Patent Publication Number: US-11395508-B1

Title: Spiral insert with flavor releasing mechanisms

Description:
FIELD OF THE INVENTION 
     The present invention relates to smokable pre-rolls, including smokable pre-rolls with embedded flavor releasing mechanisms. 
     BACKGROUND 
     Ready-to-smoke smokables come in many forms and shapes, ranging from cigarettes to pre-rolls (e.g., pre-rolled cones as shown in  FIG. 1 ). For those who wish to form his/her own smokable, empty cones are available into which the user adds his/her own smokable materials. In either case, the smokable oftentimes includes an insert system (such as a filter or crutch) that serves as a mouthpiece at one end of the smokable. 
     A new phenomenon is happening within the smokables industry involving the inclusion of flavor releasing mechanisms within the smokable insert system. In many cases, the flavor releasing mechanisms include small spheres filled with a flavoring substance (also known as “click balls”) that are designed to be squeezed by the user to effectively explode and release the flavoring. However, it is oftentimes costly and labor intensive to place and secure the flavor releasing mechanism properly within the insert during the manufacturing process. 
     Accordingly, there is a need for an insert system that includes an easy to use system and method to incorporate one or more flavor releasing mechanisms into a smokable insert to maximize the user&#39;s smoking experience. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein: 
         FIG. 1  show aspects of a smokable cone (prior art); 
         FIGS. 2-5  show aspects of a section for forming an insert system according to exemplary embodiments hereof; 
         FIG. 6  show aspects of a flavor releasing mechanism according to exemplary embodiments hereof; 
         FIGS. 7-13  show aspects of a folded section including a flavor releasing mechanism for forming an insert system according to exemplary embodiments hereof; 
         FIG. 14  show aspects of a folded section including a flavor releasing mechanism for forming an insert system according to exemplary embodiments hereof; and 
         FIG. 15  shows aspects of a smokable cone configured with an insert system according to exemplary embodiments hereof. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For the purposes of this specification, the terms below will mean the following. 
     Cigarette generally refers to a smokable comprising a thin cylinder of finely cut tobacco, cannabis, other types of leaves, flowers, herbs, and/or other smokable materials, rolled in a suitable paper for smoking. 
     Cone generally refers to a conical- or frustum-shaped cigarette (or “joint”) wherein the shape flares from a smaller diameter proximal base to a larger diameter distal tip (see  FIG. 1 ). Cones may typically comprise paper, hemp, palm leaves, rice, cotton cellulose, glycerin, and/or other suitable materials. 
     Pre-roll generally refers to a cigarette or cone that has been formed prior to its sale and is therefore consumer-ready (i.e., a consumer is not required to fill or otherwise form the smokable). 
     Empty cone refers to an empty cone into which a consumer may place smokable materials (e.g., tobacco, cannabis, etc.) to form a smokable cone. 
     Insert system generally refers to a mouthpiece or tip coupled with a cone or cigarette (see  FIG. 1 ) that acts to support the proximal end of the smokable (e.g., the end that is pressed against one&#39;s lips for smoking). An insert system may include a “crutch” formed of thick paper, glass or other materials, a filter (e.g., a cotton filter), other types of insert systems, and any combinations thereof. Insert systems may be used with cigarettes, cones (pre-rolled, empty, etc.), rolling papers, and other types of smokable items. 
     In general, and according to exemplary embodiments hereof, an insert system  10  including an internal spiral and cutout for securing flavor releasing mechanisms (e.g., flavored “click balls”) and for use with a smokable item (e.g., a pre-roll cone, an empty cone, a pre-rolled or hand-rolled cigarette, etc.) is provided. In some embodiments, the insert system with an internal spiral and cutout is provided as a standalone item for use in pre-rolling and/or hand rolling a cone or cigarette. In this case, flavor releasing mechanisms may be inserted into the insert system&#39;s internal spiral and cutout and the insert system may be coupled with the proximal end of a rolling paper or cone to form the smokable item. In other embodiments, the insert system includes (e.g., is coupled with) an empty cone and is provided to the consumer. In this case, it may be preferable that the insert system include flavor releasing mechanisms already placed within the insert system&#39;s internal spiral and cutout and ready for use by the consumer. The consumer then may fill the empty cone with smokable materials to form a smokable cone wherein the insert system is used as the cone&#39;s mouthpiece. Any combinations of these embodiments also are contemplated. 
