Abstract:
Herein described is a cigarette filling apparatus for loading substrate into blank cigarette tubes and adapted for use with conventional cigarette filling machines. The invention furthermore relates to methods of filling blank cigarette tubes using the apparatus described herein. The apparatus described herein reduces human error and increases filling speeds of conventional personal use cigarette filling machines. The apparatus generally comprises a tube dispensing member, a filler dispensing member, a tube loading arm, packing foot, filler hopper, and a tube hopper.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Patent Application Ser. No. 61/757,781 filed Jan. 29, 2013. The disclosure of U.S. Provisional Patent Application 61/757,781 is incorporated by reference herein in its entirety. 
     
    
     FIELD 
       [0002]    The present invention relates to a cigarette filling apparatus for loading substrate into blank cigarette tubes and adapted for use with conventional cigarette filling machines. The invention furthermore relates to methods of filling blank cigarette tubes using the apparatus described herein. 
       BACKGROUND 
       [0003]    Off the shelf cigarette filling machines currently on the market (particularly those for home or personal use) are slow, lack durability or dependability, and result in frequent mauling of the cigarette blanks and resulting in significant time, effort, and money wasted. One problem frequently encountered in existing machines for personal home use is that the blanks are extremely delicate and are typically loaded for filling by hand. Thus, human error frequently results in a mangled, ripped, or shredded blank. For example, even a small amount of pressure exerted by the user&#39;s finger tips often bends the blank as it is being transferred to the nipple extruder on apparatus resulting in tears and mangling. Furthermore, the blank must be transferred to the nipple of the apparatus in the proper position and failure to do so may also result in mauling of the blank as the tobacco or other substrate is fed into it. As mentioned above, these personal use machines are very slow since the user must pick up and load the blanks one by one by hand. The human error caused by dropped blanks, as well as torn or ripped blanks dramatically slows down the process as does the number of arm and hand movements necessary for each blank. User fatigue is also a factor. What is needed therefore is an apparatus that loads cigarettes using the small, personal use machines, improving efficiency and speed, reducing user fatigue, and also minimizing damage to the blanks. 
       SUMMARY 
       [0004]    One object of the present invention is to provide a cigarette filling apparatus for loading substrate into blank cigarette tubes that is adapted for use with conventional cigarette filling machines. Another object of the present invention is to provide an apparatus for loading substrate into blank cigarette tubes comprising a tube dispensing member and a filler dispensing member. 
         [0005]    In some embodiments the tube dispensing member temporarily stores blank cigarette tubes, dispenses blank cigarette tubes for filling in a controlled manner, and presents said blank cigarette tubes to said cigarette filling machine for filling with desired substrate and a filler chamber. In some embodiments, the filler dispensing member temporarily stores the desired substrate in said filler chamber, advances the substrate to the cigarette filling machine in a controlled manner, and packs the substrate into the cigarette filling machine for loading into the blank tube with said packing foot. 
         [0006]    In one embodiment, the tube dispensing member comprises a tube hopper, a tube loading arm, and a platform. In some embodiments, the tube hopper further comprises a ramp for advancement of tubes for filling. In another embodiment, the ramp may further comprise a secondary wall or barrier for restricting the size of the blank positioned within said hopper on said ramp. In yet another embodiment, the ramp comprises a slot at one end of the ramp wherein an empty cigarette blank may pass through. In yet another embodiment, the tube loading arm rests upon said platform wherein each of the tube loading arm and the platform are positioned underneath the ramp. In some embodiments, the tube loading arm further comprises an extension protruding from the underside of the arm which may further comprise a hook for receiving a rubber band or other retention element, such as a spring. In other embodiments, the platform, upon which the tube loading arm may rest, comprises one or more slots for receiving the tube loading arm extension. Said slots may be set at a predetermined angles to the side of the cigarette filling machine and the nipple for guiding the extension, the tube loading arm, and thereby the open end of the cigarette blank carefully and precisely to the nipple of a conventional cigarette filling machine. In an alternative embodiment, the tube loading arm pivots about a central pivot point through its engagement with the platform. In some embodiments, the tube loading arm is connected to a retention element which is used to return the arm to a primary position for loading with an empty blank. In some embodiments, the tube loading arm may comprise a tube press, a tube contact surface, and a tab each of which is designed hold the blank tube in the proper position for presentation to the cigarette rolling machine nipple. 
