WO2023122825A1

WO2023122825A1 - Packing technology for a vented pre-roll

Info

Publication number: WO2023122825A1
Application number: PCT/CA2022/051423
Authority: WO
Inventors: Daniel Frederick LEMOTTEE
Original assignee: Rolling Room Corporation
Priority date: 2021-12-30
Filing date: 2022-09-26
Publication date: 2023-07-06

Abstract

Apparatus for packing a biomass, such as a cannabis, pre-roll including packing mold, skewer, plunger and top cap that create and maintain a tightly packed biomass core with a vent hole. A filter that may be used with the packing mold includes a baffle with elongate planar filter parts that holds the core in place.

Description

Packing Technology for a Vented Pre-Roll

TECHNICAL FIELD

[0001] The present invention relates to apparatus and methods for packing a biomass, such as a cannabis, pre-roll.

BACKGROUND

[0002] Biomass pre-roll products, such as those containing cannabis or other plant material, are often relatively fragile. They burn quickly and unevenly. Consumers have started to demand a pre-roll that is more durable and consistent. Consumers have also started to demand a more clean-burning pre-roll.

[0003] Consumers also may complain of an unsatisfactory smoking experience, where the pre-roll does not have an adequate filter.

SUMMARY OF THE INVENTION

[0004] In accordance with a broad aspect of the present invention, there is provided a mold assembly for packing a biomass pre-roll, comprising: mold parts connectable to define a mold with a cavity therein, the cavity having an open end on a top end of the mold; a skewer sized to extend along a length of the cavity between the mold parts; a plunger sized to be inserted into the cavity and the plunger including a skewer channel passing up through the plunger, the plunger operable to be driven into the cavity and down over the skewer, while the skewer remains in place in the cavity; and a top cap configured to connect on the top end of the mold, the top cap including a plug extension protruding from an inner surface, the plug extension sized to protrude into the cavity.

[0005] In accordance with another broad aspect of the present invention, there is provided an apparatus for packing a biomass pre-roll, comprising: a base including a support area for holding a pre-roll mold in an upright position; guide rails coupled to the base and extending upwardly beside the support area; a top plate mounted to ride along the guide rails; and a first plunger mounted on an underside of the top plate, the plunger being elongate with a long axis extending substantially parallel to the guide rails and aligned with the support area.

[0006] In accordance with another broad aspect of the present invention, there is provided a method for producing a biomass product for a pre-roll, the method comprising: assembling a mold to define a cavity within the mold; positioning a skewer in the cavity in a position with the skewer protruding from an open end of the cavity; threading the skewer through a lengthwise channel in a plunger; and driving the plunger into the cavity while introducing biomass material between the plunger and the open end of the cavity, such that the biomass is packed into the cavity around the skewer to produce the biomass product.

[0007] In accordance with another broad aspect of the present invention, there is provided a filter for a biomass pre-roll, comprising: a cylindrical housing including an open inner diameter extending from a first end to an opposite end, a long axis defined between the first end and the opposite end; a ledge in the inner diameter; and a baffle in the cylindrical housing stopped against the ledge, the baffle including a plurality of planar filter media substructures extending parallel to the long axis.

[0008] It is to be understood that other aspects of the present invention will become readily apparent to those skilled in the art from the following detailed description, wherein various embodiments of the invention are shown and described by way of illustration. As will be realized, the invention is capable of other and different embodiments and its several details are capable of modification in various other respects, all within the present invention. Furthermore, the various embodiments described may be combined, mutatis mutandis, with other embodiments described herein. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not as restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Referring to the drawings, several aspects of the present invention are illustrated by way of example, and not by way of limitation, in detail in the figures, wherein:

Figure 1 is an exploded isometric view of a mold assembly useful in a preroll packing apparatus;

Figure 2 is a front top isometric view of a mold part;

Figure 3 is a top plan view of the mold part of Figure 2;

Figure 4 is a perspective, enlarged, side view of a skewer useful with the mold assembly of Figure 1 ;

Figure 5 is a perspective, enlarged, side view of a skewer useful with the mold assembly of Figure 1 ;

Figure 6 is a side elevation of an assembled mold and top cap with a skewer extending along the long axis and through the inner cavity of the assembled mold;

Figure 7 is a top isometric view of a top cap sectioned along its long axis;

Figure 8 is a bottom plan view of the top cap of Figure 7;

