WO2019140237A1

WO2019140237A1 - Automated multi-tamp herbal rod filling apparatus, system and method

Info

Publication number: WO2019140237A1
Application number: PCT/US2019/013256
Authority: WO
Inventors: Mitchell Aaron WAGNER
Original assignee: Wagner Mitchell Aaron
Priority date: 2018-01-11
Filing date: 2019-01-11
Publication date: 2019-07-18

Abstract

An assembly system can include a paper holder assembler, a paper loader, a filler unit and a tamping unit. The paper holder assembler can include a plurality of pockets, each pocket shaped to accommodate a plurality of paper containers and defining a longitudinal axis. The paper loader can be configured to dispense a plurality of paper containers into the plurality of pockets of the paper holder assembler. The filler unit can be configured to dispense a predetermined volume of a smoking herb into the plurality of paper containers when the paper containers are received within the plurality of pockets. The tamping unit can include a plurality of tamp rods, each configured to apply compression to a portion of the smoking herb within a pocket of the plurality pockets along a longitudinal axis thereof.

Description

AUTOMATED MULTI-TAMP HERBAL ROD FILLING APPARATUS, SYSTEM

AND METHOD

Cross-Reference to Related Applications

[0001] This application claims priority to and benefit of U.S. Provisional Application No. 62/616,373, titled “Automated Multi-Tamp Herbal Rod Filling Apparatus, System and Method,” filed on January 11, 2018, the disclosure of which is incorporated herein by reference in its entirety.

Background

[0001] Herb insertion and rolling machines such as those for inserting smoking herbs into empty smoking article tubes are becoming quite popular. One reason for this increased popularity is that finished products like cigarettes are expensive and have been taxed heavily in the recent past. Thus, it has become less expensive for users to fill their own empty smoking article tubes with smoking herbs.

Summary

[0002] Various aspects of herb insertion apparatuses, systems and methods are described and shown herein with reference to exemplary embodiments. Herb insertion apparatuses, systems and methods of the present disclosure can be used for introducing smoking herbs into empty smoking article tubes (e.g., paper rolls or cylinders) and smoking cones. In some embodiments, an assembly system can include a paper holder assembler, a paper loader, a filler unit and a tamping unit. The paper holder assembler can include a plurality of pockets, each pocket shaped to accommodate a corresponding one or more paper containers and defining a longitudinal axis. The paper loader can be configured to dispense a plurality of paper containers into the plurality of pockets of the paper holder assembler. The filler unit can be configured to dispense a predetermined volume of a smoking herb into the plurality of paper containers when (i.e., after) the paper containers are received within the plurality of pockets. The tamping unit can include a plurality of tamp rods, each configured to apply compression to a portion of the smoking herb within a pocket of the plurality pockets along a longitudinal axis thereof.

[0003] In some embodiments, an assembly method includes dispensing a plurality of paper containers into a plurality of pockets of a paper holder assembler; dispensing a predetermined volume of a smoking herb into the plurality of paper containers when received within the plurality of pockets of the paper holder assembler; and applying compression, to portions of the smoking herb within each corresponding pocket of the plurality pockets, along a longitudinal axis of the corresponding pocket of the plurality of pockets, so as to compress the smoking herb.

[0004] In some embodiments, the assembly method further includes removing excess smoking herb disposed on a cover plate of the paper holder assembler, for example by passing a brush over the cover plate of the paper holder assembler.

[0005] In some embodiments, the compression results in a substantially uniform particle size distribution of the smoking herb.

[0006] In some embodiments, an apparatus includes a housing, a cover plate, a plurality of pockets, a plurality of cylinder rod holders, a plurality of ejector rods, and a plurality of actuators. The housing can have a proximal end and a distal end. The cover plate can be removably coupled to the proximal end of the housing, and the plurality of pockets can be disposed at the proximal end of the housing. Each pocket of the plurality of pockets can have an associated proximal end, distal end, and longitudinal axis, and can be shaped to accommodate a corresponding smoking product of a plurality of smoking products when received therein. The apparatus can be configured such that the proximal ends of the pockets are exposed when the cover plate is in an open position. The plurality of cylinder rod holders can be disposed within the housing, between the proximal end and the distal end thereof. Each actuator of the plurality of actuators can be disposed at the distal end of the housing, and be configured to actuate an associated ejector rod of the plurality of ejector rods along a direction defined by the longitudinal axis of said associated ejector rod. The actuation can cause the ejector rod to slide/translate within the associated cylinder rod holder such that, when the cover plate is in the open position and the plurality of smoking products is received in the plurality of pockets during use, each ejector rod of the plurality of ejector rods causes a smoking product of the plurality of smoking products to be ejected via the proximal end of the housing.

[0007] In some embodiments, each pocket of the plurality of pockets has a substantially conical shape. In other embodiments, each pocket of the plurality of pockets has a substantially cylindrical shape. In still other embodiments, the plurality of pockets includes both conical and cylindrical pockets. Brief Description of the Drawings

[0008] FIG. 1 shows example components of an assembly apparatus, including a paper holder assembler, a paper loader, a filler unit, a tamping unit, a finisher unit, and a twister unit, according to an embodiment.

[0009] FIG. 2A shows a paper holder assembler configured for automated linear actuation, according to an embodiment.

[0010] FIG. 2B shows the paper holder assembler of FIG. 2A with the cover plate in an open position for the loading of unfilled paper cones or the ejecting of filled paper cones.

[0011] FIG. 2C shows the paper holder assembler FIG. 2A with the cover plate in the open position and eject rods in an up/raised position.

[0012] FIG. 3A shows an example herbal rod assembly process, according to an embodiment.

[0013] FIG. 3B shows a stage of the assembly process of FIG. 3A during which the paper loader is advancing/dropping paper cones into corresponding cone holes of a paper holder assembler.

[0014] FIG. 3C shows the assembly process of FIG. 3A, after the paper loader has dropped the paper cones into the cone holes of paper holder assembler.

[0015] FIG. 3D shows the assembly process of FIG. 3A, after the paper cones have completely settled into the cone holes of paper holder assembly 1000.

[0016] FIG. 4A shows front and side views of a filler unit, according to some embodiments.

[0017] FIG. 4B shows a top view of the grid of FIG. 4A.

[0018] FIG. 5A shows a paper holder assembler being loaded with paper cones and then moving to a filler unit, according to some embodiments.