         [0007]    In one embodiment the filler dispenser member comprises a filler chamber and, in yet additional embodiments, the filler chamber further comprises a filler hopper, a filler roller, and a packing foot. The packing foot may comprise a first member and a second member for securing one end of a retention element. Likewise the filler hopper may comprise a first member and a second member for securing a second end of a retention element. In some embodiments, the filler chamber may comprise a rear extension, a first front leg, and a second front leg for securing to a front side and a rear side of a cigarette filling machine. The filler chamber may also comprise a base which secures to or engages with a top surface of a cigarette filling machine. 
         [0008]    Another object of the present invention is to provide a method for filling empty cigarette tubes with filler. In one embodiment, the method may comprise the steps of placing empty tubes in a tube dispenser member comprising a tube hopper and a tube loading arm, placing filler in a filler dispenser member comprising a filler chamber and a packing foot, advancing filler through the tube hopper and into a filler receptacle defined in a conventional cigarette filling machine by filler roller, sliding said packing foot downward and compacting the filler into the filler receptacle of a conventional cigarette filling machine, activating said tube loading arm loaded with a blank tube toward the nipple of a conventional cigarette filling machine open end first, releasing said tube loading arm wherein said blank tube remains suspended on said nipple; and activating the filling mechanism of a conventional cigarette filling machine. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    Representative embodiments of the invention are disclosed in more detail with reference to the following figures. Like reference numerals designate corresponding parts or steps throughout the different views. 
           [0010]      FIG. 1  shows a front view of an embodiment of the present invention. 
           [0011]      FIG. 2  shows a front view of an alternative embodiment of the present invention. 
           [0012]      FIG. 3  shows a front view of an embodiment of the present invention with tube loading arm in motion and presenting a tube to the cigarette machine nipple. 
           [0013]      FIG. 4A-B  shows embodiments of the filler dispenser member. 
           [0014]      FIG. 5  shows a tube dispensing member ramp and tube barrier attachment. 
           [0015]      FIG. 6A-B  shows an embodiment of the tube loading arm extension guided by slots and retention elements. 
           [0016]      FIG. 7A-B  shows an embodiment of a spring activated tube loading arm pivoting about a central point. 
           [0017]      FIG. 8A-B  shows an embodiment of a filler dispenser member with the packing foot being pressed. 
           [0018]      FIG. 9A-B  shows an embodiment of certain critical angles and measurements associated with a fully functioning tube dispenser member mechanism. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]    The present invention now will be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments by which the invention may be practiced. 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. Among other things, the present invention may be embodied as methods or devices. 
         [0020]    Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrase “in one embodiment” or “in some embodiments” or “in a preferred embodiment” (or similar phrases) as used herein does not necessarily refer to the same embodiment, though it may. Furthermore, the phrase “in another embodiment” (or similar phrases) as used herein does not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments of the invention may be readily combined, without departing from the scope or spirit of the invention. 
         [0021]    In addition, as used herein, the term “or” is an inclusive “or” operator, and is equivalent to the term “and/or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.” 
         [0022]    it should be noted that although the discussions herein may refer to a specific order and composition of method steps, it is understood that the order of these steps may differ from what is described. For example, two or more steps may be performed concurrently or with partial concurrence. Also, some method steps that are performed as discrete steps may be combined, steps being performed as a combined step may be separated into discrete steps, the sequence of certain processes may be reversed or otherwise varied, and the nature or number of discrete processes may be altered or varied. The order or sequence of any element or apparatus may be varied or substituted according to alternative embodiments. Accordingly, all such modifications are intended to be included within the scope of the present invention. 
