Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS FOR FORMING SMOKING PRODUCTS
Cross-Reference To Related Applications
[0001] This application claims the benefit of US provisional patent
application serial no.
63/322,833, entitled "Method of Making Formed Insert for Pre-Roll
Joint/Cigarette," filed
March 23, 2022, and also claims the benefit of US provisional patent
application serial number
no. 63/274,147, entitled "Design of Formed Insert for Pre-Roll
Joint/Cigarette," filed
November 1, 2021. Each of the above-referenced provisional applicalions is
herein
incorporated by reference herein in its entirety.
Field of the Invention
[0002] The present invention discloses an apparatus and method for making
smoking
products. More specifically, the present invention discloses an apparatus and
method for
forming a smoking product including one or more of marijuana, tobacco, and
cannabidiol.
Background
[0003] Among those who use smoking products, the desirability of marijuana as
a smoking
product has increased, while the use of only tobacco as a smoking product has
decreased. Some
users prefer a more substantially pure marijuana smoking product, while other
users prefer
materials, such as, for example, but not by way of limitation, marijuana,
tobacco, and/or
cannabidiol, more commonly known by the abbreviation -CBD." Some users prefer
the
addition of CBD, for some of its reported benefits, such as reduction of
anxiety and insomnia,
control of chronic pain, reduction of inflammation, and reduction of cravings
for certain
addictive drugs.
[0004] Therefore, making a cigarette-type smoking product would seem to be a
simple
task. However, to easily manufacture a smoking product that reliably smokes
well when
smoked like a cigarette has been difficult. Marijuana and CBD can be "sticky-
when ground,
making it difficult to dispense equal amounts for each cigarette-type smoking
product. Many
users have bought smoking papers to hand-roll a small amount of marijuana
(substantially
whole or ground) into a cigarette-type smoking product. Disadvantages in this
method became
apparent, though, when the hand-rolled marijuana smoking product was smoked.
The hand-
rolled marijuana smoking product did not smoke consistently like a cigarette
or cigar. The
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marijuana burned at inconsistent rates, and therefore produced inconsistent
amounts of smoke
to the user, thereby reducing user satisfaction with the smoking product and
the smoking
experience.
[0005] What is needed is an apparatus which would reliably make a marijuana,
or a blended
material smoking product that when smoked, provides a reliable size and shape
of smoking
product which produces a continuous and reliable amount of smoke from the
smoking product,
similar to that of a cigarette or cigar.
Summary of the Invention
[0006] In a first embodiment of the present invention, a machine assembly for
forming a
smoking product comprises a base plate carrying a die block assembly that
includes a die block
including a plurality of cavities extending therethrough, and a needle punch.
The machine
assembly further includes a bottom punch assembly having a plurality of
punches. The bottom
punch assembly is positioned below the die block. The machine assembly also
includes a top
punch assembly having a plurality of punches and positionable above the die
block. In addition,
the machine assembly further includes a hopper assembly including a hopper
configured to
carry a material to form a smoking product. The hopper is positionable above
the die block.
When the hopper is positioned over the die block, the material therein flows
into and fills the
plurality of cavities of the die block. The top punch assembly is movable to a
position above
the die block, and at least a portion of the bottom punch assembly and a
portion of the top
punch assembly move toward the die block to compress the material in the
plurality of cavities
of the die block. During compression of the material, the needle punch extends
through a
portion of the material at one end of each of the plurality of cavities to
form an opening defined
by an inner perimeter. The opening extends axially from one end of the
material a distance
toward an opposite end of the material. After compression of the material is
withdrawn, a
smoking product is formed from each cavity, and each smoking product is
ejected from each
cavity of the die block.
[0007] In one aspect of the first embodiment, the machine assembly includes a
mounting
plate positioned above the base plate and slidably connected thereto. The
hopper assembly and
the top punch assembly are each movably carried by the mounting plate as well.
[0008] In another aspect of the first embodiment, the die plate assembly
further includes a
first end punch for forming a first end of the smoking product, and a second
end punch for
forming a second end of the smoking product.
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[0009] In yet a further aspect of the first embodiment, the needle punch is
connected to the
first end punch.
100101 In yet another aspect of the first embodiment, each punch has a psi
during
compression in a range of between 5 and 25 psi.
[0011] In still yet a further aspect of the first embodiment, the bottom punch
assembly is
movable to control the amount of material that forms the smoking product.
[0012] Moreover, in another aspect of the first embodiment, the plurality of
bottom punches
move upward to eject each smoking product from each cavity of the die block.
[0013] In a further aspect of the first embodiment, the plurality of bottom
punches move
upward to eject each smoking product from each cavity of the die block.