Figure 9 is a front, perspective view of a disassembled mold assembly including components according to Figures 1 to 8, including a filter in position in the cavity of one mold part;

Figure 10 is a front, isometric view of a dual plunger embodiment of an assembled packing apparatus in an initial position and with molds in place during packing;

Figure 11 is the packing apparatus of Figure 10 in a position during packing; Figure 12 is the packing apparatus of Figure 10 in a lower position during packing;

Figure 13 is a vertical section through the packing apparatus of Figure 11 ;

Figure 14 is a vertical section through the packing apparatus of Figure 12;

Figure 15 is an enlarged view of Figure 14 showing the plungers;

Figure 16 is a vertical sectional view along the length of the plungers in a four plunger apparatus for packing;

Figure 17 is a sectional view along a long axis of a filter useful for a pre-roll;

Figure 18A is an end view of the filter of Figure 17;

Figure 18B is an end view of the filter with a skewer inserted;

Figure 19 is an end perspective view of a step inserting a baffle into a filter housing;

Figure 20 is a plan view of the sheet for manufacturing a filter housing and a baffle; and

Figures 21 A to 21 C are side perspective, side elevation and end views, respectively, of a pre-roll according to the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

[0010] The detailed description set forth below in connection with the appended drawings is intended as a description of various embodiments of the present invention and is not intended to represent the only embodiments contemplated by the inventor. The detailed description includes specific details for providing a comprehensive understanding of the present invention. However, it will be apparent to those skilled in the art that the present invention may be practiced without these specific details. [0011] An apparatus and method have been invented through which a vented pre-roll can be produced. The apparatus and method are configured to produce a well-compacted cannabis core that can be wrapped to manufacture a pre-roll. The pre-roll with the cannabis core has slow and consistent burn characteristics. The pre-roll can include a filter that further enhances the consumption.

[0012] A mold assembly has been invented that can be used to manufacture a well- compacted cannabis core for a smoking product, such as a pre-roll. With reference to Figures 1 - 9, the mold assembly includes a mold 10 including mold parts 10a, 10b (Figures 1 - 3 and 9), a skewer 12 (Figures 1 , 4, 5 and 9), a plunger 14 (Figure 1 ) and retainer apparatus (sometimes referred to as clamps) such as a bottom sleeve 16 (Figure 9) and/or a top cap 18 (Figures 6 - 9), to hold the mold parts together.

[0013] A well-compacted cannabis core has been found to burn evenly and at a desired slow pace. A pre-roll 20 is shown in Figures 21A-21 C. The illustrated pre-roll has a cannabis core 21 and a filter 28, that are rolled within a wrapping paper 46. With the desired degree of compaction, a vent hole 22 (also sometimes called a worm or a galaxy hole) is useful to extend through the cannabis core 21 to support the burn and to act as a conduit for the cannabis smoke to be moved axially through the pre-roll.

[0014] The mold 10 includes an inner cavity into which cannabis is packed to create the cannabis core. The mold accommodates the skewer 12 passing through the cavity 24. During manufacture, cannabis is packed into the inner cavity and around the skewer. The skewer, when removed from the packed cannabis, creates the empty vent hole.

[0015] A mold can, if desired, include more than one cavity. For example, as shown in Figure 16, mold 10 is a multi-cavity mold that includes a plurality of cavities 24 (in that embodiment eleven). The cavities are positioned side by side, with their long axis substantially in parallel with their open ends aligned along one end of the assembled mold.

[0016] The mold includes an open end 10c, which includes an opening 26 in communication with the inner cavity 24, and through which the cannabis is introduced to the cavity during manufacture. The opening may be frustoconical, shaped like a funnel, tapering from a wide diameter at the end surface 20a to a smallest diameter where the opening opens to the inner cavity. This funnel shape facilitates introduction of cannabis through the opening to the cavity. The opening's smallest diameter is about the same dimension as the diameter across the cavity orthogonal to the cavity's long axis x.

[0017] The end 10d of the mold that is opposite the open end 10c, herein termed the lower or bottom end, defines the lower end of the mold cavity. The lower end of mold cavity may be an end wall 24a against which the cannabis is packed. Alternately, a filter 28 may be installed in the cavity at the end wall 24a and the cannabis can be packed against the filter. In such an embodiment, the cavity may have an extra length to accommodate the filter therein on top of which the cannabis is packed. The end 10d of the mold that is opposite the open end, may take many forms for example, it may be closed, have a skewer recess 30, etc.