[0019] FIG. 5B shows the paper holder assembler disposed beneath and aligned with the filler unit, as shown in FIG. 5A, but with the grid in a down/lowered position. [0020] FIG. 6A shows a first step of a cone filling process, including a filling process, according to an embodiment.

[0021] FIG. 6B shows a further step of the cone filling process of FIG. 6A, including a sweeping process and movement to a tamping unit.

[0022] FIG. 7A shows a further step of the cone filling process of FIG. 6A, including movement to a tamping unit.

[0023] FIG. 7B shows a further step of the cone filling process of FIG. 6A, including a tamping process.

[0024] FIG. 8 shows an example sequencing of the steps outlined in FIGS. 5A, 5B, 6A, 6B, 7A, and 7B, according to some implementations.

[0025] FIG. 9A shows a paper holder assembler 1000 aligned beneath a stationary finisher unit 5000 in an up/raised position, according to an embodiment.

[0026] FIG. 9B shows the lowering of spinning geared rods onto filled cones for flattening, according to an embodiment.

[0027] FIG. 10A shows an example paper holder assembler disposed beneath and aligned with a stationary twister unit, according to an embodiment.

[0028] FIG. 10B shows the paper holder assembler of FIG. 10A, with the filled paper cones being pushed upward along a direction“G” beneath clamps of the stationary twister unit.

[0029] FIG. 11 A shows the paper holder assembler and stationary twister unit of FIG.

10A, with the unfilled top end portions of the paper cones being pinched closed.

[0030] FIG. 11B shows the paper holder assembler and stationary twister unit of FIG. 10A, with the pinched unfilled portions of the paper cones being twisted at their ends.

[0031] FIG. 12 shows the paper holder assembler and stationary twister unit of FIG. 10A, with the clamps being released.

[0032] FIG. 13 shows the paper holder assembler of FIG. 10A, with rods pressing upward on the filled paper cones having twisted ends until they fall out of the paper holder assembler [0033] FIG. 14 shows a front view of a round track automated assembly system configuration (with a top view shown in FIG. 15), according to some implementations.

[0034] FIG. 16 shows a top view of a rotary automated assembly system configuration, according to some embodiments.

[0035] FIG. 17 shows a conveyor paper holder assembler for paper cones, and a conveyor paper holder assembler for paper cylinders, according to some embodiments.

[0036] FIG. 18A shows a conveyor filler, according to some embodiments.

[0037] FIG. 18B shows an example grid 3061 configured to fit or couple to a larger paper holder module with more holes (e.g., as compared with the grid of FIG. 4B).

[0038] FIG. 19A shows front and side views of a filler unit mount, according to an embodiment.

[0039] FIGS. 19B-19C show the attachment between a conveyor filler unit and the filler unit mount of FIG. 19A.

[0040] FIG. 20 shows a side view of a conveyor filler unit attached to a stationary filler unit mount, according to an embodiment.

[0041] FIG. 21A shows side and front views of a tamping conveyor unit in an up/raised position, according to an embodiment.

[0042] FIG. 21B shows a side view of the tamping conveyor unit of FIG. 21 A, illustrating that, during use, the lift actuators are configured to move the carriage assembly up and down along direction“P.”

[0043] FIG. 21C shows a side view of the tamping conveyor unit of FIG. 21 A, in a down/lowered position.

[0044] FIG. 22A shows a side view (with FIG. 22B a front view thereof) of a conveyor finisher unit, according to an embodiment.

[0045] FIG. 23 shows a front view of an assembly system having an automated, multi- tamp conveyor belt design, according to some implementations. [0046] FIG. 24A shows a conveyor filler, according to some embodiments.

[0047] FIG. 24B shows an example grid configured to fit or couple to a paper holder module, according to some embodiments.

Detailed Description

[0048] Apparatuses, systems and methods for manufacturing finished smoking products, such as herbal rods, are described herein. In some embodiments, vertical compression is applied to smoking herbs received within paper cones or cylinders of a paper holder assembly component, to compress the smoking herbs and/or to improve the uniformity of the particle size distribution of the smoking herbs. Some systems described herein include automated conveyor mechanisms for transporting the paper holder assembly component, sequentially, to each of a plurality of assembly“modules” that perform steps such as insertion of paper cones and/or tubes, dispensing of smoking herbs, sweeping of excess smoking herbs, and compression of the smoking herbs when received in the paper cones and/or tubes.

[0049] FIG. 1 shows example components of an assembly apparatus/system, including a paper holder assembly component (“paper holder assembler”) 1000 (in an open position), paper loading component (“paper loader”) 2000, filling component (“filler unit”) 3000, tamping unit 4000, finisher unit 5000, and twister unit 6000. These components can be altered and/or configured in a variety of ways, for use in the process of filling and finishing smoking cones. The paper holder assembler 1000 includes multiple pockets, each pocket shaped and/or sized to accommodate a corresponding one or more paper containers, and defining a longitudinal axis. The multiple pockets can all have a common size and/or shape (e.g., substantially conical or substantially cylindrical), or can differ from one another. In some embodiments, each pocket from the plurality of pockets can have a sidewall profile with a predefined shape, e.g., vertical, tapered, inverse tapered, nonlinear, curved, etc. In some embodiments, each pocket from the plurality of pockets has an imparted surface finish, or a surface roughness within a predetermined tolerance. The paper loader 2000, during operation, dispenses multiple paper containers into the pockets of the paper holder assembler. The filler unit 3000 dispenses a predetermined volume of a smoking herb into the paper containers when (i.e., after) the paper containers are received within the pockets. [0050] In some embodiments, each of the pockets of the paper holder assembler 1000 includes an adjustable-height floor or baseplate, adjustable for example by a controller of the assembly apparatus during one or more of operation, filling, finishing, or ejection, for example such that an effective depth (or height) of the pockets corresponds to (or deliberately overshoots or undershoots) a height of the paper containers to be filled. The assembly apparatus, in some such implementations, can be configured to automatically measure or detect (e.g., through optical and/or mechanical detection) a paper container height prior to loading the paper containers, and based on the measured/detected height (or in response to a height value that is input, e.g., via a graphical user interface (GUI) of a controller thereof) can adjust the floor height of the pockets such that it is suitable for operations.