[0014] In still another aspect of the first embodiment, the plurality of
bottom punches move
upward to eject each smoking product from each cavity of the die block.
[0015] In yet another aspect of the first embodiment, the hopper assembly
includes a feed
shoe, and the feed show moves each smoking product over a base plate to a
chute loading
assembly. Each smoking product moves down a chute of the chute assembly and
into one
preformed paper of a plurality of preformed papers held in a row of a loading
machine. When
each smoking product moves into a preformed paper, a pusher arm presses an end
of the
smoking product to seat the smoking product within the preformed paper.
[0016] In a further aspect of the first embodiment, the machine assembly is
carried by a
frame, and a portion of the frame includes a plurality of wheels.
[0017] In a second embodiment of the present invention, a method of making a
smoking
product comprises providing a smoking material comprising at least one of
marijuana,
cannabidiol, and tobacco. The method also comprises providing a machine
assembly for
producing the smoking product, and the machine assembly comprises a base plate
carrying a
die block assembly including a die block having plurality of cavities
extending therethrough,
and a needle punch. The machine assembly also includes a bottom punch assembly
positioned
below the die block, a top punch assembly positionable above the die block,
and a hopper
assembly including a hopper configured to carry a smoking material to form the
smoking
product, the hopper having an open lower end. The method further includes
filling a portion
of the hopper with a smoking material, and positioning the hopper over the die
block to permit
the material therein to flow and fill the plurality of cavities of the die
block. And the method
includes moving the top punch assembly to a position above the die block,
moving at least a
portion of the bottom punch assembly and a portion of the top punch toward the
die block and
compressing the material in the plurality of cavities, and moving the needle
punch into a
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portion of the material at one end of each of the plurality of cavities to
form an opening defined
by an inner perimeter axially positioned through a portion of a central
interior of the material.
The method also includes retracting the top punch assembly and the needle
assembly from each
cavity of the plurality of cavities, thereby forming the smoking product in
each cavity, and
ejecting each smoking product from each cavity.
[0018] In one aspect of the second embodiment, in the step of providing a
machine assembly,
the machine assembly further comprises a mounting plate positioned above the
base plate and
slidably connected thereto. The hopper assembly and the top punch assembly are
each movably
carried by the mounting plate.
[0019] In another aspect of the second embodiment the die plate assembly
further
includes a first end punch for forming a first end of the smoking product, and
a second end
punch for forming a second end of the smoking product. The needle punch is
connected to the
first end punch.
[0020] In a further aspect of the second embodiment, the bottom punch assembly
movement
controls the amount of material that forms the smoking product The plurality
of bottom
punches move upward to compress the material to form the smoking product, and
after
compression, the bottom punches are moved further upward to eject each smoking
product
from each cavity of the die block.
[0021] In a third embodiment of the present invention, a smoking product
comprises a
material comprising at least one of marijuana, cannabidiol, and tobacco,
wherein the material
is formed into a frusto-conical configuration, wherein an opening defined by
an internal
perimeter is formed at one end of the smoking product and extends axially
along a portion of
the length of the frusto-conical configuration, the opening ending before
reaching an opposite
end of the frusto-conical configuration.
Brief Description of the Drawings
[0022] The disclosure will be better understood, and features set forth above
will become
apparent when consideration is given to the following detailed description
thereof Such
description makes reference to the annexed drawings wherein:
100231 FIG. 1 is a perspective view of a smoking product of the present
invention;
[0024] FIG. 2 is a perspective view of the smoking product of FIG. 1, but
showing an opening
positioned internally within a portion of a length of the smoking product;
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[0025] FIG. 3 is a cross-sectional view of FIG. 1, showing the shape and
length of the
opening formed within the smoking product;
[0026] FIG. 4 is a perspective view of the smoking product of FIG. 1 which may
be inserted
into a preformed paper configured to hold the smoking product for smoking by a
user;
[0027] FIG. 5 is a perspective view of a smoking product machine assembly
carried by a
frame of the present invention;
[0028] FIG. 6 is a perspective view of the smoking product machine assembly of
FIG. 5;
[0029] FIG. 7 is a cross sectional view of a portion of the smoking product
machine assembly
of FIG. 6, positioned in an inactive position;
[0030] FIG. 8 is a cross sectional view similar to FIG. 7, but showing a
position of the hopper
which permits material to be removed from the hopper assembly;
[0031] FIG. 9 is a cross sectional view similar to FIG. 7, but showing the
hopper assembly
in an initial fill position to begin formation of smoking products;
