Pub. No. WO 05/041699 to Quinter et al., each of which is incorporated herein by reference. In some instances, the flavoring agent may be provided in a spray-dried form or a liquid form.

The flavoring agent generally comprises at least one volatile flavor component. As used herein, "volatile" refers to a chemical substance that forms a vapor readily at ambient temperatures (i.e., a chemical substance that has a high vapor pressure at a given temperature relative to a nonvolatile substance). Typically, a volatile flavor component has a molecular weight below about 400 Da, and often include at least one carbon-carbon double bond, carbon-oxygen double bond, or both. In one embodiment, the at least one volatile flavor component comprises one or more alcohols, aldehydes, aromatic hydrocarbons, ketones, esters, terpenes, terpenoids, or a combination thereof. Non-limiting examples of aldehydes include vanillin, ethyl vanillin, p-anisaldehyde, hexanal, furfural, isovaleraldehyde, cuminaldehyde, benzaldehyde, and citronellal. Non-limiting examples of ketones include 1 -hydroxyl- propanone and 2-hydroxy-3-methyl-2-cyclopentenone-l-one. Non-limiting examples of esters include allyl hexanoate, ethyl heptanoate, ethyl hexanoate, isoamyl acetate, and 3 -methylbutyl acetate. Nonlimiting examples of terpenes include sabinene, limonene, gamma-terpinene, beta-famesene, nerolidol, thujone, myrcene, geraniol, nerol, citronellol, linalool, and eucalyptol. In one embodiment, the at least one volatile flavor component comprises one or more of ethyl vanillin, cinnamaldehyde, sabinene, limonene, gamma-terpinene, beta-farnesene, or citral. In one embodiment, the at least one volatile flavor component comprises ethyl vanillin.

The amount of flavoring agent utilized in the reconstituted tobacco can vary, but is typically up to about 10 weight percent, and certain embodiments are characterized by a flavoring agent content of at least about 0.1 weight percent, such as about 0.5 to about 10 weight percent, about 1 to about 6 weight percent, or about 2 to about 5 weight percent, based on the total weight of the final dried reconstituted tobacco sheet.

Salts

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

Sweeteners

The reconstituted tobacco can further include one or more sweeteners. The sweeteners can be any sweetener or combination of sweeteners, in natural or artificial form, or as a combination of natural and artificial sweeteners. Examples of natural sweeteners include isomaltulose, fructose, sucrose, glucose, maltose, mannose, galactose, lactose, stevia, honey, and the like. Examples of artificial sweeteners include sucralose, maltodextrin, saccharin, aspartame, acesulfame K, neotame and the like. In some embodiments, the sweetener comprises one or more sugar alcohols. Sugar alcohols are polyols derived from monosaccharides or disaccharides that have a partially or fully hydrogenated form. Sugar alcohols have, for example, about 4 to about 20 carbon atoms and include erythritol, arabitol, ribitol, isomalt, maltitol, dulcitol, iditol, mannitol, xylitol, lactitol, sorbitol, and combinations thereof (e.g., hydrogenated starch hydrolysates). When present, a representative amount of sweetener may make up from about 0. 1 to about 20 percent or more of the of the mixture by weight, for example, from about 0. 1 to about 1%, from about 1 to about 5%, from about 5 to about 10%, or from about 10 to about 20% of the mixture on a weight basis, based on the total weight of the reconstituted tobacco.

Binding agents

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

A binder may be employed in amounts sufficient to provide the desired physical attributes and physical integrity to the reconstituted tobacco. The amount of binder utilized in the reconstituted tobacco can vary, but is typically up to about 30 weight percent, and certain embodiments are characterized by a binder content of at least about 0.1% by weight, such as about 1 to about 30% by weight, or about 5 to about 10% by weight, based on the total weight of the reconstituted tobacco.

In certain embodiments, the binder includes a gum, for example, a natural gum. As used herein, a natural gum refers to polysaccharide materials of natural origin that have binding properties, and which are also useful as a thickening or gelling agents. Representative natural gums derived from plants, which are typically water soluble to some degree, include xanthan gum, guar gum, gum arabic, ghatti gum, gum tragacanth, karaya gum, locust bean gum, gellan gum, and combinations thereof. When present, natural gum binder materials are typically present in an amount of up to about 5% by weight, for example, from about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9, or about 1%, to about 2, about 3, about 4, or about 5% by weight, based on the total weight of the reconstituted tobacco.

Buffering agents

In certain embodiments, the reconstituted tobacco of the present disclosure can comprise pH adjusters or buffering agents. Examples of pH adjusters and buffering agents that can be used include, but are not limited to, metal hydroxides (e.g., alkali metal hydroxides such as sodium hydroxide and potassium hydroxide), and other alkali metal buffers such as metal carbonates (e.g., potassium carbonate or sodium carbonate), or metal bicarbonates such as sodium bicarbonate, and the like. Where present, the buffering agent is typically present in an amount less than about 5 percent based on the weight of the reconstituted tobacco, for example, from about 0.5% to about 5%, such as, e.g., from about 0.75% to about 4%, from about 0.75% to about 3%, or from about 1% to about 2% by weight, based on the total weight of the reconstituted tobacco. Non-limiting examples of suitable buffers include alkali metals acetates, glycinates, phosphates, glycerophosphates, citrates, carbonates, hydrogen carbonates, borates, or mixtures thereof.

Colorants

A colorant may be employed in amounts sufficient to provide the desired physical attributes to the reconstituted tobacco. Examples of colorants include various dyes and pigments, such as caramel coloring and titanium dioxide. The amount of colorant utilized in the mixture can vary, but when present is typically up to about 3 weight percent, such as from about 0.1%, about 0.5%, or about 1%, to about 3% by weight, based on the total weight of the reconstituted tobacco.

Active ingredient

The reconstituted tobacco as disclosed herein can include one or more active ingredients. As used herein, an "active ingredient" refers to one or more substances belonging to any of the following categories: API (active pharmaceutical ingredient), food additives, natural medicaments, and naturally occurring substances that can have an effect on humans. Example active ingredients include any ingredient known to impact one or more biological functions within the body, such as ingredients that furnish pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or which affect the structure or any function of the body of humans (e.g., provide a stimulating action on the central nervous system, have an energizing effect, an antipyretic or analgesic action, or an otherwise useful effect on the body). In some embodiments, the active ingredient may be of the type generally referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods." These types of additives are sometimes defined in the art as encompassing substances typically available from naturally -occurring sources (e.g., botanical materials) that provide one or more advantageous biological effects (e.g., health promotion, disease prevention, or other medicinal properties), but are not classified or regulated as drugs.

Non-limiting examples of active ingredients include those falling in the categories of botanical ingredients, stimulants, amino acids, nicotine components, and/or pharmaceutical, nutraceutical, and medicinal ingredients (e.g., vitamins, such as A, B3, B6, B12, and C, and/or cannabinoids, such as tetrahydrocannabinol (THC) and cannabidiol (CBD)). Each of these categories is further described herein below. The particular choice of active ingredients will vary depending upon the desired flavor, texture, and desired characteristics of the particular reconstituted tobacco product. Furthermore, any of the aforementioned types of active ingredients may be encapsulated in the composition, the final product, or both to avoid chemical degradation or reduce strong taste of these actives, including but not limited to caffeine, Vitamin A, and iron (Fe). Additionally, these encapsulated actives may need to be paired with an excipient in the composition to increase their solubility and/or bioavailability. Non-limiting examples of these excipients include beta-carotene, lycopene, Vitamin D, Vitamin E, Co-enzyme Q10, Vitamin K, and curcumin.

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

In some embodiments, the active ingredient as described herein may be sensitive to degradation (e.g., oxidative, photolytic, thermal, evaporative) during processing or upon storage of the oral product. In such embodiments, the active ingredient (such as caffeine, vitamin A, and iron (Fe)) may be encapsulated, or the matrix otherwise modified with fillers, binders, and the like, to provide enhanced stability to the active ingredient. For example, binders such as functional celluloses (e.g., cellulose ethers including, but not limited to, hydroxypropyl cellulose) may be employed to enhance stability of such actives toward degradation. Additionally, encapsulated actives may need to be paired with an excipient in the composition to increase their solubility and/or bioavailability. Non-limiting examples of suitable excipients include beta-carotene, lycopene, Vitamin D, Vitamin E, Co-enzyme Q10, Vitamin K, and curcumin.