         [0023]    Referring now to the embodiment depicted in  FIG. 1 , the cigarette filling machine adapter  100  may comprise a base or platform  101  upon which the apparatus rests. Base  101  may partially engage a surface of an off the shelf cigarette filling machine such that the adapter  100  is substantially stationary with little to no change in position while used for its intended purpose. As shown in the embodiment depicted in  FIG. 1 , engaged to a first surface  102  of base  101  is a filler dispenser member  103  comprising an arm  104  (not shown in this illustration) engaged to or resting upon the first surface  102  of base  101 , filler chamber  105 , filler hopper  106 , filler roller  107 , and a packing foot  108 . As shown in  FIG. 1 , however, the base  101  of filler dispenser member  103  may rest directly and engage the surface of the cigarette filling machine directly and omit arm  104  altogether. Alternatively, as illustrated in  FIG. 2 , the apparatus may not have a base  101 . 
         [0024]    In yet another embodiment, base  101  may be engaged to and positioned underneath the filler chamber  105 , for example, as depicted in  FIG. 1  and  FIG. 4B . In this embodiment base  101  is a flat surface and is secured (e.g. snapped) to existing structures present on the top surface of the conventional cigarette filling machine. 
         [0025]    In another embodiment, filler dispenser member  103  may comprise stabilizing extension  109 , first arm  110 , and second arm  111  which extend down the front and rear sides of the cigarette filling machine providing additional support to the filler dispenser member  103 . This embodiment is illustrated in  FIGS. 2 ,  3  and  4 A. In said embodiment, the filler dispenser member  103  rests upon the top surface of the cigarette filling machine and is supported by extension  109 , first arm  110 , and second arm  111 . 
         [0026]    The apparatus may comprise a tube dispenser member  112  engaged to first surface  102  of base  101  (not illustrated). In the embodiment illustrated in  FIG. 2 , tube dispenser member  112  comprises a first leg  113  and second leg  114  each engaged to first surface  102  of base  101  (not illustrated) to support and elevate the other components of tube dispenser member  112  to their proper position for accurate tube filling. In some embodiments, the tube dispenser member  112  may comprise more than two legs or may omit legs altogether. It should be recognized that other structures for supporting tube dispenser member  112  may be equally suitable for the purposes of the present invention as long as said tube dispenser member is stable, substantially supported and elevated to the proper position/height for accurate delivery and placement of the blank cigarette tube&#39;s open end to the cigarette filling machine nipple for filling with substrate. For example, the embodiment shown in  FIGS. 2 and 3  omits a base  101  positioned underneath said tube dispensing member. Rather, the tube dispenser member  112  in said embodiment is supported by a first leg  113  and an opposing second leg  114  which directly engages or rests upon a support surface such as a table, countertop, or tray. 
         [0027]    Tube dispenser member  112  further comprises a tube hopper  115  for placement and positioning of tubes for filling. It will be recognized by those of skill in the art that tube hopper  116  may be of any size and shape and may be loaded with any number of tubes (one or more). As shown in  FIGS. 1 and 4B , tube dispenser member  112  may be engaged to filler dispenser member  103  and, in fact, may form a unitary structure with filler dispenser member  103  such that first leg  113  and second leg  114  are not needed to support the structure. Legs or some other support element may be used, however, in this embodiment. 
