CA3151142A1 - Smokable article and related methods and systems - Google Patents

Abstract

Smokable articles are provided. In some embodiments, the smokable article may comprise a sheet of smokable material formed into a tubular body and having a glueless seam sealing opposed longitudinal edges of the sheet. In some embodiments, the glueless seam may comprise a knurled seam or a compressed seam. In some embodiments, the glueless seam may allow the smokable article to be smoked by a user without generating unwanted fumes or altering the taste of a smoking substance therein. Also provided are related methods and systems for making a smokable article.

Description

SMOKABLE ARTICLE AND RELATED METHODS AND SYSTEMS
RELATED APPLICATION:
[0001] The present disclosure claims priority to U.S.
Provisional Patent Application No. 62/901,322, filed September 17, 2019, the entire contents of which are incorporated by reference herein.
TECHNICAL FIELD:

[0002] The present disclosure relates to products for consumption of smoking substances. More particularly, the present disclosure relates to smokable articles and related methods and systems.
BACKGROUND:

[0003] Dried smoking substances, such as tobacco and dried herbs, may be consumed in a variety of ways. One common method is to roll the smoking substance in a sheet of smokable material into a tube and then lighting one end of the tube to generate smoke for inhalation from the opposite end. However, rolling the smoking substance by hand may be messy and time-consuming_

[0004] Pre-rolled cones are an alternative to hand-rolling and may be filled with a variety of smoking substances. Pre-rolled cones may be formed by rolling a sheet of smokable material into a conical or frusto-conical tube and sealing opposed longitudinal edges of the sheet together. However, conventional pre-rolled cones are formed with an adhesive to glue the opposed edges of the sheet together, which may result in undesirable fumes when the cone is lit and the smoke is inhaled by the user.
The adhesive may also alter the taste of the smoking substance which may be undesirable to the user.

[0005] Although some glueless methods of forming cylindrical smokable articles such as cigarettes are known, such methods may not be applicable to pre-rolled cones.
A frusto-conical or conical tube may need to engage a sealing device at an angle which may prohibit the use of conventional sealing devices. In addition, glueless methods have not been known to be used with the rice or hemp paper that is commonly used as the sheet of smokable material for pre-rolled cones.
SUMMARY:

[0006] In one aspect, there is provided a smokable article comprising: a sheet of smokable material having a first longitudinal edge and an opposed second longitudinal edge, the sheet of smokable material formed into a tubular body such that the first longitudinal edge overlaps the second longitudinal edge; and a glueless seam formed by sealing the first longitudinal edge and the second longitudinal edge together.

[0007] In some embodiments, the glueless seam comprises a knurled seam.

[0008] In some embodiments, the glueless seam comprises a compressed seam.

[0009] In some embodiments, the tubular body is frustoconical or conical in shape.

[0010] In some embodiments, the smokable article further comprises one of a crutch and a filter received into the tubular body.

[0011] In some embodiments, the sheet of smokable material comprises a non-wood paper.

[0012] In another aspect, there is provided a method for making a smokable article, the method comprising: providing a sheet of smokable material;
forming the sheet of smokable material into a tubular body; overlapping longitudinal edges of the sheet of smokable material to form an overlapped section; and sealing the overlapped section into a glueless seam.

[0013] In some embodiments, forming the sheet of smokable material into the tubular body comprises wrapping the sheet of smokable material around a shape-forming device.

[0014] In some embodiments, sealing the overlapped section comprises knurling the overlapped section.

[0015] In some embodiments, sealing the overlapped section comprises compressing the overlapped section under pressure.

[0016] In some embodiments, the overlapped section is compressed at an elevated temperature.

[0017] In some embodiments, the method further comprises inserting one of a crutch and a filter into the tubular body.

[0018] In some embodiments, providing the sheet of smokable material comprises providing a sheet of non-wood paper.

[0019] In another aspect, there is provided a system for making a smokable article, the system comprising: a shape-forming device for forming a sheet of smokable material into a tubular body; and a sealing device for sealing overlapped longitudinal edges of the sheet of smokable material into a glueless seam.

[0020] In some embodiments, the shape-forming device comprises a body having an outer wall, the outer wall comprising a shape-forming portion such that the tubular body is formed by wrapping the sheet of smokable material around the shape-forming portion.

[0021] In some embodiments, the shape-forming portion is frustoconical or conical in shape.

[0022] In some embodiments, the sealing device comprises a knurled roller.

[0023] In some embodiments, the shape-forming device comprises a knurled surface and the sealing device comprises a polished roller.

[0024] In some embodiments, the sealing device comprises a first high-pressure plate and an approximately parallel second high-pressure plate, the first high-pressure plate being received into the tubular body such that the overlapped longitudinal edges of the sheet are compressed between the first high-pressure plate and the second high-pressure plate.

[0025] In some embodiments, at least one of the first and second high-pressure plates comprises a fluid conduit for a heated fluid.

[0026] In some embodiments, the system further comprises a first vacuum source operatively connected to the shape-forming device and operable to exert a vacuum pull to hold the sheet of smokable material to the shape-forming device.

[0027] In some embodiments, the system further comprises an actuator that moves one of the shape-forming device and the sealing device with respect to the other one of the shape-forming device and the sealing device.

[0028] In some embodiments, the system further comprises a crutch-insertion device, the crutch-insertion device comprising an internal cavity that receives the tubular body therein.

[0029] In some embodiments, the system further comprises a second vacuum source operatively connected to the crutch-insertion device and operable to exert a vacuum pull to hold the tubular body in an open position.