[0018] The cavity 24 can be sized to accommodate a selected amount of cannabis. For example, the cavity has a diameter d and a length I (with the known volume needed for the filter, if any) selected to accommodate a particular weight of cannabis, as knowledge/verification of such weight may be important for marketing or meeting regulatory requirements. In embodiments, the cavity can have a diameter d to make cores of 5 to 100mm.

[0019] In one embodiment, the mold includes a skewer placement recess 30 in end wall 24a of the cavity. The skewer placement recess is a hole into which a portion, such as an end, of the skewer 12 can be placed to ensure that the skewer remains in place in the mold inner cavity. In one embodiment, the end 10d includes the skewer placement recess 30 positioned to open into the mold cavity. The skewer placement recess has a diameter slightly larger than the diameter of the skewer to be used and has a depth extending along an axis that is substantially parallel to the long axis x of the cavity. The recess, for example, may be co-axial with the mold cavity so that when the skewer is retained in the recess, the skewer is centered within the cavity. The recess may be, as shown in Figures 1 -9, an open-ended hole or, as shown in Figure 16, a close-ended hole. By open-ended hole, it means that the skewer placement recess is open and extends from the cavity 24 to and through the bottom end 10d of the mold. If the skewer placement hole is open- ended, the location of the skewer in the recess can be verified even when the mold is closed. In particular, during manufacture of a compacted core, the skewer can be inserted to protrude out through the recess.

[0020] As will be appreciated, molds are often comprised of separate mold parts. Herein, the above-noted features of the mold 10 are realized in the form of the mold parts 10a, 10b. While there could be any number of mold parts, two mold parts are sufficient for the production of most cores, even where the mold includes a plurality of cavities 24. Each mold part includes a face 32 on which is a cavity indentation 24' that defines one-half of the cavity 24. Face 32 also includes mating alignment pins 33 (herein pins are elongated like ridges/slots). The two mold parts can be, as shown, substantially identical. Each cavity indentation 24' is shaped such that when the two mold parts are brought together, the indentations are aligned and form the mold inner cavity 24 therebetween. As noted, the cannabis is packed into the mold inner cavity to manufacture the cannabis core. As such, the shape of the cavity 24 defines the shape of the cannabis core. In the illustrated example, each cavity indentation is an elongated semi-cylindrical groove. The cavity could be shaped to define a faceted shape such that the overall cavity in cross section, and therefore the resulting core, is square, triangle, heart or hexagonal, etc. - shaped in cross section.

[0021] Each mold part has an end with an indentation 26' that defines one-half of the opening 26 to the cavity.

[0022] In the illustrated embodiment, where it is intended that the skewer be installed coaxially with the long axis x of the cavity, each mold part includes at a lower end (which is the end opposite the upper end), one half 30' of the skewer recess, which when the mold parts are bought together, define the cylindrical recess.

[0023] The outer surface 10e of the mold/mold parts can take many forms. In one embodiment, the outer surface is generally cylindrical but may have protrusions or a flat surface 10f to steady the mold against spinning or rolling. [0024] The skewer 12 is selected to create the vent hole 22. The skewer has a diameter selected to produce the size of the vent hole needed. The diameter of the vent hole may be selected based on the diameter of the cannabis core. A larger diameter cannabis core needs a larger diameter vent hole to maintain correct airflow (along with the compression of the cannabis core), creating desired slow burn. The smaller cannabis cores need a smaller vent hole, so the core does not get too hot or burn too fast. This maintains that correct airflow to again create the desired slow burn. A skewer diameter, for example, of 0.5mm - 5.5mm is most useful with a cured/solid cannabis core. For example, cannabis cores with a diameter between 5mm and 8mm, may use a skewer diameter between 1 mm - 1 ,75mm (average diameter 1 .35 to 1 ,55mm). Cannabis cores with diameters between 8mm and 30mm may use a skewer diameter between 1 .75 mm - 5mm (average diameter 2mm to 3mm). A larger cannabis core could be made with multiple vent holes and thereby the use of multiple skewers. The skewer creates the vent hole that extends along the length through the cannabis core. The skewer can also extend though and create a vent hole through the filter, if a filter is employed. The skewer diameter dictates the vent hole size.