[0032] FIG. 10 is a cross sectional view similar to FIG. 9, but showing air
flow and stirring
of the material in the hopper;
[0033] FIG. 11 is a perspective view of the die block assembly;
[0034] FIG. 12 is a cross sectional view of a portion of the machine assembly,
showing the
material from the hopper positioned within one die punch of the die punch
assembly, with the
bottom punch assembly positioned below the die punch, the top punch assembly
positioned
above the material in the die punch, a front punch positioned at one end of
the die punch, a rear
punch positioned at an opposite end of the die punch, and a needle punch
positioned adjacent
the rear punch;
[0035] FIG. 13 is a cross sectional view similar to FIG. 12, but showing the
actuation of the
top punch assembly, the bottom punch assembly, the front punch, the rear
punch, and the needle
punch to form the smoking product of FIGS. 1-3;
[0036] FIG. 14 is a cross sectional view similar to FIG. 13, but showing the
withdrawal of
all upward punches and the top punch assembly, with the exception of the
bottom punch
assembly whose bottom punches move upward to raise the newly formed smoking
product(s);
[0037] FIG. 15 is a side view of the hopper assembly and the top and bottom
punch
assemblies, a hopper feed shoe positioned to move each of the smoking
products:
[0038] FIG. 16 is a perspective view of a portion of the machine assembly,
showing a
plurality of smoking products held and moved by the hopper feed shoe to a
loading chute;
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[0039] FIG. 17 is a cross sectional view of a portion of the machine assembly,
showing a
smoking product traveling down a cute to a loading magazine holding a
plurality of preformed
papers, each paper configured to hold a smoking product therein;
[0040] FIG. 18 is a perspective view of the top punch have a plurality of
movable punches
positioned therein, and a pair of spacers positioned on a surface of the top
punch; and
[0041] FIG. 19 is a perspective view of the bottom punch having a plurality of
movable
punches positioned therein.
Detailed Description
[0042] One or more specific embodiments of the present disclosure will be
described
below. In an effort to provide a concise description of these embodiments, all
features of an
actual implementation may not be described in the specification. It should be
appreciated that
in the development of any such actual implementation, as in any engineering or
design project,
numerous implementation-specific decisions must be made to achieve the
developers' specific
goals, such as compliance with system-related and business-related
constraints, which may
vary from one implementation to another. Moreover, it should be appreciated
that such a
development effort might be complex and time consuming, but would nevertheless
be a routine
undertaking of design, fabrication, and manufacture for those of ordinary
skill having the
benefit of this disclosure.
[0043] When introducing elements of various embodiments of the present
disclosure, the
articles "a,- "an,- "the,- and -said- are intended to mean that there are one
or more of the
elements. The terms "comprising," "including," and "having" are intended to be
inclusive and
mean that there may be additional elements other than the listed elements. The
variations of
-comprising", -including" and -having", such as, but not by way of limitation,
-comprise",
"include", "have- or "has", are also included in this definition. Any examples
of operating
parameters and/or environmental conditions are not exclusive of other
parameters/conditions
of the disclosed embodiments.
[0044] Referring to FIGS. 1 to 3, a formed smoking product 10 is illustrated.
The formed
smoking product 10 may desirably, but not by way of limitation, be formed from
at least one
of marijuana, tobacco, and cannabidiol, as noted previously, more commonly
known by the
abbreviation "CBD". In its organic and natural form, marijuana maybe provided
as flowers
with leaves and/or stems, tobacco may be provided as primarily leaves, and CBD
may be
provided primarily as flowers. Desirably, marijuana, tobacco, and CBD may
lightly ground
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into a consistency like, for example only, basil, oregano, and the like. Other
materials known
in the art and used for consumption via smoking may also be used in the
smoking product. The
smoking product 10 is desirably formed and configured for insertion into a
commercially
available preformed paper 12 (FIG. 4).
[0045] FIG. 2 discloses that there is an opening 14 formed by an internal
peripheral surface
16 in a body 17 of the smoking product 10. As shown in FIGS. 1 and 2, the
smoking product
may desirably have an outer frusto-conical shape, and the internal peripheral
surface 16, as
defined by the phantom lines of FIG. 2, also may include, but not by way of
limitation, a frusto-
conical shape as well. The smoking product 10 may be slightly indented or
concave at a first
end 18 which has the opening 14 formed therein, and the first end 18 provides
the widest
portion of the body 17 of the smoking product 10. An opposite second end 20 is
desirably
tapered to provide the most narrow portion of the frusto-conical smoking
product 10. As
illustrated in both FIGS. 2 and 3, the opening 14 defined by the internal
peripheral surface 16
is formed through a central interior 22 of the smoking product 10. The opening
14 is desirably
formed an equal distance from every surrounding outer surface 24 of the
smoking product 10.
