DEVICES AND METHODS FOR FRICTIONLESS COMPACTION OF SMOKABLE PRODUCTS

Devices and methods for frictionless compaction of smokable material 141s are described herein. The methods and systems include a device, which moves into place to sit, inset, to a filled smoking cone with an integrated airline. The system then discharges a sequence of controlled air bursts to compact the unit completely.

TECHNICAL FIELD

The present disclosure relates to frictionless compaction systems and methods for smokable products.

BACKGROUND

In production of cannabis and other herbal smokeable products. Current compaction methods and devices utilize a compaction rod which comes into contact with the material and may build up resin on the tip of the rod. This configuration makes it unable to properly compact larger-format pre-rolled smoking cones. In addition, current frictionless compaction systems do not allow for interchangeability of parts to allow for compaction for smoking cones of various sizes and diameters. In addition, current methods do not provide for the configurability of the interval amount, duration, and amount of pressure applied. There is therefore a need to provide a frictionless compaction system that is interchangeable and configurable for production of smokable material 141s.

SUMMARY

An embodiment of the present disclosure is a device for use with a smoking cone. The device includes a base. The device further includes one or more vertical actuators coupled to the base and configured to be inserted into smoking cone and deliver pressurized gas to the smoking cone. The device further includes an interchangeable side plug mechanism coupled to the base. The device further includes a dial carriage couplable to the side plug mechanism and the vertical actuators. The duration, number of intervals, and amount of pressure applied to the smoking cone is adjustable.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Referring to FIG. 1, embodiments of the present disclosure include a compaction device 100 utilized with one or more smoking cones 140 having smoking material 141 in the cones to provide frictionless compaction of the material. The compaction device 100 is configured to sit, inset, in the filled smoking cone and is connected to an integrated airline that discharges a sequence of controlled gas bursts to compact the smoking material 141 completely. The gas bursts are controlled via manual adjusted, fixed, or electrically adjusted flow and pressure regulation by a user. Once the compaction sequence is completed, the compaction device 100 may retracted and may be utilized as part of a larger smoking cone manufacturing system.

This configuration allows for consistent compaction given a wide range of variable inputs by the user. The configuration further provides improved compactions near the crutch and the ability to manufacture various sizes of smoking cones with the same compaction and smoking material 141 uniformity. Furthermore, the system allows for custom formulas based off manual or electrically controlled airflow and air pressure, and an overall reduction in cleaning and improvement to production cycle time when manufacturing smoking cones with smoking material 141 products.

Referring to FIG. 1, the compaction device 100 includes a base 104, one or more vertical actuators 108 coupled to the base 104, an interchangeable side plug mechanism 112 coupled to the base 104, and a dial carriage 116 that is couplable to the side plug mechanism 112 and the vertical actuators 108A, 108B.

Referring to FIGS. 2-3, in the illustrated embodiment, the compaction device 100 includes two vertical actuators 108A, 108B. In alternative embodiments, the compaction device 100 may include more than two vertical actuators 108 . . . n. The vertical actuators 108A, 108B have a proximal end 120 and a distal end 122 opposite the proximal end 120 along a longitudinal direction L. The vertical actuators 108A, 108B move along the longitudinal direction L. The distal end 122 includes an interchangeable nozzle assembly 124. The nozzle assembly 124 includes one or more interchangeable nozzles 128 held by one or more nozzle holders 130, each coupled to the vertical actuators 108, respectively. In the illustrated embodiment, the compaction device 100 includes two nozzles 128A, 128B held by two nozzle holders 130A, 130B. In other embodiments, more than two nozzles 128 . . . n may be held by more than two nozzle holders 130 . . . n.

The nozzle holders 130A, 130B include a release spring 131 configured to hold the desired nozzle 128A, 128B in place and subsequently release the nozzle 128A, 128B, from the nozzle holder 130A, 130B when the release spring 131 is actuated. In the illustrated embodiment, the release spring 131 is a plunger. In other embodiments, the release spring may utilize known release mechanisms for holding and releasing the nozzles 128A, 128B from the nozzle holder 130A, 130B.