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

Botanical

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

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

The botanical materials useful in the present disclosure may comprise, without limitation, any of the compounds and sources set forth herein, including mixtures thereof. Certain botanical materials of this type are sometimes referred to as dietary supplements, nutraceuticals, "phytochemicals" or "functional foods." Certain botanicals, as the plant material or an extract thereof, have found use in traditional herbal medicine, and are described further herein. Non-limiting examples of botanical materials include without limitation acai berry (Euterpe oleracea martins), acerola (Malpighia glabra), alfalfa, allspice, Angelica root, anise (e.g., star anise), annatto seed, apple (Mains domestica), apricot oil, ashwagandha, bacopa monniera, baobab, basil (Ocimum basilicum), bee balm, beet root, bergamot, blackberry (Morus nigra), black cohosh, black pepper, black tea, blueberries, boldo (Peumus boldus), borage, bugleweed, cacao, calamus root, camu (Myrcaria dubia), cannabis/hemp, caraway seed, catnip, catuaba, cayenne, cayenne pepper, Centella asiatica, chaga mushroom, Chai-hu, chamomile, cherry, cherry blossom, chervil, chlorophyll, chocolate, cinnamon (Cinnamomum cassia), citrus, citron grass (Cymbopogon citratus), clary sage, cloves, coconut (Cocos nucifera), cocoa, coffee, comfrey leaf and root, cordyceps, coriander seed, cranberry, curcumin, damiana, dandelion, Dorstenia arifolia, Dorstenia odorata, Echinacea, elderberry, elderflower, endro (Anethum graveolens), evening primrose, essential oils, eucalyptus, fennel, feverfew, garlic, Galphimia glauca, ginger (Zingiber officinale), gingko biloba, ginseng, goji berries, goldenseal, grape seed, grapefruit, grapefruit rose (Citrus paradisi), graviola (Annona muricata), green tea, Griffonia simplicifolia, guarana, gutu kola, hawthorn, hemp, hops, hibiscus flower (Hibiscus sabdariffa), honeybush, jiaogulan, kava, jambu (Spilanthes oleraceae), jasmine (Jasminum officinale), juniper berry (Juniperus communis), Kaempferia parviflora (Thai ginseng), kava, lavender, lemon (Citrus limori), lemon balm, lemongrass, licorice, lilac, Lion’s mane, lutein, maca (Lepidium meyenii), matcha, marjoram, milk thistle, mints (menthe), Nardostachys chinesis, oil-based extract of Viola odorata, oolong tea, orange (Citrus sinensis)' , oregano, papaya, pennyroyal, peppermint (Mentha piperita), potato peel, quercetin, quince, red clover, resveratrol, Rhizoma gastrodiae, Rhodiola, rooibos (red or green), rosehip (Rosa canina), rose essential oil, rosemary, sage, Saint John's Wort, salvia (Salvia officinalis), savory, saw palmetto, Sceletium tortuosum, Schisandra, silybum marianum, slippery elm bark, Skullcap, sorghum bran hi-tannin, sorghum grain hi-tannin, spearmint (Mentha spicata), Spikenard, spirulina, sumac bran, terpenes, thyme, tisanes, turmeric, Turnera aphrodisiaca, uva ursi, valerian, vanilla, white mulberry, wild yam root, wintergreen, withania somnifera, yacon root, yellow dock, yerba mate, and yerba santa. In some embodiments, the botanical material is in encapsulated form

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

In some embodiments, the active ingredient comprises ginseng. Ginseng is the root of plants of the genus Panax, which are characterized by the presence of unique steroid saponin phytochemicals

(ginsenosides) and gintonin. Ginseng finds use as a dietary supplement in energy drinks or herbal teas, and in traditional medicine. Cultivated species include Korean ginseng (P. ginseng), South China ginseng (P. notoginseng), and American ginseng (P. quinque folius). American ginseng and Korean ginseng vary in the type and quantity of various ginsenosides present. In some embodiments, the ginseng is American ginseng or Korean ginseng. In specific embodiments, the active ingredient comprises Korean ginseng. In some embodiments, ginseng is present in an amount of from about 0.4 to about 0.6% by weight, based on the total weight of the reconstituted tobacco.

In some embodiments, the non-tobacco botanical material is present in particulate form. The nontobacco botanical material in particulate form may have a range of particle sizes. For example, in some embodiments, the non-tobacco botanical material has a particle size of from about 0.05 mm to about 1 mm. In some instances, the non-tobacco botanical material particles may be sized to pass through a screen mesh to obtain the particle size range required. In some embodiments, the non-tobacco botanical material in particulate form comprises eucalyptus, rooibos, star anise, fennel, or combinations thereof.

In some embodiments, the non-tobacco botanical material is present in the form of an extract. "Botanical extract" as used herein refers to the isolated components of a botanical material that are extracted from a solid botanical material by a solvent (e.g., water, alcohol, or the like) that is brought into contact with the solid botanical material in an extraction process. Various extraction techniques of solid botanical materials can be used to provide a botanical material extract. In some embodiments, the botanical extract is an extract of Angelica root, caraway seed, cinnamon, clove, coriander seeds, elderberry, elderflower, ginger, jasmine, lavender, lilac, peppermint Mentha piperita), quince, or combinations thereof.

Stimulants

In some embodiments, the active ingredient comprises one or more stimulants. As used herein, the term "stimulant" refers to a material that increases activity of the central nervous system and/or the body, for example, enhancing focus, cognition, vigor, mood, alertness, and the like. Non-limiting examples of stimulants include caffeine, theacrine, theobromine, and theophylline. Theacrine (1 , 3,7,9- tetramethyluric acid) is a purine alkaloid which is structurally related to caffeine, and possesses stimulant, analgesic, and anti-inflammatory effects. Present stimulants may be natural, naturally derived, or wholly synthetic. For example, certain botanical materials (guarana, tea, coffee, cocoa, and the like) may possess a stimulant effect by virtue of the presence of e.g., caffeine or related alkaloids, and accordingly are "natural" stimulants. By "naturally derived" is meant the stimulant (e.g., caffeine, theacrine) is in a purified form, outside its natural (e.g., botanical) matrix. For example, caffeine can be obtained by extraction and purification from botanical sources (e.g., tea). By "wholly synthetic", it is meant that the stimulant has been obtained by chemical synthesis.

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

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

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

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

Vitamins

In some embodiments, the active ingredient comprises a vitamin or combination of vitamins. As used herein, the term "vitamin" refers to an organic molecule (or related set of molecules) that is an essential micronutrient needed for the proper functioning of metabolism in a mammal. There are thirteen vitamins required by human metabolism, which are: vitamin A (as all-trans-retinol, all-trans-retinyl- esters, as well as all-trans-beta-carotene and other provitamin A carotenoids), vitamin B 1 (thiamine), vitamin B2 (riboflavin), vitamin B3 (niacin), vitamin B5 (pantothenic acid), vitamin B6 (pyridoxine), vitamin B7 (biotin), vitamin B9 (folic acid or folate), vitamin B12 (cobalamins), vitamin C (ascorbic acid), vitamin D (calciferols), vitamin E (tocopherols and tocotrienols), and vitamin K (quinones). In some embodiments, the active ingredient comprises vitamin C. In some embodiments, the active ingredient is a combination of vitamin C, caffeine, and taurine.

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

Antioxidants

In some embodiments, the active ingredient comprises one or more antioxidants. As used herein, the term "antioxidant" refers to a substance which prevents or suppresses oxidation by terminating free radical reactions, and may delay or prevent some types of cellular damage. Antioxidants may be naturally occurring or synthetic. Naturally occurring antioxidants include those found in foods and botanical materials. Non-limiting examples of antioxidants include certain botanical materials, vitamins, polyphenols, and phenol derivatives.

Examples of botanical materials which are associated with antioxidant characteristics include without limitation acai berry, alfalfa, allspice, annatto seed, apricot oil, basil, bee balm, wild bergamot, black pepper, blueberries, borage seed oil, bugleweed, cacao, calamus root, catnip, catuaba, cayenne pepper, chaga mushroom, chervil, cinnamon, dark chocolate, potato peel, grape seed, ginseng, gingko biloba, Saint John's Wort, saw palmetto, green tea, black tea, black cohosh, cayenne, chamomile, cloves, cocoa powder, cranberry, dandelion, grapefruit, honeybush, echinacea, garlic, evening primrose, feverfew, ginger, goldenseal, hawthorn, hibiscus flower, jiaogulan, kava, lavender, licorice, marjoram, milk thistle, mints (menthe), oolong tea, beet root, orange, oregano, papaya, pennyroyal, peppermint, red clover, rooibos (red or green), rosehip, rosemary, sage, clary sage, savory, spearmint, spirulina, slippery elm bark, sorghum bran hi-tannin, sorghum grain hi-tannin, sumac bran, comfrey leaf and root, goji berries, gutu kola, thyme, turmeric, uva ursi, valerian, wild yam root, wintergreen, yacon root, yellow dock, yerba mate, yerba santa, bacopa monniera, withania somnifera, Lion’s mane, and silybum marianum. Such botanical materials may be provided in fresh or dry form, essential oils, or may be in the form of an extracts. The botanical materials (as well as their extracts) often include compounds from various classes known to provide antioxidant effects, such as minerals, vitamins, isoflavones, phytoesterols, allyl sulfides, dithiolthiones, isothiocyanates, indoles, lignans, flavonoids, polyphenols, and carotenoids. Examples of compounds found in botanical extracts or oils include ascorbic acid, peanut endocarb, resveratrol, sulforaphane, beta-carotene, lycopene, lutein, co-enzyme Q, carnitine, quercetin, kaempferol, and the like. See, e.g., Santhosh et al., Phytomedicine, 12(2005) 216-220, which is incorporated herein by reference.

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

When present, an antioxidant is typically at a concentration of from about 0.001% w/w to about 10% by weight, such as, e.g., from about 0.001%, about 0.005%, about 0.01% w/w, about 0.05%, about 0.1%, or about 0.5%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10%, based on the total weight of the composition.

Nicotine component

In certain embodiments, the reconstituted tobacco of the present disclosure can include a nicotinic compound. Various nicotinic compounds, and methods for their administration, are set forth in US Pat. Pub. No. 2011/0274628 to Borschke, which is incorporated herein by reference. As used herein, “nicotinic compound” or “source of nicotine” often refers to naturally-occurring or synthetic nicotinic compound unbound from a plant material, meaning the compound is at least partially purified and not contained within a plant structure, such as a tobacco leaf. Most preferably, nicotine is naturally-occurring and obtained as an extract from aNicotiana species (e.g., tobacco). The nicotine can have the enantiomeric form S(-)-nicotine, R(+)-nicotine, or a mixture of S(-)-nicotine and R(+)-nicotine. Most preferably, the nicotine is in the form of S(-)-nicotine (e.g., in a form that is virtually all S(-)-nicotine) or a racemic mixture composed primarily of predominantly of S(-)-nicotine (e.g., a mixture composed of about 95 weight parts S(-)-nicotine and about 5 weight parts R(+)-nicotine). Most preferably, the nicotine is employed in virtually pure form or in an essentially pure form. Highly preferred nicotine that is employed has a purity of greater than about 95 percent, more preferably greater than about 98 percent, and most preferably greater than about 99 percent, on a weight basis.