[0046] The internal peripheral surface 16 may desirably be formed to tailor
air flow through
the smoking product 10 during smoking by a user/consumer. The opening 16
formed by the
internal peripheral surface 16 may be desirable to control the burning
characteristics of a
specific material or blend/combination of materials used to form the smoking
product 10. In
addition, the opening 16 may also desirably ease the air flow during the
inhalation process so
that these variables can be tailored to provide the most efficient and
enjoyable smoking
experience by a user. The internal peripheral surface 16 may form a variety of
cross-sectional
shapes, and it may be of various ratios in comparison to the distance to the
outer surface 24.
The opening 14 may be formed from the first end 18 through various depths and
lengths of the
smoking product 10 in order to produce the desired effect. Dependent upon the
selected
material properties, however, it will be understood that the opening 18 may be
excluded.
[0047] Returning to FIGS. 2 and 3, the opening 12 extends axially through a
substantial
portion of the central interior 22. However, the opening 12 ends a distance
from the second
end 20. -Substantial portion," as used herein, means that the opening 12 may
desirably extend
in a range of twenty (20) to forty (40) percent from the first end 18 toward
the second end 20.
Alternatively, the opening 12 may extend in a range of forty (40) to sixty
(60) percent from the
first end 18 toward the second end 20. In a further alternative, the opening
12 may extend in a
range of forty (40) to eighty (80) percent from the first end 18 toward the
second end 20. It
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will be understood that the internal peripheral surface 16 and the opening
formed thereby 12
are desirably axially aligned with an axial length of the smoking product 10.
[0048] Referring to FIG. 4, the second end 20 of the body 17 may desirably be
inserted into
a preformed paper 12. The second end 20, as well as the first end 18, may be
flat, convex, or
concave, depending upon selected material properties, desired smoking
characteristics, and
process considerations such as, for example only, ease of insertion into the
preformed paper
12. The first end 18 of the body 17 will be ignited to initiate the smoking
process. The second
end 20 of the body 17 is the end a user places in the mouth in order to smoke
the smoking
product 10.
[0049] As illustrated in FIGS. 1 to 4, the smoking product 10 has, but not by
way of
limitation, a frusto-conical shape. The preformed paper 24 may be somewhat
frusto-conical,
as shown in FIG. 4. or, the preformed paper 24 may be cylindrical, as shown in
FIG. 17. The
smoking product 10 may be formed in a frusto-conical or cylindrical
configuration. The frusto-
conical configuration, however, facilitates the rapid insertion of the smoking
product into the
preformed paper 12 (shown in FIG 17). Tolerance for material spring-hack,
which may occur
after the forming process, may be expected and is desirably factored into a
final outer surface
24 of the smoking product 10 held within a preformed paper 12 (such adaptation
to the
cylindrical preformed paper 12 shown in FIG. 17). It will therefore be
understood that while
the smoking product 10 may retain its original frusto-conical shape, it may
also be desirable
for the frusto-conical smoking product 10 to expand within the cylindrical
preformed paper 12
(shown in FIG. 17) to form a cylindrical final smoking product 10. It will be
appreciated that
the smoking product 10 may comprise any configuration, as may the preformed
paper 12, so
long as the smoking product 10 and the preformed paper 12 performs as shown
and/or
described herein.
[0050] Returning to FIG. 4, the preformed paper 12 desirably is a standard
commercially
available preformed paper product which is offered in a variety of materials,
shapes, and sizes,
to accommodate various volumes of product in different configurations. In
general, the
preformed paper 12 consists of a rolled paper cylindrical body 26 that forms a
hollow cavity
28 therethrough for containment of smoking materials, such as the smoking
product 10. The
preformed paper 12 may also include a filter 30, which permits the user to
inhale the smoke
therethrough. Like the preformed paper 12, the filter 30 is commercially
available and may
also be offered in a variety of materials, shapes, and sizes, to accommodate
various smoking
products 10.
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[0051] Turning now to a machine assembly 32 for forming a smoking product 10,
FIG. 5
illustrates a support frame 34 used to hold and carry the machine assembly 32.
The frame 34
desirably includes a plurality of support structures 36 to support both the
frame 34 and the
machine assembly 32. A plurality of rollers 38 connected to the frame 34
desirably may
provide an apparatus to permit movement of the frame 34 and the machine
assembly 32.
Further, the frame 34 also may desirably provide a mounting platform for
ancillary equipment,
described below, and structure for attachment of operator protection guards
known in the art
and commercially available (not shown).