[0051] In some embodiments, a liner is“mated with,” or received within, a paper holder assembler prior to operation of the assembly apparatus/system, for example to modify a geometry of the paper holder assembler. The liner may be said to effectively modify the size and/or shape of the pockets, and may be readily interchangeable with another liner from a set, to change the size and/or shape of the pockets between product runs. Properties of the pockets that can be modified using the liner can include, but are not limited to: pocket volume, upper/top pocket opening diameter, upper/top pocket opening shape, lower/bottom pocket opening diameter, lower/bottom pocket opening shape, and pocket sidewall geometry (e.g., curved, tapered, vertical/straight-walled, etc.). The pockets can be defined via a split or unibody holder that receives inserts having a desired pocket geometry.

[0052] In some embodiments, the pockets and/or the paper holder assembler 1000 include one or more features (e.g., fiducial markings and/or registration markings) to facilitate the positioning, orientation and/or registration within two-dimensional (x/y) or three-dimensional (x/y/z) space within the assembly apparatus/system. The registration of the pockets in x, y and/or z space can be adaptively/dynamically adjusted during operation of the assembly apparatus/system (e.g., during loading, filling, tamping, finishing and/or ejection). The paper holder assembler 1000 can be configured to move into and out of the assembly apparatus/system, according to the phase of the assembly operations (e.g., driven by the controller). The pockets can be distributed/defined, within the paper holder assembler 1000, in any pattern and/or geometry (e.g., hexagonally close-packed, square grid/array, meandering rows, etc.). In some embodiments, a packing density of the pockets is maximized to increase throughput. The assembly apparatus/system can be configured to measure (i.e., automatically, via a controller and/or sensors, such as an optical sensor and light source) one or more of: placement relative to the pocket base opening, placement relative to the pocket top opening, pocket height, paper crutch diameter, paper crutch height, paper opening diameter, paper height, taper, and thickness..

[0053] In some embodiments, the paper holder assembler includes one or more registration marks, fiducial marks, or other features (collectively,“markings”) suitable for achieving alignment of the paper holder assembler with one or more other components of the assembly system (e.g., with a filler unit, a tamping unit, a finisher system, an ejector unit, etc.). The markings can be configured to be detected during operation, for example based on optical detection, weight, physically/mechanical registration/alignment, etc., for alignment of the paper holder assembler.

[0054] In some embodiments, an assembly apparatus/system includes a finisher system, for example that performs all operations that occur after the tamping operation. The finisher system can include a twister unit, an ejector unit, a cutter unit, and optionally a cleaning unit. The twister unit can be configured, during operation, to at least one of pinch and twist unfilled portions of paper cones disposed within a plurality of pockets defined within a holder, to form a plurality of smoking articles. The ejector unit can include a plurality of ejector rods configured, during operation, to slide within the plurality of pockets to cause the plurality of smoking articles to be ejected from the holder. The cutter unit can be configured to cut the smoking articles, and the cleaning unit can be configured to clean the holder and/or any other component of the assembly apparatus/system (e.g., by applying at least one of a sanitizer or an anti-fungal material to the holder). The finisher system can also include a controller compute device configured to control at least one of the twister unit, the ejector unit, the cutter unit, or the cleaning unit. The controller compute device can be dedicated to the finisher system operations, or a system controller can be used to control finisher operations as well as other assembly operations (e.g., loading, filling and/or tamping/compression). The finisher system can also include a shaper configured to modify an exterior shape of at least a subset of the plurality of smoking articles, for example by one or more of: the application of pressure, force, temperature, etc. to an exterior surface thereof.

[0055] Each component of FIG. 1 (paper holder assembler 1000, paper loader 2000, filler unit 3000, tamping unit 4000, finisher unit 5000, and twister unit 6000) can have any one of a plurality of different designs while serving substantially similar or the same functions. Such designs can be configured to be interchangeably usable in systems of the present disclosure. Component designs can depend, for example, on an automation configuration. A plurality of configurations are disclosed herein, together with corresponding component variations for each of those configurations. Each configuration and component can facilitate the tamping of smoking material, e.g., via a rod within a smoking paper. In many configurations, the paper holder assembler 1000 passes under the paper loader 2000, the filling component 3000, the tamping unit 4000, the finisher unit 5000, and/or the twister unit 6000 during use.

[0056] Although the finisher unit 5000 and the twister unit 6000 are shown and described, with reference to FIG. 1, as being distinct components, in some embodiments, the finisher unit 5000 can include any combination of the following (or subset thereof), in any order: a twister unit, a cutter unit, a cleaning unit (e.g., including one or more of: a blowout unit for removal of excess/dry material, a sanitizing unit, and a drying unit), a rod molding unit, a marking unit (e.g., a laser and/or printer personalization/marking unit), and/or an ejection unit (e.g., any or all steps performed after a tamping step as part of completing the finished product (i.e., a filled, closed rod).). In some embodiments, the cleaning unit is configured to perform a sequence of cleaning steps in an automated fashion (e.g., based on a process recipe stored in a memory that is operably coupled to a processor of a controller compute device, where the process recipe includes processor-executable instructions to perform the cleaning steps). The cleaning steps can include one or more of: removing dry material from a surface of any component of the assembly apparatus, sanitizing any component of the assembly apparatus, applying an anti fungal material to any component of the assembly apparatus, mechanically wiping down any component of the assembly apparatus, and drying any component of the assembly apparatus.

[0057] FIG. 2A shows a paper holder assembler 1000 configured for automated linear actuation and configured to be mechanically fixed to a rotating carrier (not shown). The cover plate 1001 is in a closed position, with the eject rods 1003 in a“down” position (i.e., fully inserted within respective cylinders 1004). FIG. 2A also shows unfilled paper cones 200A inside substantially cone-shaped holes (i.e., openings, pockets or orifices) 1002. Eject rods 1003 are configured to actuate/move up and down within cylinders 1004 during use, and can be powered by associated lines 1005 (e.g., pistons, electrically and/or pneumatically powered lines, etc.).

[0058] FIG. 2B shows the paper holder assembler 1000 of FIG. 2A with the cover plate 1001 in an open position. During use, the cover plate 1001 can be in the open position, for example, when unfilled paper cones 200A are being loaded or when filled paper cones 200B are being ejected.

[0059] FIG. 2C shows the paper holder assembler 1000 of FIG. 2A with the cover plate 1001 in the open position. Eject rods 1003 are in an“up” position (i.e., not fully inserted within the respective cylinders 1004), ejecting filled paper cones 200B.