         [0028]    As shown in the embodiment illustrated in  FIGS. 1-3  and  5 , tube hopper  115  may comprise ramp  116  and a first side  117 , second side  118  and third side  119 . Ramp  116  may be inclined whereby tubes placed within tube hopper  115  are drawn by gravity toward third side  119  which in this embodiment is the lower end of the ramp. In one embodiment, ramp  116  is adapted to receive a tube barrier  120  for accommodating different sizes of tubes. For example, in the embodiment shown in  FIG. 5 , tube barrier  120  may be placed within tube hopper  115  on ramp  116  and engaged thereto with tube barrier supports which, in this embodiment, are slots  121   a  and  121   b  and extensions  122   a  and  122   b . Tube barrier  120  is used when shorter blank tubes and thus shorter cigarettes are desired. In the embodiment shown in  FIG. 5 , proximal to third side  119 , ramp  116  comprises slot  123  of sufficient dimension to allow a blank tube to pass through. In this embodiment, slot  123  is formed within the floor of ramp  116  proximal said third side  119 . As blank tubes progress down the ramp  116 , they pass through slot  123  onto platform  124  if slot  123  is not occluded by tube loading arm. The platform and tube loading arm elements are discussed more fully below. 
         [0029]    With continued reference to the embodiment illustrated in  FIGS. 1-3 , tube dispenser member  112  may comprise a platform  124  substantially underneath slot  123  in ramp  116  of tube hopper  115 . Once a blank tube passes through slot  123  it comes to rest on platform  124  and awaits engagement with a tube loading arm  125  which is supported by and engaged to tube dispenser member  112 . 
         [0030]    In the embodiment shown in  FIGS. 1 and 2 , tube loading arm  126  may comprise a press or lever  126 , tube contact surface  127 , and tab  128  which prevents unwanted movement of a tube once engaged with tube loading arm  125 . In one embodiment (see  FIGS. 7A-7B ), tube loading arm  126  engages platform  124  at pivot  129  which allows tube loading arm  125  to rotate about a central axis point defined by the center point of pivot  129 . The tube loading arm  125  shown in  FIGS. 7A-7B , further comprises a first spring retention element  130  that engages first end  131  of spring  132 . Platform  124  also comprises second spring retention element  133  that engages the second end  134  of spring  132 . Spring  132  applies a retraction force to tube loading arm whereby tube loading arm  125  is returned to loading position after delivery of a tube to filler dispenser member  103  for filling. 
         [0031]    In another embodiment illustrated in  FIG. 6A-6B , tube loading arm  125  may engage platform  124  through extension  135  defined on the underside of tube loading arm  126  and grooves  136   a  and  136   b  defined in platform  124 . In this embodiment, two grooves are provided to accommodate two different sizes or lengths of blank tubes; however, it is noted that a single groove or more than two grooves may be provided. In this embodiment, the grooves defined in platform  124  are at a precisely defined and predetermined angle (e.g. a as illustrated in  FIG. 9 ) and position whereby as the extension  135  travels through grooves  136   a  or  136   b , the tube loading arm  125  guides the blank tube directly to the cigarette filling machine nipple such that the open end is carefully inserted onto the nipple (e.g. overlapping the hard exterior surface of the nipple) without molesting, tearing, or bending the delicate paper. In one embodiment, a is about 25.3129° in relation to the axis shown as A- 1  in  FIG. 9 . Moreover, it should be noted that grooves  136   a  and  136   b  are each positioned precisely to direct a blank tube of two different sizes to the nipple of the cigarette filling machine. The positioning (depending on the tube size) and the angle of the groove are important to the successful delivery of the blank tube to the nipple without molestation, tearing or bending. In one embodiment, the distance between the two grooves  136   a  and  136   b , which proportionally relates to the difference in length between two sizes of cigarettes, is about 0.5993 inches. 
         [0032]    As shown in this embodiment, tube loading arm  125  and platform  124  may not be engaged at pivot  129  as illustrated in  FIGS. 6A-6B  or use springs as retention elements for the arm  125 . Rather, tube loading arm  125  may use other equally suitable retention elements, such as a rubber band or the like. For example, in the embodiment shown in  FIG. 6A , extension  135  is defined as a hook for receiving retention element  137  (in this embodiment a rubber band) at one end. The other end of retention element  137  is received by a second hook  138  defined within first leg  113  of tube dispenser member  112 . In this embodiment, connecting retention element  137  to extension  135  (or first hook) and extension  138  (or second hook) yields tension on the tube loading arm  125  causing the arm  125  to return to its primary position after delivery of a blank tube to the nipple. The primary position of tube loading arm  125  may be defined as the position necessary to receive a blank tube from tube hopper through slot  123 . 
