WO2023076728A1

WO2023076728A1 - Apparatus for forming smoking products

Info

Publication number: WO2023076728A1
Application number: PCT/US2022/048585
Authority: WO
Inventors: Evan PILOT; Nikolas KASSLER
Original assignee: Gen Three Solutions, Llc
Priority date: 2021-11-01
Filing date: 2022-11-01
Publication date: 2023-05-04

Abstract

A machine assembly for forming a smoking product comprises a base plate and includes a die block assembly having a plurality of cavities and a needle punch. A bottom punch assembly including a plurality of punches is positioned below the die block assembly. A top punch assembly having a plurality of punches is positioned above the die block assembly. A hopper carrying a material to form smoking products is positioned over the plurality of cavities and fills the cavities. The plurality of punches of the top punch assembly and the bottom punch assembly compress the material in the plurality of cavities of the die block. During this compression, the needle punch extends through one end of each of the plurality of cavities to form an opening in the compressed material therein. After compression is released, each compressed material provides a smoking product.

Description

APPARATUS FOR FORMING SMOKING PRODUCTS

Cross-Reference To Related Applications

[0001] This application claims the benefit of US provisional patent application serial no. 63/322,833, entitled “Method of Making Formed Insert for Pre-Roll Joint/Cigarette,” filed March 23, 2022, and also claims the benefit of US provisional patent application serial number no. 63/274,147, entitled “Design of Formed Insert for Pre-Roll Joint/Cigarette,” filed November 1, 2021. Each of the above-referenced provisional applications is herein incorporated by reference herein in its entirety.

Field of the Invention

[0002] The present invention discloses an apparatus and method for making smoking products. More specifically, the present invention discloses an apparatus and method for forming a smoking product including one or more of marijuana, tobacco, and cannabidiol.

Background

[0003] Among those who use smoking products, the desirability of marijuana as a smoking product has increased, while the use of only tobacco as a smoking product has decreased. Some users prefer a more substantially pure marijuana smoking product, while other users prefer materials, such as, for example, but not by way of limitation, marijuana, tobacco, and/or cannabidiol, more commonly known by the abbreviation “CBD.” Some users prefer the addition of CBD, for some of its reported benefits, such as reduction of anxiety and insomnia, control of chronic pain, reduction of inflammation, and reduction of cravings for certain addictive drugs.

[0004] Therefore, making a cigarette-type smoking product would seem to be a simple task. However, to easily manufacture a smoking product that reliably smokes well when smoked like a cigarette has been difficult. Marijuana and CBD can be “sticky” when ground, making it difficult to dispense equal amounts for each cigarette-type smoking product. Many users have bought smoking papers to hand-roll a small amount of marijuana (substantially whole or ground) into a cigarette-type smoking product. Disadvantages in this method became apparent, though, when the hand-rolled marijuana smoking product was smoked. The hand- rolled marijuana smoking product did not smoke consistently like a cigarette or cigar. The marijuana burned at inconsistent rates, and therefore produced inconsistent amounts of smoke to the user, thereby reducing user satisfaction with the smoking product and the smoking experience.

[0005] What is needed is an apparatus which would reliably make a marijuana, or a blended material smoking product that when smoked, provides a reliable size and shape of smoking product which produces a continuous and reliable amount of smoke from the smoking product, similar to that of a cigarette or cigar.

Summary of the Invention

[0006] In a first embodiment of the present invention, a machine assembly for forming a smoking product comprises a base plate carrying a die block assembly that includes a die block including a plurality of cavities extending therethrough, and a needle punch. The machine assembly further includes a bottom punch assembly having a plurality of punches. The bottom punch assembly is positioned below the die block. The machine assembly also includes a top punch assembly having a plurality of punches and positionable above the die block. In addition, the machine assembly further includes a hopper assembly including a hopper configured to carry a material to form a smoking product. The hopper is positionable above the die block. When the hopper is positioned over the die block, the material therein flows into and fills the plurality of cavities of the die block. The top punch assembly is movable to a position above the die block, and at least a portion of the bottom punch assembly and a portion of the top punch assembly move toward the die block to compress the material in the plurality of cavities of the die block. During compression of the material, the needle punch extends through a portion of the material at one end of each of the plurality of cavities to form an opening defined by an inner perimeter. The opening extends axially from one end of the material a distance toward an opposite end of the material. After compression of the material is withdrawn, a smoking product is formed from each cavity, and each smoking product is ejected from each cavity of the die block.

[0007] In one aspect of the first embodiment, the machine assembly includes a mounting plate positioned above the base plate and slidably connected thereto. The hopper assembly and the top punch assembly are each movably carried by the mounting plate as well.

[0008] In another aspect of the first embodiment, the die plate assembly further includes a first end punch for forming a first end of the smoking product, and a second end punch for forming a second end of the smoking product. [0009] In yet a further aspect of the first embodiment, the needle punch is connected to the first end punch.

[0010] In yet another aspect of the first embodiment, each punch has a psi during compression in a range of between 5 and 25 psi.

