Method for purifying crystals using solvent vapors

Abstract

A Reflux Rinsing method for purifying crystals using solvent vapor through dynamic equilibrium recrystallization. Feed material having tetrahydrocannabinol acid (THCA) is inserted into a reaction vessel having walls, and upper portion, and a lower portion with a bottom surface. The feed material is exposed to a hydrocarbon liquid in the reaction vessel in a quantity sufficient to keep liquid present in equilibrium with gas in the reaction vessel through the recrystallization process, forming a raw extract having THCA. The walls and bottom surface of the reaction vessel are coated with raw extract. The reaction vessel is heated and then the heating is discontinued. Vapor/thin-film DER is promoted in the reaction vessel for a predetermined length of time with no solvent reflux, resulting in formation of purified crystals of THCA under pressure. The hydrocarbon solvent is reclaimed from the reaction vessel, leaving the purified crystals and impurities. When the reaction vessel is opened, the purified crystals and impurities are removed.

Claims

1. A method of purifying THC acid using solvent vapor through dynamic equilibrium recrystallization, comprising: inserting feed material having THC acid into a vessel; exposing the feed material to a hydrocarbon liquid in the vessel to form at least one of a raw extract having THC acid or a suspension containing THC acid crystals; heating the vessel and contents therein; forming purified crystals of THC acid or further purifying crystals of THC acid on a surface of the vessel; and reclaiming a hydrocarbon solvent from the vessel, leaving therein purified crystals of THC acid and impurities.

2. The method according to claim 1, wherein the hydrocarbon liquid includes a mixture of butane and propane.

3. The method according to claim 1, wherein heating the vessel and contents therein includes heating the contents therein under pressure.

4. The method according to claim 3, wherein the hydrocarbon liquid includes a mixture of butane and propane.

5. The method according to claim 4, wherein the pressure is adjustable and is dependent on a butane:propane ratio of the hydrocarbon liquid.

6. The method according to claim 1, wherein the feed material includes at least one of flowers, trim or stems from a plant.

7. The method according to claim 1, wherein the feed material includes THC acid crystals.

8. The method according to claim 1, wherein heating the vessel and contents therein includes heating at least one of the vessel or the contents therein to 115° F.

9. The method according to claim 1, wherein the vessel includes structure configured to increase surface area therein.

10. The method according to claim 9, wherein forming purified crystals of THC acid or further purifying crystals of THC acid on a portion of the vessel includes at least one of forming purified crystals of THC acid or further purifying crystals of THC acid on the structure of the vessel.

11. The method according to claim 1, further including opening the vessel and removing the purified crystals of THC acid and impurities therefrom.

12. The method according to claim 11, wherein opening the vessel and removing the purified crystals of THC acid and impurities therefrom includes scraping the purified crystals of THC acid from the surface of the vessel.

13. The method according to claim 1, further including discontinuing heating the vessel and contents therein.

14. The method according to claim 13, further including repeating heating the vessel and contents therein, and repeating discontinuing heating the vessel and contents therein.

15. The method according to claim 1, further including cooling the contents of the vessel.

16. The method according to claim 1, wherein the hydrocarbon liquid includes at least one of butane or propane.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) A complete understanding of the present invention may be obtained by reference to the accompanying drawings, when considered in conjunction with the subsequent detailed description, in which:

(2) FIG. 1 is a diagram of thin-film/vapor recrystallization in accordance with the present invention;

(3) FIG. 2 is a diagram of Reflux Rinsing;

(4) FIG. 3 is a combination of Reflux Rinsing and DER;

(5) FIG. 4 illustrates a simple tube vessel with ends, temperature control on top and bottom;

(6) FIG. 5 illustrates a tube vessel with surfaces attached to top;

(7) FIG. 6 illustrates a tube with block insert;

(8) FIG. 7 illustrates a tube with side-arm vapor channel and funnel-shaped Inserts in body of vessel;

(9) FIG. 8 illustrates nesting funnel inserts in body of vessel;

(10) FIG. 9 illustrates nipples, rods and ridges for surface area;

(11) FIG. 10 illustrates a honeycomb insert for surface area;

(12) FIG. 11 illustrates a gauze for surface area;

(13) FIG. 12 illustrates ridges for depth of crystal bed and solvent flow, channeling FIG. 13 illustrates controlling flow by angle of crystal bed;

(14) FIG. 14 illustrates a stackable design feature;

(15) FIG. 15 illustrates a sight glass design feature;

(16) FIG. 16 illustrates a vibration source; and

(17) FIG. 17 depicts a flow chart of system operations.