The nozzles 128A, 128B have an opening 132A, 132B axially through the center to allow compressed gas to be delivered through the nozzle holder 130A, 130B to enter the smoking cone. The opening 132A, 132B is greater at a portion towards the nozzle holder 130A, 130B than a portion inserted into the smoking cone 140. The nozzles 128A, 128B include angled exit holes 133 surrounding the opening 132A, 132B, for better compaction of smoking material 141 in the smoking cone 140, as further explained below. In the illustrated embodiment, the nozzles 128A, 128B have a length of about 2.88 mm. In other embodiments, the nozzles 128A, 128B may be less than 3.0 mm. In addition, the opening 132A, 132B has a diameter D1 of about 0.5 mm at the portion near the nozzle holder 130A, 130B. The opening 132A, 132B further has a diameter D2 of about 0.3 mm at the portion that's inserted into the smoking cone 140. However, in the illustrated embodiment, the nozzles 128A, 128B are interchangeable such that various nozzles of differing length, diameter, and shape may be utilized based on the size and shape of the smoking cone.

The nozzle assembly 124 further includes one or more lines 134 connected to a gas source to supply pressurized gas (e.g., air) to the device. In the illustrated embodiment the nozzle holder 130A, 130B receives its gas supply through the lines 134 via a process tube connection into the rear of the nozzle holder 130A, 130B. The gas then is directed downward through the nozzle 128A, 128B.

In the illustrated embodiment, the vertical actuators 108 are configured to provide a closed loop absolute encoder linear actuator to raise and lower the nozzle assembly 124. In one embodiment, the movement of the vertical actuators 108A, 108B and distance of longitudinal movement can be manipulated by the user to provide precise positional movement of the actuators 108A, 108B.

Referring to FIGS. 4-6, the dial carriage 116 is configured to transport one or more smoking cones 140 to the vertical actuators 108. The dial carriage 116 includes a base 150 and one or more interchangeable nests 154 coupled to the base 150.

Continuing with FIGS. 5-6, in the illustrated embodiment, the dial carriage 116 includes two nests 154A, 154B coupled to the base 150. In other embodiments, the dial carriage 116 may include more than two nests 154 . . . n. The nests 154A, 154B include a channel 153A, 153B, responsible for holding the smoking cones 140 during the compaction sequence. The nests 154A, 154B are designed for each specific cone size and shape and are therefore interchangeable (i.e. a user may change out the nest) in order to incorporate a specific cone size and shape. The nests 154A, 154B further include an opening 155A, 155B that allow for coupling of the nests 154A, 154B with the side plug mechanism 112.

Referring to FIGS. 7 and 8, the side plug mechanism 112 includes a side plug activator 158 and a side plug assembly 162. The side plug activator 158 includes a pneumatic slide table 166 to provide horizontal translation of the side plug assembly 162 from a retracted position, to an extended position where the side plug couples with the nest 154A, 154B. The side plug assembly 162 is fastened to the side plug activator 158 via a thumb screw 170. The side plug assembly 162 is unique and is interchangeable based on the specific size of the smoking cone 140 that is being utilized. When the side plug assembly 162 is inserted into the nest 154A, 154B at the opening 155A, 155B via the pneumatic actuation, the opening 155 in the nest 154A, 154B is filled. This configuration prevents the smoking cone 140 from experiencing blow outs, breaking, and/or bulging of the cone though the opening due to the increased pressure difference inside the smoking cone 140 during compaction.

Referring to FIG. 9, in the illustrated embodiment, the smoking cone 140 is a standard tapered paper cone & filter assembly. The cone 140 is comprised of a filter 174 and a cone body 178. The filter 174 includes an open tip 179. The cone body 178 includes a large opening 180 at the end of the cone body 178 such that smokable material 141 may be inserted into the cone via the opening 180 and pressurized gas may be applied to the smokable material 141 in the smoking cone 140 via the opening.