[0011] In still yet a further aspect of the first embodiment, the bottom punch assembly is movable to control the amount of material that forms the smoking product.

[0012] Moreover, in another aspect of the first embodiment, the plurality of bottom punches move upward to eject each smoking product from each cavity of the die block.

[0013] In a further aspect of the first embodiment, the plurality of bottom punches move upward to eject each smoking product from each cavity of the die block.

[0014] In still another aspect of the first embodiment, the plurality of bottom punches move upward to eject each smoking product from each cavity of the die block.

[0015] In yet another aspect of the first embodiment, the hopper assembly includes a feed shoe, and the feed show moves each smoking product over a base plate to a chute loading assembly. Each smoking product moves down a chute of the chute assembly and into one preformed paper of a plurality of preformed papers held in a row of a loading machine. When each smoking product moves into a preformed paper, a pusher arm presses an end of the smoking product to seat the smoking product within the preformed paper.

[0016] In a further aspect of the first embodiment, the machine assembly is carried by a frame, and a portion of the frame includes a plurality of wheels.

[0017] In a second embodiment of the present invention, a method of making a smoking product comprises providing a smoking material comprising at least one of marijuana, cannabidiol, and tobacco. The method also comprises providing a machine assembly for producing the smoking product, and the machine assembly comprises a base plate carrying a die block assembly including a die block having plurality of cavities extending therethrough, and a needle punch. The machine assembly also includes a bottom punch assembly positioned below the die block, a top punch assembly positionable above the die block, and a hopper assembly including a hopper configured to carry a smoking material to form the smoking product, the hopper having an open lower end. The method further includes filling a portion of the hopper with a smoking material, and positioning the hopper over the die block to permit the material therein to flow and fill the plurality of cavities of the die block. And the method includes moving the top punch assembly to a position above the die block, moving at least a portion of the bottom punch assembly and a portion of the top punch toward the die block and compressing the material in the plurality of cavities, and moving the needle punch into a portion of the material at one end of each of the plurality of cavities to form an opening defined by an inner perimeter axially positioned through a portion of a central interior of the material. The method also includes retracting the top punch assembly and the needle assembly from each cavity of the plurality of cavities, thereby forming the smoking product in each cavity, and ejecting each smoking product from each cavity.

[0018] In one aspect of the second embodiment, in the step of providing a machine assembly, the machine assembly further comprises a mounting plate positioned above the base plate and slidably connected thereto. The hopper assembly and the top punch assembly are each movably carried by the mounting plate.

[0019] In another aspect of the second embodiment the die plate assembly further includes a first end punch for forming a first end of the smoking product, and a second end punch for forming a second end of the smoking product. The needle punch is connected to the first end punch.

[0020] In a further aspect of the second embodiment, the bottom punch assembly movement controls the amount of material that forms the smoking product. The plurality of bottom punches move upward to compress the material to form the smoking product, and after compression, the bottom punches are moved further upward to eject each smoking product from each cavity of the die block.

[0021] In a third embodiment of the present invention, a smoking product comprises a material comprising at least one of marijuana, cannabidiol, and tobacco, wherein the material is formed into a frusto-conical configuration, wherein an opening defined by an internal perimeter is formed at one end of the smoking product and extends axially along a portion of the length of the frusto-conical configuration, the opening ending before reaching an opposite end of the frusto-conical configuration.

Brief Description of the Drawings

[0022] The disclosure will be better understood, and features set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:

[0023] FIG. 1 is a perspective view of a smoking product of the present invention;

[0024] FIG. 2 is a perspective view of the smoking product of FIG. 1, but showing an opening positioned internally within a portion of a length of the smoking product; [0025] FIG. 3 is a cross-sectional view of FIG. 1, showing the shape and length of the opening formed within the smoking product;

[0026] FIG. 4 is a perspective view of the smoking product of FIG. 1 which may be inserted into a preformed paper configured to hold the smoking product for smoking by a user;

[0027] FIG. 5 is a perspective view of a smoking product machine assembly carried by a frame of the present invention;

[0028] FIG. 6 is a perspective view of the smoking product machine assembly of FIG. 5;

[0029] FIG. 7 is a cross sectional view of a portion of the smoking product machine assembly of FIG. 6, positioned in an inactive position;

[0030] FIG. 8 is a cross sectional view similar to FIG. 7, but showing a position of the hopper which permits material to be removed from the hopper assembly;

[0031] FIG. 9 is a cross sectional view similar to FIG. 7, but showing the hopper assembly in an initial fill position to begin formation of smoking products;

[0032] FIG. 10 is a cross sectional view similar to FIG. 9, but showing air flow and stirring of the material in the hopper;

[0033] FIG. 11 is a perspective view of the die block assembly;

[0034] FIG. 12 is a cross sectional view of a portion of the machine assembly, showing the material from the hopper positioned within one die punch of the die punch assembly, with the bottom punch assembly positioned below the die punch, the top punch assembly positioned above the material in the die punch, a front punch positioned at one end of the die punch, a rear punch positioned at an opposite end of the die punch, and a needle punch positioned adjacent the rear punch;