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

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

In some embodiments, at least a portion of the nicotine can be in the form of a resin complex of nicotine, where nicotine is bound in an ion-exchange resin, such as nicotine polacrilex, which is nicotine bound to, for example, a polymethacrilic acid, such as Amberlite IRP64, Purolite Cl 15HMR, or Doshion P551. See, for example, US Pat. No. 3,901,248 to Lichtneckert et al., which is incorporated herein by reference. Another example is a nicotine-polyacrylic carbomer complex, such as with Carbopol 974P. In some embodiments, nicotine may be present in the form of a nicotine polyacrylic complex.

Typically, the nicotine component (calculated as the free base) when present, is in a concentration of at least about 0.001% by weight of the reconstituted tobacco, such as in a range from about 0.001% to about 10%. In some embodiments, the nicotine component is present in a concentration from about 0.1% w/w to about 10% by weight, such as, e.g., from about 0.1% w/w, about 0.2%, about 0.3%, about 0.4%, about 0.5% about 0.6%, about 0.7%, about 0.8%, or about 0.9%, to about 1%, about 2%, about 3%, about 4%, about 5%, about 6%, about 7%, about 8%, about 9%, or about 10% by weight, calculated as the free base and based on the total weight of the reconstituted tobacco. In some embodiments, the nicotine component is present in a concentration from about 0.1% w/w to about 3% by weight, such as, e.g., from about 0.1% w/w to about 2.5%, from about 0.1% to about 2.0%, from about 0. 1% to about 1.5%, or from about 0.1% to about 1% by weight, calculated as the free base and based on the total weight of the reconstituted tobacco. These ranges can also apply to other active ingredients noted herein. In some embodiments, the reconstituted tobacco of the disclosure can be characterized as free of any nicotine component (e.g., any embodiment as disclosed herein may be completely or substantially free of any nicotine component). By "substantially free" is meant that no nicotine has been intentionally added, beyond trace amounts that may be naturally present in e.g., a botanical material. For example, certain embodiments can be characterized as having less than 0.001% by weight of nicotine, or less than 0.0001%, or even 0% by weight of nicotine, calculated as the free base.

Cannabinoids

In some embodiments, the active ingredient comprises one or more cannabinoids. As used herein, the term "cannabinoid" refers to a class of diverse chemical compounds that acts on cannabinoid receptors, also known as the endocannabinoid system, in cells that alter neurotransmitter release in the brain. Ligands for these receptor proteins include the endocannabinoids produced naturally in the body by animals; phytocannabinoids, found in cannabis; and synthetic cannabinoids, manufactured artificially. Cannabinoids found in cannabis include, without limitation: cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN), cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabinolic acid (THCA), and tetrahydrocannabivarinic acid (THCV A). In certain embodiments, the cannabinoid is selected from tetrahydrocannabinol (THC), the primary psychoactive compound in cannabis, and cannabidiol (CBD) another major constituent of the plant, but which is devoid of psychoactivity. All of the above compounds can be used in the form of an isolate from plant material or synthetically derived.

In some embodiments, the cannabinoid is selected from the group consisting of cannabigerol (CBG), cannabichromene (CBC), cannabidiol (CBD), tetrahydrocannabinol (THC), cannabinol (CBN) and cannabinodiol (CBDL), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), cannabinerolic acid, cannabidiolic acid (CBDA), Cannabinol propyl variant (CBNV), cannabitriol (CBO), tetrahydrocannabinolic acid (THCA), tetrahydrocannabivarinic acid (THCV A), and mixtures thereof. In some embodiments, the cannabinoid comprises at least tetrahydrocannabinol (THC). In some embodiments, the cannabinoid is tetrahydrocannabinol (THC). In some embodiments, the cannabinoid comprises at least cannabidiol (CBD). In some embodiments, the cannabinoid is cannabidiol (CBD). In some embodiments, the CBD is synthetic CBD. The choice of cannabinoid and the particular percentages thereof which may be present within the disclosed oral product will vary depending upon the desired flavor, texture, and other characteristics of the oral product.

Alternatively, the active ingredient can be a cannabimimetic, which is a class of compounds derived from plants other than cannabis that have biological effects on the endocannabinoid system similar to cannabinoids. Examples include yangonin, alpha-amyrin or beta-amyrin (also classified as terpenes), cyanidin, curcumin (tumeric), catechin, quercetin, salvinorin A, N-acylethanolamines, and N- alkylamide lipids. Such compounds can be used in the same amounts and ratios noted herein for cannabinoids.

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

Terpenes

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

In some embodiments, the terpene is a terpene derivable from a phytocannabinoid producing plant, such as a plant from the stain of the cannabis sativa species, such as hemp. Suitable terpenes in this regard include so-called “CIO” terpenes, which are those terpenes comprising 10 carbon atoms, and so- called “Cl 5” terpenes, which are those terpenes comprising 15 carbon atoms. In some embodiments, the active ingredient comprises more than one terpene. For example, the active ingredient may comprise one, two, three, four, five, six, seven, eight, nine, ten or more terpenes as defined herein. In some embodiments, the terpene is selected from pinene (alpha and beta), geraniol, linalool, limonene, carvone, eucalyptol, menthone, iso-menthone, piperitone, myrcene, beta-bourbonene, germacrene and mixtures thereof. Pharmaceutical ingredients

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

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

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

In some embodiments, the active ingredient as described herein may be sensitive to degradation (e.g., oxidative, photolytic, thermal, evaporative) during processing or upon storage of the oral product. In such embodiments, the active ingredient may be encapsulated (such as caffeine, Vitamin A, and iron (Fe)), or the matrix otherwise modified with fillers, binders, and the like, to provide enhanced stability to the active ingredient. For example, binders such as functional celluloses (e.g., cellulose ethers including, but not limited to, hydroxypropyl cellulose) may be employed to enhance stability of such actives toward degradation. Additionally, these encapsulated actives may need to be paired with an excipient in the composition to increase their solubility and/or bioavailability. Non-limiting examples of these excipients include beta-carotene, lycopene, Vitamin D, Vitamin E, Co-enzyme Q10, Vitamin K, and curcumin.

In other embodiments, in order to provide a desired concentration of the active ingredient by weight, an initial quantity of the active ingredient may be increased to compensate for a gradual degradative loss. Accordingly, larger initial amounts than those disclosed herein are contemplated by the present disclosure.

Other additives

Other additives can be included in the disclosed reconstituted tobacco. For example, the mixture can be processed, blended, formulated, combined and/or mixed with other materials or ingredients. The additives can be artificial, or can be obtained or derived from herbal or biological sources. Examples of further types of additives include thickening or gelling agents (e.g., fish gelatin), emulsifiers, oral care additives (e.g., thyme oil, eucalyptus oil, and zinc), preservatives (e.g., potassium sorbate and the like), zinc or magnesium salts selected to be relatively water soluble for compositions with greater water solubility (e.g., magnesium or zinc gluconate) or selected to be relatively water insoluble for compositions with reduced water solubility (e.g., magnesium or zinc oxide), disintegration aids, or combinations thereof. See, for example, those representative components, combination of components, relative amounts of those components, and manners and methods for employing those components, set forth in US Pat. No. 9,237,769 to Mua et al., US Pat. No. 7,861,728 to Holton, Jr. et al., US Pat. App. Pub. No. 2010/0291245 to Gao et al., and US Pat. App. Pub. No. 2007/0062549 to Holton, Jr. et al., each of which is incorporated herein by reference. Typical inclusion ranges for such additional additives can vary depending on the nature and function of the additive and the intended effect on the final reconstituted tobacco, with an example range of up to about 10% by weight, based on total weight of the reconstituted tobacco (e.g., about 0.1 to about 5% by weight). The aforementioned additives can be employed together (e.g., as additive formulations) or separately (e.g., individual additive components can be added at different stages involved in the preparation of the final reconstituted tobacco).

In some embodiments, any one or more of a reconstituted tobacco sheet, an active ingredient, a tobacco material, any additional components, and the overall input material for the reconstituted tobacco described herein can be described as a particulate material. As used herein, the term "particulate" refers to a material in the form of a plurality of individual particles, some of which can be in the form of an agglomerate of multiple particles, wherein the particles have an average length to width ratio less than 2:1, such as less than 1.5: 1, such as about 1 :1. In various embodiments, the particles of a particulate material can be described as substantially spherical or granular.

The particle size of a particulate material may be measured by sieve analysis. As the skilled person will readily appreciate, sieve analysis (otherwise known as a gradation test) is a method used to measure the particle size distribution of a particulate material. Typically, sieve analysis involves a nested column of sieves which comprise screens, preferably in the form of wire mesh cloths. A pre-weighed sample may be introduced into the top or uppermost sieve in the column, which has the largest screen openings or mesh size (i.e. the largest pore diameter of the sieve). Each lower sieve in the column has progressively smaller screen openings or mesh sizes than the sieve above. Typically, at the base of the column of sieves is a receiver portion to collect any particles having a particle size smaller than the screen opening size or mesh size of the bottom or lowermost sieve in the column (which has the smallest screen opening or mesh size).