[0052] Turning now to FIGS. 6 and 7, the machine assembly 32 desirably
includes a base
plate 40 that includes a pair of spaced-apart sidewalls 42 connected thereto.
An upper edge 44
of each sidewall 42 includes a guide rail 46 upon which a mounting plate 48
moves. The
mounting plate 48 may include, but not by way of limitation, a plurality of
sliders 50 configured
to permit the mounting plate 48 to move to various positions along the guide
rails 46. The base
plate 40 desirably is the main structure of the machine assembly 32. The base
plate 40 provides
the necessary structure for locating, fastening, and supporting individual
components of the
machine assembly 32 as well as fastening considerations for the frame 34.
[0053] A hopper assembly 52 includes a hopper 54 which may have an open lower
end 56
which contacts and moves over the base plate 48 that extends through and is
connected to the
mounting plate 48. The hopper 54 includes an outer surface 60 and an inner
surface 62 forming
a compartment 64 therein, which is configured to hold the material 66, namely,
the at least one
of marijuana, tobacco, and CBD, used to form the smoking product 10.
Desirably, but not by
way of limitation, the hopper 54 is tapered toward the open lower end 56 to
promote gravity
feed of the material 66. The hopper 54 may include a cover 67 positioned over
the upper end
58.
[0054] The machine assembly 32 also desirably includes a die block assembly 68
positioned
in the base plate 40. The die block assembly 68 includes a die block 70
including a plurality of
cavities 72 formed therethrough, which operates to hold material 66 therein
and to form a
portion of the smoking products 10. The die block assembly 68 includes
additional punches
used to form each smoking product 10.
100551 A top punch assembly 74 is positioned below the mounting plate 48 and
operably
connected to the mounting plate 48. The top punch 76 carries a plurality of
top punches 77
(FIG. 18) which correspond to the plurality of cavities 72 in the die block
70. A top punch
actuator 78 is desirably connected to the top punch assembly 74 and operates
to move the top
punch 76 upward and downward over the die block 70 holding material 66 in the
plurality of
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cavities 72 therein, using the force and pressure of the top punch actuator 78
in order to form
an upper portion of the body 17 of the smoking product 10. A pair of spacers
79 limit the
downward movement of the top punch 74.
[0056] A bottom punch assembly 80 is positioned below the die block assembly
68 carried
by the base plate 40. The bottom punch assembly 80 includes a bottom punch 82
which carries
a plurality of bottom punches 83, one of which will be inserted into a
respective one of the
plurality of cavities 72 of the die block 70 to form a lower or bottom part of
the body 17 of the
smoking product 10 utilizing force and pressure provided by a bottom punch
actuator 84 which
may be mounted to the frame 34. The bottom punch 82 is positioned to move
downward and
upward relative to the die block assembly 68. The bottom punch assembly 80 may
be moved
to control the amount of material 66 received in the plurality of cavities 72
in the die block 70.
The bottom punch actuator 84 is desirably operably connected to the bottom
punch assembly
80 and operates to move the bottom punch 82 upward and downward, underneath
and through
at least a portion of the die block 70, to permit the plurality of bottom
punches therein to form
a lower portion of the body 17 of each of the smoking products 10.
[0057] The mounting plate 48 moves into a variety of positions which move
various
components over the base plate 40 and the die block assembly 68 positioned
therein to further
form the smoking product 10. These various positions and components will be
discussed in
further detail below. However, once formed, each smoking product 10 is
desirably moved via
a chute loading assembly 86 to a loading magazine 88 holding a plurality of
preformed papers
12. Desirably, each smoking product 10 is moved into one of the plurality of
preformed papers
12 held the by loading magazine 88.
[0058] As illustrated in FIGS. 6 and 17, the loading magazine 88 may also
include a form
pusher assembly 90. The form pusher assembly 90 desirably includes a pusher
arm 92 activated
by a pusher arm actuator 94 (FIG. 17) to seat each smoking product 10 to a
desired depth within
each preformed paper 12.
[0059] A gripper/picker assembly 96 is used to grasp the smoking product 10
held within the
preformed paper 12 to move the partially finished smoking product 10 for
additional finishing
and/or to bulk storage (not shown). The gripper/picker assembly 96 is known in
the art and is
commercially available. A pre-roll/ cigarette closing assembly 97 may be
included with the
machine assembly 32 or the process may be completed externally as a secondary
operation. In
order for the smoking product 10 to remain inside the preformed paper 12 to be
smoked, the
preformed paper 12 desirably is closed via twisting or crimping via the pre-
roll/cigarette
closing assembly 97. Often, the preformed paper 12 is longer than the smoking
product 10 held
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therein, as illustrated in FIGS. 4 and 17. In these circumstances, it is often
desirable to trim the
excess length of the preformed paper 12, so that the undesirable excess
flammable material is
removed for aesthetic as well as safety purposes. A trimmer assembly 98 may be
used for this
purpose. Trimmer assemblies are also known in the art and commercially
available.