(18) Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

(19) Although the following detailed description contains specific details for the purposes of illustration, those of ordinary skill in the art will appreciate that variations and alterations to the following details are within the scope of the invention. Accordingly, the exemplary embodiments of the invention described below are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.

(20) The Reflux Rinsing method for purifying crystals of the present invention uses solvent vapor through dynamic equilibrium recrystallization. A pressure vessel contains a liquefied gas solvent, impure crystalline starting material initially, and a purified crystalline mass at the conclusion of the purifying process. A mechanism is provided for providing pressure to contents of the pressure vessel and for heating the lower portion thereof. A timer is also connected to the mechanism, the timer being set to heat the pressure vessel to drive vapors and reflux rinsing to remove impurities at the surface of an impure crystalline mass, to reclaim the solvent, leaving purified crystals and impurities in the pressure vessel, and to open the pressure vessel to remove the purified crystals from the vessel walls and bottom surface and to remove the impurities from the vessel.

(21) Referring now to FIG. 1, a diagram of thin-film/vapor recrystallization apparatus 100 is shown for purifying crystals in an initial crystalline mass 106 using solvent vapor through dynamic equilibrium recrystallization (DER). The recrystallization at the surface of the crystals in the thin film is provided in a butane vapor (gas)-saturated vessel 102.

(22) A pressure vessel 104 is provided, into which is placed impure crystalline starting material 106, portions of crystallized biological plants in the preferred embodiment.

(23) Liquified gas solvent 108 is introduced into pressure vessel 104.

(24) Purified crystalline mass 110 with impurities is provided. The impurities are removed and crystal reforms, while impurities increase in the solvent layer, pulling more solvent 108, and becoming less viscous to flow down the walls 112 of vessel 104, not by vapor pressure, but by solubility. Solvent 108 with impurities running down walls 112 is replaced by vapor condensation on the new, purified crystal surface.

(25) Referring now to FIG. 2, a process known as Reflux Rinsing is performed, using a thin film of solvent 108 flowing over crystalline mass 106. This solvent 108 is the result of reflux action that heats the bottom 104a of vessel 104, so vapors rise to the top 104b thereof, where they condense into a film. This film flows over the crystalline mass 106 as in the DER hereinabove described. The driving force is reflux and the cycle time for rinsing is short, so as not to redissolve the crystals in a continuous stream of fresh reflux solvent 108 and recombine with the impurities at the bottom 104a of vessel 104. This process can be combined with the DER process to control the balance between recrystallization and rinsing the surface of purified crystalline mass 110.

(26) In the Reflux Rinsing procedure, pressure vessel 104 is provided for containing crystalline starting material with surface impurities 106, liquefied gas solvent 108, and vapor. A film of liquid is permitted to flow over crystalline mass 106, rinsing off the surface thereof. The crystal or purified crystalline mass 110 is then spread on the surfaces of pressure vessel 104.

(27) Referring now to FIG. 3, there is shown a combination process. DER and Reflux Rinsing processes are combined in the overall process to optimize crystal purity and yield. Once again, pressure vessel 104 is loaded with impure crystalline starting material 106. Liquefied gas solvent 108 is then introduced into pressure vessel 104, forming solvent vapor. A thin film of liquid flows over purified crystalline mass 110, rinsing off the surface thereof.