In some embodiments, the column of sieves may be placed on or in a mechanical agitator. The agitator causes the vibration of each of the sieves in the column. The mechanical agitator may be activated for a pre-determined period of time in order to ensure that all particles are collected in the correct sieve. In some embodiments, the column of sieves is agitated for a period of time from 0.5 minutes to 10 minutes, such as from 1 minute to 10 minutes, such as from 1 minute to 5 minutes, such as for approximately 3 minutes. Once the agitation of the sieves in the column is complete, the material collected on each sieve is weighed. The weight of each sample on each sieve may then be divided by the total weight in order to obtain a percentage of the mass retained on each sieve. As the skilled person will readily appreciate, the screen opening sizes or mesh sizes for each sieve in the column used for sieve analysis may be selected based on the granularity or known maximum/minimum particle sizes of the sample to be analysed. In some embodiments, a column of sieves may be used for sieve analysis, wherein the column comprises from 2 to 20 sieves, such as from 5 to 15 sieves. In some embodiments, a column of sieves may be used for sieve analysis, wherein the column comprises 10 sieves. In some embodiments, the largest screen opening or mesh sizes of the sieves used for sieve analysis may be 1000 pm, such as 500 pm, such as 400 pm, such as 300 pm.

In some embodiments, any particulate material referenced herein (e.g., tobacco material, active ingredient, additional component, and the overall input material) can be characterized as having at least 50% by weight of particles with a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, at least 60% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, at least 70% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, at least 80% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, at least 90% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, at least 95% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, at least 99% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, approximately 100% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of no greater than about 1000 pm, such as no greater than about 500 pm, such as no greater than about 400 pm, such as no greater than about 350 pm, such as no greater than about 300 pm. In some embodiments, at least 50% by weight, such as at least 60% by weight, such as at least 70% by weight, such as at least 80% by weight, such as at least 90% by weight, such as at least 95% by weight, such as at least 99% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of from about 0.01 pm to about 1000 pm, such as from about 0.05 pm to about 750 pm, such as from about 0.1 pm to about 500 pm, such as from about 0.25 pm to about 500 pm. In some embodiments, at least 50% by weight, such as at least 60% by weight, such as at least 70% by weight, such as at least 80% by weight, such as at least 90% by weight, such as at least 95% by weight, such as at least 99% by weight of the particles of any particulate material referenced herein have a particle size as measured by sieve analysis of from about 10 pm to about 400 pm, such as from about 50 pm to about 350 pm, such as from about 100 pm to about 350 pm, such as from about 200 pm to about 300 pm.

Products Incorporating Reconstituted Tobacco

Reconstituted tobacco produced according to the methods of the present disclosure can be used in various products and processes. For example, reconstituted tobacco formed from a first reconstituted tobacco input can be used as an input in producing other cellulosic materials such as, but not limited to, microcrystalline cellulose (MCC), regenerated cellulose, etc.

Alternatively, the reconstituted tobacco material can be used as part of an article (also referred to herein as a consumable). A consumable is an article, part or all of which is intended to be consumed during use by a user. A consumable may comprise or consist of a reconstituted tobacco material as described herein. A consumable may comprise one or more other elements, such as a filter or an aerosol modifying substance. A consumable may comprise a heating element that emits heat to cause the reconstituted tobacco material to generate aerosol in use. The heating element may, for example, comprise combustible material, or may comprise a susceptor that is heatable by penetration with a varying magnetic field.

A susceptor is material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The heating material may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The heating material may be both electrically-conductive and magnetic, so that the heating material is heatable by both heating mechanisms.

Induction heating is a process in which an electrically-conductive object is heated by penetrating the object with a varying magnetic field. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electrical current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably relatively positioned so that the resultant varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of electrical currents. Therefore, when such eddy currents are generated in the object, their flow against the electrical resistance of the object causes the object to be heated. This process is called Joule, ohmic, or resistive heating.

In some embodiments, the susceptor is in the form of a closed circuit. It has been found that, when the susceptor is in the form of a closed circuit, magnetic coupling between the susceptor and the electromagnet in use is enhanced, which results in greater or improved Joule heating.

Magnetic hysteresis heating is a process in which an object made of a magnetic material is heated by penetrating the object with a varying magnetic field. A magnetic material can be considered to comprise many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such material, the magnetic dipoles align with the magnetic field. Therefore, when a varying magnetic field, such as an alternating magnetic field, for example as produced by an electromagnet, penetrates the magnetic material, the orientation of the magnetic dipoles changes with the varying applied magnetic field. Such magnetic dipole reorientation causes heat to be generated in the magnetic material.

When an object is both electrically-conductive and magnetic, penetrating the object with a varying magnetic field can cause both Joule heating and magnetic hysteresis heating in the object. Moreover, the use of magnetic material can strengthen the magnetic field, which can intensify the Joule heating.

In each of the above processes, as heat is generated inside the object itself, rather than by an external heat source by heat conduction, a rapid temperature rise in the object and more uniform heat distribution can be achieved, particularly through selection of suitable object material and geometry, and suitable varying magnetic field magnitude and orientation relative to the object. Moreover, as induction heating and magnetic hysteresis heating do not require a physical connection to be provided between the source of the varying magnetic field and the object, design freedom and control over the heating profile may be greater, and cost may be lower.

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

For example, filter materials, filter elements, and filter rods for various aerosol delivery devices that include reconstituted tobacco produced in accordance with the present disclosure can be used to provide multi-segment filter rods. Such multi-segment filter rods can be employed for the production of filtered cigarettes possessing multi-segment filter elements. The production of multi-segment filter rods can be carried out using the types of rod-forming units that have been employed to provide multi-segment cigarette filter components. Multi-segment cigarette filter rods can be manufactured using a cigarette filter rod making device available under the brand name Mulfi from Hauni-Werke Korber & Co. KG of Hamburg, Germany. Filter element components or segments for filter elements for multi-segment filtered cigarettes typically are provided from filter rods that are produced using traditional types of rod-forming units, such as those available as KDF-2 and KDF-3E from Hauni-Werke Korber & Co. KG. Typically, filter material, such as filter tow (i.e., pulp in esterified form), is provided using a tow processing unit. An exemplary tow processing unit has been commercially available as E-60 supplied by Arjay Equipment Corp., Winston-Salem, NC. Other exemplary tow processing units have been commercially available as AF-2, AF-3, and AF-4 from Hauni-Werke Korber & Co. KG. In addition, representative manners and methods for operating a filter material supply units and filter-making units are set forth in US Patent Nos. 4,281,671 to Byrne; 4,862,905 to Green, Jr. et al.; 5,060,664 to Siems et al.; 5,387,285 to Rivers; and 7,074,170 to Lanier, Jr. et al. Other types of technologies for supplying filter materials to a filter rodforming unit are set forth in US Patent Nos. 4,807,809 to Pryor et al. and 5,025,814 to Raker; which are incorporated herein by reference.

Aerosol delivery devices incorporating filter elements incorporating reconstituted tobacco produced in accordance with the present disclosure can be manufactured using traditional types of cigarette making techniques. For example, so-called “six-up” filter rods, “four-up” filter rods and “two- up” filter rods that are of the general format and configuration conventionally used for the manufacture of filtered cigarettes can be handled using conventional-type or suitably modified cigarette rod handling devices, such as tipping devices available as Lab MAX, MAX, MAX S or MAX 80 from Hauni-Werke Korber & Co. KG. See, for example, the types of devices set forth in U.S. Pat. Nos. 3,308,600 to Erdmann et al.; 4,281,670 to Heitmann et al.; 4,280,187 to Reuland et al.; 6,229,115 to Vos et al.; 7,296,578 to Read, Jr.; and 7,434,585 to Holmes; each of which is incorporated herein by reference. The operation of those types of devices will be readily apparent to those skilled in the art of automated cigarette manufacture. While the disclosed filter materials and filter elements are generally described herein in terms of embodiments associated with aerosol delivery devices, it should be understood that the mechanisms, components, and features of such aerosol delivery devices may be embodied in many different forms and/or associated with a variety of aerosol delivery devices as would be understood by a person of ordinary skill in the art. For example, the filter materials and filter elements provided herein may be employed in conjunction with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-bum cigarettes, electronic aerosol delivery devices, and the like. Accordingly, it should be understood that use of various filter materials and filter elements comprising reconstituted tobacco according to the present disclosure with aerosol delivery devices as described herein below are discussed in terms of embodiments relating to aerosol delivery devices by way of example only, and such filter materials and filter elements may be embodied and used in various other products and devices.

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

At one end of the tobacco rod 200 is the lighting end 208, and at the mouth end 210 is positioned a filter element 212 (e.g., including one or more segments of a filter material as disclosed herein). The filter element 212 can be produced according to methods known in the art. Filter elements generally include a cellulose material, which can include reconstituted tobacco produced according to the present disclosure. The filter element 212 can have a generally cylindrical shape, and the diameter thereof can be essentially equal to the diameter of the tobacco rod 202. The filter element 212 is circumscribed along its outer circumference or longitudinal periphery by a layer of outer plug wrap 214 to form a filter element. It is noted that any of the paper-like materials used in forming a smoking article (e.g., the plug wrap, tipping material, etc.) can include reconstituted tobacco produced according to the present disclosure. The filter element is positioned adjacent one end of the tobacco rod 202 such that the filter element and tobacco rod are axially aligned in an end-to-end relationship, preferably abutting one another. The ends of the filter element permit the passage of air and smoke therethrough.