[0030] Other aspects and features of the present disclosure will become apparent, to those ordinarily skilled in the art, upon review of the following description of the specific embodiments of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS:

[0031] Some aspects of the disclosure will now be described in greater detail with reference to the accompanying drawings_ In the drawings:

[0032] Figure 1 is a perspective view of a smokable article, according to some embodiments;

[0033] Figure 2 is a side view of a sheet of smokable material of the smokable article of Figure 1;

[0034] Figure 3A shows top views of a crutch having internal folded portions of various shapes, according to some embodiments;

[0035] Figure 3B is a top view of a filter, according to some embodiments;

[0036] Figure 4 is a flowchart of a method for making a smokable article, according to some embodiments;

[0037] Figure 5 is a side view of a sheet of smokable material, according to some embodiments;

[0038] Figure 6 is a block diagram of a flipper, according to some embodiments;

[0039] Figures 7A to 7D are perspective views of a system for making a smokable article, according to some embodiments, at various stages of a process of making of the smokable article of Figure 1;

[0040] Figure 8 is a perspective view of various steps for inserting a crutch into the smokable article of Figure 1 using a crutch-insertion device of the system of Figures 7A to 7D;

[0041] Figures 9A to 9D are perspective view of another system for making a smokable article, according to some embodiments, at various stages of a process of making the smokable article of Figure 1;

[0042] Figure 10A is a perspective view of a sealing device, according to some embodiments, shown sealing the smokable article of Figure 1; and

[0043] Figure 10B is a perspective view of another sealing device, according to some embodiments, shown sealing the smokable article of Figure 1.

DETAILED DESCRIPTION OF EMBODIMENTS:

[0044]
Generally, the present disclosure provides a smokable article. In some embodiments, the smokable article may comprise a sheet of smokable material formed into a tubular body and having a glueless seam sealing opposed longitudinal edges of the sheet. In some embodiments, the glueless seam may comprise a knurled seam or a compressed seam. Also provided are related methods and systems for making a smokable article.

[0045]
As used herein the terms "a," "an," and "the" may include plural referents unless the context clearly dictates otherwise.

[0046]
It is to be understood that directional or relative terms such as -forward", "front", "rearward", "back", "vertical", "horizontal", "upper", "lower", "side", "top", "bottom"
and the like are used for ease of description and illustrative purposes, and embodiments are not limited to a particular orientation of the smokable articles and systems described herein during use or normal operation.

[0047]
The smokable articles described herein may be used with any suitable smoking substance. As used herein, "smoking substance" may refer to any substance that can be burned, combusted, or otherwise heated to generate smoke or vapor for inhalation by a user. In some embodiments, the smoking substance is a plant material.
Non-limiting examples of plant materials include dried herb, dried tobacco, and dried cannabis.

[0048]
An example smokable article 100 will be described with reference to Figure 1.

[0049]
The smokable article 100 in this embodiment may comprise a sheet 102 of smokable material. As used herein, a "sheer may refer to a relatively thin and relatively flat article. As used herein, "smokable material" may refer to any material that can be used to at least partially enclose a smoking substance therein and that may itself bum/combust when the smokable article 100 is lit to generate smoke. In some embodiments, the smokable material may comprise a natural or synthetic fiber-based material such as a cellulose-based material. In some embodiments, the smokable material may comprise paper. In some embodiments, the paper may be a non-wood paper. Non-limiting examples of non-wood paper include hemp paper and rice paper. In other embodiments, the smokable material may comprise any other suitable material.

[0050] The sheet 102 of smokable material may be formed into a tubular body 104. In this embodiment, the tubular body 104 may be approximately frusto-conical or conical in shape. In other embodiments, the tubular body 104 may be approximately cylindrical or any other suitable shape.

[0051] The tubular body 104 may have an outer face 103 and an inner face 105.
The inner face 105 may define an internal chamber 107 to receive a smoking substance (not shown) therein.

[0052] The tubular body 104 may have a first end 116 and a second end 118.
The sheet 102 of smokable material may define a first opening (not shown) at the first end 116 and a second opening 120 at the second end 118. The first opening may have a diameter D1 and the second opening 120 may have a diameter D2. In this embodiment, the diameter D2 of the second opening 120 may be greater than the diameter D1 of the first opening. In other embodiments, the diameter D2 of the second opening 120 may be approximately the same as the diameter D1 of the first opening.
The tubular body 104 may have a length Z1 between the first end 116 and the second end 118. The length Z1 may be any suitable length such that the internal chamber 107 is a suitable volume to receive the smoking substance therein.

[0053] In use, a user may load smoking substance into the internal chamber 107 of the tubular body 104 via the second opening 120. The user may then fold or twist a portion of the tubular body 104 proximate the second end 118 to close the second opening 120. The user may then light the twisted or folded portion of the tubular body 104 to generate smoke. The user may place their mouth over the first end 116 of the tubular body 104 to draw the smoke through the internal chamber 107 and out of the first opening into the users mouth and lungs for consumption. As the tubular body 104 and the smoking substance therein are burned, the length Z1 of the tubular body 104 may gradually decrease until the length Z1 is too short for the user to continue smoking.

[0054] Figure 2 shows a side view of the sheet 102 of smokable material, prior to being formed into the tubular body 104. The sheet 102 may have a first longitudinal edge 108 and an opposed second longitudinal edge 110. The sheet 102 may also have a first lateral edge 112 and an opposed second lateral edge 114.

[0055] As shown in Figure 1, when the sheet 102 is formed into the tubular body 104, the first longitudinal edge 108 may overlap with the second longitudinal edge 110 to form an overlapped section 111. The overlapped section 111 may be sealed to form a glueless seam 106. In this embodiment, the glueless seam 106 may comprise a knurled seam. As used herein, a "knurled seam" may refer to a seam formed by pressing a plurality of indentations into the overlapped section 111 to bond the first longitudinal edge 108 to the second longitudinal edge 110. In some embodiments, the plurality of indentations may form a pattern, for example, a diamond shaped pattern, straight-line pattern, a criss-cross pattern, or any other suitable pattern.

[0056] In other embodiments, the glueless seam 106 may comprise a compressed seam. As used herein, a "compressed seam" may refer to a seam formed by compressing the overlapped section 111 by application of pressure to bond the first longitudinal edge 108 to the second longitudinal edge 110. In some embodiments, the compressed seam may be formed under a high pressure. In some embodiments, the compressed seam may also be formed at a high temperature. For example, the compressed seam can be formed by application of high pressure in the presence of a heated fluid such as steam.