[0035] FIG. 13 is a cross sectional view similar to FIG. 12, but showing the actuation of the top punch assembly, the bottom punch assembly, the front punch, the rear punch, and the needle punch to form the smoking product of FIGS. 1-3;

[0036] FIG. 14 is a cross sectional view similar to FIG. 13, but showing the withdrawal of all upward punches and the top punch assembly, with the exception of the bottom punch assembly whose bottom punches move upward to raise the newly formed smoking product(s); [0037] FIG. 15 is a side view of the hopper assembly and the top and bottom punch assemblies, a hopper feed shoe positioned to move each of the smoking products:

[0038] FIG. 16 is a perspective view of a portion of the machine assembly, showing a plurality of smoking products held and moved by the hopper feed shoe to a loading chute; [0039] FIG. 17 is a cross sectional view of a portion of the machine assembly, showing a smoking product traveling down a cute to a loading magazine holding a plurality of preformed papers, each paper configured to hold a smoking product therein;

[0040] FIG. 18 is a perspective view of the top punch have a plurality of movable punches positioned therein, and a pair of spacers positioned on a surface of the top punch; and

[0041] FIG. 19 is a perspective view of the bottom punch having a plurality of movable punches positioned therein.

Detailed Description

[0042] One or more specific embodiments of the present disclosure will be described below. In an effort to provide a concise description of these embodiments, all features of an actual implementation may not be described in the specification. It should be appreciated that in the development of any such actual implementation, as in any engineering or design project, numerous implementation-specific decisions must be made to achieve the developers’ specific goals, such as compliance with system-related and business-related constraints, which may vary from one implementation to another. Moreover, it should be appreciated that such a development effort might be complex and time consuming, but would nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill having the benefit of this disclosure.

[0043] When introducing elements of various embodiments of the present disclosure, the articles “a,” “an,” “the,” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including,” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. The variations of “comprising”, “including” and “having”, such as, but not by way of limitation, “comprise”, “include”, “have” or “has”, are also included in this definition. Any examples of operating parameters and/or environmental conditions are not exclusive of other parameters/conditions of the disclosed embodiments.

[0044] Referring to FIGS. 1 to 3, a formed smoking product 10 is illustrated. The formed smoking product 10 may desirably, but not by way of limitation, be formed from at least one of marijuana, tobacco, and cannabidiol, as noted previously, more commonly known by the abbreviation “CBD”. In its organic and natural form, marijuana maybe provided as flowers with leaves and/or stems, tobacco may be provided as primarily leaves, and CBD may be provided primarily as flowers. Desirably, marijuana, tobacco, and CBD may lightly ground into a consistency like, for example only, basil, oregano, and the like. Other materials known in the art and used for consumption via smoking may also be used in the smoking product. The smoking product 10 is desirably formed and configured for insertion into a commercially available preformed paper 12 (FIG. 4).

[0045] FIG. 2 discloses that there is an opening 14 formed by an internal peripheral surface 16 in a body 17 of the smoking product 10. As shown in FIGS. 1 and 2, the smoking product 10 may desirably have an outer frusto-conical shape, and the internal peripheral surface 16, as defined by the phantom lines of FIG. 2, also may include, but not by way of limitation, a frusto- conical shape as well. The smoking product 10 may be slightly indented or concave at a first end 18 which has the opening 14 formed therein, and the first end 18 provides the widest portion of the body 17 of the smoking product 10. An opposite second end 20 is desirably tapered to provide the most narrow portion of the frusto-conical smoking product 10. As illustrated in both FIGS. 2 and 3, the opening 14 defined by the internal peripheral surface 16 is formed through a central interior 22 of the smoking product 10. The opening 14 is desirably formed an equal distance from every surrounding outer surface 24 of the smoking product 10. [0046] The internal peripheral surface 16 may desirably be formed to tailor air flow through the smoking product 10 during smoking by a user/consumer. The opening 16 formed by the internal peripheral surface 16 may be desirable to control the burning characteristics of a specific material or blend/combination of materials used to form the smoking product 10. In addition, the opening 16 may also desirably ease the air flow during the inhalation process so that these variables can be tailored to provide the most efficient and enjoyable smoking experience by a user. The internal peripheral surface 16 may form a variety of cross-sectional shapes, and it may be of various ratios in comparison to the distance to the outer surface 24. The opening 14 may be formed from the first end 18 through various depths and lengths of the smoking product 10 in order to produce the desired effect. Dependent upon the selected material properties, however, it will be understood that the opening 18 may be excluded.

[0047] Returning to FIGS. 2 and 3, the opening 12 extends axially through a substantial portion of the central interior 22. However, the opening 12 ends a distance from the second end 20. “Substantial portion,” as used herein, means that the opening 12 may desirably extend in a range of twenty (20) to forty (40) percent from the first end 18 toward the second end 20. Alternatively, the opening 12 may extend in a range of forty (40) to sixty (60) percent from the first end 18 toward the second end 20. In a further alternative, the opening 12 may extend in a range of forty (40) to eighty (80) percent from the first end 18 toward the second end 20. It will be understood that the internal peripheral surface 16 and the opening formed thereby 12 are desirably axially aligned with an axial length of the smoking product 10.