Additionally, the smoking article can include an outer tipping material 220 that circumscribes the tobacco rod 202, the wrapping material 204, the filter element 212, and the plug wrap 214. A ventilated or air diluted smoking article can be provided with an optional air dilution means, such as a series of perforations 222, each of which extend through the tipping material 220 and plug wrap 214. The optional perforations 222 can be made by various techniques known to those of ordinary skill in the art, such as laser perforation techniques. Alternatively, so-called off-line air dilution techniques can be used (e.g., through the use of porous paper plug wrap and pre-perforated tipping material). For cigarettes that are air diluted or ventilated, the amount or degree of air dilution or ventilation can vary. Frequently, the amount of air dilution for an air diluted cigarette is greater than about 10 percent, generally is greater than about 20 percent, often is greater than about 30 percent, and sometimes is greater than about 40 percent. Typically, the upper level for air dilution for an air diluted cigarette is less than about 80 percent, and often is less than about 70 percent. As used herein, the term “air dilution” is the ratio (expressed as a percentage) of the volume of air drawn through the air dilution means to the total volume and air and smoke drawn through the cigarette and exiting the extreme mouth end portion of the cigarette. The filter element 212 can be attached to the tobacco rod 202 using the tipping material 220 (e.g., essentially air impermeable tipping material), that circumscribes both the entire length of the filter element and an adjacent region of the tobacco rod 202. The inner surface of the tipping material 220 is fixedly secured to the outer surface of the plug wrap 214 and the outer surface of the wrapping material 204 of the tobacco rod 202, using a suitable adhesive; and hence, the filter element and the tobacco rod are connected to one another to form the cigarette 200.

FIG. 3 illustrates a perspective view of an aerosol delivery device according to another example embodiment of the present disclosure, and FIG. 4 illustrates a perspective view of the aerosol delivery device of FIG. 3 with an outer wrap removed. In particular, FIG. 3 illustrates aerosol delivery device 300 that includes an outer wrap 302 and a heat source 304. In the embodiment depicted in FIG. 3, for example, the aerosol delivery device 300 has a lighting end 303 positioned proximate the heat source 304 and a mouth end 301 positioned at the opposing end of the aerosol delivery device. FIG. 4 illustrates the aerosol delivery device 300 wherein the outer wrap 302 is removed to reveal the other, interior components of the aerosol delivery device 300. In the embodiment depicted in FIG. 4, for example, the aerosol delivery device 300 includes a heat source 304, a tobacco rod or substrate portion 310, an intermediate component 308, and a filter element 312. Similar to a tobacco rod in a smoking article, the substrate portion of a heat-not-bum device can include reconstituted tobacco produced according to the present disclosure. In the depicted embodiment, the intermediate component 308 and the filter element 312 together comprise a mouthpiece 314.

In various embodiments, the heat source 304 may be configured to generate heat upon ignition thereof. In the depicted embodiment, the heat source 304 comprises a combustible fuel element that has a generally cylindrical shape and that incorporates a combustible carbonaceous material. In other embodiments, the heat source 304 may have a different shape, for example, a prism shape having a triangular, cubic or hexagonal cross-section. Carbonaceous materials generally have a high carbon content. Preferred carbonaceous materials may be composed predominately of carbon, and/or typically may have carbon contents of greater than about 60 percent, generally greater than about 70 percent, often greater than about 80 percent, and frequently greater than about 90 percent, on a dry weight basis.

In some instances, the heat source 304 may incorporate elements other than combustible carbonaceous materials (e.g., tobacco components, such as powdered tobaccos or tobacco extracts; flavoring agents; salts, such as sodium chloride, potassium chloride and sodium carbonate; heat stable graphite fibers; iron oxide powder; glass filaments; powdered calcium carbonate; alumina granules; ammonia sources, such as ammonia salts; and/or binding agents, such as guar gum, ammonium alginate and sodium alginate). Although specific dimensions of an applicable heat source may vary, in some embodiments, the heat source 304 may have a length in an inclusive range of approximately 7 mm to approximately 20 mm, and in some embodiments may be approximately 17 mm, and an overall diameter in an inclusive range of approximately 3 mm to approximately 8 mm, and in some embodiments may be approximately 4.8 mm (and in some embodiments, approximately 7 mm). Although in other embodiments, the heat source may be constructed in a variety of ways, in the depicted embodiment, the heat source 304 is extruded or compounded using a ground or powdered carbonaceous material, and has a density that is greater than about 0.5 g/cm³, often greater than about 0.7 g/cm³, and frequently greater than about 1 g/cm³, on a dry weight basis. See, for example, the types of fuel source components, formulations and designs set forth in U.S. Pat. No. 5,551,451 to Riggs et al. and U.S. Pat. No. 7,836,897 to Borschke et al., which are incorporated herein by reference in their entireties. Although in various embodiments, the heat source may have a variety of forms, including, for example, a substantially solid cylindrical shape or a hollow cylindrical (e.g., tube) shape, the heat source 304 of the depicted embodiment comprises an extruded monolithic carbonaceous material that has a generally cylindrical shape but with a plurality of grooves 316 extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end of the extruded monolithic carbonaceous material. In some embodiments, the aerosol delivery device, and in particular, the heat source, may include a heat transfer component. In various embodiments, a heat transfer component may be proximate the heat source, and, in some embodiments, a heat transfer component may be located in or within the heat source. Some examples of heat transfer components are described in in U.S. Pat. App. No. 15/923,735, filed on March 16, 2018, and titled Smoking Article with Heat Transfer Component, which is incorporated herein by reference in its entirety.

Although in the depicted embodiment, the grooves 316 of the heat source 304 are substantially equal in width and depth and are substantially equally distributed about a circumference of the heat source 304, other embodiments may include as few as two grooves, and still other embodiments may include as few as a single groove. Still other embodiments may include no grooves at all. Additional embodiments may include multiple grooves that may be of unequal width and/or depth, and which may be unequally spaced around a circumference of the heat source. In still other embodiments, the heat source may include flutes and/or slits extending longitudinally from a first end of the extruded monolithic carbonaceous material to an opposing second end thereof. In some embodiments, the heat source may comprise a foamed carbon monolith formed in a foam process of the type disclosed in U.S. Pat. No. 7,615,184 to Lobovsky, which is incorporated herein by reference in its entirety. As such, some embodiments may provide advantages with regard to reduced time taken to ignite the heat source. In some other embodiments, the heat source may be co-extruded with a layer of insulation (not shown), thereby reducing manufacturing time and expense. Other embodiments of fuel elements include carbon fibers of the type described in U.S. Pat. No. 4,922,901 to Brooks et al. or other heat source embodiments such as is disclosed in U.S. Pat. App. Pub. No. 2009/0044818 to Takeuchi et al., each of which is incorporated herein by reference in its entirety.

Generally, the heat source is positioned sufficiently near the tobacco rod or substrate portion 310 (e.g., containing reconstituted tobacco produced according to the present disclosure and one or more aerosolizable components therein) so that the aerosol formed/volatilized by the application of heat from the heat source to the aerosolizable components (as well as any flavorants, medicaments, and/or the like that are likewise provided for delivery to a user) is deliverable to the user by way of the mouthpiece. That is, when the heat source heats the tobacco rod or substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are meant to be interchangeable such that reference to release, releasing, releases, or released includes form or generate, forming or generating, forms or generates, and formed or generated. Specifically, an inhalable substance is released in the form of a vapor or aerosol or mixture thereof. As depicted in FIG. 4, the aerosol delivery device 304 of the depicted embodiment also includes an intermediate component 308 and at least one filter element 312. It should be noted that in various embodiments, the intermediate component 308 or the filter element 312, individually or together, may be considered a mouthpiece 314 of the aerosol delivery device 300. In one or more embodiments, the intermediate component may be omitted, for example, some examples of aerosol delivery devices according to the disclosure may comprise only a heat source 304, a tobacco rod or substrate material 310, and a filter element 312. Although in various embodiments, the intermediate component need not be included, in the depicted embodiment the intermediate component 308 comprises a substantially rigid member that is substantially inflexible along its longitudinal axis. In the depicted embodiment, the intermediate component 308 comprises a hollow tube structure, and is included to add structural integrity to the aerosol delivery device 300 and provide for cooling the produced aerosol. In some embodiments, the intermediate component 308 may be used as a container for collecting the aerosol. In various implementations, such a component may be constructed from any of a variety of materials and may include reconstituted tobacco prepared according to the present disclosure and one or more adhesives. Example materials include, but are not limited to, paper, paper layers, paperboard, plastic, cardboard, and/or composite materials. For example, in some embodiments, the intermediate component may comprise a hollow cylindrical element constructed of a paper or plastic material (such as, for example, ethyl vinyl acetate (EVA), or other polymeric materials such as poly ethylene, polyester, silicone, etc. or ceramics (e.g., silicon carbide, alumina, etc.), or other acetate fibers).

As noted, in some embodiments, the mouthpiece 314 may comprise a filter element 312 configured to receive the aerosol therethrough in response to the draw applied to the mouthpiece 314. In various embodiments, the filter element 312 is provided as a rod-like element radially and/or longitudinally disposed proximate the second end of the intermediate component 308. In particular, the filter element 312 may comprise one or more segments of a filter material as described herein above. In this manner, upon draw on the mouthpiece 314, the filter element 312 receives the aerosol flowing through the intermediate component 308 of the aerosol delivery device 300. In some embodiments, the filter element 312 may comprise discrete segments, for example, including one or more discrete segments of a filter material prepared according to the methods provided herein.