[0060] Turning to FIG. 7, the machine assembly 32 is positioned in an unactive
position.
That is, the top punch assembly 74 is located above the die block assembly 68.
A base plate
cover 100 may desirably be positioned over an upper surface 102 of the base
plate 40. The
base plate cover 100 is a thin sheet that acts as an interface between the
open lower end 56 of
the hopper 54 and the upper surface 102 of the base plate 40. The base plate
cover 100 may be
constructed, for example, but not by way of limitation, of a polymer material
such as
polytetrafluoroethylene ("PTFE"), or, alternatively, a polished metallic
material such as
stainless steel. The purpose of the base plate cover 100 is used to provide a
low friction, non-
stick, high wear, and easy clean-up surface. The open lower end 56 of the
hopper 54 desirably
forms a seal and closure to the hopper 54 against the base plate cover 102. By
using various
gaskets, wipers, brushes, and/or spring compression, spillage of material 66
from the hopper
54 is desirably reduced or eliminated. In addition, the base plate cover 100
may also cover
access apertures, and the like, in the base plate 40 which might allow leakage
of the material
66 therefrom. As shown in FIG. 7, in the inactive position, the open lower end
56 of the hopper
54 is blocked by the base plate cover 100 to prevent any flow of material 66
therefrom, and the
bottom punch assembly 80 is desirably lowered, which leaves the plurality of
cavities 72 (only
one cavity 72 shown in FIG. 7) in the die block 70 open and ready to receive
material 66. The
continued use of the term "base plate 40- herein desirably may also include
the base plate cover
100. It will further be understood that material (plastic and/or metal) used
to form the base
plate cover 100, as described above, may also be used over a surface of any
other component
shown and/or described herein which comes into contact with the material 66.
[0061] The machine assembly 32 may also be positioned in an emptying position,
as shown
in FIG. 8. In the emptying position, the open lower end 56 of the hopper 54 is
moved over an
opening 104 in the base plate 40 which includes a chute 105 which may be
positioned below
the opening 104 to permit removal of material 66 from the hopper 54. The
material 66, as
illustrated, flows through the opening 104 and down the chute 105, desirably
to a container
(not shown). Removal of the material 66 from the hopper 54 permits cleaning
and inspection
of the hopper 54 and associated components of the hopper assembly 52 and the
machine
assembly 32.
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[0062] When activated by a mounting plate actuator 51 (FIG. 6), as illustrated
in FIGS. 9 and
10, in an initial step for forming smoking products 10, the mounting plate 48
moves via the
mounting plate actuator 51 the hopper assembly 52 and other components, such
as, for example
but not by way of limitation, the top punch assembly 74 to a position where
the open lower end
56 of the hopper 54 is positioned over the die plate assembly 68 and the
plurality of cavities 72
(only one cavity 72 shown in FIGS. 9 and 10) of the die plate 70. The bottom
punch assembly
80, as noted earlier, is lowered. This position of the bottom punch assembly
permits the
material 66 to flow from the open lower end 56 of the hopper 54 to move into
and to desirably
the plurality of cavities 72. In this position, as shown in FIG. 10, one or
more air flow tubes
108, each of which desirably include a plurality of openings 110, are used to
mix and move the
material 66 within the compartment 64 of hopper 54 so that the material 66
desirably moves
and flows downward through the open lower end 56 of the hopper 54. A
controlled flow of
compressed air is introduced into the air flow tubes 108 to agitate the
material 66 to encourage
a downward flow. In addition, a stirring paddle 112 may also be introduced
into the
compartment 64 to further agitate and encourage the material to flow downward
to desirably
completely fill each of the plurality of cavities 72 in the die block 70. A
motor 114 may be
connected to the stirring paddle 112. It will also be understood that the
motor 114 may desirably
connect to other components, such as, for example, but not by way of
limitation, at least one
or more actuators shown and/or described herein, or to any other component
shown and/or
described herein, to create movement thereof The motor may be an electric
motor. Finally,
vibration may also be utilized to assist in the movement of the material 66 to
completely fill
the plurality of cavities 72. One or more ultrasonic transducers 116 may be
located on the
bottom punch assembly 80, as shown in FIG. 10, or, alternatively, on the die
block assembly
68, the base plate 40, and/or a portion of the hopper assembly 52 (not shown)
to create a
vibratory effect to aid the movement of the material 66.