     In one exemplary embodiment hereof as shown in  FIGS. 2 and 6 , the insert system  10  includes a section  100  and one or more flavor releasing mechanisms  200 . As described herein, the section  100  is formed into an insert and the flavor releasing mechanism  200  is placed within the insert to form the insert system  10 . 
     Section  100   
     As shown in  FIGS. 2 and 3 , the section  100  includes a left side  102 , a right side  104 , a top side  106 , a bottom side  108 , a front  110 , and a back  112 . As described in other sections, the section  100  may be rolled upon itself to form an elongate member with an inner volume  113  (see  FIG. 14 ) adapted to receive, contain, and secure one or more flavor releasing mechanisms  200 . 
     The section  100  may comprise a flat piece of paper, cardboard, plastic, silicon, rubber, leaves, composite material(s), any other suitable material(s), and any combinations thereof. The section  100  is preferably a thin type of suitable material that is preferably non-toxic, flavorless, and burnable without adding any residual flavor to the smokable. In addition, the section  100  also is preferably porous so that it may disperse the flavoring released by the one or more flavor releasing mechanisms  200  evenly (however, this may not be necessary). 
     In some embodiments as shown in  FIG. 2 , the section  100  is generally rectangular in shape and may be used to form a generally cylindrical insert system  10 . In other embodiments as shown in  FIG. 3 , the section  100  is shaped as an opened frustrum wherein the shape includes a leftward slanting left side  102 , and a rightward slanting right side  104 , a convex top side  106 , and a concave bottom side  110 . In this embodiment, the section  100  is used to form a generally frustum-shaped insert system  10 . It is understood that the shapes described above are meant for demonstration and that the section  100  may be formed as any suitable shape (e.g., trapezoidal, etc.). 
     In some embodiments as shown in  FIGS. 2 and 3 , the section  10  includes a cutout  114  (also referred to as an aperture) in the front  110  and extending to the back  112 . In some embodiments, the cutout  114  includes a generally circular shape, however, other suitable shapes also may be used. For example, as shown in  FIG. 4 , the cutout  14  may be rectangular or square shaped. In another example, as shown in  FIG. 5 , the cutout  14  may be formed as a parallelogram. It is understood that the cutout  14  may be formed as any additional suitable shape, e.g., as an opened frustum, a trapezoid, an oval, pill-shaped, as other shapes, and as any combinations thereof. As will be described in other sections, the shape and size of the cutout  114  is preferably chosen to correspond to the shape and size of the flavor releasing mechanism(s)  200  that may be secured within the cutout out  114  once the insert system  10  is formed using the section  100 . 
     In some embodiments as shown in  FIGS. 2 and 3 , the section  100  includes a midpoint Mp located midway between the left side  102  and the right side  104 . In some embodiments the cutout  114  is preferably located between the right side  104  and the midpoint Mp. It also is understood that the cutout  114  may be located between the left side  102  and the midpoint Mp, depending on the direction that the section  100  may be rolled as described in other sections. 
     In some embodiments, as shown in  FIGS. 2 and 3 , the cutout  114  is located at a distance D 1  from the right side  104 . For the purposes of this specification, the portion of the section  100  between the cutout  114  and the right side  104  having a width of D 1  will be referred to as the first side portion  116 , the portion extending from left side of the cutout  114  to the right side of the cutout will be referred to as second side portion  117 , and the portion of the section  100  including the first and second side portions  116 ,  117  (and the cutout  114 ) will be referred to as the third side portion  118  (with the third side portion  118  having a width equivalent to the first side portion  116  plus the width of the second side portion  117 ). 
     In some embodiments, the width D 1  of the first side portion  116  is chosen to facilitate the rolling of the section  100  while securing a flavor releasing mechanism within the cutout  114 . For example, the width D 1  may be chosen to be about 0.1 to 3 times the diameter of the cutout  114  (and/or the flavor ball  202 ), and preferably about 0.2 to 2 times the diameter of the cutout  114  (and/or the flavor ball  202 ), and more preferably about 0.3 to 1.5 times the diameter of the cutout  114  (and/or the flavor ball  202 ), and more preferably about 0.5 to 1 times the diameter of the cutout  114  (and/or the flavor ball  202 ). It also is contemplated that the cutout  114  extend all the way to the right side  104 . 