In various embodiments, the size and shape of the intermediate component 308 and/or the filter element 312 may vary, for example the length of the intermediate component 308 may be in an inclusive range of approximately 10 mm to approximately 30 mm, the diameter of the intermediate component 308 may be in an inclusive range of approximately 3 mm to approximately 8 mm, the length of the filter 312 may be in an inclusive range of approximately 10 mm to approximately 20 mm, and the diameter of the filter element 312 may be in an inclusive range of approximately 3 mm to approximately 8 mm. In the depicted implementation, the intermediate component 308 has a length of approximately 20 mm and a diameter of approximately 4.8 mm (and in some implementations, approximately 7 mm), and the filter 312 has a length of approximately 15 mm and a diameter of approximately 4.8 mm (or in some implementations, approximately 7 mm).

The type and configuration of an aerosol delivery device according to the present disclosure may vary and is not intending to be limited by the figures and/or descriptions which are provided herein for exemplary purposes only. For example, FIG. 5 illustrates another example embodiment of an aerosol delivery device 400 according to the present disclosure. The aerosol delivery device 400 may include a control body 402 and an aerosol generating component 404, which can contain a reconstituted tobacco prepared according to the present disclosure. In some embodiments, the aerosol generating component is configured for use with a conductive and/or inductive heat source to heat a substrate material to form an aerosol. In various embodiments, a conductive heat source may comprise a heating assembly that comprises a resistive heating member. Resistive heating members may be configured to produce heat when an electrical current is directed therethrough. Electrically conductive materials useful as resistive heating members may be those having low mass, low density, and moderate resistivity and that are thermally stable at the temperatures experienced during use. Useful heating members heat and cool rapidly, and thus provide for the efficient use of energy. Rapid heating of the member may be beneficial to provide almost immediate volatilization of an aerosol forming materials in proximity thereto. Rapid cooling prevents substantial volatilization (and hence waste) of the aerosol forming materials during periods when aerosol formation is not desired. Such heating members may also permit relatively precise control of the temperature range experienced by the aerosol forming materials, especially when time based current control is employed. Useful electrically conductive materials are typically chemically non-reactive with the materials being heated (e.g., aerosol forming materials and other inhalable substance materials) so as not to adversely affect the flavor or content of the aerosol or vapor that is produced. Some example, non-limiting, materials that may be used as the electrically conductive material include carbon, graphite, carbon/graphite composites, metals, ceramics such as metallic and non- metallic carbides, nitrides, oxides, silicides, inter-metallic compounds, cermets, metal alloys, and metal foils. In particular, refractory materials may be useful. Various, different materials can be mixed to achieve the desired properties of resistivity, mass, and thermal conductivity. In specific embodiments, metals that can be utilized include, for example, nickel, chromium, alloys of nickel and chromium (e.g., nichrome), and steel. Materials that can be useful for providing resistive heating are described in U.S. Pat. No. 5,060,671 to Counts et al.; U.S. Pat. Nos. 5,093,894 to Deevi et al.; 5,224,498 to Deevi et al.; 5,228,460 to Sprinkel Jr., et al.; 5,322,075 to Deevi et al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No. 5,468,936 to Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No. 5,659,656 to Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 to Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No. 5,573,692 to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entireties.

In various embodiments, a heating member may be provided in a variety of forms, such as in the form of a foil, a foam, a mesh, a hollow ball, a half ball, discs, spirals, fibers, wires, films, yams, strips, ribbons, or cylinders. Such heating members often comprise a metal material and are configured to produce heat as a result of the electrical resistance associated with passing an electrical current therethrough. Such resistive heating members may be positioned in proximity to, and/or in direct contact with, the substrate portion. For example, in one embodiment, a heating member may comprise a cylinder or other heating device located in the control body 402, wherein the cylinder is constructed of one or more conductive materials, including, but not limited to, copper, aluminum, platinum, gold, silver, iron, steel, brass, bronze, carbon (e.g., graphite), or any combination thereof. In various embodiments, the heating member may also be coated with any of these or other conductive materials. The heating member may be located proximate an engagement end of the control body 402, and may be configured to substantially surround a portion of the heated end 406 of the aerosol generating component 404 that includes the substrate portion 410. In such a manner, the heating member may be located proximate the substrate portion 410 of the aerosol generating component 404 when the aerosol generating component 404 is inserted into the control body 402. In other examples, at least a portion of a heating member may penetrate at least a portion of an aerosol generating component (such as, for example, one or more prongs and/or spikes that penetrate an aerosol generating component), when the aerosol generating component is inserted into the control body. Although in some embodiments the heating member may comprise a cylinder, it should be noted that in other embodiments, the heating member may take a variety of forms and, in some embodiments, may make direct contact with and/or penetrate the substrate portion.

As described above, in addition to being configured for use with a conductive heat source, the presently disclosed aerosol generating component may also be configured for use with an inductive heat source to heat a substrate portion to form an aerosol. In various embodiments, an inductive heat source may comprise a resonant transformer, which may comprise a resonant transmitter and a resonant receiver (e.g., a susceptor). In some embodiments, the resonant transmitter and the resonant receiver may be located in the control body 402. In other embodiments, the resonant receiver, or a portion thereof, may be located in the aerosol generating component 404. For example, in some embodiments, the control body 402 may include a resonant transmitter, which, for example, may comprise a foil material, a coil, a cylinder, or other structure configured to generate an oscillating magnetic field, and a resonant receiver, which may comprise one or more prongs that extend into the substrate portion or are surrounded by the substrate portion. In some embodiments, the aerosol generating component is in intimate contact with the resonant receiver. Example resonant transformer components, including resonant transmitters and resonant receivers, are described in U.S. Pat. App. Pub. No. 2019/0124979 to Sebastian et al., which is incorporated herein by reference in its entirety.

In various embodiments, the aerosol generating component 404 and the control body 402 may be permanently or detachably aligned in a functioning relationship. In this regard, FIG. 5 illustrates the aerosol delivery device 400 in a coupled configuration, whereas FIG. 6 illustrates the aerosol delivery device 400 in a decoupled configuration. Various mechanisms may connect the aerosol generating component 404 to the control body 402 to result in a threaded engagement, a press-fit engagement, an interference fit, a sliding fit, a magnetic engagement, or the like.

In various embodiments, the aerosol delivery device 400 according to an example embodiment of the present disclosure may have a variety of overall shapes, including, but not limited to an overall shape that may be defined as being substantially rod-like or substantially tubular shaped or substantially cylindrically shaped. In the embodiments of FIGS. 5-6, the device 400 has a substantially round cross-section; however, other cross-sectional shapes (e.g., oval, square, triangle, etc.) also are encompassed by the present disclosure. For example, in some embodiments one or both of the control body 402 or the aerosol generating component 404 (and/or any subcomponents) may have a substantially rectangular shape, such as a substantially rectangular cuboid shape (e.g., similar to a USB flash drive). In other embodiments, one or both of the control body 402 or the aerosol generating component 404 (and/or any subcomponents) may have other handheld shapes. For example, in some embodiments the control body 402 may have a small box shape, various pod mod shapes, or a fob-shape. Thus, such language that is descriptive of the physical shape of the article may also be applied to the individual components thereof, including the control body 402 and the aerosol generating component 404.

Alignment of the components within the aerosol delivery device of the present disclosure may vary across various embodiments. In some embodiments, the substrate portion may be positioned proximate a heat source so as to maximize aerosol delivery to the user. Other configurations, however, are not excluded. Generally, the heat source may be positioned sufficiently near the substrate portion so that heat from the heat source can volatilize the substrate portion (e.g., the aerosol forming material therein) and form an aerosol for delivery to the user. When the heat source heats the substrate portion, an aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are meant to be interchangeable such that reference to release, releasing, releases, or released includes form or generate, forming or generating, forms or generates, and formed or generated. Specifically, an inhalable substance is released in the form of a vapor or aerosol or mixture thereof, wherein such terms are also interchangeably used herein except where otherwise specified.

As noted above, the aerosol delivery device 400 of various embodiments may incorporate a battery and/or other electrical power source to provide current flow sufficient to provide various functionalities to the aerosol delivery device, such as powering of the heat source, powering of control systems, powering of indicators, and the like. As will be discussed in more detail below, the power source may take on various embodiments. The power source may be able to deliver sufficient power to rapidly activate the heat source to provide for aerosol formation and power the aerosol delivery device through use for a desired duration of time. In some embodiments, the power source is sized to fit conveniently within the aerosol delivery device so that the aerosol delivery device can be easily handled. Examples of useful power sources include lithium- ion batteries that are typically rechargeable (e.g., a rechargeable lithium-manganese dioxide battery). In particular, lithium polymer batteries can be used as such batteries can provide increased safety. Other types of batteries - e.g., N50-AAA CADNICA nickel-cadmium cells - may also be used. Additionally, an example power source is of a sufficiently light weight to not detract from a desirable smoking experience. Some examples of possible power sources are described in U.S. Pat. No. 9,484,155 to Peckerar et al., and U.S. Pat. App. Pub. No. 2017/0112191 to Sur et al., the disclosures of which are incorporated herein by reference in their respective entireties.

In specific embodiments, one or both of the control body 402 and the aerosol generating component 404 may be referred to as being disposable or as being reusable. For example, the control body 402 may have a replaceable battery or a rechargeable battery, solid-state battery, thin-film solid-state battery, rechargeable supercapacitor or the like, and thus may be combined with any type of recharging technology, including connection to a wall charger, connection to a car charger (i.e., cigarette lighter receptacle), and connection to a computer, such as through a universal serial bus (USB) cable or connector (e.g., USB 2.0, 3.0, 3.1, USB Type-C), connection to a photovoltaic cell (sometimes referred to as a solar cell) or solar panel of solar cells, a wireless charger, such as a charger that uses inductive wireless charging (including for example, wireless charging according to the Qi wireless charging standard from the Wireless Power Consortium (WPC)), or a wireless radio frequency (RF) based charger. An example of an inductive wireless charging system is described in U.S. Pat. App. Pub. No. 2017/0112196 to Sur et al., which is incorporated herein by reference in its entirety. Further, in some embodiments, the aerosol generating component 404 may comprise a single-use device. A single use component for use with a control body is disclosed in U.S. Pat. No. 8,910,639 to Chang et al., which is incorporated herein by reference in its entirety.