[0048] Referring to FIG. 4, the second end 20 of the body 17 may desirably be inserted into a preformed paper 12. The second end 20, as well as the first end 18, may be flat, convex, or concave, depending upon selected material properties, desired smoking characteristics, and process considerations such as, for example only, ease of insertion into the preformed paper 12. The first end 18 of the body 17 will be ignited to initiate the smoking process. The second end 20 of the body 17 is the end a user places in the mouth in order to smoke the smoking product 10.

[0049] As illustrated in FIGS. 1 to 4, the smoking product 10 has, but not by way of limitation, a frusto-conical shape. The preformed paper 24 may be somewhat frusto-conical, as shown in FIG. 4, or, the preformed paper 24 may be cylindrical, as shown in FIG. 17. The smoking product 10 may be formed in a frusto-conical or cylindrical configuration. The frusto- conical configuration, however, facilitates the rapid insertion of the smoking product into the preformed paper 12 (shown in FIG. 17). Tolerance for material spring-back, which may occur after the forming process, may be expected and is desirably factored into a final outer surface 24 of the smoking product 10 held within a preformed paper 12 (such adaptation to the cylindrical preformed paper 12 shown in FIG. 17). It will therefore be understood that while the smoking product 10 may retain its original frusto-conical shape, it may also be desirable for the frusto-conical smoking product 10 to expand within the cylindrical preformed paper 12 (shown in FIG. 17) to form a cylindrical final smoking product 10. It will be appreciated that the smoking product 10 may comprise any configuration, as may the preformed paper 12, so long as the smoking product 10 and the preformed paper 12 performs as shown and/or described herein.

[0050] Returning to FIG. 4, the preformed paper 12 desirably is a standard commercially available preformed paper product which is offered in a variety of materials, shapes, and sizes, to accommodate various volumes of product in different configurations. In general, the preformed paper 12 consists of a rolled paper cylindrical body 26 that forms a hollow cavity 28 therethrough for containment of smoking materials, such as the smoking product 10. The preformed paper 12 may also include a filter 30, which permits the user to inhale the smoke therethrough. Like the preformed paper 12, the filter 30 is commercially available and may also be offered in a variety of materials, shapes, and sizes, to accommodate various smoking products 10. [0051] Turning now to a machine assembly 32 for forming a smoking product 10, FIG. 5 illustrates a support frame 34 used to hold and carry the machine assembly 32. The frame 34 desirably includes a plurality of support structures 36 to support both the frame 34 and the machine assembly 32. A plurality of rollers 38 connected to the frame 34 desirably may provide an apparatus to permit movement of the frame 34 and the machine assembly 32. Further, the frame 34 also may desirably provide a mounting platform for ancillary equipment, described below, and structure for attachment of operator protection guards known in the art and commercially available (not shown).

[0052] Turning now to FIGS. 6 and 7, the machine assembly 32 desirably includes a base plate 40 that includes a pair of spaced-apart sidewalls 42 connected thereto. An upper edge 44 of each sidewall 42 includes a guide rail 46 upon which a mounting plate 48 moves. The mounting plate 48 may include, but not by way of limitation, a plurality of sliders 50 configured to permit the mounting plate 48 to move to various positions along the guide rails 46. The base plate 40 desirably is the main structure of the machine assembly 32. The base plate 40 provides the necessary structure for locating, fastening, and supporting individual components of the machine assembly 32 as well as fastening considerations for the frame 34.

[0053] A hopper assembly 52 includes a hopper 54 which may have an open lower end 56 which contacts and moves over the base plate 48 that extends through and is connected to the mounting plate 48. The hopper 54 includes an outer surface 60 and an inner surface 62 forming a compartment 64 therein, which is configured to hold the material 66, namely, the at least one of marijuana, tobacco, and CBD, used to form the smoking product 10. Desirably, but not by way of limitation, the hopper 54 is tapered toward the open lower end 56 to promote gravity feed of the material 66. The hopper 54 may include a cover 67 positioned over the upper end 58.

[0054] The machine assembly 32 also desirably includes a die block assembly 68 positioned in the base plate 40. The die block assembly 68 includes a die block 70 including a plurality of cavities 72 formed therethrough, which operates to hold material 66 therein and to form a portion of the smoking products 10. The die block assembly 68 includes additional punches used to form each smoking product 10.

[0055] A top punch assembly 74 is positioned below the mounting plate 48 and operably connected to the mounting plate 48. The top punch 76 carries a plurality of top punches 77 (FIG. 18) which correspond to the plurality of cavities 72 in the die block 70. A top punch actuator 78 is desirably connected to the top punch assembly 74 and operates to move the top punch 76 upward and downward over the die block 70 holding material 66 in the plurality of cavities 72 therein, using the force and pressure of the top punch actuator 78 in order to form an upper portion of the body 17 of the smoking product 10. A pair of spacers 79 limit the downward movement of the top punch 74.