The filter 174 may be comprised of paper, wood, or ceramic materials. The cone body 178 may be made from rice paper, hemp paper, or other known combinations. In other embodiments, the cones 140 may utilize various configurations including tapered walls, straight walls, ceramic filter tips, hemp blunt paper, etc. In the illustrated embodiment, the length of the cone 140 ranges from about 84.0 mm to 140.0 mm. The smoking cone 140 may be prepared and may include characteristics as described in U.S. application Ser. No. 17/876,902 file on Jul. 29, 2022, the entire contents of which are incorporated herein.

FIGS. 10-14 depict the nozzle 128A, 128B being inserted into the cones 140 for compaction. As shown in FIGS. 10-13, the nozzle 128A, 128B is inserted directly into the opening 180 of the cones 140, which are seated in the nests 154A, 154B, respectively. The cones 140 sit in the nests 154A, 154B such that a portion of the cone is outside of the nest 154A, 154B, respectively.

The nozzle 128A, 128B is tapered to match the angle of the cone 140. In the illustrated embodiment, the nozzle 128A, 128B is tapered in a 25 degree angle. This configuration creates a seal between the nozzle 128A, 128B and the cone 140, allowing the gas (e.g., air) discharged from the nozzle to pressurize the internal body of the cone 140, forcing the smokable material 141 downward toward the tip 179. The nozzle 128A, 128B also includes angled exit holes 181 surrounding the opening 180, to create an air shield outward to the wall of the cone 140, preventing material 141 from escaping through any air gaps formed between the cone 140 and the nozzle 128A, 128B during pressurization.

The filter 174 allows the gas to escape during pressurization via the filter tip 179. This allows the compressible smoking material 141 to move downward into the base of the cone 140 and reach a level of compaction relative to the pressure of the gas supplied (as shown in FIG. 14).

FIG. 15 shows the process in which the compaction device 100 is utilized for compacting smokable material 141 in the smoking cones 140. The cones are transported to the vertical actuator 108 via the dial carriage 116. The side plug assembly 162 extends forward, inserting the side plug mechanism 112 into the opening 155A, 155B of the nest 154A, 154B. The vertical actuator 108 is lowered into position such that the nozzle 128A, 128B is inserted into a portion of the smoking cone based on the user's desire as prescribed by the specific product recipe. Compressed gas (e.g., air) is dynamically regulated via the product recipe as desired by the user and exits the nozzle 128A, 128B via the opening 132A, 132B at desired intervals, for a desired duration, and at a desired pressure as set by the user.

Thus, the duration, amount of pressure, and number of intervals of pressurized gas applied are all configurable by the user. For example, a typical compaction cycle may include three blasts of gas (e.g., air) with a duration of 500 milliseconds on, and 500 milliseconds off between each blast. In the illustrated embodiment, the gas may be released at various pressures that ranges from 12-20 psi. In another embodiment, the gas may be released at a maximum pressure of 120 psi. The compaction profile are configurable by the user to not only supply unique pressures per smokable material/product, but to also supply unique pressures per air blast. In addition, flow of gas is controllable by the user as well. For example, pressure may be increased or decreased during compaction within a specific puff/blast of pressurized gas or across any number of puffs/blasts of pressurized gas.

Once the air compaction portion of the sequence has completed, the vertical actuators 108 is returned to a resting position, and the side plug assembly 162 is returned to a retracted position.

Referring to FIGS. 16 and 17, the compaction device is utilized in conjunction with a smoking cone manufacturing system 1000. The smoking cone manufacturing system 1000 is configured to create and produced a smoking cone packed with smokable material 141 for use by a consumer. The smoking cone manufacturing system 1000 includes, in addition to the compaction device 100, a cone open station device 200, a cone load station device 300, a cone pull station device 400, an offload station device 500, a clip and tamp station device 600, a twist station device 700, and a weigh station device 800. The dial carriage 116 as described herein is positioned around a circumference of the system 1000. The dial carriage 116 is therefore further configured to index and transport the cones 140 through each device 200, 300, 400, 500, 600, 700, 100, and 800 in the manufacturing process.

While the disclosure is described herein, using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the disclosure as otherwise described and claimed herein. The precise arrangement of various elements and order of the steps of articles and methods described herein are not to be considered limiting. For instance, although the steps of the methods are described with reference to sequential series of reference signs and progression of the blocks in the figures, the method may be implemented in an order as desired.