In further embodiments, the power source may also comprise a capacitor. Capacitors are capable of discharging more quickly than batteries and can be charged between puffs, allowing the battery to discharge into the capacitor at a lower rate than if it were used to power the heat source directly. For example, a supercapacitor - e.g., an electric double-layer capacitor (EDLC) - may be used separate from or in combination with a battery. When used alone, the supercapacitor may be recharged before each use of the article. Thus, the device may also include a charger component that can be attached to the smoking article between uses to replenish the supercapacitor.

Further components may be utilized in the aerosol delivery device of the present disclosure. For example, the aerosol delivery device may include a flow sensor that is sensitive either to pressure changes or air flow changes as the consumer draws on the article (e.g., a puff-actuated switch). Other possible current actuation/deactuation mechanisms may include a temperature actuated on/off switch or a lip pressure actuated switch. An example mechanism that can provide such puff-actuation capability includes a Model 163PC01D36 silicon sensor, manufactured by the MicroSwitch division of Honeywell, Inc., Freeport, Ill. Representative flow sensors, current regulating components, and other current controlling components including various microcontrollers, sensors, and switches for aerosol delivery devices are described in U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to the control schemes described in U.S. Pat. No. 9,423,152 to Ampolini et al., which is incorporated herein by reference in its entirety.

In another example, an aerosol delivery device may comprise a first conductive surface configured to contact a first body part of a user holding the device, and a second conductive surface, conductively isolated from the first conductive surface, configured to contact a second body part of the user. As such, when the aerosol delivery device detects a change in conductivity between the first conductive surface and the second conductive surface, a vaporizer is activated to vaporize a substance so that the vapors may be inhaled by the user holding unit. The first body part and the second body part may be a lip or parts of a hand(s). The two conductive surfaces may also be used to charge a battery contained in the personal vaporizer unit. The two conductive surfaces may also form, or be part of, a connector that may be used to output data stored in a memory. Reference is made to U.S. Pat. No. 9,861,773 to Terry et al., which is incorporated herein by reference in its entirety.

In addition, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses indicators for smoking articles; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can be associated with the mouth-end of a device to detect user lip activity associated with taking a draw and then trigger heating of a heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow into a heating load array in response to pressure drop through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses receptacles in a smoking device that include an identifier that detects a non-uniformity in infrared transmissivity of an inserted component and a controller that executes a detection routine as the component is inserted into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al. describes a defined executable power cycle with multiple differential phases; U.S. Pat. No. 5,934,289 to Watkins et al. discloses photonic- optronic components; U.S. Pat. No. 5,954,979 to Counts et al. discloses means for altering draw resistance through a smoking device; U.S. Pat. No. 6,803,545 to Blake et al. discloses specific battery configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoking devices; U.S. Pat. No. 8,402,976 to Fernando et al. discloses computer interfacing means for smoking devices to facilitate charging and allow computer control of the device; U.S. Pat. No. 8,689,804 to Fernando et al. discloses identification systems for smoking devices; and PCT Pat. App. Pub. No. WO 2010/003480 by Flick discloses a fluid flow sensing system indicative of a puff in an aerosol generating system; all of the foregoing disclosures being incorporated herein by reference in their entireties.

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

Referring to FIG. 6, in the depicted embodiment, the aerosol generating component 404 comprises a heated end 406, which is configured to be inserted into the control body 402, and a mouth end 408, upon which a user draws to create the aerosol. At least a portion of the heated end 406 includes a substrate portion 410. In some embodiments, the substrate portion 410 comprises a substrate comprising the aerosol forming material, each as disclosed herein. In various embodiments, the aerosol generating component 404, or a portion thereof, may be wrapped in an exterior overwrap material 412. In various embodiments, the mouth end 408 of the aerosol generating component 404 may include a filter 414, which may, for example, be made of a cellulose acetate or polypropylene material. The filter 414 may additionally or alternatively contain strands of tobacco containing material, such as described in U.S. Pat. No. 5,025,814 to Raker et al., which is incorporated herein by reference in its entirety. In various embodiments, the filter 414 may increase the structural integrity of the mouth end of the aerosol generating component 404, and/or provide filtering capacity, if desired, and/or provide resistance to draw. In some embodiments, the filter may comprise discrete segments. For example, some embodiments may include a segment providing filtering, a segment providing draw resistance, a hollow segment providing a space for the aerosol to cool, a segment providing increased structural integrity, other filter segments, and any one or any combination of the above.

In some embodiments, the material of the exterior overwrap 412 may comprise a material that resists transfer of heat, which may include a paper or other fibrous material, such as a cellulose material. The exterior overwrap material may also include at least one filler material imbedded or dispersed within the fibrous material. In various embodiments, the filler material may have the form of water insoluble particles. Additionally, the filler material may incorporate inorganic components. In various embodiments, the exterior overwrap may be formed of multiple layers, such as an underlying, bulk layer and an overlying layer, such as a typical wrapping paper in a cigarette. Such materials may include, for example, lightweight "rag fibers" such as flax, hemp, sisal, rice straw, and/or esparto. The exterior overwrap may also include a material typically used in a filter element of a conventional cigarette, such as cellulose acetate. Further, an excess length of the exterior overwrap at the mouth end 408 of the aerosol generating component may function to simply separate the substrate portion 410 from the mouth of a consumer or to provide space for positioning of a filter material, as described below, or to affect draw on the article or to affect flow characteristics of the vapor or aerosol leaving the device during draw. Further discussions relating to the configurations for exterior overwrap materials that may be used with the present disclosure may be found in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

Although in some embodiments an aerosol generating component and a control body may be provided together as a complete aerosol delivery article generally, the components may be provided separately. For example, the present disclosure also encompasses a disposable unit for use with a reusable smoking article or a reusable pharmaceutical delivery article. In specific embodiments, such a disposable unit (which may be an aerosol generating component as illustrated in the appended figures) can comprise a substantially tubular shaped body having a heated end configured to engage the reusable aerosol delivery article, an opposing mouth end configured to allow passage of an inhalable substance to a consumer, and a wall with an outer surface and an inner surface that defines an interior space. Various embodiments of an aerosol generating component (or cartridge) are described in U.S. Pat. No. 9,078,473 to Worm et al., which is incorporated herein by reference in its entirety.

Although some figures described herein illustrate the control body and aerosol generating component in a working relationship, it is understood that the control body and the aerosol generating component may exist as individual devices. Accordingly, any discussion otherwise provided herein in relation to the components in combination also should be understood as applying to the control body and the aerosol generating component as individual and separate components. It should be noted that the types of aerosol delivery devices described herein and depicted in the embodiments referred to above are not meant to be limiting of the present disclosure. In particular, filter materials and/or filter elements of the present disclosure may be incorporated into a variety of different aerosol delivery devices, including but not limited to, conventional cigarettes, heat-not-bum devices, tobacco heating products, electronic aerosol delivery devices, and the like. Some example of aerosol delivery devices that would be suitable for use with the filter materials and filter elements as described herein are set forth in US Pat. Nos. 4,756,318 to Clearman et al.; 4,714,082 to Banerjee et al.; 4,771,795 to White et al.; 4,793,365 to Sensabaugh et al.; 4,989,619 to Clearman et al.; 4,917,128 to Clearman et al.; 4,961,438 to Korte; 4,966,171 to Serrano et al.; 4,969,476 to Bale et al.; 4,991,606 to Serrano et al.; 5,020,548 to Farrier et al.; 5,027,836 to Shannon et al.; 5,033,483 to Clearman et al.; 5,040,551 to Schlatter et al.; 5,050,621 to Creighton et al.; 5,052,413 to Baker et al.; 5,065,776 to Lawson; 5,076,296 to Nystrom et al.; 5,076,297 to Farrier et al.; 5,099,861 to Clearman et al.; 5,105,835 to Drewett et al.; 5,105,837 to Barnes et al.; 5,115,820 to Hauser et al.; 5,148,821 to Best et al.; 5,159,940 to Hayward et al.; 5,178,167 to Riggs et al.; 5,183,062 to Clearman et al.; 5,211,684 to Shannon et al.; 5,240,014 to Deevi et al.; 5,240,016 to Nichols et al.; 5,345,955 to Clearman et al.; 5,396,911 to Casey, III et al.; 5,551,451 to Riggs et al.; 5,595,577 to Bensalem et al.; 5,727,571 to Meiring et al.; 5,819,751 to Barnes et al.; 6,089,857 to Matsuura et al.; 6,095,152 to Beven et al; and 6,578,584 to Beven; which are incorporated herein by reference. Still further, filter elements of the present invention can be incorporated within the types of aerosol delivery devices that have been commercially marketed under the brand names “Premier” and “Eclipse” by R. J. Reynolds Tobacco Company. See, for example, those types of aerosol delivery devices described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Bum Tobacco, R. J. Reynolds Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, p. 1-58 (2000); which are incorporated herein by reference.