     In some embodiments, the cutout  114  is located about midway between the top side  106  and the bottom side  108 , but it is understood that the cutout  114  may be located at any suitable location between the top side  106  and the bottom side  108  (e.g., towards the top side  106  or towards the bottom side  108 ). 
     It is preferable that the size and shape of the cutout  114  generally matches the size and shape of the flavor releasing mechanism  200  (as described in other sections) so that the flavor releasing mechanism  200  fits within the cutout  114 . For example, if the flavor releasing mechanism  200  is spherically shaped, it is preferable that the cutout  114  is circular with a diameter that generally matches the diameter of the mechanism  200 . In any event, depending on the shape of the flavor releasing mechanism  200  and the corresponding cutout  114 , it is preferable that the height and width of the cutout  114  generally matches the height and width of the flavor releasing mechanism  200  so that the flavor releasing mechanism  200  may fit within the cutout  114 . 
     In some embodiments, the height of the cutout  116  is about 1%-50% the height of the section  100 , and preferably about 3%-30% the height of the section  100 , and more preferably about 10%-20% the height of the section  100 , and more preferably about 12.5% the height of the section  100 . 
     It is understood that the section  100  may include more than one cutout  114  (e.g., a second cutout  114  above or below a first cutout  114 ) that may be adapted to hold additional flavor releasing mechanisms  200 . It is understood that any number of cutouts  114  may be included in any orientation and/or positional relationship with one another to hold any number of flavor releasing mechanisms  200 . 
     Flavor Releasing Mechanisms  200   
     In some embodiments as shown in  FIG. 6 , the flavor releasing mechanisms  200  include any type of solid, liquid, or gas (and any combinations thereof) that may release one or more flavors when activated. The mechanisms  200  may be designed to be activated by heat (e.g., during smoking), by pressure (e.g., may be squeezed, pricked, or otherwise exploded, etc.), by other activation techniques, and by any combinations thereof. 
     In some embodiments as shown in  FIG. 6 , the flavor releasing mechanisms  200  include one or more flavor balls  202  (also referred to as click balls) comprising a crushable spherical container with a flavoring substance inside. The click balls  202  may be adapted to generally burst (or otherwise open) when squeezed thereby releasing the flavoring substance. In this way, a user may squeeze a click ball  202  embedded within the insert system  10  when a flavoring is desired during the smoking experience. While the flavor balls  202  described herein are described primarily as spherical shaped, it is understood that the flavor balls  202  may be formed as an ovoid, a cuboid, a cylinder, pill-shaped, as any other suitable shape, and as any combinations thereof. It also is understood that the cutout  114  is preferably formed to generally match or at least accommodate the shape of the flavor releasing mechanism  200  as described herein. 
     It is understood that any other type(s) and/or shapes of flavor releasing mechanisms  200  may be used with the insert system  10 , and that the scope of the insert system  10  is not limited in any way by the type of flavor releasing mechanism(s)  200  used. 
     Forming and Using the Insert System 
     For the purposes of this specification, the forming of the insert system  10  using the section  100  and the flavor releasing mechanism  200  will be described primarily with respect to the section  100  embodiment of  FIG. 7  (i.e., the embodiment of  FIG. 3  as described above). However, it is understood that the methodology described herein also may be applied to any other embodiment(s) described herein or otherwise. 
     First, as shown in  FIG. 7 , with the section  100  generally flat, the third side portion  118  is folded upward at the fold line F L  in the direction of the arrow A such that the portion  118  extends upward as shown in  FIG. 8 . In some embodiments, the third side portion  118  may extend upward at an angle of about 45° with respect to the unfolded portion of the section  100 , but it is understood that the third side portion  118  may be folded at any suitable angle in order for the section  100  to perform its functionalities. 
     Next, the flavor releasing mechanism  200  (e.g., a flavor ball  20 ) is placed into the cutout  114 . This results in the configuration shown in  FIGS. 8 and 9 .  FIG. 9  shows the section  100  and flavor ball  202  of  FIG. 8  taken from the perspective of the arrow B in  FIG. 8 . 
     Next, as shown in  FIG. 9 , the first side portion  116  is folded in the direction of the arrow C resulting in the configuration shown in  FIG. 10  with the first side portion  116  generally folded over an outer surface portion of the flavor ball  202  as shown. This action leaves the second side portion  117  extending transverse across the flavor ball  202  as shown in  FIG. 10 . 