[0025] The skewer 12 is an elongate substantially rigid, rod-like structure. The skewer should be selected to release from the packed cannabis when the final preparations are underway. In one embodiment, a skewer is employed with a corkscrew/helix shaped spiral surface contour, such as a groove or ridge 34 that extends around the skewer outer diameter on its outer surface (Figures 4 and 5). While the overall skewer shape remains elongate and straight, the spiral surface contour, such as one or more helically extending shallow grooves or low profile ridges 34 on the surface, creates a twist on the surface of the skewer. The twist may be either clockwise or counter clockwise and may be single or double, meaning two helical scores or twists are close together. In one embodiment, the skewer has a grooved twist every 0.5cm - 3cm (average 1 twist every 1.5 to 2 cm). Figure 4, for example, shows a portion of a skewer with higher frequency spiral groove than the skewer of Figure 5. The twist may be manufactured by scoring the skewer surface or physically twisting elongate material during manufacture of the skewer. For example, a raw steel wire with a square or otherwise faceted cross section can be clamped at one end and twisted about its long axis to create the twist permanently in the wire. This action also makes the wire more rigid and straightens it. The skewer could alternatively be constructed from extruded polymer.

[0026] The skewer 12 can be constructed of various materials such as carbon fiber, plastic, wood or metal. Generally, however, a skewer constructed of wood is not preferred. Wood may leave wood fibers or splinters in the cannabis core. Wood can also transfer undesired smells and tastes to the cannabis core. Wood also is sensitive to moisture and can expand or contract depending on humidity and temperature of environment. This can result in an unstable worm/galaxy hole, and higher breakage of the cannabis core. During processing, after packing, the cannabis shrinks and can stick to the porous surface of a wooden skewer, making it extremely difficult to release. Again, this causes breakage of the cannabis cores.

[0027] Instead, a skewer of either carbon fiber or stainless steel has been found to facilitate the release of the skewer from the core and overcomes a lot of the difficulties found with wood skewers. In particular, a non-galvanized stainless steel, for example one rated as food grade, readily separates from the cannabis core when the skewer is pulled out. The stainless steel skewer reduces breakage of the cannabis core. The twist reduces breakage even further and lets the cannabis release from the skewer with minimal effort. It is believed that the benefits are due to the solid, non-porous surface of the stainless steel, along with the pattern created from the twist.

[0028] In one embodiment, the skewer 12 includes a non-stick surface such as a polish or a coating 36.

[0029] The mold assembly further includes a plunger 14 that packs the cannabis into the cavity of the mold. The plunger is configured to be driven into the mold inner cavity 24 through the opening 26. The plunger has a diameter just slightly less than the diameter d of the cavity 24 so that it sweeps with close tolerance along the cavity walls and pushes and compacts the cannabis ahead of it into the cavity.

[0030] The shape of the leading, face end 14a of the plunger will determine the shape of the end of the core that it contacts. In one embodiment, the plunger can have a frustoconical indentation on face end 14a such that the resulting core 21 has a conical form on its end.

[0031] The plunger also includes a skewer channel 38, which accommodates the skewer passing up through the plunger. The plunger skewer channel 38 is best seen in Figure 15. In other words, the plunger is a hollow tube with an axially extending conduit. The conduit forms channel 38 into which the skewer 12 can be inserted. The skewer channel opens at the leading, face end 14a of the plunger and extends at least long enough to accommodate the length of the skewer that resides in the mold cavity 24 and may extend up to the full length of the plunger. The skewer channel may be centered on, co-axial with, the long axis of the plunger.

[0032] The plunger pushes and packs the cannabis into the mold cavity in the annular area between the skewer and the cavity walls. The plunger 14, by accommodating the skewer 12 in the skewer channel 38, maintains and stabilizes the location of the skewer while packing. Thus, the vent hole 22 produced can be precisely shaped about the skewer.

[0033] The mold assembly further includes clamps to hold the mold parts together during packing and thereafter, such as during processing. For example, there may be a lower sleeve 16 shaped with an inner diameter that can be installed over the outer diameter of the assembled mold parts 10a, 10b. The lower sleeve may have an end wall. If the lower sleeve has an end wall, it includes at least a small port that avoids a pressure lock and facilitates installation and removal from the mold. In one embodiment, the port is positioned to align with an open-ended skewer placement recess on the mold, so that the skewer can extend therethrough.

[0034] If the lower sleeve 16 is the only structure used to hold the mold parts together during packing, then it may have a length that is 1/3 or more, such as 2/3, the length of the mold.