[0057] Therefore, in some embodiments, the smokable article 100 may be secured by the glueless seam 106 in the desired shape of the tubular body 104 to facilitate loading and smoking of a smoking substance by a user. Moreover, as the glueless seam 106 does not include an adhesive, the smokable article 100 may be smoked by the user without generating unwanted fumes or altering the taste of the smoking substance therein.

[0058] Referring again to Figure 1, in some embodiments, the smokable article 100 may further comprise a crutch 122. In Figure 1, the crutch 122 is shown in stippled lines as the crutch 122 may not typically be visible through the tubular body 104. As used herein, the term "crutch" may refer to an article that acts as a mouthpiece for the tubular body 104 and may serve one or more additional functions, including but not limited to: keeping the first opening (not shown) of the tubular body 104 open to allow the user to inhale smoke; acting as a filter to prevent pieces of the smoking substance from entering the user's mouth; putting distance between the user's lips and the smoking substance to prevent bums; and providing a portion of the tubular body that may be safely gripped between the user's fingers.

[0059] The crutch 122 may be received in the internal chamber 107 of the tubular body 104, proximate the first end 116. The crutch 122 may have a length Z2 that is less than the length Z1 of the tubular body 104. In some embodiments, the length Z2 may be one third or less of the length Z1. In some embodiments, the crutch 122 may be dimensioned to provide a friction fit with the inner face 105 of the tubular body 104. In other embodiments, the crutch 122 may be dimensioned to provide any other suitable fit with the tubular body 104.

[0060] In some embodiments, the crutch 122 may be formed from a sheet 124 of material. In some embodiments, the material may comprise a natural or synthetic fiber-based material such as a cellulose-based material. In some embodiments, the material may be paper or cardboard. In some embodiments, the paper may be a heavier paper than that used to form the tubular body 104. In other embodiments, the crutch 122 may be made of any other suitable material and embodiments are not limited to the specific materials described herein.

[0061] The sheet 124 may be formed into a tubular outer portion 125 and an internal folded portion 127. The internal folded portion 127 may be folded into a variety of shapes. As shown in Figure 3A, the internal folded portion 127 may be one of an M-shape, a W-shape, an e-shape, an E-shape, an A-shape, a spiral, a leaf, a star, a peace symbol, a foldover or zig-zag shape, a target, and a shamrock. However, embodiments are not limited by the shapes described herein and the internal folded portion 127 may be any suitable shape.

[0062] In some embodiments, the smokable article 100 may comprise two or more tubular bodies formed from respective sheets of smokable material (not shown). In some embodiments, two or more tubular bodies may be twisted or braided with one another. In other embodiments, a first tubular body may be engaged with a second tubular body in a cross-like or X-Iike structure. In other embodiments, two or more tubular bodies may be engaged with one another in any suitable structure.

[0063] In other embodiments, the smokable article 100 may further comprise a filter. As shown in Figure 3B, the filter may comprise a synthetic filter 132.
As one example, the synthetic filter 132 may comprise a cellulose acetate filter. In other embodiments, the smokable article 100 may further comprise any other suitable type of filter. The synthetic filter 132 may be received into the tubular body 104, proximate the first end 116 in a similar manner to the crutch 122 as shown in Figure 1.

[0064] Also provided herein is a smokable product comprising the smokable article 100 with a smoking substance received within the internal chamber 107 of the tubular body 104. The smoking substance may comprise, for example, a dried herb, tobacco, or cannabis.

[0065] A method for making a smokable article is also provided. The method may be used to make embodiments of the smokable article 100 described herein.

[0066] Figure 4 is a flowchart of an example method 200 for making a smokable article, according to some embodiments. At block 202, a sheet of smokable material may be provided. As used here, "providing" the sheet of smokable material may refer to making, manufacturing, receiving, or otherwise obtaining the sheet of smokable material.

[0067] In some embodiments, the sheet of smokable material may be provided as a single sheet, such as the sheet 102 in Figure 2 as described above. In other embodiments, as shown in Figure 5, providing the sheet of smokable material may comprise providing a roll or bobbin 134 of smokable material and cutting the roll or bobbin 134 into individual sheets 102. In some embodiments, cut lines 135 may be provided on the roll or bobbin 134 to facilitate cutting the individual sheets 102 to the desired shape and size.

[0068] In some embodiments, the individual sheets 102 may be flipped or rotated into a desired orientation. The desired orientation may comprise, for example, an orientation in which the first lateral edge 112 of the sheet 102 is proximate the operator and the second lateral edge 114 is distal the operator as shown in Figure 2.
In some embodiments, as shown in Figure 6, a flipping device 136 may be used to flip or rotate the cut sheets 102 as indicated by arrows L into the desired orientation. In other embodiments, the sheets 102 may be flipped or rotated manually into the desired orientation.

[0069] At block 204, the sheet may be formed into a tubular body. The tubular body may be similar to the tubular body 104 of Figure 1 as described above. In some embodiments, the tubular body may be frusto-conical or conical in shape. In other embodiments, the tubular body may be cylindrical or any other suitable shape.
In some embodiments, the tubular body may be formed by wrapping the sheet around a shape-forming device, such as one of the shape-forming devices described below. In other embodiments, the tubular body may be formed by rolling the sheet by hand.

[0070] At block 206, longitudinal edges of the sheet may be overlapped to form an overlapped section. The overlapped section may be similar to the overlapped section 111 of tubular body 104 as described above.

[0071] At block 208, the overlapped section of the sheet may be sealed into a glueless seam. In some embodiments, sealing the overlapped section may comprise knurling the overlapped section. As used herein, "knurling" may refer to pressing a plurality of indentations into the overlapped section to form a knurled seam as described above.