     The flavor ball  202  and the second side portion  117  (including the folded first side portion  116 ) is next folded further along the fold line F L  in the direction of the arrow D as shown in  FIG. 10 . This results in the configuration shown in  FIG. 11 . 
     Next, as shown in  FIG. 11 , the flavor ball  202 , the folded first side portion  116  and the second side portion  117  are rolled in the direction of the arrow E resulting in the configuration shown in  FIG. 12 . In this configuration, it is preferable that the right side  104  of the section  100  is tucked under the flavor ball  202  between the section  100  and the flavor ball  202  as shown. In this way, the right side  104  is held in place as originally folded over the ball  202  with the remaining portion  120  of the section  100  extending to the left as shown in  FIG. 12 . 
     Next, as shown in  FIG. 12 , the combination of the flavor ball  202 , the first side portion  116 , the second side portion  117 , and any additional portion of the section  100  that extends around the outer circumference of the flavor ball  202  due to the rolling procedure described above is further rolled in the direction of the arrow F until the remaining unfolded portion  120  of the section  100  is rolled around the ball  202  forming side walls  122  of the filter  10 . This results in the filter  10  depicted in  FIG. 13 . 
     As shown in the configuration of  FIG. 13 , the rolling of the section  100  forming the side walls  122  creates the inner volume  113  within the rolled section  100  with the second side portion  117  extending transverse across the inner volume  113 . In addition, the second side portion  117  includes a cutout  114  and a flavor ball  202  held therein. 
       FIG. 14  shows a side view of the filter system  10  of  FIG. 13 . As shown, the folding of the second side portion  117  as described herein forms a partition  115  that divides the inner volume  113  into two elongate inner compartments  119 ,  121  that generally extend from a first open end  123  of the insert  10  to a second open end  125  of the insert  10 . In this arrangement, the partition  115  includes at least a portion of the cutout  114 . Accordingly, with the flavor ball  202  located within the cutout  114 , the partition holds the flavor ball  202  in place within the inner volume  113 . 
     Given the above, it is preferable that the length of the unfolded portion  120  of  FIG. 12  be sufficient to encircle the flavor ball  202  at least once so that the sidewalls  122  hold the flavor ball  202  secure within the rolled up section  100 . This may better ensure that the flavor releasing mechanism  200  is held securely within the cutout  114 . However, in other embodiments, it may be sufficient for the unfolded portion  120  to only partially encircle the flavor ball  202 . In this case, it may be preferable that the sidewalls  122  encircle at least enough of the flavor ball  202  to hold it secure within the resulting filter  10 . 
     It is understood that the actions described above to form an insert system  10  using a section  100  and a flavor releasing mechanism  200  are meant for demonstration and that the method of forming the insert system  10  may include other actions not necessarily described, may not include all of the actions described, and/or any combinations thereof. For example, the insert system  10  may be formed a first time without inserting the flavor releasing mechanism  200  into the cutout  114  in order to create an empty insert system  10 . The empty insert system  10  may then be at least partially unfolded (e.g., the sidewalls  122  may be unwrapped to expose the cutout  114 , and to place the flavor releasing mechanism  200  into the cutout  114 ). The sidewalls  122  may then be rewrapped around the flavor releasing mechanism  200  to create the filter  10  and to secure the flavor releasing mechanism  200  therein. 
     In some embodiments as shown in  FIG. 15 , once the insert system  10  has been formed as described above or otherwise, it may be used as a tip, a mouthpiece, a crutch, a filter, as any type of base for a pre-roll, cone, empty cone, cigarette, other type of smokable, and for any combinations thereof as known in the art or otherwise. For example, in some embodiments, the insert system  10  may be provided to manufacturers of pre-roll cones and/or cigarettes, of empty cones, etc. to be coupled to these types of products and then sold to consumers. In another example, the insert system  10  may be coupled with a pre-roll cone and/or cigarette, and/or to an empty cone during its manufacturing and made for sale to consumers as the combination. In another example, the insert system  10  may be sold directly to consumers such that the consumers themselves may couple the insert system  10  with a rolling paper to form a cigarette, a cone, an empty cone, or other type of smokable item. It is understood that the examples described above are meant for demonstration and are non-limiting. It is notable that  FIG. 15  depicts two flavor release mechanisms  200  embedded within two cutouts  114  in the filter system  10  to demonstrate that the filter system  10  may include a plurality of flavor release mechanisms  200 . 