[0056] A bottom punch assembly 80 is positioned below the die block assembly 68 carried by the base plate 40. The bottom punch assembly 80 includes a bottom punch 82 which carries a plurality of bottom punches 83, one of which will be inserted into a respective one of the plurality of cavities 72 of the die block 70 to form a lower or bottom part of the body 17 of the smoking product 10 utilizing force and pressure provided by a bottom punch actuator 84 which may be mounted to the frame 34. The bottom punch 82 is positioned to move downward and upward relative to the die block assembly 68. The bottom punch assembly 80 may be moved to control the amount of material 66 received in the plurality of cavities 72 in the die block 70. The bottom punch actuator 84 is desirably operably connected to the bottom punch assembly 80 and operates to move the bottom punch 82 upward and downward, underneath and through at least a portion of the die block 70, to permit the plurality of bottom punches therein to form a lower portion of the body 17 of each of the smoking products 10.

[0057] The mounting plate 48 moves into a variety of positions which move various components over the base plate 40 and the die block assembly 68 positioned therein to further form the smoking product 10. These various positions and components will be discussed in further detail below. However, once formed, each smoking product 10 is desirably moved via a chute loading assembly 86 to a loading magazine 88 holding a plurality of preformed papers 12. Desirably, each smoking product 10 is moved into one of the plurality of preformed papers 12 held the by loading magazine 88.

[0058] As illustrated in FIGS. 6 and 17, the loading magazine 88 may also include a form pusher assembly 90. The form pusher assembly 90 desirably includes a pusher arm 92 activated by a pusher arm actuator 94 (FIG. 17) to seat each smoking product 10 to a desired depth within each preformed paper 12.

[0059] A gripper/picker assembly 96 is used to grasp the smoking product 10 held within the preformed paper 12 to move the partially finished smoking product 10 for additional finishing and/or to bulk storage (not shown). The gripper/picker assembly 96 is known in the art and is commercially available. A pre-roll/ cigarette closing assembly 97 may be included with the machine assembly 32 or the process may be completed externally as a secondary operation. In order for the smoking product 10 to remain inside the preformed paper 12 to be smoked, the preformed paper 12 desirably is closed via twisting or crimping via the pre-roll/cigarette closing assembly 97. Often, the preformed paper 12 is longer than the smoking product 10 held therein, as illustrated in FIGS. 4 and 17. In these circumstances, it is often desirable to trim the excess length of the preformed paper 12, so that the undesirable excess flammable material is removed for aesthetic as well as safety purposes. A trimmer assembly 98 may be used for this purpose. Trimmer assemblies are also known in the art and commercially available.

[0060] Turning to FIG. 7, the machine assembly 32 is positioned in an unactive position. That is, the top punch assembly 74 is located above the die block assembly 68. A base plate cover 100 may desirably be positioned over an upper surface 102 of the base plate 40. The base plate cover 100 is a thin sheet that acts as an interface between the open lower end 56 of the hopper 54 and the upper surface 102 of the base plate 40. The base plate cover 100 may be constructed, for example, but not by way of limitation, of a polymer material such as polytetrafluoroethylene (“PTFE”), or, alternatively, a polished metallic material such as stainless steel. The purpose of the base plate cover 100 is used to provide a low friction, nonstick, high wear, and easy clean-up surface. The open lower end 56 of the hopper 54 desirably forms a seal and closure to the hopper 54 against the base plate cover 102. By using various gaskets, wipers, brushes, and/or spring compression, spillage of material 66 from the hopper 54 is desirably reduced or eliminated. In addition, the base plate cover 100 may also cover access apertures, and the like, in the base plate 40 which might allow leakage of the material 66 therefrom. As shown in FIG. 7, in the inactive position, the open lower end 56 of the hopper 54 is blocked by the base plate cover 100 to prevent any flow of material 66 therefrom, and the bottom punch assembly 80 is desirably lowered, which leaves the plurality of cavities 72 (only one cavity 72 shown in FIG. 7) in the die block 70 open and ready to receive material 66. The continued use of the term “base plate 40” herein desirably may also include the base plate cover 100. It will further be understood that material (plastic and/or metal) used to form the base plate cover 100, as described above, may also be used over a surface of any other component shown and/or described herein which comes into contact with the material 66.