[0072] In other embodiments, sealing the overlapped section may comprise compressing the overlapped section under pressure. As used herein, "under pressure"
may refer to the application of a pressure greater than ambient pressure. In some embodiments, the overlapped section may be compressed at a high pressure. In some embodiments, the overlapped section may be compressed at an elevated temperature.
As used herein, "elevated temperature" may refer to a temperature greater than ambient temperature. In some embodiments, the overlapped section may be compressed at a high temperature. In some embodiments, the overlapped section may be compressed in the presence of a heated fluid. In some embodiments, the heated fluid may comprise a gas or vapor. In some embodiments, the heated fluid may comprise steam. In other embodiments, the heated fluid may comprise any other suitable fluid.

[0073] In some embodiments, the overlapped section of the sheet may be sealed using a sealing device, such as one of the sealing devices described below. In other embodiments, the overlapped section of the sheet may be sealed by any other suitable means.

[0074] In some embodiments, the method 200 may further comprise inserting a crutch or a filter into the tubular body. The crutch may be similar to the crutch 122 of Figures 1 and 3A as described above. The filter may be similar to the synthetic filter 132 of Figure 3B as described above. In some embodiments, a sheet of crutch material may be cut from a roll or bobbin of crutch material, placed into a desired orientation, and then formed into the crutch prior to insertion. In some embodiments, the crutch or filter may be inserted into the tubular body using a crutch-insertion device, such as one of the crutch-insertion devices described below. In other embodiments, the crutch or filter may be inserted into the tubular body by hand.

[0075] In some embodiments, the crutch or filter may be inserted into the tubular body after the overlapped section of the sheet is sealed. In other embodiments, the crutch or filter may be inserted into the tubular body prior to sealing the overlapped section of the sheet.

[0076] Optionally, the method 200 may further comprise loading a smoking substance into the tubular body of the smokable article. The smoking substance may comprise, for example, dried herb, tobacco, or cannabis.

[0077] A system for making a smokable article is also provided. The system may implement embodiments of the method 200 described herein.

[0078] Figures 7A to 7D show an example system 300 for making a smokable article, according to some embodiments. Figures 7A to 7D show the system 300 at various stages of making the smokable article 100 of Figure 1.

[0079] The system 300 may comprise a shape-forming device 302 and a sealing device 304 (the sealing device 304 is not shown in Figure 7A). The shape-forming device 302 may comprise a body 303 having an outer wall 305. In some embodiments, the body 303 may be formed of stainless steel or any other suitable material.
In some embodiments, the outer wall 305 may comprise a substantially smooth surface such as a polished surface.

[0080] The outer wall 305 may comprise a shape-forming portion 307 that is approximately the same shape as the desired shape of the tubular body 104 of the smokable article 100. In some embodiments, the shape-forming portion 307 may be approximately frusto-conical or conical in shape. In other embodiments, the shape-forming portion 307 may be approximately cylindrical or any other suitable shape.

[0081] As shown in Figures 7A and 7B, the sheet 102 of smokable material may be wrapped around the shape-forming portion 307 to form the tubular body 104 with the overlapped section 111. The overlapped section 111 may be oriented on the outer wall 305 such that the overlapped section 111 faces towards the sealing device 304 to allow the sealing device 304 to contact the overlapped section 111, as described in more detail below.

[0082] In some embodiments, the body 303 of the shape-forming device 302 may define an internal chamber therein (not shown). The outer wall 305 of the body 303 may comprise at least one aperture (not shown) therethrough to fluidly connect the internal chamber with the external environment. In some embodiments, the outer wall 305 may comprise a plurality of apertures at various locations along the outer wall 305.

[0083] In some embodiments, the system 300 may further comprise at least one vacuum source (not shown). In some embodiments, a first vacuum source (not shown) may be operatively connected to the shape-forming device 302. In some embodiments, the first vacuum source may comprise a vacuum pump. The vacuum pump may comprise a peristaltic pump, a Venturi pump, or any other suitable type of pump. In some embodiments, the first vacuum source may be fluidly connected to the internal chamber of the shape-forming device 302 by a fluid conduit (not shown). The fluid conduit may comprise, for example, a hose, a tube, or any other suitable type of fluid conduit.

[0084] The first vacuum source may apply a vacuum to the internal chamber of the body 303 and thereby pull air from the external environment through the apertures in the outer wall 305. The vacuum source may thereby exert a vacuum pull on the outer wall 305, as indicated by arrows A in Figures 7A and 7B, to hold the inner face 105 of the sheet 102 of smokable material to the outer wall 305 of the body 303. By holding the sheet 102 of smokable material to the outer wall 305, the opposed longitudinal edges 108 and 110 of the sheet 102 may be secured in the overlapped section 111 such that the longitudinal edges 108 and 110 are not inadvertently separated.

[0085] The sealing device 304 in this embodiment may comprise a knurled roller 306. In this embodiment, the knurled roller 306 may be approximately cylindrical in shape. In other embodiments, the knurled roller 306 may be any other suitable shape.
The knurled roller 306 may be made of stainless steel or any other suitable material.

[0086] The knurled roller 306 may have an outer surface 312 with a pattern of projections 314 that are the reverse of the indentations to be pressed into the overlapped section 111 of the sheet 102 of smokable material. In some embodiments, the projections 314 may be in a diamond shaped pattern, a straight-line pattern, a criss-cross pattern, or any other suitable pattern.

[0087] The knurled roller 306 may be rotatably mounted on an axle 310. The axle 310 may be operatively connected to a drive mechanism (not shown) to drive rotation of the knurled roller 306. In some embodiments, the drive mechanism may comprise a motor such as an electric motor. In other embodiments, the drive mechanism may comprise any other suitable drive mechanism.

[0088] In some embodiments, the system 300 may further comprise an actuator 308. The actuator 308 may move the shape-forming device 302 longitudinally with respect to the sealing device 304. Alternatively, the actuator 308 may move the sealing device 304 longitudinally with respect to the shape-forming device 302. In some embodiments, the actuator 308 may comprise a push-rod. In other embodiments, the actuator 308 may comprise any other suitable type of actuator.

