Devices and Methods for Frictionless Compaction of Smokable Products

The present application claims priority to and the benefit of U.S. Provisional Patent Application No. 63/480,177, filed Jan. 17, 2023, the contents of which are hereby incorporated in their entirety.

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

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

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.

Referring to, embodiments of the present disclosure include a compaction deviceutilized with one or more smoking coneshaving smoking materialin the cones to provide frictionless compaction of the material. The compaction deviceis 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 materialcompletely. 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 devicemay 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 materialuniformity. 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 materialproducts.

Referring to, the compaction deviceincludes a base, one or more vertical actuatorscoupled to the base, an interchangeable side plug mechanismcoupled to the base, and a dial carriagethat is couplable to the side plug mechanismand the vertical actuatorsA,B.

Referring to, in the illustrated embodiment, the compaction deviceincludes two vertical actuatorsA,B. In alternative embodiments, the compaction devicemay include more than two vertical actuators. . .. The vertical actuatorsA,B have a proximal endand a distal endopposite the proximal endalong a longitudinal direction L. The vertical actuatorsA,B move along the longitudinal direction L. The distal endincludes an interchangeable nozzle assembly. The nozzle assemblyincludes one or more interchangeable nozzlesheld by one or more nozzle holders, each coupled to the vertical actuators, respectively. In the illustrated embodiment, the compaction deviceincludes two nozzlesA,B held by two nozzle holdersA,B. In other embodiments, more than two nozzles. . .may be held by more than two nozzle holders. . .

The nozzle holdersA,B include a release springconfigured to hold the desired nozzleA,B in place and subsequently release the nozzleA,B, from the nozzle holderA,B when the release springis actuated. In the illustrated embodiment, the release springis a plunger. In other embodiments, the release spring may utilize known release mechanisms for holding and releasing the nozzlesA,B from the nozzle holderA,B.

The nozzlesA,B have an openingA,B axially through the center to allow compressed gas to be delivered through the nozzle holderA,B to enter the smoking cone. The openingA,B is greater at a portion towards the nozzle holderA,B than a portion inserted into the smoking cone. The nozzlesA,B include angled exit holessurrounding the openingA,B, for better compaction of smoking materialin the smoking cone, as further explained below. In the illustrated embodiment, the nozzlesA,B have a length of about 2.88 mm. In other embodiments, the nozzlesA,B may be less than 3.0 mm. In addition, the openingA,B has a diameter Dof about 0.5 mm at the portion near the nozzle holderA,B. The openingA,B further has a diameter Dof about 0.3 mm at the portion that's inserted into the smoking cone. However, in the illustrated embodiment, the nozzlesA,B 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 assemblyfurther includes one or more linesconnected to a gas source to supply pressurized gas (e.g., air) to the device. In the illustrated embodiment the nozzle holderA,B receives its gas supply through the linesvia a process tube connection into the rear of the nozzle holderA,B. The gas then is directed downward through the nozzleA,B.

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

Referring to, the dial carriageis configured to transport one or more smoking conesto the vertical actuators. The dial carriageincludes a baseand one or more interchangeable nestscoupled to the base.

Continuing with, in the illustrated embodiment, the dial carriageincludes two nestsA,B coupled to the base. In other embodiments, the dial carriagemay include more than two nests. . .. The nestsA,B include a channelA,B, responsible for holding the smoking conesduring the compaction sequence. The nestsA,B 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 nestsA,B further include an openingA,B that allow for coupling of the nestsA,B with the side plug mechanism.

Referring to, the side plug mechanismincludes a side plug activatorand a side plug assembly. The side plug activatorincludes a pneumatic slide tableto provide horizontal translation of the side plug assemblyfrom a retracted position, to an extended position where the side plug couples with the nestA,B. The side plug assemblyis fastened to the side plug activatorvia a thumb screw. The side plug assemblyis unique and is interchangeable based on the specific size of the smoking conethat is being utilized. When the side plug assemblyis inserted into the nestA,B at the openingA,B via the pneumatic actuation, the openingin the nestA,B is filled. This configuration prevents the smoking conefrom experiencing blow outs, breaking, and/or bulging of the cone though the opening due to the increased pressure difference inside the smoking coneduring compaction.

Referring to, in the illustrated embodiment, the smoking coneis a standard tapered paper cone & filter assembly. The coneis comprised of a filterand a cone body. The filterincludes an open tip. The cone bodyincludes a large openingat the end of the cone bodysuch that smokable materialmay be inserted into the cone via the openingand pressurized gas may be applied to the smokable materialin the smoking conevia the opening.

The filtermay be comprised of paper, wood, or ceramic materials. The cone bodymay be made from rice paper, hemp paper, or other known combinations. In other embodiments, the conesmay utilize various configurations including tapered walls, straight walls, ceramic filter tips, hemp blunt paper, etc. In the illustrated embodiment, the length of the coneranges from about 84.0 mm to 140.0 mm. The smoking conemay 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.

depict the nozzleA,B being inserted into the conesfor compaction. As shown in, the nozzleA,B is inserted directly into the openingof the cones, which are seated in the nestsA,B, respectively. The conessit in the nestsA,B such that a portion of the cone is outside of the nestA,B, respectively.

The nozzleA,B is tapered to match the angle of the cone. In the illustrated embodiment, the nozzleA,B is tapered in a 25 degree angle. This configuration creates a seal between the nozzleA,B and the cone, allowing the gas (e.g., air) discharged from the nozzle to pressurize the internal body of the cone, forcing the smokable materialdownward toward the tip. The nozzleA,B also includes angled exit holessurrounding the opening, to create an air shield outward to the wall of the cone, preventing materialfrom escaping through any air gaps formed between the coneand the nozzleA,B during pressurization.

The filterallows the gas to escape during pressurization via the filter tip. This allows the compressible smoking materialto move downward into the base of the coneand reach a level of compaction relative to the pressure of the gas supplied (as shown in).

shows the process in which the compaction deviceis utilized for compacting smokable materialin the smoking cones. The cones are transported to the vertical actuatorvia the dial carriage. The side plug assemblyextends forward, inserting the side plug mechanisminto the openingA,B of the nestA,B. The vertical actuatoris lowered into position such that the nozzleA,B 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 nozzleA,B via the openingA,B 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 actuatorsis returned to a resting position, and the side plug assemblyis returned to a retracted position.

Referring to, the compaction device is utilized in conjunction with a smoking cone manufacturing system. The smoking cone manufacturing systemis configured to create and produced a smoking cone packed with smokable materialfor use by a consumer. The smoking cone manufacturing systemincludes, in addition to the compaction device, a cone open station device, a cone load station device, a cone pull station device, an offload station device, a clip and tamp station device, a twist station device, and a weigh station device. The dial carriageas described herein is positioned around a circumference of the system. The dial carriageis therefore further configured to index and transport the conesthrough each device,,,,,,, andin 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.