         [0033]    In one embodiment, tube loading arm  125  and platform  124  are designed such that at the precise moment the open end of the blank tube is placed on the nipple of the cigarette filling machine the blank tube has cleared platform  124  allowing the tube to be forced off the nipple upon filling and fall to a support surface (countertop, table, floor) thereby automatically clearing the way for another blank tube to be loaded on the nipple. As illustrated in  FIG. 9  (designated as “B”), in one embodiment, distance along the Y axis that the tube loading arm travels from start to finish (delivery and positioning of the cigarette tube on the nipple) is about 0.5289 inches. Furthermore, in some embodiments, at the fully extended, open or start position, the distance between tube contact surface  127  and the base of the cigarette filling machine nipple (or side of the cigarette filling machine) (designated as “A” in  FIG. 9 ) is about 4.4683 inches. In another embodiment, at the closed or load position (where the cigarette blank has been placed on the nipple), the distance between tube contact surface  127  and the base of the cigarette filling machine nipple (designated as “D” in  FIG. 9 ) is about 3.3500 inches. In these embodiments, the distance along the X axis that is traveled as the tube loading arm moves from start position to the load position (designated as “C” in  FIG. 9 ) is about 1.1183 inches. 
         [0034]    Referring now to the embodiments depicted in  FIGS. 1-3  and  FIGS. 8A-B , filler chamber  105  of filler dispenser member  103  comprises a first side  139 , a second side  140 , a third side  141 , and a fourth side  142 . In this embodiment, engaged to first side  139  and second side  140 , is a packing foot  143 . In the embodiment shown in  FIGS. 8A-B  packing foot  143  is slidably engaged to said first side  139  and second side  140  such that a user of the device may raise or lower (“slide”) the packing foot  143  vertically upwards and downwards by hand. In another embodiment, packing foot  143  may be spring activated whereby the foot  143  rebounds to a raised position (e.g. primary position) upon user release. In yet another embodiment, packing foot  143  may be engaged to other suitable retention element[s] other than a spring, such as a rubber band or the like, whereby said foot  143  is caused to return to its primary position upon release of downward pressure by the user. In the embodiments most clearly shown in  FIGS. 8A-B , packing foot  143  may comprise a first hook, knob or extension  144  and a second hook, knob or extension  145  on its opposite side for engaging the first end of a rubber band or other retention element. Likewise filler chamber  105  comprises a first hook, knob or extension  146  and a second hook, knob or extension  147  for engaging the second end of a rubber band. Compression of the packing foot  143  causes the rubber band to stretch increasing the tension and thereby causing the packing foot  143  to return to the upward position upon release. 
         [0035]    The packing foot  143  is designed to compress the filler or substrate within the substrate receptacle  148  built into the off the shelf cigarette rolling machine. In the embodiment depicted in  FIGS. 8A-B , as the packing foot  143  is pressed downward by the user, the bottom end of the foot  143  contacts the substrate or filler that has been dropped into the substrate receptacle from the filler hopper via roller  149 . In the embodiment shown in  FIG. 8A , the primary position of the packing foot  143  may be defined as a fully open position whereby the packing foot is at its utmost vertical position and wherein the substrate receptor on the cigarette filling machine is unobstructed and can receive filling substrate from the filler hopper. 