[0089] In some embodiments, the system 300 may further comprise a control system (not shown). In some embodiments, the control system may be operatively connected to at least one of the actuator 308 and the drive mechanism of the knurled roller 306 to control operation thereof. In some embodiments, the control system may also be operatively connected to the first vacuum source of the shape-forming device 302 to activate and de-activate the first vacuum source. In some embodiments, the system 300 may further comprise at least one power source (not shown). In some embodiments, a single power source may be operatively connected to the actuator 308, the drive mechanism, and the first vacuum source to supply power thereto. In other embodiments, one or more of the actuator 308, the drive mechanism, and the first vacuum source may be operatively connected to a separate power source.

[0090] As shown in Figure 7B, the actuator 308 in this embodiment may move the shape-forming device 302 towards the knurled roller 306 as indicated by arrows B.
As the shape-forming device 302 moves longitudinally along the actuator 308, the knurled roller 306 may contact the overlapped section 111 of the sheet 102.
The knurled roller 306 may rotate about the axle 310 and press the plurality of indentations into the overlapped section 111, thereby forming the glueless seam 106. In other embodiments, the shape-forming device 302 may be stationary and the actuator 308 may move the knurled roller 306 with respect to the shape-forming device 302 to roll the plurality of indentations into the overlapped section 111 and form the glueless seam 106.

[0091] As shown in Figures 7C and 7D, the system 300 may further comprise a crutch-insertion device 316. In Figures 7C and 7D, the crutch-insertion device 316 is shown as transparent for illustrative purposes to show the internal structure thereof;
however, the crutch-insertion device 316 may be made of any suitable material and may be opaque in some embodiments. In addition, although the device 316 is referred to as a crutch-insertion device, it will be understood that the device 316 may also be used to insert a filter or any other suitable component.

[0092] The crutch-insertion device 316 may comprise a body 318 having an outer wall 319 and an inner wall 320. The inner wall 320 may define an internal cavity 322 having an opening 321 thereto. The internal cavity 322 of the crutch-insertion device 316 may be a complementary size and shape to the shape-forming portion 307 of the shape-forming device 302 such that the shape-forming portion 307 (and the tubular body 104 thereon) may be at least partially received into the internal cavity 322 of the crutch-insertion device 316 via the opening 321.

[0093] In some embodiments, the body 318 of the crutch-insertion device 316 may define an internal chamber 324 therein, between the outer wall 319 and inner wall 320. The inner wall 320 of the body 318 may further comprise at least one aperture (not shown) therethrough to fluidly connect the internal chamber 324 with the internal cavity 322 and thereby the external environment (via the opening 321). In some embodiments, the inner wall 320 may comprise a plurality of apertures at various locations along the inner wall 320.

[0094] As shown in Figure 7C, the shape-forming device 302 may be moved longitudinally along the actuator 308, past the knurled roller 306, towards the crutch-insertion device 316. The shape-forming portion 307 of the shape-forming device 302 may at least partially be received into the crutch-insertion device 316. In some embodiments, the first vacuum source of the shape-forming device 302 may be de-activated to break the vacuum pull and allow the tubular body 104 to be released from the shape-forming device 302.

[0095] As shown in Figure 7D, the tubular body 104 may be received into the internal cavity 322 of the crutch-insertion device 316. The shape-forming device 302 may then be moved away from the crutch-insertion device 316, along the actuator 308, as indicated by arrows D. The shape-forming device 302 may return to a starting position to receive a new sheet 102 of smokable material and to start the process of forming another smokable article 100.

[0096] In some embodiments, system 300 may comprise a second vacuum source (not shown). The second vacuum source may be operatively connected to the crutch-insertion device 316. In some embodiments, the second vacuum source may comprise a vacuum pump. The vacuum pump may comprise a peristaltic pump, a Venturi pump, or any other suitable type of pump. In some embodiments, the second vacuum source may be fluidly connected to the internal chamber 324 of the crutch-insertion device 316 by a fluid conduit (not shown). The fluid conduit may comprise, for example, a hose, tube, or any other suitable type of fluid conduit.

[0097] The second vacuum source may apply a vacuum to the internal chamber 324 of the body 318 and thereby pull air from external environment through the apertures in the inner wall 320 (via the opening 321 and the internal cavity 322). The second vacuum source may thereby exert a vacuum pull on the inner wall 320, as indicated by arrows C, to hold the outer face 103 of the tubular body 104 to the inner wall 320 of the crutch-insertion device 316. By holding the outer face 103 of the tubular body 104 to the inner wall 320, the second opening 120 of the tubular body 104 may be prevented from collapsing inward and may be held in an open position. As used herein,

98 an "open position", when used in reference to the tubular body 104, may refer to a position in which the second opening 120 is open to provide access to the internal chamber 107. When the tubular body 104 is in the open position, a crutch or filter may be inserted into the internal chamber 107 as described in more detail below.
[0098] In some embodiments, the second vacuum source may be operatively connected to the control system described above, or to a separate control system, to activate and de-activate the second vacuum source. In some embodiments, the second vacuum source may also be operatively connected to the power source described above, or to a separate power source, to provide power thereto.

[0099] It will be understood that although the first and second vacuum sources of the system 300 are described as individual vacuum sources in this embodiment, in other embodiments, the first vacuum source may be the same as the second vacuum source (e.g. the same vacuum pump) and a single vacuum source may be operatively connected to both the shape-forming device 302 and the crutch-insertion device 316.

[00100] An example of how the crutch 122 may be inserted into the tubular body 104 of the smokable article 100 is shown in Figure 8. A sheet 124 of crutch material may be cut from a roll or bobbin 123 of crutch material and placed into a desired orientation. In some embodiments, a flipping device 137 may be used to flip or rotate the cut sheets 124 as shown by arrows M such that the all of the cut sheets 124 are in a desired orientation. The sheet 124 may be formed into the tubular outer portion 125 with the internal folded portion 127. In some embodiments, a folding device (not shown) may be used to form the sheet 124 into the crutch 122. The crutch 122 may then be inserted into the internal chamber 107 of the tubular body 104 via the second opening 120, as the outer face 103 of the tubular body 104 is held to the inner wall 320 of the crutch-insertion device 316 by the vacuum pull of the second vacuum source. In other embodiments, the filter 132 or any other suitable component can be inserted into the tubular body 104 in a similar manner.