[0061] The machine assembly 32 may also be positioned in an emptying position, as shown in FIG. 8. In the emptying position, the open lower end 56 of the hopper 54 is moved over an opening 104 in the base plate 40 which includes a chute 105 which may be positioned below the opening 104 to permit removal of material 66 from the hopper 54. The material 66, as illustrated, flows through the opening 104 and down the chute 105, desirably to a container (not shown). Removal of the material 66 from the hopper 54 permits cleaning and inspection of the hopper 54 and associated components of the hopper assembly 52 and the machine assembly 32. [0062] When activated by a mounting plate actuator 51 (FIG. 6), as illustrated in FIGS. 9 and 10, in an initial step for forming smoking products 10, the mounting plate 48 moves via the mounting plate actuator 51 the hopper assembly 52 and other components, such as, for example but not by way of limitation, the top punch assembly 74 to a position where the open lower end 56 of the hopper 54 is positioned over the die plate assembly 68 and the plurality of cavities 72 (only one cavity 72 shown in FIGS. 9 and 10) of the die plate 70. The bottom punch assembly 80, as noted earlier, is lowered. This position of the bottom punch assembly permits the material 66 to flow from the open lower end 56 of the hopper 54 to move into and to desirably the plurality of cavities 72. In this position, as shown in FIG. 10, one or more air flow tubes 108, each of which desirably include a plurality of openings 110, are used to mix and move the material 66 within the compartment 64 of hopper 54 so that the material 66 desirably moves and flows downward through the open lower end 56 of the hopper 54. A controlled flow of compressed air is introduced into the air flow tubes 108 to agitate the material 66 to encourage a downward flow. In addition, a stirring paddle 112 may also be introduced into the compartment 64 to further agitate and encourage the material to flow downward to desirably completely fill each of the plurality of cavities 72 in the die block 70. A motor 114 may be connected to the stirring paddle 112. It will also be understood that the motor 114 may desirably connect to other components, such as, for example, but not by way of limitation, at least one or more actuators shown and/or described herein, or to any other component shown and/or described herein, to create movement thereof. The motor may be an electric motor. Finally, vibration may also be utilized to assist in the movement of the material 66 to completely fill the plurality of cavities 72. One or more ultrasonic transducers 116 may be located on the bottom punch assembly 80, as shown in FIG. 10, or, alternatively, on the die block assembly 68, the base plate 40, and/or a portion of the hopper assembly 52 (not shown) to create a vibratory effect to aid the movement of the material 66.

[0063] Referring now to FIG. 11, the die block 70 of the die block assembly 68 desirably provide the plurality of cavities 72 which are formed completely through the die block 70. Each of the plurality of cavities 72 includes an inner perimeter 118 which defines at least a portion of the outer surface 24 of the frusto-conical shape of the smoking product 10. It will be appreciated that more or fewer cavities 72 may be provided (not shown). Additionally, the die block 70 provides location and mounting for a first end punch 120 to form the first end 18 of the smoking product 10, and a location and mounting for a second end punch 122 to form the second end 20 of the smoking product 10. The first end punch 120 and the second end punch 122 will each provide a compaction force via a punch motion actuator 124 to the body 17 of the smoking product 10 to form and shape the first end 18 and the second end 18 thereof, respectively. The needle punch 126 is located inside of the first end punch 120 and will be inserted via the punch motion actuator 126 into the central interior 22 of the body 17 to form the internal peripheral surface 16 of the opening 14 in the body 17. A die compression spring 128 is included under a head 130 of the second end punch 122 to facilitate the extraction of the needle punch 126 from each cavity 72 in the die block 70 since the punch motion actuator 124 must travel further in order to completely pull the needle punch 126 away from the die block 70 and the body 17.

[0064] Once material 66 is deposited in the plurality of cavities 72 in the die block 70, as illustrated in FIG. 12, the top punch assembly 74 is vertically aligned with the die block 70 and the bottom punch assembly 80. The material 66 desirably may extend, as shown in FIG. 12, from an upper surface 132 of the bottom punch assembly 80 to the upper surface 102 of the base plate 40. Also, all punches within the die block 70, namely, the first end punch 120, the second end punch 122, and the needle punch 126, are positioned in a retracted position. The travel distance of the second end punch 122 is limited by a dowel pin 134 inserted inside a slot cut into the second end punch 122. The top punch assembly 74 is positioned in a retracted position, and the bottom punch assembly 80 is positioned in its retracted position as well. The height of the bottom punch assembly 80 relative to the base plate 40 is desirably adjustable in order to change the overall volume of the plurality of cavities 72 during the filling process, as shown previously in FIG. 9. This is necessary to tailor the weight and density of the final smoking product 10 to meet desired product criteria.

[0065] Turning now to FIG. 13, the compression process discloses the formation of the body 17 of the smoking product 32. That is, the top punch 76 of the top punch assembly 74 is deployed downward to form an upper portion of the outer surface 24 of the body 17, while the bottom punch 82 of the bottom punch assembly 80 is shown in a raised position, to form a lower portion of the outer surface 24 of the body 17. The first end punch 120, the second end punch 122, and the needle punch 126 are all shown in a deployed, extended position. Each punch shown and/or described herein desirably may provide 5 to 25 psi to form the body 17 of the smoking product 10. However, it will be understood that the psi ranges may vary, based on, for example, but not by way of limitation, the materials used, the desired thickness of the body 17, and the like.

