Smoking articles and methods of making same

Abstract

The disclosed technology pertains to a customizable smokable whole leaf wrap and its multi-step manufacturing process that includes size screening, curing, pasteurization, adhesive application, sheet formation, cutting, and drying. The process is adaptable, offering various alternative methods and embodiments, enabling a wide array of wrap properties, flavors, and functionalities. This flexibility extends to the use of different strains, plant materials, infusions, adhesives, treatments, and manufacturing techniques. Certain embodiments can incorporate flavor-enhancing compounds, essential oils, herbal extracts, heat-resistant coatings, odor-absorbing treatments, built-in filters, or ventilation systems for an optimized smoking experience. The technology also emphasizes environmental sustainability with possibilities such as biodegradable adhesives, closed-loop manufacturing, and natural insect repellents, delivering a safe, quality, and environmentally responsible product tailored to consumer needs and preferences.

1 . A smokable article comprising:
 two or more overlapping whole hemp leaves adhered together with a smokable adhesive and configured to hold smokable product.   
     
     
         2 . The smokable article of  claim 1 , wherein the two or more overlapping whole hemp leaves are cured. 
     
     
         3 . The smokable article of  claim 1 , wherein the two or more overlapping whole hemp leaves are pasteurized. 
     
     
         4 . The smokable article of  claim 1 , wherein the two or more overlapping whole hemp leaves include at least one of flavor-enhancing compounds, essential oils, herbal extracts, heat-resistant coatings, and odor-absorbing treatments. 
     
     
         5 . The smokable article of  claim 1 , wherein the two or more overlapping whole hemp leaves include at least one of built-in filters, ventilation systems, insect repellents, and biodegradable adhesives. 
     
     
         6 . A method of making a smokable article comprising;
 applying a smokable adhesive to at least two whole hemp leaves;   overlapping the at least two whole hemp leaves;   affixing the at least two whole hemp leaves together; and   configuring the at least two whole hemp leaves to hold smokable product.   
     
     
         7 . The method of  claim 6 , further comprising:
 cleaning the at least two whole hemp leaves via pasteurization process, wherein the hemp leaves are heated to a minimum temperature of 105° Fahrenheit.   
     
     
         8 . The method of  claim 6 , further comprising:
 cleaning the at least two whole hemp leaves by at least one of steaming, immersion bath, dry heat treatment, UV treatment, ozone treatment, microwave pasteurization, infrared pasteurization, ultrasonic pasteurization, cold plasma treatment, high pressure processing, electrolyzed water, cold pasteurization, and resin coating.   
     
     
         9 . The method of  claim 6 , further comprising:
 cutting the at least two whole hemp leaves to produce a plurality of smokable wraps by at least one of die cutting, laser cutting, Guillotine cutting, Waterjet cutting, ultrasonic blasé cutting, knife cutting, plasma cutting, hot-wire cutting, scissor cutting, rotary cutting, and ultrasonic wave cutting.   
     
     
         10 . The method of  claim 6 , further comprising:
 screening the at least two whole hemp leaves by at least one of manual sorting, automated sorting, light sorting, weight-based sorting, optical scanning, conveyor belt sorting, air classification, vibrating table sorting, manual grading, mesh-based sorting, and ultrasonic measurement.   
     
     
         11 . The method of  claim 6 , further comprising:
 drying the at least two whole hemp leaves in a temperature and humidity-controlled environment for up to 72 hours at a temperature range from 32° to 450° Fahrenheit at approximately 10-80% humidity.   
     
     
         12 . The method of  claim 6 , further comprising:
 drying the at least two whole hemp leaves by at least one of natural drying, infrared drying, forced-air drying, vacuum drying, microwave drying, freeze drying, oven drying, dehumidification drying, radiant drying, and desiccant drying.   
     
     
         13 . The method of  claim 6 , further comprising:
 fermenting the at least two whole hemp leaves.   
     
     
         14 . The method of  claim 6 , further comprising:
 curing the at least two whole hemp leaves in an environment in a range from 55-80° Fahrenheit and 50-95% relative humidity for a duration of 1 to 30 days.   
     
     
         15 . The method of  claim 6 , further comprising:
 curing the at least two whole hemp leaves by at least one of natural curing, artificial curing, light curing, UV curing, vacuum curing, slow curing, accelerated curing, temperature-based curing, humidity-based curing, enzymatic curing, microbial curing, stack curing, flue curing, sun curing, and freeze curing.   
     
     
         16 . The method of  claim 6 , further comprising:
 hot pressing or cold pressing the at least two whole hemp leaves.   
     
     
         17 . The method of  claim 6 , further comprising:
 applying a smokable adhesive to the at least two whole hemp leaves by at least one of brush application, spray application, roll-on application, dip coating, slot die coating, doctor blade coating, screen printing, electrostatic spraying, curtain coating, Gravure coating, Leaf Fusion, one-sided coating, and dehydrated adhesive.   
     
     
         18 . The method of  claim 6 , further comprising:
 affixing the at least one whole hemp leaf together by at least one of leaf weaving, stitching, heat sealing, smokable tape, and flash freezing.   
     
     
         19 . A method of making a smokable article comprising;
 screening whole leaves for size and quality;   selecting at least two whole leaves responsive to screening;   curing the at least two whole leaves in a temperature-controlled and humidity-controlled environment for a duration of 1 to 30 days;   cleaning the at least two whole leaves via a pasteurization process, wherein the pasteurization process includes heating the at least two whole leaves to a minimum of 105° F.;   applying a smokable adhesive to the at least two whole leaves;   overlapping edges of the at least two whole leaves;   applying pressure to the overlapped edges of the at least two whole leaves to form a sheet of whole leaves;   cutting the sheet of whole leaves into individual smokable whole wraps of desired size;   drying the individual smokable whole wraps in a temperature-controlled and humidity-controlled environment for a duration of up to 72 hours in a temperature range of 32° F. to 450° F. and in between 10-80% humidity; and   configuring the whole wraps to hold smokable product.   
     
     
         20 . The method of  claim 19 , wherein the whole leaves are from a cannabis plant.