[00101] Other variations of the system 300 are also possible. In some embodiments, the actuator 308 may be omitted and the shape-forming device 302 may be moved manually with respect to the knurled roller 306 or vice versa. In embodiments in which the actuator is omitted, the tubular body 104 may be released from the the shape-forming device 302 and manually inserted into the crutch-insertion device 316.

[00102] Figures 9A to 90 show another example system 400 for making a smokable article, according to some embodiments. Figures 9A to 9D show the system 400 at various stages of making the smokable article 100 of Figure 1.

[00103] The system 400 in this embodiment may comprise a shape-forming device 402 and a sealing device 404 (the sealing device 404 is not shown in Figure 9A). The shape-forming device 402 may comprise a body 403 having an outer wall 405 with a shape-forming portion 407. The shape-forming portion 407 may be similar in shape to the shape-forming portion 307 of the shape-forming device 302 in Figures 7A to 70 as discussed above.

[00104] In this embodiment, the outer wall 405 may comprise a knurled surface 409. The knurled surface 409 may comprise a pattern of projections 411 that are the reverse of the indentations to be pressed into the overlapped section 111 of the sheet 102 of smokable material_ In some embodiments, the entire outer wall 405 of the body 403 may comprise the knurled surface 409. In other embodiments, only the shape-forming portion 407 may comprise the knurled surface 409. The knurled surface may be made of stainless steel or any other suitable material.

[00105] The sheet 102 of smokable material may be wrapped around the shape-forming portion 407 to form the tubular body 104 with the overlapped section 111. In Figures 9A to 90, the sheet 102 is shown as transparent for illustrative purposes to show the knurled surface 409 of the shape-forming device 402. The overlapped section 111 may be positioned on the knurled surface 409 such that the overlapped section 111 faces towards the sealing device 404 to allow the sealing device 404 to contact the overlapped section 111 as described below.

[00106] In some embodiments, the shape-forming device 402 may comprise an internal chamber (not shown) and at least one aperture (not shown) extending through the outer wall 405 of the body 403 into the internal chamber. In some embodiments, the system 400 may comprise a first vacuum source (not shown) operatively connected to the shape-forming device 402. The first vacuum source may be similar to the first vacuum source of the system 300 as described above.

[00107] The first vacuum source may apply a vacuum to the internal chamber of the body 403 and thereby pull air from the external environment through the apertures in the outer wall 405. The vacuum source may thereby exert a vacuum pull on the outer wall 405 as indicated by arrows E in Figures 9A and 9B, to hold the sheet 102 of smokable material to the outer wall 405.

[00108] The sealing device 404 in this embodiment may comprise a polished roller 406 having a substantially smooth outer surface 412. The polished roller 406 may be approximately cylindrical or any other suitable shape. The polished roller 406 may be made of stainless steel or any other suitable material. The polished roller 406 may be rotatably mounted on an axle 410 and operatively connected to a drive mechanism to drive rotation of the polished roller 406.

[00109] In some embodiments, the system 400 may further comprise an actuator 408. The actuator 408 may be similar to the actuator 308 of the system 300 as described above. The actuator 408 may move the shape-forming device 402 longitudinally with respect to the polished roller 406 (or vice versa).

[00110] As shown in Figure 9B, the shape-forming device 402 may be moved along the actuator 408 towards the polished roller 406 as indicated by arrows F. As the shape-forming device 402 moves along the actuator 408, the polished roller 406 may contact the overlapped section 111. The polished roller 406 may rotate about the axle 410 and press the overlapped section 111 into the knurled surface 409, such that the projections 411 of the knurled surface 409 press a plurality of indentations in the overlapped section 111, thereby forming the glueless seam 106.

[00111] In some embodiments, as shown in Figures 9C and 9D, the system 400 may further comprise a crutch-insertion device 416. In Figures 9C and 9D, the crutch-insertion device 416 is shown as transparent for illustrative purposes to show the internal structure of the crutch-insertion device 416.

[00112] The crutch-insertion device 416 may comprise a body 418 having an outer wall 419 and an inner wall 420. The inner wall 420 may define an internal cavity 422.
The internal cavity 422 may be a complementary size and shape to the shape-forming portion 407 of the shape-forming device 402 such that the shape-forming portion 407 (and the tubular body 104 thereon) may be at least partially received into the internal cavity 422. In some embodiments, the body 418 of the crutch-insertion device 416 may define an internal chamber 424 therein, between the outer wall 419 and inner wall 420.
The inner wall 420 of the body 418 may further comprise at least one aperture (not shown) therethrough.

[00113] As shown in Figure 9C, the shape-forming portion 407 of the shape-forming device 402 may be received into the crutch-insertion device 416. As shown in Figure 9D, the tubular body 104 may thereby be received into the crutch-insertion device 416 and the shape-forming device 402 may be moved away from the crutch-insertion device 416, along the actuator 408, as indicated by arrows H. The shape-form ing device 402 may return to a starting position to receive a new sheet 102 of smokable material.

[00114] In some embodiments, the system 400 may further comprise a second vacuum source (not shown) operatively connected to the crutch-insertion device 416.
The second vacuum source may be similar to the second vacuum source of the system 300 as described above.

[00115] The second vacuum source may apply a vacuum to the internal chamber 424 of the body 418 and thereby pull air from the external environment through the apertures in the inner wall 420. The vacuum source may thereby exert a vacuum pull towards the inner wall 420, as indicated by arrows G in Figure 90, to hold the outer face 103 of the tubular body 104 to the inner wall 420. The tubular body 104 may thereby be held in the open position such that the crutch 122 or any other suitable component may be inserted into the tubular body 104 in a similar manner as described above for the system 300.

[00116] In some embodiments, the system 400 may further comprise a control system and at least one power source. The control system and at least one power source may be similar to that described above with respect to the system 300.