[0066] FIG. 14 illustrates the smoking product 10 after formation and in the ejected position. The top punch assembly 74, the first end punch 120, the second end punch 122, and the needle punch 126, are all positioned in a retracted position. In contrast, however, the bottom punch 82 and the punches thereon is moved upward, into an extended position into each cavity 72 of the die block 70, in order to move and eject each smoking product 10 from the die block 70. It will be understood, however, that no portion of the bottom punch 70 extends above the upper surface 102 of the base plate 40. The mounting plate 48 on components connected thereto is moved away from the die block assembly 68 in the base plate 40 to the inactive position shown in FIG. 7 when the newly formed plurality of smoking products 10 are moved to the upper surface 102 of the base plate 40.

[0067] A hopper feed shoe 136 may be positioned in front of and may desirably extend from a front side 138 of the hopper assembly 52 and may form a portion of the hopper assembly 52, as illustrated in FIGS. 15 and 16. Desirably, the hopper assembly 52 moves forward, shown in FIG. 9, until hopper feed shoe 136 contacts the plurality of newly formed smoking products, as shown in FIGS. 14 and 15. As the hopper feed shoe 136 contacts each of the plurality of smoking products 10, each smoking product 10 is positioned between two guide walls 140 which separate each smoking product 10 from another. The plurality of smoking products 10 are then moved forward over the upper surface 102 of the base plate 40. As will be noted in FIG. 16, the guide walls 140 act to align each smoking product 10 with each chute of a plurality of chutes 144 formed in the chute loading assembly 86, which functions to transfer each smoking product 10 for insertion into a preformed paper 12. During this stage, the bottom punch assembly 80 including the bottom punch 82 desirably lowers, returning to the initial fill position described previously and shown in FIG. 9.

[0068] The during the above-described process, the top punch assembly 74 is desirably moved by the mounting plate 48 over cleaning brushes 142 mounted on a portion of the base plate 40 (FIG. 17). This movement functions to clean and to remove debris remaining on any portion of the top punch assembly 74, in order to leave a clean surface thereon, in preparation for the next smoking product formation/compression cycle.

[0069] Thereafter the above-described process, the mounting plate 48 moves the hopper assembly 52 carried thereon back to the initial fill position, as shown in FIG. 9. Therefore, the initial fill position begins again, to begin a new cycle of forming/compacting new smoking products 10.

[0070] Turning now to FIGS. 16 and 17, as noted above, newly formed smoking materials 10 are moved by the hopper feed shoe 136 into the loading chutes 138 of the chute loading assembly 86 so that the plurality of newly formed smoking products are aligned to continue through their respective chute channels 146 via gravitational force. Each smoking item 10 falls or moves into a preformed paper 12 (which may desirably include a filter 30 positioned in a lower end 147 thereol) through an open upper end 148 of the preformed paper 12. Desirably, each preformed paper 12 is held in one of a plurality of a paper holders 150 of the loading magazine 88. It will be appreciated that a respective plurality of preformed papers 12 are each held in one of a respective plurality of paper holders 150. It will also be understood that each newly formed smoking product 10 moves toward the chute loading assembly 86 with the smaller, tapered second end 20 positioned to lead each smoking product 10 into each loading chute 144 and into each preformed paper 12 as well, as shown in FIG. 17.

[0071] When each paper holder 150 in a row 152 of a plurality of paper holders 150 is filled with a smoking product 10, the loading magazine 88 moves forward so that a next row 150 of a plurality of paper holders 152, holding a respective plurality of preformed papers 12 is positioned under the chute loading assembly 86. The previously filled row may desirably be positioned directly under a form pusher assembly 90. The form pusher assembly 90 functions to ensure that each smoking product 10 is seated firmly in the lower end 147 of the preformed paper 12 by applying downward force against the first end 18 of the smoking product 10 via a pusher head 154 of the pusher arm 92 which is moved by upward and downward by the pusher motion actuator 94.

[0072] The loading magazine 88 provides storage of a large quantity of preformed papers 12 along with an apparatus for providing and supporting the plurality of preformed papers 12. Desirably, the loading magazine 88 may operate for extended periods of time with minimal operator interaction. This is accomplished by allowing an operator to load a plurality of preformed papers 12 at one time into the plurality of paper holders 150, and at the same time preparing the machine assembly 32 to run for an extended period of time to fill a respective plurality of preformed papers 12 with a respective plurality of smoking products 10. To accomplish this task, the loading magazine 88 via use of one or more motion actuators 156 on multiple axis may present a plurality of rows 154 of paper holders 150, each holding a preformed paper 12, on multiple tiers so that the entire storage quantity of preformed papers 12 provided by the loading magazine 88 may each be loaded with a seated smoking product 10 without external support by the operator.

[0073] The foregoing is considered as illustrative only of the principles of the disclosure. Further, since numerous modifications and changes will readily occur to those of ordinary skill in the art, it is not desired to limit the disclosure to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, and fall within the scope of this disclosure. [0074] While only certain features of the disclosure have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the disclosure.

[0075] The techniques presented and claimed herein are referenced and applied to material objects and concrete examples of a practical nature that demonstrably improve the present technical field and, as such, are not abstract, intangible or purely theoretical. Further, if any claims appended to the end of this specification contain one or more elements designated as “means for [perform]ing [a function]... ” or “step for [perform]ing [a function]... ”, it is intended that such elements are to be interpreted under 35 U.S.C. 112(f). However, for any claims containing elements designated in any other manner, it is intended that such elements are not to be interpreted under 35 U.S.C. 112(f).