[0035] In addition or alternatively, there may be a top cap 18 that is installed after the compacting operation with the plunger is complete. The top cap includes a cylindrical side wall 18a and an end wall 18b extending across one end of the cylindrical wall, while the other end is open. The top cap has an inner diameter dis across the cylindrical wall that can be installed over the outer diameter of the assembled mold 10 (Figure 6).

[0036] The top cap may have a skewer accommodating port 42 on its end wall. The skewer accommodating port extends from the lower face up into and possibly through the upper end wall of the top cap.

[0037] In one embodiment, the top cap can include a feature to assist with and maintain the compaction of the cannabis core. After the cannabis is packed into the mold cavity, there will be an empty space between the upper end of the packed core and the upper end of the mold. The depth of the empty space between the compacted core and the upper end of the mold will be known, or can be readily determined, for any particular amount of cannabis compacted in a particular mold. Therefore, as illustrated in Figures 7 and 8, the top cap 18 may include a plug extension 40 that protrudes from the top wall concentrically within the cylindrical wall 18a. The plug extension is shaped such that it can be inserted into the opening 26 and possibly down into the cavity 24 of a mold to which the top cap is secured. In one embodiment, the plug extension is shaped to fit snugly against the opening and possibly down within the cavity walls. The length of the plug extension from the top wall 18b to the plug's lower face 40a is selected to extend down into the empty space and contact the upper end of the compacted cannabis core within the cavity.

[0038] In one embodiment, the plug extension 40 has a length that more than accommodates the empty space after packing between the upper end of the cannabis and the top wall of the top cap. For example, inside the cap the plug extension acts like a built in plunger in the center. When the cap is slid onto the mold the built in plunger, presses onto the top of the cannabis core, to stop the cannabis from expanding upwards after packing and processing, such as during a curing step. This maintains the desired compression of the cannabis core, resulting in a solid and stable core. In such an embodiment, there may be a releasable lock 44a, 44b between the cap and the mold to ensure that the top cap remains in place and continues to apply pressure axially against the compacted cannabis core. [0039] In such an embodiment, the top cap is configured to fit over the upper open end of the cannabis mold (the end from which the mold was packed) and the releasable lock 44a, 44b is between the mold 10 and the cap 18, for example, with either a snap lock (click/pressure) or a twist lock such as a j-lock or threads.

[0040] For example, for a click/pressure lock with built-in plug extension, the mold may have a lip or extensions on its upper end. On the inside top of the cap there may be a recessed portion, into which the lip of the mold can click. Again, inside the cap there is a built in plunger-like plug extension in the center, the skewer port of the cap continues down the center of the plug extension. When the cap is installed onto the mold the built in plunger, presses onto the top of the cannabis core, to stop the cannabis from expanding upwards after packing and during cure. This maintains the desired compression of the cannabis core, resulting in a solid and stable core. Pressures of 8 psi or more can be maintained against the cannabis core.

[0041] In one twist lock (key lock) embodiment, as shown in Figures 2 and 7 there may be a L- or J- shaped key slots 44a adjacent the top of the mold, for example one on either side. The length of the cap will correspond with the length of the channel on the mold. In the cap there are small protruding keys 44b on either side that fit into the key slots on the mold. To operate, line the keys 44b up with the key slot in the mold. Slid cap onto mold, press firmly down and with a small clockwise/counter clockwise twist, to lock the cap into place. Twist cap in the opposite direction to release the lock and remove the cap 18 from the mold 10.

[0042] Figure 16 shows a mold 10 with threads 44a around the opening 26 to each cavity to accept a cap by threaded engagement.

[0043] To install the cap 18 onto the mold 10, the cap's skewer port 42 is inserted onto the skewer 12. The cap rides along the skewer, while the skewer remains in place. The cap is locked onto the mold with the skewer extending through the skewer port.

[0044] In operation, a mold is assembled by aligning the faces 32 of the mold parts 10a, 10b and bringing them together. The alignment pins 33 are fit together. Together the aligned cavity indentations 24' create the mold cavity 24. A clamping force is applied to hold the mold parts together during packing. For example, the lower sleeve 16 is slid over the outer diameter of the assembled mold. The skewer 12 is also installed to pass thought the inner mold cavity and is set in the skewer placement recess 30. The skewer is also installed to extend up into the skewer channel 38 of the plunger 14 and the plunger is aligned with the cavity 24. Cannabis is introduced between the cavity opening 26 and the plunger and the plunger is rammed into the cavity. This pushes and packs the cannabis into the cavity about the skewer.