(28) The steps in the Reflux Rinsing method are:

(29) a) applying the initial, impure purified crystalline mass 106 to walls 112 of pressure vessel 104;

(30) b) adding hydrocarbon liquid to pressure vessel 104, enough to keep liquid present in equilibrium with the gas through the recrystallization process; and

(31) c) initially heating the bottom 104a of pressure vessel 104 to drive vapors to the top 104b thereof, where they condense on the cooler surface and rinse the surface of a purified crystalline mass 110 using reflux.

(32) Following a brief period of initial reflux rinsing controlled by a timing mechanism 105, vapor/thin-film DER is promoted in pressure vessel 104 for hours at a constant temperature with no solvent reflux. The Reflux Rinsing process then continues:

(33) d) gently heating the bottom 104a of pressure vessel 104 again to drive vapors and reflux rinsing to remove the final impurities that have migrated to, or accumulated at, the surface of purified crystalline mass 110;

(34) e) cycling step (d) with control over temperature, pressure, and other variables as necessary to maximize crystal yield and purity;

(35) f) reclaiming the hydrocarbon solvent 108, leaving the crystals and impurities in pressure vessel 104; and

(36) g) opening pressure vessel 104, removing the purified crystals 110 from the walls 112 thereof and the impurities (i.e., other cannabinoids, essential oils, etc.) from the bottom 104a of pressure vessel 104.

(37) Referring now to FIGS. 4-8, a Reflux Rinsing apparatus 400 is provided for performing the Reflux Rinsing process controls temperature, pressure, surface area of crystallization, angle of interior surfaces to control flow velocity, length of the path of crystallization relative to the surface area, thickness of purified crystalline mass 110, and the pressure/vapor density of the liquid/vapor solvent 108.

(38) Reflux Rinsing apparatus 400 is sealed, with the ability to Reflux Rinse and DER with a temperature control zone at the bottom 402 thereof, and a temperature control zone 404 at the top thereof for rapid refluxing, or merely to heat bottom 402 of apparatus 400 and allow the cooler top 404 to condense vapors over time. Reflux Rinsing apparatus 400 can switch between Reflux Rinsing and DER sequentially, as necessary.

(39) A key component of any apparatus used for the Reflux Rinsing process is creating surface area for crystal growth to occur. Thus, any mechanism by which surface area is increased within vessel 104 is considered within the scope of the invention.

(40) Moreover, since the force of gravity and the angle of vessel walls 112 also affect crystal growth and overall process time, increasing force at the walls 112 of vessel 104 through use of a centrifuge or any other method of adjusting force, and changing the angle of vessel walls 112 is considered within the scope of the invention.

(41) Referring now still to FIG. 4, a simple tube vessel 404 with ends 404a and 404b is shown as a design feature of Reflux Rinsing apparatus 400. Temperature control mechanisms are provided on top 404 and bottom 402 of Reflux Rinsing apparatus 400.

(42) Referring now to FIG. 5, a tube vessel 504 is provided with lid 505 removably attached by engagement fingers to top 504b and surface area enhancement 505a as a design feature of Reflux Rinsing apparatus 400. Lid 505 facilitates loading, harvesting, and cleaning Reflux Rinsing apparatus 400. Crystalline mass 510 is spread on surfaces of Reflux Rinsing apparatus 400.

(43) Referring now to FIG. 6, a tube vessel 604 with block 605 is inserted into vessel 604 as a design feature of Reflux Rinsing apparatus 400. Block 605 is used to facilitate loading, removing, harvesting, and cleaning Reflux Rinsing apparatus 400. Once again, crystalline mass 610 is spread on the surfaces of Reflux Rinsing apparatus 400.

(44) Referring now to FIG. 7, a tube vessel 704 is equipped with a side-arm vapor channel 708 and a set of funnel-shaped inserts 710 as a design feature of Reflux Rinsing apparatus 400.

(45) Referring now to FIG. 8, nesting funnels 810 are inserted in the body of pressure vessel 804 as a design feature of Reflux Rinsing apparatus 400. Once again, crystalline mass 810 is spread on the surfaces of Reflux Rinsing apparatus 400.