Claims

Claims: What is claimed is:

1. A machine assembly for forming a smoking product, the machine assembly comprising: a base plate carrying a die block assembly that includes a die block including a plurality of cavities extending therethrough, and a needle punch, a bottom punch assembly having a plurality of punches, the bottom punch assembly positioned below the die block; a top punch assembly having a plurality of punches and positionable above the die block; a hopper assembly including a hopper configured to carry a material to form a smoking product, the hopper positionable above the die block; wherein when the hopper is positioned over the die block, the material therein flows into and fills the plurality of cavities of the die block, wherein the top punch assembly is movable to a position above the die block, wherein at least a portion of the bottom punch assembly and a portion of the top punch assembly move toward the die block to compress the material in the plurality of cavities of the die block, wherein during compression of the material, the needle punch extends through a portion of the material at one end of each of the plurality of cavities to form an opening defined by an inner perimeter, the opening extending axially from one end of the material a distance toward an opposite end of the material, and wherein after compression of the material in the cavities is withdrawn, a smoking product is formed from each cavity, and each smoking product is ejected from each cavity of the die block.

2. The machine assembly of claim 1, wherein the machine assembly includes a mounting plate positioned above the base plate and slidably connected thereto.

3. The machine assembly of claim 2, wherein the hopper assembly and the top punch assembly are each movably carried by the mounting plate.

4. The machine assembly of claim 1, wherein the die plate assembly further includes a first end punch for forming a first end of the smoking product, and a second end punch for forming a second end of the smoking product.

5. The machine assembly of claim 4, wherein the needle punch is connected to the first end punch.

6. The machine assembly of claim 1, wherein each punch asserts as psi in a range of between 5 and 25 psi.

7. The machine assembly is claim 1, wherein the bottom punch assembly is movable to control the amount of material that forms the smoking product.

8. The machine assembly of claim 1, wherein the plurality of bottom punches move upward to eject each smoking product from each cavity of the die block.

9. The machine assembly of claim 1, wherein the hopper assembly includes a feed shoe, and the feed shoe moves each smoking product over a base plate to a chute loading assembly.

10. The machine assembly of claim 9, wherein each smoking product moves down a chute of the chute assembly and into one preformed paper of a plurality of preformed papers held in row in a loading magazine.

11. The machine assembly of claim 10, wherein when each smoking product moves into the preformed paper, a pusher arm presses a first end of the smoking product to seat the smoking product within the preformed paper.

12. The machine assembly of claim 1, wherein the machine assembly is carried by a frame, and a portion of the frame includes a plurality of wheels.

13. A method of making a smoking product, the method comprising: providing a smoking material comprising at least one of marijuana, cannabidiol, and tobacco; providing machine assembly for producing the smoking product, the machine assembly comprising a base plate carrying a die block assembly including a die block having plurality of cavities extending therethrough, and a needle punch; a bottom punch assembly positioned below the die block; a top punch assembly positionable above the die block; a hopper assembly including a hopper configured to carry a smoking material to form the smoking product, the hopper having an open lower end; filling a portion of the hopper with a smoking material; positioning the hopper over the die block to permit the material therein to flow and fill the plurality of cavities of the die block; moving the top punch assembly to a position above the die block; moving at least a portion of the bottom punch assembly and a portion of the top punch toward the die block and compressing the material in the plurality of cavities; moving the needle punch into a portion of the material at one end of each of the plurality of cavities to form an opening defined by an inner perimeter axially positioned through a portion of a central interior of the material, retracting the top punch assembly and the needle assembly from each cavity of the plurality of cavities, thereby forming the smoking product in each cavity; ejecting each smoking product from each cavity.

14. The method of claim 13, wherein in the step of providing a machine assembly, the machine assembly further comprises a mounting plate positioned above the base plate and slidably connected thereto.

15. The machine assembly of claim 14, wherein the hopper assembly and the top punch assembly are each movably carried by the mounting plate.

16. The method of claim 13, wherein in the step of providing a machine, the die plate assembly further includes a first end punch for forming a first end of the smoking product, and a second end punch for forming a second end of the smoking product.

17. The method of claim 16, wherein the needle punch is connected to the first end punch.

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18. The method of claim 13, wherein in the step of moving at least a portion of the bottom punch assembly, the bottom punch assembly movement controls the amount of material that forms the smoking product.

19. The machine assembly of claim 18, wherein the plurality of bottom punches move upward to compress the material to form the smoking product, and after compression the bottom punches are moved further upward to eject each smoking product from each cavity of the die block.

20. A smoking product, comprising: a material comprising at least one of marijuana, cannabidiol, and tobacco, wherein the material is formed into a frusto-conical configuration, wherein an opening defined by an internal perimeter is formed at one end of the smoking product and extends axially along a portion of the length of the frusto-conical configuration, the opening ending before reaching an opposite end of the frusto-conical configuration.

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