[0063] Referring now to FIG. 11, the die block 70 of the die block assembly 68
desirably
provide the plurality of cavities 72 which are formed completely through the
die block 70.
Each of the plurality of cavities 72 includes an inner perimeter 118 which
defines at least a
portion of the outer surface 24 of the frusto-conical shape of the smoking
product 10. It will
be appreciated that more or fewer cavities 72 may be provided (not shown).
Additionally, the
die block 70 provides location and mounting for a first end punch 120 to form
the first end 18
of the smoking product 10, and a location and mounting for a second end punch
122 to form
the second end 20 of the smoking product 10. The first end punch 120 and the
second end
punch 122 will each provide a compaction force via a punch motion actuator 124
to the body
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17 of the smoking product 10 to form and shape the first end 18 and the second
end 18 thereof,
respectively. The needle punch 126 is located inside of the first end punch
120 and will be
inserted via the punch motion actuator 126 into the central interior 22 of the
body 17 to form
the internal peripheral surface 16 of the opening 14 in the body 17. A die
compression spring
128 is included under ahead 130 of the second end punch 122 to facilitate the
extraction of the
needle punch 126 from each cavity 72 in the die block 70 since the punch
motion actuator 124
must travel further in order to completely pull the needle punch 126 away from
the die block
70 and the body 17.
[0064] Once material 66 is deposited in the plurality of cavities 72 in the
die block 70, as
illustrated in FIG. 12, the top punch assembly 74 is vertically aligned with
the die block 70 and
the bottom punch assembly 80. The material 66 desirably may extend, as shown
in FIG. 12,
from an upper surface 132 of the bottom punch assembly 80 to the upper surface
102 of the
base plate 40. Also, all punches within the die block 70, namely, the first
end punch 120, the
second end punch 122, and the needle punch 126, are positioned in a retracted
position. The
travel distance of the second end punch 122 is limited by a dowel pin 134
inserted inside a slot
cut into the second end punch 122. The top punch assembly 74 is positioned in
a retracted
position, and the bottom punch assembly 80 is positioned in its retracted
position as well. The
height of the bottom punch assembly 80 relative to the base plate 40 is
desirably adjustable in
order to change the overall volume of the plurality of cavities 72 during the
filling process, as
shown previously in FIG. 9. This is necessary to tailor the weight and density
of the final
smoking product 10 to meet desired product criteria.
[0065] Turning now to FIG. 13, the compression process discloses the formation
of the body
17 of the smoking product 32. That is, the top punch 76 of the top punch
assembly 74 is
deployed downward to form an upper portion of the outer surface 24 of the body
17, while the
bottom punch 82 of the bottom punch assembly 80 is shown in a raised position,
to form a
lower portion of the outer surface 24 of the body 17. The first end punch 120,
the second end
punch 122, and the needle punch 126 are all shown in a deployed, extended
position. Each
punch shown and/or described herein desirably may provide 5 to 25 psi to form
the body 17 of
the smoking product 10. However, it will be understood that the psi ranges may
vary, based
on, for example, but not by way of limitation, the materials used, the desired
thickness of the
body 17, and the like.
[0066] FIG. 14 illustrates the smoking product 10 after formation and in the
ejected position.
The top punch assembly 74, the first end punch 120, the second end punch 122,
and the needle
punch 126, are all positioned in a retracted position. In contrast, however,
the bottom punch
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82 and the punches thereon is moved upward, into an extended position into
each cavity 72 of
the die block 70, in order to move and eject each smoking product 10 from the
die block 70. It
will be understood, however, that no portion of the bottom punch 70 extends
above the upper
surface 102 of the base plate 40. The mounting plate 48 on components
connected thereto is
moved away from the die block assembly 68 in the base plate 40 to the inactive
position shown
in FIG. 7 when the newly formed plurality of smoking products 10 are moved to
the upper
surface 102 of the base plate 40.
[0067] A hopper feed shoe 136 may be positioned in front of and may desirably
extend from
a front side 138 of the hopper assembly 52 and may form a portion of the
hopper assembly 52,
as illustrated in FIGS. 15 and 16. Desirably, the hopper assembly 52 moves
forward, shown
in FIG. 9, until hopper feed shoe 136 contacts the plurality of newly formed
smoking products,
as shown in FIGS. 14 and 15. As the hopper feed shoe 136 contacts each of the
plurality of
smoking products 10, each smoking product 10 is positioned between two guide
walls 140
which separate each smoking product 10 from another. The plurality of smoking
products 10
are then moved forward over the upper surface 102 of the base plate 40. As
will be noted in
FIG. 16, the guide walls 140 act to align each smoking product 10 with each
chute of a plurality
of chutes 144 formed in the chute loading assembly 86, which functions to
transfer each
smoking product 10 for insertion into a preformed paper 12. During this stage,
the bottom
punch assembly 80 including the bottom punch 82 desirably lowers, returning to
the initial fill
position described previously and shown in FIG. 9.