[0045] If there is a filter 28: it is placed in the cavity 24, for example by resting in the cavity indentation 24' on one of the faces before the mold parts are brought together, the skewer may be inserted through the filter and the cannabis is packed against the filter. If there is no filter, the cannabis is packed against an end wall of the cavity.

[0046] The length of the plunger or marks thereon can be used to indicate when a particular amount of cannabis is properly packed into a mold. In other words, the depth that the plunger must be driven into the core can be marked to know that the core has been properly packed with the correct compression.

[0047] The cannabis can be packed without a binder. The mold assembly enables the cannabis, on its own, to be packed tightly and to hold together.

[0048] When a selected amount of cannabis has been packed into the cavity, the plunger 14 is removed and slid off the skewer 12. Then, the top cap 18 is applied. In so doing, the skewer hole 42 in the plug extension 40 is inserted over the skewer 12 and the top cap is moved towards the upper, open end 10c of the mold. The plug extension 40 is inserted through the upper opening 26 and into the cavity 24 to bear against the packed cannabis core. The top cap can then be releasably locked in place on the mold.

[0049] The assembled mold assembly can be cured with the top cap and skewer in place. Once the curing process is complete, the cap 18 and lower sleeve 16 (if used) are removed, leaving the skewer in place. In particular, the top cap and lower sleeve are removed to remove the clamping force on the mold parts, and the mold parts are separated, all while the skewer remains in place.

[0050] The cannabis core can then be lifted out of the mold cavity and covered with a wrapper 46 ready for sale/use. The skewer remains in place within the core until the rolling is completed. If the skewer is removed too early, this may result in a collapsed vent hole, and higher core breakage. The skewer extends out the top and possibly the bottom of the mold and the core and facilitates handling. For example, the length of the skewer that extends out the end of the core can be gripped when removing it from the core 21.

[0051] Once the core is cured and rolled, when the pre-roll is substantially complete, then the skewer is pulled out. The skewer can be pulled through the top, which is the core 21 (biomass) end of the pre-roll. Pulling the skewer away from the filter, avoids pulling cannabis down into the filter and tends to reduce breakage.

[0052] The mold assembly can be used to make one pre-roll at a time. However, if desired, the mold assembly can be incorporated into an apparatus that is more mechanized. For example, one where the mold can be secured in a base and the plunger is on a top plate mount configured to guide the plunger towards and into the inner cavity of the secured mold, for packing cannabis material therein. With reference to Figures 10- 15, for example, a dual, manual embodiment of a packing apparatus 50 is shown, which has a base 52 configured to secure two assembled molds 10 and a top plate mount 54 on which a plunger 14 is coupled for each mold. It is to be understood that while the illustrated packing apparatus is configured for two molds, it can reconfigured for one mold and it can be scaled up to handle other numbers of molds. An apparatus 50 for packing four mold cavities simultaneously is shown in Figure 16, for example.

[0053] The base 52 (Figures 10-16) can take various forms but at least includes a structure for receiving and securing a mold. In the illustrated embodiment, the base includes upwardly opening cups 56 into which the molds 10 can be installed and held in a known orientation with close tolerance. In one embodiment, an intermediate skirt, similar to sleeve 16, is employed to hold the mold with the parts assembled and then the skirt fits, for example slides, with the mold into the cup on the base. The intermediate skirt has a slot opening to accommodate an assembled mold with close tolerance. In one embodiment, the skirt has two slots, so termed a double skirt, with each slot shaped for holding an assembled mold, but this could be reduced to one slot or expanded to more than two slots depending on how may pre-rolls are to be packed at the same time. In this embodiment, the intermediate skirt is used as the lower sleeve to hold the mold parts together during packing and can remain in place even during curing, etc. The slots can be separated slightly if room is needed between the molds, for example, for the attachment of the top caps.

[0054] The base is illustrated with support points 58 to support or attach it to a support surface such as a table, possibly a vibration table. While fastener holes are shown in Figure 10, other means such as suction cups or feet (Figure 16) for holding the base stable are also contemplated. Of course, this may not be necessary if the base is larger or incorporated into a machine.

[0055] The apparatus includes guide rails 60 coupled to the base and on which the mount 54 slides. The guide rails may be offset from the center of the base.