[0060] FIG. 3A shows an example assembly process in which paper loader 2000 is disposed above a paper holder assembler 1000. Paper loader 2000 contains a plurality of stacked, unfilled paper containers (in this case, cones) 200. The paper loader 2000 includes a plurality of rollers 2001 to facilitate the dropping of the paper cones 200 into corresponding cone holes 1002 (or“pockets”) of the paper holder assembler 1000 while cover plate 1001 of the paper holder assembler 1000 is in the open position.

[0061] FIG. 3B shows a stage of the assembly process of FIG. 3A during which, using rollers 2001, the paper loader 2000 is advancing/dropping the paper cones 200 into corresponding cone holes 1002 of paper holder assembler 1000 while cover plate 1001 is still in the open position.

[0062] In some embodiments, the paper containers are pre-processed prior to being dispensed into the plurality of pockets of the paper holder assembler. The pre-processing can include, for example, reducing deformation of crutches of the paper containers. As used herein, a“crutch” refers to a filtered base of a paper container (i.e., a portion of a paper container that includes a filter). Reducing the deformation can include recircularizing (or recircularization) of the crutches, for example via rolling or spinning the crutches and/or via the application of force thereto. Alternatively or in addition, pre-processing can include reorientation of the paper containers such that they are aligned with a desired longitudinal axis prior to loading. The pre processing of the paper containers can be performed sequentially (i.e., one at a time, for example in a linear fashion), in groups that are pre-processed simultaneously or substantially simultaneously.

[0063] FIG. 3C shows the assembly process of FIG. 3A, after which time the paper loader 2000 has dropped the paper cones 200 completely into the cone holes 1002 of paper holder assembler 1000. [0064] FIG. 3D shows the assembly process of FIG. 3 A at a stage in which the paper cones 200 have completely settled into the cone holes 1002 of paper holder assembly 1000. Cover plate 1001 is in the closed position, and the paper cones 200 are now ready to be filled, for example with smoking herbs.

[0065] FIG. 4A shows front and side views of a filler unit 3000, according to some embodiments. The filler unit 3000 is configured to dispense predetermined (e.g., measured) amounts of smoking herbs 182 by rotating a toothed conveyor belt 3004 under a hopper 3003 containing the smoking herbs 182. Hopper 3003 and conveyor sizes can be enlargened to accommodate the filling of more paper cones. A sweeper arm 3001 is connected to a grid 3011 and configured, during use, to move vertically along direction“A” (e.g., to drop the assembly downward and move the assembly upward), and to move horizontally (i.e., back and forth) along direction“B.” The filler unit 3000 can include one or more guides and/or“de-clumpers” along a pathway therein, to maintain flow properties of the filler unit 3000.

[0066] In some embodiments, the smoking herbs can be pre-processed, prior to being loaded into the filler unit 3000. The pre-processing of the smoking herbs can include modifying the smoking herbs to adjust one or more of: water content, grind size, strain, phenotype, and chemotype of the smoking herbs. Alternatively or in addition, different grind sizes of the smoking herbs can be separated based on grind size (e.g., into large particle and small particle components/streams) and optionally reconstituted to achieve one or more desired properties (e.g., for mass variance control, blend ratios, dispense volumes, etc.). The volume/mass of smoking herbs being dispensed during operation can be dynamically adjusted (e.g., in response to a detected parameter and/or feedback received at the controller) to reach an objective parameter, such as a mass target or a blend target. In some cases, a quality control process (e.g., computer-implemented or performed by a human operator) can be used to generate feedback. In other words, one or more parameters of the smoking herbs and/or finished products can be automatically detected and the associated data can be transmitted to the controller to cause the controller to adjust one or more operating variables. Alternatively, a human operator can make quality control observations and enter data into the controller computer device such that the controller can make operational adjustments.

[0067] In some embodiments, smoking herbs are combined with one or more additives and/or modifiers, at any stage of the operation (e.g., prior to loading, prior to filling, prior to tamping, or prior to finishing). [0068] FIG. 4B shows a top view of the grid 3011 of FIG. 4A. The grid can be configured to funnel the smoking herbs downward via a plurality of openings defined therein, and to move the smoking herbs back and forth. The pass-through capacity of grid 3011 can be increased, for example by enlarging the openings defined therein and/or by adding additional openings, to accommodate the filling of more paper cones.

[0069] FIG. 5 A shows a paper holder assembler 1000 being loaded with paper cones 200 from paper loader 2000, and then moving from under the paper loader 2000 to beneath a filler unit 3000. During alignment of the paper holder assembler 1000 with the filler unit 3000, the cover plate 1001 of the paper holder assembler 1000 is in the down position, and grid 3011 of the filler unit 3000 is in an up/raised position.

[0070] FIG. 5B shows the paper holder assembler 1000 disposed beneath and aligned with the filler unit 3000, as shown in FIG. 5A, but with grid 3011 now in a down/lowered position.

[0071] FIG. 6A shows a first step of a cone filling process, where the paper holder assembler 1000 is disposed beneath and aligned with the filler unit 3000, with grid 3011 in the down position, as shown in FIG. 5B. During filling, a toothed conveyor 3004 rotates, thereby drawing smoking herbs 182 from hopper 3003 and through grid 3011 and cover plate 1001 into paper cones 200. Although shown and described, with reference to FIG. 6A, as being a toothed conveyor, the conveyor 3004 can alternatively be a smooth conveyor (i.e., having a substantially flat surface). A sweeper arm 3001 actuates forward and backward using grid 3011 to move/direct the falling smoking herbs through holes in cover plate 1001 and into the paper cones 200.

[0072] FIG. 6B shows a further step of the cone filling process, with paper holder assembler 1000 still disposed beneath filler unit 3000, but with grid 3011 in the up/raised position. While moving left to right, paper holder assembler 1000 passes under a sweeper brush 3002 to remove any remaining smoking herbs 182 from cover plate 1001. Subsequently, paper holder assembler 1000 can be moved to a tamping unit 4000, as shown and described with reference to FIG. 7A.