[00117] Figures 10A and 10B show alternative embodiments of sealing devices, according to some embodiments. The sealing devices of Figures 10A and 10B may be used to produce smokable articles with compressed seams.

[00118] An example sealing device 504 is shown in Figure 10A. The sealing device 504 is shown in the process of sealing the smokable article 100 of Figure 1. The sealing device 504 may comprise at least one high-pressure plate. As used herein, "high-pressure plate" may refer to an elongate element to which pressure is applied. In this embodiment, the sealing device 504 may comprise a first high-pressure plate 506 and a second high-pressure plate 507. Each of the first and second high-pressure plates 506, 507 may be comprised of a suitable material capable of withstanding high pressure including, but not limited to, a metal such as stainless steel.

[00119] In some embodiments, at least one of the high-pressure plates 506, 607 may be configured to be received into the internal chamber 107 of the tubular body 104.
In this embodiment, the first high-pressure plate 506 may be configured to be received into the internal chamber 107 of the tubular body 104 via the second opening

120. In some embodiments, the first high-pressure plate 506 may be approximately cylindrical in shape. In other embodiments, the first high-pressure plate 506 may be approximately rectangular, pyramidal, or any other suitable shape. The first high-pressure plate 506 may have any suitable diameter to be received into the internal chamber 107.
In some embodiments, the first high-pressure plate 506 may have a length that is approximately the same as the length Z1 of the tubular body 104 (length Z1 is shown in Figure 1). In other embodiments, the first high-pressure plate 506 may be longer than the length of the tubular body 104 and may extend past the second opening 120 of the tubular body 104.
[00120] In some embodiments, the second high-pressure plate 507 may be approximately the same size and shape as the first high-pressure plate 506. In embodiments in which the second high-pressure plate 507 is approximately the same size and shape as the first high-pressure plate 506, the first and second high-pressure plates 506, 507 may be interchangeable such that either of the first and second high-pressure plates 506, 507 may be received into the tubular body 104. In other embodiments, the second high-pressure plate 507 may be wider and/or longer than the first high-pressure plate 506 and, in these embodiments, only the first high-pressure plate 506 may be received into the tubular body 104. In other embodiments, the second high-pressure plate 507 may be any other suitable size and shape.

[00121] The first high-pressure plate 506 may have a first end 509 and a second end 511. The first high-pressure plate 506 may comprise a first sealing surface 514 extending from the first end 509 to the second end 511. The second high-pressure plate 507 may have a first end 510 and a second end 512 and may comprise a second sealing surface 515 extending from the first end 510 to the second end 512. In some embodiments, the first and second sealing surfaces 514 and 515 may each be substantially planar. The first and second high-pressure plate 506 and 507 may be disposed approximately parallel one another with the first and second sealing surfaces 514 and 517 facing inwards towards one another.

[00122] In some embodiments, when the first high-pressure plate 506 is received into the internal chamber 107 of the tubular body 104, the first end 509 of the first high-pressure plate 506 may be approximately aligned with the first end 116 of the tubular body 104 and the second end 511 of the first high-pressure plate 506 may be approximately aligned with the second end 118 of the tubular body 104. The overlapped section 111 (not visible in Figure 10A) of the sheet 102 may be positioned at the first sealing surface 514, facing towards the second sealing surface 515.

[00123] In some embodiments, the tubular body 104 may be formed first and then the first high-pressure plate 506 may be inserted into the tubular body 104.
In other embodiments, the sheet 102 of smokable material may be wrapped around the first high-pressure plate 506 to form the tubular body 104.

[00124] As shown in Figure 10A, pressure may be applied to the first and second high-pressure plates 506 and 507 to move the first and second high-pressure plates 506 and 507 towards one another as indicated by arrows I. In some embodiments, the pressure may be applied by engaging the first and second high-pressure plates 506 and 507 with a high-pressure device. In some embodiments, the high-pressure device may comprise a high-pressure vise, e.g. a high-pressure hydraulic vise. In other embodiments, pressure may be applied using any other suitable mechanism. The overlapped section 111 may thereby be compressed between the first and second sealing surfaces 514 and 515 of the first and second high-pressure plates 506 and 507, respectively, to form the glueless seam 106 (the glueless seam 106 is not visible in Figure 10A).

[00125] In this example, Figure 10A shows the first and second high-pressure plates 506 and 507 moving towards one another; however, in other embodiments, the first high-pressure plate 506 may be held stationary and pressure may be applied to move the second high-pressure plate 507 towards the first high-pressure plate 506 (or vice versa).

[00126] Another embodiment of a sealing device 604 is shown in Figure 10B. The sealing device 604 is shown in the process of sealing the smokable article 100 of Figure 1. The sealing device 604 may comprise a first high-pressure plate 606 having a first sealing surface 614 and a second high-pressure plate 607 having a second sealing surface 615. The first and second high-pressure plates 606 and 607 may be similar in size and shape to the first and second high-pressure plates 506 and 507 of the sealing device 504. The first high-pressure plate 607 may be received into the internal chamber 107 of the tubular body 104 via the second opening 120. The overlapped section 111 of the sheet 102 may be positioned at the first sealing surface 614, facing towards the second sealing surface 615.

[00127] At least one of the first and second high-pressure plates 606 and 607 may comprise at least one fluid conduit 608. In some embodiments, each of the first and second high-pressure plates 606 and 607 may comprise at least one respective fluid conduit 608. In the embodiment shown in Figure 10B, each of the first and second high-pressure plates 606 and 607 comprises three fluid conduits 608. In other embodiments, each of the first and second high-pressure plates 606 and 607 may comprise any other suitable number of fluid conduits 608 and embodiments are not limited to the specific number and arrangement of fluid conduits 608 described herein.

[00128] In some embodiments, each fluid conduit 608 of the first high-pressure plate 606 may be approximately aligned with a respective fluid conduit 608 of the second high-pressure plate 607. In other embodiments, the fluid conduits 608 of the first high-pressure plate 606 may be axially offset from the fluid conduits 608 of the second high-pressure plate 607 (not shown). The fluid conduits 608 may extend through the first and second high-pressure plates 606 and 607 to the first and second sealing surfaces 614 and 615, respectively.