(46) Referring now to FIGS. 9-13, various configurations of the interior surfaces of Reflux Rinsing apparatus 400 control the amount of solvent 108 (FIGS. 1-3) in the film covering the crystalline mass 910, the residence time of solvent 108 on crystalline mass 910, and the flow of fresh solvent 108 thereover. The starting crystalline mass 910 can be sprayed, smeared, or added to vessel 904. The slope, length of smear, depth of smear (ribs), flow of impurities, and crystal creep down the walls 412 can be controlled.

(47) Referring now again to FIG. 9, nipples, rods, and ridges 912 are attached to surface areas of Reflux Rinsing apparatus 400 as a design feature thereof. Once again, crystalline mass 910 is spread on the surfaces of Reflux Rinsing apparatus 400.

(48) Referring now again to FIG. 10, a honeycomb 1012 is shown and is insertable into and attachable to surface areas of Reflux Rinsing apparatus 400 (e.g., FIG. 4).

(49) Referring now also to FIG. 11, gauze 1112 is attached to surface areas of Reflux Rinsing apparatus 400 as a design feature thereof.

(50) Referring now also to FIG. 12, ridges 1212 are formed on surface areas of Reflux Rinsing apparatus 400 as a design feature thereof. Ridges 1212 provide depth of the crystal bed 1214 and facilitate channeling flow of solvent 1208. Once again, crystalline mass 1210 is spread on the surfaces of Reflux Rinsing apparatus 400 (e.g., FIG. 4).

(51) Referring now to FIG. 13, the flow of solvent 1308 over the crystal bed 1314 is controlled by the angle thereof relative to a horizontal plane of Reflux Rinsing apparatus 400 (e.g., FIG. 4). Any mechanism 1315 for adjusting the angle of crystal bed 1314 can be incorporated in Reflux Rinsing apparatus 400 (e.g., FIG. 4). Once again, crystalline mass 1310 is spread on the surfaces of Reflux Rinsing apparatus 400 (e.g., FIG. 4).

(52) Reflux Rinsing apparatus 400 can be modular, making it easy to load and unload, with the ability to add vibration of controlled frequency and to control all variables over multiple cycle times. Moreover, Reflux Rinsing apparatus 400 has design features necessary to prevent disruption of crystalline mass 1310 during solvent addition or removal.

(53) Referring now to FIGS. 14-16, examples of other design features for Reflux Rinsing apparatus 400 are shown.

(54) Referring now again to FIG. 14, a plurality of vessels 1404 can be stacked, as shown, in Reflux Rinsing apparatus 400 as a design feature thereof.

(55) Referring now also to FIG. 15, sight glass 1514 can be placed anywhere on apparatus 400, as shown, as a design feature of Reflux Rinsing apparatus 400.

(56) Referring now also to FIG. 16, a source of vibration 1616 can be operatively connected to Reflux Rinsing apparatus 400 as a design feature thereof.

(57) Referring now to FIG. 17, a flow chart of operations 1700 is shown. Flowers and trim of one or more cannabis plants are provided, step 1710. The plant material is soaked with a mixture of butane and propane in a reaction or collection vessel, step 1720. The walls and/or bottom surface of the reaction or collection vessel are coated with the material, step 1730.

(58) The collection vessel is heated to a temperature of approximately 115° F., step 1740, after which the heat is no longer applied, step 1750.

(59) The vapor/thin-film DER is promoted, step 1760a, forming purified crystals under pressure by allowing the mixture to cool or heat, step 1760b, after which the hydrocarbon solvent is reclaimed, step 1760c. Thermal cycling, if required, can occur among steps 1740, 1760a, and 1760b. It has been found that a predetermined range is most efficient for forming crystals, so thermal cycling occurs within the boundary temperatures of the range.

(60) The hydrocarbon solvent is reclaimed from the reaction vessel, step 1760c, leaving behind purified crystals, which are scraped from the sides of the reaction or collection vessel once it is opened, step 1770.

(61) Since other modifications and changes varied to fit particular operating requirements and environments will be apparent to those skilled in the art, the invention is not considered limited to the example chosen for purposes of disclosure and covers all changes and modifications which do not constitute departures from the true spirit and scope of this invention.