[0073] FIG. 7A shows a further step of the cone filling process, in which the paper holder assembler 1000 is disposed beneath a tamping unit 4000 in an up/raised position. Tamping unit 4000 is configured to actuate upwards and downwards along a direction“C,” and includes a plurality of tamp rods 150 configured to move through cover plate 1001 of a paper holder assembler 1000 and compress smoking herbs 182 within paper cones 200. The compression of the smoking herbs 182 can be caused, for example, at least in part by the weight of the tamp rods 150 themselves. Tamp rods 150 can be vertically driven (and, correspondingly, cause vertical compression of the smoking herbs within the paper tubes and/or cylinders) by one or more of: their own weight, an air cylinder, actuators, an electric motor, a hydraulic cylinder, or a spring. The actuation of the tamp rods 150 can be performed according to a predefined velocity profile, momentum profile and/or force profile (e.g., under control of a controller compute device executing a predefined program/recipe), any of which may depend on one or more properties of the tamp rods 150. Adjustments may be made (e.g., automatically) during operation to ensure a desired and/or consistent result. Such features can be highly beneficial, for example since if the tamping force is too great (and, consequently, the imparted compression is too great), undesirable results (such as visible “banding” due to uneven compression among multiple cycles, improper length (i.e., too short if compression is too great), tom paper containers, accordioning, protrusion of stems through the paper containers, blowout of glue lines, blowout of heat-crimped joints, blowout of mechanically crimped joints, unsmokeable finished products due to an inability to pull air through the smoking rod, or overly-dense smoking rods that prematurely extinguish after lighting/use) can occur. By contrast, if the tamping force is too low (and, consequently, the imparted compression is too low), undesirable results such as overfilling, or smoking rods that pull too much air (and“bum hot”) can occur. In some such implementations, a height of the tamping unit can be adjusted (e.g., dynamically and/or automatically, before and/or during operation) to set a separation distance between the paper container and smoking herb, relative to the tamp rod 150 received therein and optionally based on the velocity profile of the tamp rod 150.

[0074] In some embodiments, the compression of the smoking herbs occurs only inside the paper tubes or cones, unlike in injection machines, thus minimizing the material contact between the smoking herbs and other machine components apart from the tamp rod tips. In some embodiments, the overall assembly process/method (e.g., due to the filling unit operations) results in a substantially uniform particle size distribution of the smoking herbs, e.g., within the finished smoking article and/or along a horizontal axis of the finished smoking article, within the paper cones and/or tubes (or other containers within the pockets of the paper holder assembler/assembly plate). Alternatively or in addition, the overall assembly process/method (e.g., due to the tamping unit operations) results in a substantially even packing and compression along the longitudinal axis of the finished smoking article. [0075] FIG. 7B shows a further step of the cone filling process, in which the paper holder assembler 1000 is disposed beneath tamping unit 4000, with the tamping unit in a down/lowered position. As shown in FIG. 7B, tamping unit 4000 has moved downward along direction“C,” and tamp rods 150 are compressing smoking herbs 182 within the paper cones 200

[0076] FIG. 8 shows an example sequencing of the steps outlined in Figs. 5A, 5B, 6A, 6B, 7A, and 7B in which a paper holder assembler 1000 is sequentially moved to beneath each of a plurality of stationary filler unit 3000 and to beneath each of a plurality of stationary tamping units 4000, in an alternating fashion, until the paper cones 200 are filled with compressed smoking herbs 182.

[0077] FIG. 9A shows a paper holder assembler 1000 aligned beneath a stationary finisher unit 5000 in an up/raised position. At least a portion of the finisher unit 5000 is configured to actuate downward along direction“D” until geared rods 5004 contact smoking herbs 182 disposed inside corresponding paper cones 200 (e.g., vertically aligned therewith). Geared rods 5004 are configured to slide independently up and down along direction F. One or motors 5001 can be operatively coupled to, and configured to tum/rotate, corresponding gears 5002, which in turn tums/rotates rod gears 5003 and spins geared rods 5004 in a rotary/rotational direction, as indicated by arrow“E.”

[0078] As shown in FIG. 9B, once the paper cones 200 have been filled with compressed smoking herbs 182, corresponding spinning geared rods 5004 are lowered onto the filled cones, contact the smoking herbs 182, and apply force sufficient to level them flat, thereby reducing a likelihood that loose smoking herbs 182 will fall out of paper cone 200.

[0079] FIG. 10A shows an example paper holder assembler 1000 disposed beneath and aligned with a stationary twister unit 6000 that is in an up/raised position. Twister unit 6000 includes rotary pulleys 6001, pull cords 6002, pull motors 6008, twist motors 6003, gears 6004, cord gears 6005, fixed tubes 6006, and clamps 6007. The paper holder assembler 1000 contains paper cones 200 substantially, but not completely, filled with smoking herbs 182 that are aligned with the clamps 6007.

[0080] FIG. 10B shows the paper holder assembler 1000 disposed beneath and aligned with the stationary twister unit 6000, with the twister unit 6000 in the up/raised position. The paper holder assembler 1000 contains aligned paper cones 200 that are substantially, but not completely, filled with compressed smoking herbs 182. The filled paper cones 200 are pushed upward along direction“G” by rods 1003, thereby exposing the unfilled portions of the filled paper cones 200, which are centered on/aligned with, and positioned directly beneath, clamps 6007.

[0081] FIG. 11A shows the paper holder assembler 1000 disposed beneath and aligned with the stationary twister unit 6000, with the twister unit 6000 in a down/lowered position. With the exposed unfilled portion of paper cones 200 centered and directly beneath clamps 6007, the pull motors 6008 pull on pull cords 6002 over rotary pulleys 6001 in an upward direction“H.” When pulling the pull cords 6002, cord gears 6005 are lifted, and clamps 6007 are forced closed (motion“I”) over the unfilled portion of paper cones 200, thereby pinching the top end 202 closed.

[0082] FIG. 11B shows the paper cones 200 filled with compressed smoking herbs 182 pinched at the top end 202. The twist motors 6003 turn gears 6004, which turn cord gears 6005, which turn pull cords 6002 inside fixed tubes 6006, thereby spinning clamps 6007 in a rotational direction“J.” When clamps 6007 spin, they twist the pinched unfilled portions of the paper cones 200 at their ends 202. This twisting of the pinched, filled paper cones reduces or prevents the smoking herbs 182 from falling out of the finished paper cones 200.