     It is understood that any details and/or aspects of any embodiments described herein may be combined with any details and/or aspects of any other embodiments in any way to form additional embodiment(s) all of which are within the scope of the filter  10 . 
     Where a process is described herein, those of ordinary skill in the art will appreciate that the process may operate without any user intervention. In another embodiment, the process includes some human intervention (e.g., a step is performed by or with the assistance of a human). 
     As used herein, including in the claims, the phrase “at least some” means “one or more,” and includes the case of only one. Thus, e.g., the phrase “at least some ABCs” means “one or more ABCs”, and includes the case of only one ABC. 
     As used herein, including in the claims, term “at least one” should be understood as meaning “one or more”, and therefore includes both embodiments that include one or multiple components. Furthermore, dependent claims that refer to independent claims that describe features with “at least one” have the same meaning, both when the feature is referred to as “the” and “the at least one”. 
     As used in this description, the term “portion” means some or all. So, for example, “A portion of X” may include some of “X” or all of “X”. In the context of a conversation, the term “portion” means some or all of the conversation. 
     As used herein, including in the claims, the phrase “using” means “using at least,” and is not exclusive. Thus, e.g., the phrase “using X” means “using at least X.” Unless specifically stated by use of the word “only”, the phrase “using X” does not mean “using only X.” 
     As used herein, including in the claims, the phrase “based on” means “based in part on” or “based, at least in part, on,” and is not exclusive. Thus, e.g., the phrase “based on factor X” means “based in part on factor X” or “based, at least in part, on factor X.” Unless specifically stated by use of the word “only”, the phrase “based on X” does not mean “based only on X.” 
     In general, as used herein, including in the claims, unless the word “only” is specifically used in a phrase, it should not be read into that phrase. 
     As used herein, including in the claims, the phrase “distinct” means “at least partially distinct.” Unless specifically stated, distinct does not mean fully distinct. Thus, e.g., the phrase, “X is distinct from Y” means that “X is at least partially distinct from Y,” and does not mean that “X is fully distinct from Y.” Thus, as used herein, including in the claims, the phrase “X is distinct from Y” means that X differs from Y in at least some way. 
     It should be appreciated that the words “first,” “second,” and so on, in the description and claims, are used to distinguish or identify, and not to show a serial or numerical limitation. Similarly, letter labels (e.g., “(A)”, “(B)”, “(C)”, and so on, or “(a)”, “(b)”, and so on) and/or numbers (e.g., “(i)”, “(ii)”, and so on) are used to assist in readability and to help distinguish and/or identify, and are not intended to be otherwise limiting or to impose or imply any serial or numerical limitations or orderings. Similarly, words such as “particular,” “specific,” “certain,” and “given,” in the description and claims, if used, are to distinguish or identify, and are not intended to be otherwise limiting. 
     As used herein, including in the claims, the terms “multiple” and “plurality” mean “two or more,” and include the case of “two.” Thus, e.g., the phrase “multiple ABCs,” means “two or more ABCs,” and includes “two ABCs.” Similarly, e.g., the phrase “multiple PQRs,” means “two or more PQRs,” and includes “two PQRs.” 
     The present invention also covers the exact terms, features, values and ranges, etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., “about 3” or “approximately 3” shall also cover exactly 3 or “substantially constant” shall also cover exactly constant). 
     As used herein, including in the claims, singular forms of terms are to be construed as also including the plural form and vice versa, unless the context indicates otherwise. Thus, it should be noted that as used herein, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. 
     Throughout the description and claims, the terms “comprise”, “including”, “having”, and “contain” and their variations should be understood as meaning “including but not limited to”, and are not intended to exclude other components unless specifically so stated. 
     It will be appreciated that variations to the embodiments of the invention can be made while still falling within the scope of the invention. Alternative features serving the same, equivalent or similar purpose can replace features disclosed in the specification, unless stated otherwise. Thus, unless stated otherwise, each feature disclosed represents one example of a generic series of equivalent or similar features. 
     The present invention also covers the exact terms, features, values and ranges, etc. in case these terms, features, values and ranges etc. are used in conjunction with terms such as about, around, generally, substantially, essentially, at least etc. (i.e., “about 3” shall also cover exactly 3 or “substantially constant” shall also cover exactly constant). 
     Use of exemplary language, such as “for instance”, “such as”, “for example” (“e.g.,”) and the like, is merely intended to better illustrate the invention and does not indicate a limitation on the scope of the invention unless specifically so claimed. 
     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.