         [0036]    With continued reference to the embodiments depicted in  FIGS. 1-3 , filler chamber  105  may comprise a filler roller  149 . As shown in  FIGS. 1-2 , filler roller  149  may be rotabably engaged to and supported by two sides of filler chamber  105 , for example, second side  140  and third side  141 . On the outside surface of second side  140  and third side  141  and connected to opposite ends of filler roller  149  is a first handle  150  and a second handle  151  (not shown). First handle  150  and second handle  151  provide user a means by which to rotate the filler roller  149  and advance the filler or substrate held by filler chamber  105  underneath a raised packing foot  143  and into a substrate receptacle built into the cigarette filling machine. Alternatively, filler roller  149  may comprise a single handle for turning the filler roller  149  or may comprise no handle. Filler roller  149  may, in said embodiment, be turned or rotated by a motor, by remote control, or the like. 
         [0037]    Filler chamber  105  may further comprise a ramp  152  that is sloped toward packing foot  143  advancing filler toward filler roller  149  and foot  143 . As filler advances toward foot  143  and filler roller  149  and as the user turns filler roller  149  the substrate substantially covers a slot or gap  153  formed between fourth side and the bottom surface of the filler chamber and descends downward to the substrate receptacle. Alternatively, filler chamber  105  does not have a sloped or inclined ramp, but rather has vertical sides as shown in  FIGS. 1-3 . Slot  153  is positioned in a manner that is substantially above and in a shared vertical plane with a substrate receptacle—a common feature in most if not all conventional cigarette filling machines. As the user rotates filler roller  149 , a sufficient quantity of substrate advances through slot  153  and downward into the substrate receptacle. The user then advances the packing foot  143  downward and compresses the substrate within the substrate receptacle providing the proper amount of substrate for loading into the blank tube. The user also advances the tube loading arm  125  and the blank tube at rest on platform  124  toward nipple  154  which, like the substrate receptacle, is a common feature of most if not all conventional cigarette filling machines. It will be recognized by those of skill in the art that the nipple  154  defines an opening in the substrate receptacle whereby a spoon feeds the filler contained within substrate receptacle into a blank tube. It will further be recognized by those of skill in the art that the outer perimeter of nipple  154  is typically angled and that the open end of a tube must be placed over the nipple at a specific predetermined angle to avoid tear or mangling of the blank tube. Thus, it should be appreciated that the tube loading arm  125  is precisely positioned whereby movement of the arm  125  guides a tube toward the nipple  154  at the appropriate predetermined angle placing the open end of the tube over nipple  154  without tear or mangling. 
         [0038]    In alternative embodiments, the apparatus may comprise additional features, for example, a button or switch press for starting or activating an automatic powered cigarette filling machine. For example, in one embodiment, an arm or shaft may extend from and be engaged to the filler chamber wherein said arm further comprises an end tab or hammer. Said hammer may be positioned proximal the cigarette filling machine power switch or button wherein said hammer may be manipulated by the user to interact with the power switch to start the machine. 
         [0039]    In one embodiment, a user attaches the apparatus (in some embodiments, the filler dispenser) to an off the shelf cigarette filling machine resting the combination of components on a support surface of the user&#39;s choice. In some embodiments, the user then loads the filler chamber  105  with a substrate or filler and blank tubes upon the ramp  116  of tube hopper  115 . Filler is advanced into the filler receptacle of the cigarette filling machine by roller  149  and compressed or packed into the filler receptacle with packing foot  143 . The user then delivers the blank tube to the nipple via tube loading arm  125  and then releases the blank tube which is at this point substantially suspended on the nipple without further support awaiting filler delivery. When the filler is delivered to the blank tube via spoon extending through filler receptacle and out nipple, the filled tube is pushed off the nipple and onto a support surface such as a countertop, a table, a tray, the floor or the like. The tube loading arm  125  has resumed its primary position and receives another blank tube. In some embodiments, the tube loading arm  125  is designed such that as it advances the blank tube to the nipple, the tube loading arm blocks the next blank tube positioned at slot  123  from falling through causing blockage. 
         [0040]    While the present invention has been described herein with respect to the exemplary embodiments, it will become apparent to one of ordinary skill in the art that many modifications, improvements and sub-combinations of the various embodiments, adaptations and variations can be made to the invention without departing from the spirit and scope thereof.