[0083] FIG. 12 shows the paper holder assembler 1000 aligned with and disposed beneath the stationary twister unit 6000, with the twister unit in the up/raised position. The pull motors 6008 release the tension on pull cords 6002 over rotary pulleys 6001 along a downward direction“K.” When released, pull cords 6002 lower their respective cord gears 6005 and the clamps 6007, in turn, release and open upward, as shown by arrows“L.” The paper holder assembler 1000 can now move from position M to position N (i.e., moving out from under the twister unit 6000).

[0084] FIG. 13 shows the paper holder assembler 1000, containing the paper cones 200 filled with compressed smoking herbs 182 and having twisted ends 202. Actuating along direction“G,” rods 1003 can press upward on paper cones 200 until they fall out of the paper holder assembler 1000. Paper holder assembler 1000, once emptied of the paper cones 200, can subsequently be reloaded with empty paper cones 200, and another assembly process, such as the process shown and described above with reference to Figs.3A through 13A, can be performed. [0085] FIG. 14 shows a front view of a round track automated assembly system configuration (with a top view shown in FIG. 15), according to some implementations. As shown in FIG. 14A, a plurality of paper holder assemblers 1000 are configured to rotate, during use, beneath a plurality of stationary“upper modules,” including one or more paper loaders 2000, one or more filler units 3000, one or more tamping units 4000, on or more finisher units 5000, and one or more twister units 6000. The filler units 3000 and tamping units 4000 can be organized in an alternating fashion, and additional filler units 3000 and tamping units 4000 can be added to the configuration, for example to accommodate larger paper cone 200 sizes. The paper holder assemblers 1000 are configured to travel along a track (e.g., having an oblong, circular, oval, elongate curved, or other shape), and to stop under each of the plurality of upper modules described above. This facilitates the continuous and substantially concurrent operation of each upper module, thereby increasing throughput and more frequently dispensing paper cones filled with compressed smoking herbs. This configuration can be customizable, i.e., a user can change and/or add modules as needed for a given implementation.

[0086] FIG. 16 shows a top view of a rotary automated assembly system configuration, according to some embodiments. As shown in FIG. 16, a plurality of paper holder assemblers 1000 travel along a substantially circular path so as to be positioned inside and/or beneath each of a plurality of stationary upper modules, which can include: one or more paper loaders 2000, filler units 3000, tamping units 4000, Finishing Module 5000, and Twist Module 6000. Filling Modules 3000 and tamping units 4000 may be added, for example in an alternating fashion, to accommodate larger paper cone sizes. As shown in FIG. 16, during operation of the assembly system, the paper holder assemblers 1000 can rotate in a circular fashion, stopping intermittently beneath each of the plurality of stationary upper modules while traveling along their path. This configuration facilitates the continuous and substantially concurrent operation of each of the plurality of upper modules, thereby increasing throughput of the system as compared with other configurations, and more frequent dispensing of paper cones filled with compressed smoking herbs. This configuration can be customizable, i.e., a user can change and/or add modules as needed for a given implementation.

[0087] FIG. 17 shows a conveyor paper holder assembler 1021 including recesses that are shaped/sized for accommodating paper cones, and a conveyor paper holder assembler 1022 including recesses that are shaped/sized for accommodating paper cylinders. They are designed for assembly systems that use straight/linear conveyor automation, and such straight/linear systems can be readily converted for use with different sizes, quantities, and/or shapes of paper cylinders and/or cones. Using conveyor paper holder assembler designs as shown in FIG. 17, papers can be inserted outside of the automated conveyor line, and run through a versatile filling conveyor line, capable of filling and compressing different sizes and shapes of smoking papers with smoking herbs. In some embodiments, a conveyor paper holder assembler includes recesses that are shaped/sized for paper cones as well as for paper cylinders (i.e., a combination thereof).

[0088] FIG. 18A shows a conveyor filler 3050 according to some embodiments, having a design that permits a conveyor belt to move beneath the conveyor filler 3050 while the conveyor belt is carrying a plurality of conveyor paper holder assemblers . Conveyor filler 3050 can be configured to dispense a predetermined (e.g., measured) quantity of smoking herbs 182 by rotating toothed conveyor belt 3054 under hopper 3053. Hopper 3053 and conveyor sizes can be enlarged, for example to accommodate the filling of a larger quantity or total volume of paper cones. A sweeper arm 3051 is connected to a grid 3061 and is configured for reciprocal motion (i.e., back and forth) along direction“A” (i.e., to drop downward or raise upward) and along direction“B” (i.e., forward and backward) to sweep the dispensed smoking material 182 (e.g., so that the dispensed smoking material passes through the grid 3061). Mounting gear motor 3055 attaches and allows filler unit 3050 to move forward and backward on a stable base.

[0089] FIG. 18B shows an example grid 3061 configured to fit or couple to a larger paper holder module with more holes (e.g., as compared with grid 3011 of FIG. 4B).

[0090] FIG. 19A shows front and side views of a filler unit mount 3060. The filler unit mount can function as a support post and is configured to attach to conveyor filler unit 3050 via a mounting track 3062.

[0091] FIG. 19B shows the attachment between a conveyor filler unit 3050 and a filler unit mount 3060 by fitting a mounting gear motor 3055 of the conveyor filler unit 3050 to the mounting track 3062 of the filler unit mount 3060. For example, the mounting gear motor 3055 is inserted in mounting track 3062. Once the filler unit mount 3060 is attached to the conveyor filler unit 3050, it appears as shown in FIG. 19C.

[0092] FIG. 20 shows a side view of a conveyor filler unit 3050 attached to a stationary filler unit mount 3060. Mounting gear motor 3055 is configured to move back and forth in mounting track 3062, thereby moving/translating the entire conveyor filler unit 3050 along direction“X.” This can facilitate a more even distribution, within the paper cones/tubes, of the smoking material falling from the conveyor 3054.

[0093] FIG. 21A shows side and front views of a tamping conveyor unit 4050 in an up/raised position. The tamping conveyor unit 4050 includes a plurality of tamp rods 150, a pair of opposing support rails 4055, a carriage assembly 4052, and a plurality of lift actuators 4054.

[0094] FIG. 21B shows a side view of the tamping conveyor unit 4050 in the up position, and illustrates that, during use, the lift actuators 4054 are configured to move the carriage assembly 4052 up and down along direction“P,” guided by the support rails 4055.