[0068] The during the above-described process, the top punch assembly 74 is
desirably
moved by the mounting plate 48 over cleaning brushes 142 mounted on a portion
of the base
plate 40 (FIG. 17). This movement functions to clean and to remove debris
remaining on any
portion of the top punch assembly 74, in order to leave a clean surface
thereon, in preparation
for the next smoking product formation/compression cycle.
[0069] Thereafter the above-described process, the mounting plate 48 moves the
hopper
assembly 52 carried thereon back to the initial fill position, as shown in
FIG. 9. Therefore, the
initial fill position begins again, to begin a new cycle of forming/compacting
new smoking
products 10.
100701 Turning now to FIGS. 16 and 17, as noted above, newly formed smoking
materials
are moved by the hopper feed shoe 136 into the loading chutes 138 of the chute
loading
assembly 86 so that the plurality of newly formed smoking products are aligned
to continue
through their respective chute channels 146 via gravitational force. Each
smoking item 10 falls
or moves into a preformed paper 12 (which may desirably include a filter 30
positioned in a
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lower end 147 thereof) through an open upper end 148 of the preformed paper
12. Desirably,
each preformed paper 12 is held in one of a plurality of a paper holders 150
of the loading
magazine 88. It will be appreciated that a respective plurality of preformed
papers 12 are each
held in one of a respective plurality of paper holders 150. It will also be
understood that each
newly formed smoking product 10 moves toward the chute loading assembly 86
with the
smaller, tapered second end 20 positioned to lead each smoking product 10 into
each loading
chute 144 and into each preformed paper 12 as well, as shown in FIG. 17.
100711 When each paper holder 150 in a row 152 of a plurality of paper holders
150 is filled
with a smoking product 10, the loading magazine 88 moves forward so that a
next row 150 of
a plurality of paper holders 152, holding a respective plurality of preformed
papers 12 is
positioned under the chute loading assembly 86. The previously filled row may
desirably be
positioned directly under a form pusher assembly 90. The form pusher assembly
90 functions
to ensure that each smoking product 10 is seated firmly in the lower end 147
of the preformed
paper 12 by applying downward force against the first end 18 of the smoking
product 10 via a
pusher head 154 of the pusher arm 92 which is moved by upward and downward by
the pusher
motion actuator 94.
[0072] The loading magazine 88 provides storage of a large quantity of
preformed papers 12
along with an apparatus for providing and supporting the plurality of
preformed papers 12.
Desirably, the loading magazine 88 may operate for extended periods of time
with minimal
operator interaction. This is accomplished by allowing an operator to load a
plurality of
preformed papers 12 at one time into the plurality of paper holders 150, and
at the same time
preparing the machine assembly 32 to run for an extended period of time to
fill a respective
plurality of preformed papers 12 with a respective plurality of smoking
products 10. To
accomplish this task, the loading magazine 88 via use of one or more motion
actuators 156 on
multiple axis may present a plurality of rows 154 of paper holders 150, each
holding a
preformed paper 12, on multiple tiers so that the entire storage quantity of
preformed papers
12 provided by the loading magazine 88 may each be loaded with a seated
smoking product 10
without external support by the operator.
[0073] The foregoing is considered as illustrative only of the principles of
the disclosure.
Further, since numerous modifications and changes will readily occur to those
of ordinary skill
in the art, it is not desired to limit the disclosure to the exact
construction and operation shown
and described, and accordingly, all suitable modifications and equivalents may
be resorted to,
and fall within the scope of this disclosure.
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[0074] While only certain features of the disclosure have been illustrated and
described
herein, many modifications and changes will occur to those skilled in the art.
It is, therefore,
to be understood that the appended claims are intended to cover all such
modifications and
changes as fall within the true spirit of the disclosure.
[0075] The techniques presented and claimed herein are referenced and applied
to material
objects and concrete examples of a practical nature that demonstrably improve
the present
technical field and, as such, are not abstract, intangible or purely
theoretical. Further, if any
claims appended to the end of this specification contain one or more elements
designated as
"means for [performling [a function]... or "step for [perform]ing [a
function]... it is
intended that such elements are to be interpreted under 35 U.S.C. 112(0.
However, for any
claims containing elements designated in any other manner, it is intended that
such elements
are not to be interpreted under 35 U.S.C. 112(0.
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