[00129] Each of the fluid conduits 608 may be fluidly connected to a heated fluid source (not shown) such that a heated fluid may be supplied from the heated fluid source to the fluid conduits 608. In some embodiments, the heated fluid may comprise steam and the heated fluid source may comprise a boiler or any suitable means to provide steam. In other embodiments, the heated fluid may comprise any other suitable fluid and the heated fluid source may comprise any suitable means for providing the heating fluid.

[00130] As shown in Figure 103, pressure may be applied to the first and second high-pressure plates 606 and 607 to move the first and second high-pressure plates 606 and 607 towards one another as indicated by arrows J. The heated fluid may flow inward through each of the fluid conduits 608 towards the first and second sealing surfaces 614 and 615 as indicated by arrows K. The overlapped section 111 may thereby be compressed between the first and second sealing surfaces 614 and 615 of the first and second high-pressure plates 606 and 607, respectively, at a high pressure and at a high temperature to form the glueless seam 106 (the glueless seam 106 is not visible in Figure 10B).

[00131] In some embodiments, the sealing devices 504 or 604 may be used in combination with one of the shape-forming devices 302 or 402 described above.
In other embodiments, the tubular body 104 may be formed manually and then sealed using one of the sealing devices 504 or 604. In some embodiments, after sealing the tubular body 104 using one of the sealing devices 504 or 604, the tubular body 104 may be inserted into a crutch-insertion device similar to crutch-insertion devices 316 or 416 described above. In other embodiments, the crutch 122 or filter 132 may be inserted into the tubular body 104 by any suitable means.

[00132] It should be apparent to those skilled in the art that more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the disclosure. Moreover, in interpreting the disclosure, all terms should be interpreted in the broadest possible manner consistent with the context_ In particular, the terms "comprises" and "comprising" should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced.

[00133] Although particular embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow.

[00134] It is to be understood that a combination of more than one of the approaches described above may be implemented. Embodiments are not limited to any particular one or more of the approaches, methods or apparatuses disclosed herein.
One skilled in the art will appreciate that variations, alterations of the embodiments described herein may be made in various implementations without departing from the scope of the claims.

Claims (25)

CLAIMS:

1. A smokable article comprising:
a sheet of smokable material having a first longitudinal edge and an opposed second longitudinal edge, the sheet of smokable material formed into a tubular body such that the first longitudinal edge overlaps the second longitudinal edge;
and a glueless seam formed by sealing the first longitudinal edge and the second longitudinal edge together.

2. The smokable article of claim 1, wherein the glueless seam comprises a knurled seam.

3. The smokable article of claim 1, wherein the glueless seam comprises a compressed seam.

4. The smokable article of any one of claims 1 to 3, wherein the tubular body is frustoconical or conical in shape.

5. The smokable article of any one of claims 1 to 4, further comprising one of a crutch and a filter received into the tubular body.

6. The smokable article of any one of claims 1 to 5, wherein the sheet of smokable material comprises a non-wood paper.

7. A method for making a smokable article, the method comprising:
providing a sheet of smokable material;
forming the sheet of smokable material into a tubular body;
overlapping longitudinal edges of the sheet of smokable material to form an overlapped section; and sealing the overlapped section into a glueless seam.

8. The method of claim 7, wherein forming the sheet of smokable material into the tubular body comprises wrapping the sheet of smokable material around a shape-form ing device.

9. The method of claim 7 or 8, wherein sealing the overlapped section comprises knurling the overlapped section.

10. The method of claim 7 or 8, wherein sealing the overlapped section comprises compressing the overlapped section under pressure.

11. The method of claim 10, wherein the overlapped section is compressed at an elevated temperature.

12. The method of any one of claims 7 to 11, further comprising inserting one of a crutch and a filter into the tubular body.

13. The method of any one of claims 7 to 12, wherein the tubular body is frustoconical or conical in shape.

14. The method of any one of claims 7 to 13, wherein providing the sheet of smokable material comprises providing a sheet of non-wood paper.

15. A system for making a smokable article, the system comprising:
a shape-forming device for forming a sheet of smokable material into a tubular body; and a sealing device for sealing overlapped longitudinal edges of the sheet of smokable material into a glueless seam.

16. The system of claim 15, wherein the shape-forming device comprises a body having an outer wall, the outer wall comprising a shape-forming portion such that the tubular body is formed by wrapping the sheet of smokable material around the shape-form ing portion.

17. The system of claim 16, wherein the shape-forming portion is frustoconical or conical in shape.

18. The system of any one of claims 15 to 17, wherein the sealing device comprises a knurled roller.

19. The system of any one of claims 15 to 17, wherein the shape-forming device comprises a knurled surface and the sealing device comprises a polished roller.

20. The system of any one of claims 15 to 17, wherein the sealing device comprises a first high-pressure plate and an approximately parallel second high-pressure plate, the first high-pressure plate being received into the tubular body such that the overlapped longitudinal edges of the sheet are compressed between the first high-pressure plate and the second high-pressure plate.

21. The system of claim 20, wherein at least one of the first and second high-pressure plates comprises a fluid conduit for a heated fluid.

22. The system of any one of claims 15 to 21, further comprising a first vacuum source operatively connected to the shape-forming device and operable to exert a vacuum pull to hold the sheet of smokable material to the shape-forming device.

23. The system of any one of claims 15 to 22, further comprising an actuator that moves one of the shape-forming device and the sealing device with respect to the other one of the shape-forming device and the sealing device.

24. The system of any one of claims 15 to 23, further comprising a crutch-insertion device, the crutch-insertion device comprising an internal cavity that receives the tubular body therein.

25. The system of claim 24, further comprising a second vacuum source operatively connected to the crutch-insertion device and operable to exert a vacuum pull to hold the tubular body in an open position.