[0095] FIG. 21C shows a side view of the tamping conveyor unit 4050 in a down/lowered position, and illustrates that the lift actuators 4054 have moved the carriage assembly 4052 down along direction“P” (e.g., guided by the support rails 4055).

[0096] FIG. 22A shows a side view (with FIG. 22B showing a front view thereof) of a conveyor finisher unit 5050, having functions similar to those of finisher unit 5000 (see Figs. 9A-9B) but including a larger number of geared rods 5004, configured to move/translate downward along direction“D” until one or more of the geared rods 5004 makes contact with smoking herbs 182 inside corresponding paper cones 200. Geared rods 5004 can be configured to slide independently up and down, along a direction F. Motors 5001 are configured to tum/rotate corresponding gears 5002, which turn rod gears 5003 and cause geared rods 5004 to spin/rotate in a rotary/rotational direction as indicated by arrow“E.”

[0097] FIG. 23 shows a front view of an assembly system having an automated, multi- tamp conveyor belt design, according to some implementations. In such implementations, a tray conveyor 5052 is configured to move a conveyor paper holder assembler 1022 forward, during use, along direction“Q,” stopping periodically under each of (or at least one of): a conveyor filler unit 3050, a conveyor tamping unit 4050, and a conveyor finisher unit 5050. It is contemplated that additional modules can be added to this configuration (or, indeed, to any configuration described herein) if a longer tray conveyor 5052 is used. When conveyor paper holder assembler 1022-A enters the tray conveyor 5052, it contains a plurality of empty/unfilled smoking tubes 100. When the conveyor paper holder assembler 1022-B stops (e.g., when vertically aligned with filler unit 3050), a sweeper arm 3051, connected to grid 3061, actuates downward/upward along direction“T” so as to make contact with the conveyor paper holder assembler 1022-B. Once the conveyor paper holder assembler 1022-B is aligned with the filler unit 3050, predetermined (e.g., measured) amounts of smoking herbs 182 can be dispensed into the conveyor paper holder assembler 1022-B by rotating a toothed conveyor belt 3054 disposed beneath hopper 3053. Grid 3061 can subsequently move/translate front to back (e.g., along dimensions parallel to a top plane of the conveyor paper holder assembler 1022-B) to move/sweep uncompressed and/or loose smoking herbs 182 into paper tubes 200 (See FIG 18A).

[0098] The sweeper brush 3052 is configured to sweep remaining smoking material 182 from the top of the conveyor paper holder assemblers 1022 (or from a cover plate thereof) as they pass under sweeper brush 3052 during their travel between modules. The excess smoking herbs can ride between paper holder assemblers 1022 until they fall off the tray conveyor 5052 into a collection bin 2300 at the end of the conveyor line. A conveyor tamping unit 4050-A is shown in the up position in FIG. 23.

[0099] In some embodiments, excess smoking herb that is collected in/captured by a collection bin or other receptacle (e.g., collection bin 2300, for example due to one or more of: gravitational force, applied vibration, incidental operational movement, etc.) is transported, guided or redirected so that it can be reintroduced into the filler unit and recycled for use in filling subsequent tubes or for otherwise being used in the production of finished products of the present disclosure. The transporting, guiding or redirection of the excess smoking herb can be perfbrmed/accomplished using one or more of: a conveyor belt, a guide channel, a vacuum feed or other suction-generating component, a blower fan, compressed air or other inert gas, or mechanical transfer device (e.g., crane, cart, etc.,).

[0100] Also in FIG. 23, the conveyor paper holder assembler 1022-C has aligned with conveyor tamping unit 4050-B, and the conveyor tamping unit 4050-B has moved into a down/lowered position, along direction“P,” such that rods 150 can be lowered into interior portions of the paper cones 200 and compress the smoking herbs 182 disposed therein. In some implementations, the translation of the conveyor tamping unit 4050-B along direction P can be repeated multiple times for a given conveyor paper holder assembler 1022-C , for example to increase a compression density of the smoking herbs within the paper tubes 200. [0101] At its position as shown in FIG. 23, the conveyor paper holder assembler 1022-D has been filled with smoking herbs, those smoking herbs have been compressed, and the conveyor paper holder assembler 1022-D has stopped in an aligned position with respect to conveyor finisher unit 5050. Conveyor finisher unit 5050 can function in a similar manner to that of finisher unit 5000 (see Figs. 9A-9B), but includes a larger number of geared rods 5004. For example, the conveyor finisher unit 5050 is configured to move downward along direction “D” until at least one of the plurality of geared rods 5004 makes contact with a top surface of compressed smoking herbs 182 inside corresponding paper tubes 200. Geared rods 5004 are configured to independently slide up and down along a direction“F,” ensuring good contact between the bottom tip of each geared rod 5004 and the compressed smoking herbs 182. In some embodiments, the geared rods 5004 are also configured to spin, for example to create heat and/or friction with the compressed smoking herbs 182 within the top tip of paper tubes 200. This can help to prevent the compressed smoking herbs from falling out of the tubes once the filled tubes are completed (e.g., once the filled tubes have been flattened by the geared rod tip surfaces).

[0102] The conveyor paper holder assembler 1022-E is finished and ready for packaging. The assembly system having an automated, multi-tamp conveyor belt design, as shown and described with reference to FIG. 23, can be expanded, for example by adding additional conveyor filler units 3050, conveyor tamping units 4050, etc. This can be desirable, for example, to achieve an even compression in the filling of various sized paper cones and paper tubes within a common automated line of modules.

[0103] FIG. 24A shows a conveyor filler 3050 according to some embodiments, having a design that permits a conveyor belt to move beneath the conveyor filler 3050 while the conveyor belt is carrying a plurality of conveyor paper holder assemblers. Conveyor filler 3050 can be configured to dispense a predetermined (e.g., measured) quantity of smoking herbs 182 by rotating toothed conveyor belt 3054 under hopper 3053. Hopper 3053 and conveyor sizes can be enlarged, for example to accommodate the filling of a larger quantity or total volume of paper cones. In some such implementations, a mass variance control of about +/- 10% can be achieved due to the use of the conveyor filler 3050 and/or hopper 3053. A grid 3061 can serve as a fill plate (rather than strictly as a guide) that dispenses a calibrated volume of the smoking herbs 182, in that the grid 3061 is calibrated to be filled with one or more predefined/specified volume(s) of the smoking herbs 182, and excess material can be removed (e.g., via shaking, blow-off, vibration, and/or brushing, etc.) before the predefined/specified volume(s) smoking herbs 182 are dispensed from the grid 3061 into paper containers aligned therewith. Mounting gear motor 3055 attaches and allows filler unit 3050 to move forward and backward on a stable base.