The dimensions of a representative smoking article and/or aerosol delivery device incorporating reconstituted tobacco produced according to the present disclosure can vary. In some embodiments, smoking articles and/or aerosol delivery devices according to the present disclosure are rod-shaped, and can have diameters of about 7.5 mm (e.g., circumferences of about 20 mm to about 27 mm, often about 22.5 mm to about 25 mm); and can have total lengths of about 70 mm to about 120 mm, often about 80 mm to about 100 mm. However, the lengths of the smoking article and/or aerosol delivery device may vary. In some embodiments, for example, smoking articles and/or aerosol delivery devices incorporating reconstituted tobacco produced according to the present disclosure can have total lengths of about 100 mm or les, about 80 mm or less, about 60 mm or less, or about 40 mm or less. The length of the filter element can also vary. Typical filter elements can have total lengths of about 15 mm to about 40 mm, often about 20 mm to about 35 mm.

Certain filter elements, smoking articles, and aerosol delivery devices incorporating reconstituted tobacco prepared according to the methods of the present disclosure may exhibit desirable resistance to draw. For example, an exemplary smoking article and/or aerosol delivery device including a filter element prepared according to the methods described herein exhibits a pressure drop of between about 40 mmWG and about 400 mmWG. In certain embodiments, smoking articles and/or aerosol delivery devices including filter elements prepared according to the methods described herein may exhibit pressure drop values of between about 100 mmWG and about 350 mmWG, about 150 mmWG to about 325 mmWG, or about 200 mmWG to about 300 mmWG. Typically, pressure drop values of aerosol delivery devices are measured using a Filtrona Quality Test Modules (QTM Series) available from Filtrona Instruments and Automation Ltd.

Filter elements incorporating reconstituted tobacco formed according to the present disclosure typically exhibit a hardness that is comparable or even increase as compared to filter elements made from conventional cellulose acetate tow. The amount of plasticizer added to the filter rod and the denier per filament of the filter tow can significantly affect hardness of the filter. Filter hardness is a measurement of the compressibility of the filter material. A test instrument that can be used for harness testing is a D61 Automatic Hardness Tester available from Sodim SAS. This instrument applies a constant load (e.g., 300 g) to the sample for a fixed period of time (e.g., 3 to 5 seconds) and digitally displays the compression value as a percentage difference in the average diameter of the filter element. In certain embodiments, filter elements incorporating reconstituted tobacco prepared according to the present disclosure can exhibit a hardness in the range of about 70% to about 99%. In some embodiments, filter elements incorporating reconstituted tobacco prepared according to the present disclosure can exhibit a hardness of about 75% or higher, about 80% or higher, about 85% or higher, or about 90% or higher. Testing procedures for cigarette filter hardness are described, for example, in in US Pat. Nos. 3,955,406 to Strydom and 4,232,130 to Baxter et al., both of which are incorporated by reference herein. EXAMPLES

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

The fiber was further mixed with 8-9% its weight of cellulosic fiber/wood pulp and subsequently water was added to dilute the mixture to a 2-5% (w/v) slurry. The slurry was subsequently refined into a pulp using a rotatory disc refiner and then further diluted into a 1% (w/v) pulp. This pulp was drained over a Fourdrinier wire to form a base web or base sheet.

Separately, the WEL was vacuum evaporated at 60-65° C and 55 psi to yield a concentrated extract liquor (CEL) of 25-30% (w/v) solids. The CEL was then mixed with glycerol in an amount of about 3-20% by weight, based on the weight of the original infeed materials. The CEL was then applied or sprayed back on the base web to yield a 40-45% hot water solubles content in the final sheet. As used herein, the term “hot water solubles” generally refers to the amount of tobacco material extract contained within the final sheet and typically contains sugars, proteins, amino acids, organic acids, polyphenols, flavonoids, waxes, TSNAs, nitrate, nitrite, traces metals, heavy metals and added glycerol. Next, the final sheet was tunnel dried at 300-325° C for about 5-10 min. The control reconstituted tobacco sheet was tested for Nicotine, NNK, NNN, and TSNA levels. The test results are provided in Table 1 below.

A reconstituted tobacco sheet A was prepared as outlined above for the control sample to include 15% milled, flue-cured tobacco stems and 85% milled, flue-cured tobacco lamina. No extract was added back to the base sheet. Reconstituted tobacco sheet A was tested for Nicotine, NNK, NNN, and TSNA levels. The test results are provided in Table 1 below.

A reconstituted tobacco sheet B was prepared as outlined above for the control sample, except that 8.1% of the milled infeed was replaced with Sheet A with the remaining 91.9% including a flue- cured lamina blend. The CEL extract was then added back to the base sheet to yield a 40-45% hot water solubles content in the final sheet and then tunnel dried at 300-325° C for 5-10 min. Reconstituted tobacco sheet B was tested for Nicotine, NNK, NNN, and TSNA levels. The test results are provided in Table 1 below. A reconstituted tobacco sheet C was prepared as outlined above for the control sample, except that the milled infeed was replaced with a combination of 60% milled Burley stems and 40% flue-cured stems. No extract was added back to the base sheet. Reconstituted tobacco sheet C was tested for Nicotine, NNK, NNN, and TSNA levels. The test results are provided in Table 1 below. A reconstituted tobacco sheet D was prepared as outlined above for the control sample, except that 20.0% of the milled infeed was replaced with Sheet C with the remaining 80% including a flue-cured lamina blend. The CEL extract was then added back to the base sheet to yield a 40-45% hot water solubles content in the final sheet and then tunnel dried at 300-325° C for 5-10 min. Reconstituted tobacco sheet D was tested for Nicotine, NNK, NNN, and TSNA levels. The test results are provided in Table 1 below.

Table 1

As illustrated in Table 1 above, using reconstituted tobacco as a portion of the tobacco input for forming reconstituted tobacco sheet B resulted in a decrease of the total TSNAs present in the reconstituted tobacco sheet as compared to the control reconstituted tobacco sheet. Furthermore, it was surprisingly discovered that reconstituted tobacco sheet B had an at least equal, and even a slightly higher, level of nicotine as compared to the control reconstituted tobacco sheet. As illustrated in Table 1 above, using reconstituted tobacco as a portion of the tobacco input for forming reconstituted tobacco sheet D resulted in a decrease of the total TSNAs present in the reconstituted tobacco sheet as compared to the control reconstituted tobacco sheet. Furthermore, it was surprisingly discovered that reconstituted tobacco sheet D had an at least equal, and even a slightly higher, level of nicotine as compared to the control reconstituted tobacco sheet. Upon visual inspection of the control reconstituted tobacco sheet and reconstituted tobacco sheets A-D, it was noted that using reconstituted tobacco in the tobacco input did not affect the overall appearance and/or structure of the final reconstituted tobacco sheet.

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

Claims

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

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

3. The method of claim 1, wherein the first reconstituted tobacco input comprises about 5 to about 50 wt. % of the tobacco input, based on the total weight of the tobacco input.

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

5. The method of claim 4, wherein the tobacco stems are present in an about of about 15 to about 95 wt. %, based on the total weight of the tobacco input.

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

7. The method of claim 6, wherein the tobacco lamina is present in an about of about 15 to about 95 wt. %, based on the total weight of the tobacco input.

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

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

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

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

12. The method according to any one of claims 1-7, further comprising adding an active ingredient and/or a flavoring agent to the tobacco pulp, the web formed from the tobacco pulp, and/or the tobacco extract applied to the web.

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

14. The method according to any one of claims 1-7, wherein the tobacco input further comprises one or more components selected from the group consisting of flavorants, fillers, binders, pH adjusters, buffering agents, colorants, disintegration aids, antioxidants, humectants, and preservatives.

15. The method according to any one of claims 1-7, further comprising adding one or more components selected from the group consisting of flavorants, fillers, binders, pH adjusters, buffering agents, colorants, disintegration aids, antioxidants, humectants, and preservatives to the tobacco pulp, the web formed from the tobacco pulp, and/or the tobacco extract applied to the web.

16. The method according to any one of claims 1-7, wherein the step of extracting the tobacco input is done at a temperature of about 55 °C to about 65 °C for approximately 0.5-2 hours.

17. The method according to any one of claims 1-7, wherein the tobacco input is extracted with water, and wherein the weight ratio of water to tobacco input is in the range of approximately 4: 1 to about 10: 1.

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

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

20. The method according to any one of claims 1-7, wherein the final reconstituted tobacco sheet has a moisture percentage of about 5 to about 15%, based on the total weight of the final reconstituted tobacco sheet.

21. The method according to any one of claims 1-7, wherein extracting the tobacco input comprises extracting each of the multiple tobacco materials separately.

22. The method according to any one of claims 1-7, wherein extracting the tobacco input comprises blending the multiple tobacco materials to form a blended material and extracting the blended material.

23. The method according to any one of claims 1-7, further comprising: receiving a second tobacco input, wherein the second tobacco input comprises the reconstituted tobacco output and at least one additional tobacco material; extracting the second tobacco input to form a second tobacco extract and a second tobacco pulp; separating the second tobacco extract and the second tobacco pulp; forming the second tobacco pulp into a second web; applying at least a portion of the second tobacco extract to the second web; and drying the second web to form a second reconstituted tobacco output.

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

25. The final reconstituted tobacco sheet of claim 24, wherein the final reconstituted tobacco sheet exhibits lower TSNA concentration as compared to a reconstituted tobacco sheet formed from a control tobacco input that is substantially free of reconstituted tobacco.

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

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

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

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

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

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

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

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

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

35. The reconstituted tobacco material according to any one of claims 27-29, wherein the reconstituted tobacco material has a moisture amount of about 5% to about 15% by weight, based on the total weight of the reconstituted tobacco material.

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

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