[0104] FIG. 24B shows an example grid 3061 compatible with the conveyor filler 3050 of FIG. 24 A.

[0105] Additional detail applicable to some embodiments of the present disclosure can be found, by way of example, in International Patent Application No. PCT/US2017/024638, titled “Vertical Multi Tamping Cigarette Hers Filling System and Method,” the entire contents of which are incorporated by reference herein for all purposes.

[0106] While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Where methods described above indicate certain events occurring in certain order, the ordering of certain events may be modified. Additionally, certain of the events may be performed concurrently in a parallel process when possible, as well as performed sequentially as described above.

[0107] Where schematics and/or embodiments described above indicate certain components arranged in certain orientations or positions, the arrangement of components may be modified. While the embodiments have been particularly shown and described, it will be understood that various changes in form and details may be made. Any portion of the apparatus and/or methods described herein may be combined in any combination, except mutually exclusive combinations. The embodiments described herein can include various combinations and/or sub-combinations of the functions, components and/or features of the different embodiments described.

Claims

What is claimed:

1. An assembly system, comprising:

a paper holder assembler including a plurality of pockets, each pocket from the plurality of pockets shaped to accommodate a plurality of paper containers, and each pocket from the plurality of pockets defining a longitudinal axis thereof;

a paper loader configured to dispense, during use, a plurality of paper containers into the plurality of pockets of the paper holder assembler;

a filler unit configured to dispense, during use, a predetermined volume of a smoking herb into the plurality of paper containers when received within the plurality of pockets of the paper holder assembler; and

a tamping unit including a plurality of tamp rods, each tamp rod of the plurality of tamp rods configured to apply, during use, compression to a corresponding portion of the smoking herb within a corresponding pocket of the plurality pockets, along the longitudinal axis thereof.

2. The assembly system of claim 1, wherein each pocket from the plurality of pockets includes an adjustable-height floor.

3. The assembly system of claim 1, wherein each pocket from the plurality of pockets has a tapered sidewall profile.

4. The assembly system of claim 1, further comprising a liner configured to be received within the paper holder assembler, to modify a geometry of the paper holder assembler.

5. The assembly system of claim 1, wherein the paper holder assembler includes a registration feature configured to be detected during operation for alignment of the paper holder assembler.

6. An assembly method, comprising:

dispensing a plurality of paper containers into a plurality of pockets of a paper holder assembler;

dispensing a predetermined volume of a smoking herb into the plurality of paper containers when received within the plurality of pockets of the paper holder assembler; and applying compression, to portions of the smoking herb within each corresponding pocket of the plurality pockets, along a longitudinal axis of the corresponding pocket of the plurality of pockets, so as to compress the smoking herb.

7. The assembly method of claim 6, further comprising removing excess smoking herb disposed on a cover plate of the paper holder assembler.

8. The assembly method of claim 6, wherein the method results in at least one of: a substantially uniform particle size distribution of the smoking herb; or a substantially even compression along a longitudinal axis of the smoking herb.

9. The assembly method of claim 6, further comprising pre-processing each paper container from the plurality of paper containers, prior to dispensing the plurality of paper containers into the plurality of pockets of the paper holder assembler, the pre-processing including reducing deformation of crutches of the paper containers.

10. The assembly method of claim 9, wherein the reducing deformation includes recircularizing of the crutches.

11. The assembly method of claim 9, wherein the pre-processing of each paper container from the plurality of paper containers is performed sequentially.

12. The assembly method of claim 10, wherein the recircularizing of the crutches includes spinning the crutches.

13. The assembly method of claim 10, wherein the recircularizing of the crutches includes spinning the crutches.

14. An apparatus, comprising:

a housing having a proximal end and a distal end;

a cover plate removably coupled to the proximal end of the housing;

a plurality of pockets disposed at the proximal end of the housing, each pocket of the plurality of pockets: (1) having an associated proximal end, distal end, and longitudinal axis, and (2) being shaped to accommodate a corresponding smoking product of a plurality of smoking products when received therein, the proximal ends of the pockets being exposed when the cover plate is in an open position;

a plurality of cylinder rod holders disposed within the housing and between the proximal end and the distal end of the housing;

a plurality of ejector rods, each ejector rod of the plurality of ejector rods: (1) at least partially received within an associated cylinder rod holder of the plurality of cylinder rod holders; (2) abutting the distal end of a corresponding pocket of the plurality of pockets; and (3) having a longitudinal axis substantially aligned with the corresponding pocket of the plurality of pockets;

a plurality of actuators disposed at the distal end of the housing, each actuator of the plurality of actuators configured to actuate an associated ejector rod of the plurality of ejector rods along a direction defined by the longitudinal axis of said associated ejector rod, such that the ejector rod slides within the associated cylinder rod holder such that, when the cover plate is in the open position and the plurality of smoking products is received in the plurality of pockets during use, each ejector rod of the plurality of ejector rods causes a smoking product of the plurality of smoking products to be ejected via one of the proximal end of the housing or the distal end of the housing.

15. The apparatus of claim 14, wherein each pocket of the plurality of pockets has a substantially conical shape.

16. The apparatus of claim 14, wherein each pocket of the plurality of pockets has a substantially cylindrical shape.

17. A finisher system, comprising:

a twister unit configured, during operation, to at least one of pinch and twist unfilled portions of paper cones disposed within a plurality of pockets defined within a holder, to form a plurality of smoking articles;

an ejector unit including a plurality of ejector rods configured, during operation, to slide within the plurality of pockets to cause the plurality of smoking articles to be ejected from the holder;

a cutter unit configured to cut the smoking articles; and

a cleaning unit configured to clean the holder.

18. The finisher system of claim 17, further comprising a controller compute device configured to control at least one of the twister unit, the ejector unit, the cutter unit, or the cleaning unit.

19. The finisher system of claim 17, wherein the cleaning unit is configured to clean the holder by applying at least one of a sanitizer or an anti-fungal material to the holder.

20. The finisher system of claim 17, further comprising a shaper configured to modify an exterior shape of at least a subset of the plurality of smoking articles.