[0056] The top plate mount 54 includes a force application means, such as handles 62 in a manual operation apparatus, and bearings 64 that slide along the guide rails. Plungers are mounted on the top plate. There is a plunger 14 for each mold that the base can accommodate. The guide rails ensure that each plunger, even when moved up and down, is maintained aligned with its cup 56 of the base. In particular, the guide rails specifically keep each plunger on the top plate 54 aligned with the location where the cavity 24 for that plunger will be held by the base 52.

[0057] As noted above, the plungers each have a skewer channel 38 (best seen in Figure 15) extending therethrough. In this embodiment, the top plate 54 includes skewer holes 66 and the plungers 14 installed on the mount top plate 54 are each positioned such that their plunger skewer channel 38 each align with a hole 66. The aligned skewer channel 38 and skewer hole 66 allow a skewer to extend through. This keeps the skewer centered, while the top plate and plungers are moved up and down during the packing process. In this embodiment, the handles are offset to the side to avoid injury, but other handle orientations are envisioned. In one embodiment (Figure 16), a shock absorber 68, such as a spring, can be installed to damper movements of the upper plate mount 54 at the bottom end of its stroke, where the plungers are deepest into the molds.

[0058] As described above, each mold cavity has an upper end with a slight funnel shaped opening 26. However, a funnel cap 70 may be employed to be positioned on an upper end of the mold, when the mold is in the packing apparatus. The funnel cap serves a number of purposes. First, the funnel cap includes a mounting end 70a. The mounting end is configured to mount on or adjacent the mold. In the embodiment of Figures 10-15 for example, mounting end 70a has a hollow cylindrical wall that is sized to slide down over an upper end of the mold with close tolerance. The mounting end, therefore, can further act as a clamp to hold the mold parts of each mold together. In addition, the funnel cap has an upper funnel end 70b on top of the mounting end. The upper funnel end 70b is shaped with a downwardly converging frustoconical wall leading to a spout 70c. The spout is, for example is concentric, within the sleeve of the sleeve end, such that when the sleeve end is fit over an end of the mold, the spout aligns with the location of the opening to the inner cavity. The underside of the upper funnel end can be shaped to fit closely against the upper end of the mold. The diameter across the spout is no smaller than the mold cavity inner diameter d. The plunger 14 passes through the spout 70c and into the inner cavity during packing.

[0059] The illustrated funnel caps are configured to fit over the tops of all the cavities that the packing apparatus is designed to handle. For example, the funnel cap 70 of Figures 10-15 is configured to fit over two molds at the same time. In addition, the funnel cap of Figure 16 is configured to fit with each of its four spouts aligned with the one of the four cavities of the mold being packed. There is a separator wall 70d between the upper funnel ends, so that the cannabis introduced to one funnel can remain separate from the adjacent funnel.

[0060] Each funnel can be sized to have a specified volume, so that a known amount of cannabis can be added to the funnel, and thereby to be packed into the mold cavity. The funnel can be used with a mold alone and not necessarily only with the packing apparatus.

[0061] A vibration force can be applied about the funnel or to the base to facilitate packing.

[0062] The overall apparatus can be stabilized by a support structure 72. The support structure may include an upper brace to secure the upper ends of the guide rails. The upper brace can include one or more further skewer holes 74, each hole aligned above a plunger skewer channel and hole 66 of the mount 54. [0063] While a manually operated packing apparatus is possible, the packing apparatus can be automated by inclusion of a motor 76 for vibration and/or for motorizing a force application means for the movement of the plungers. Alternately or in addition, a cannabis delivery hopper, and/or a system to place and remove the molds could be provided.

[0064] Using the apparatus, the above-noted method with the mold assembly is followed, but the assembled mold parts are placed in the base 52 and one or more plungers 14 are carried extending down from the top, mount plate 54. In particular, the mold parts, skewer and if employed, the filter, are assembled. A clamping force is applied to hold the mold parts together during packing. For example, the assembled molds are placed in cups 56 in the base. A lower sleeve and/or an intermediate skirt may be applied. The funnel cap 70 may be installed by passing the spout 70c over the skewers extending up from the mold cavities and fitting the mounting end 70a on top of the mold/molds. The top plate 54 is raised high enough to align the skewers with the plunger skewer channels 38 and the top plate holes 66. The top plate is then lowered to insert the skewers up into the plungers 14. The upper ends of the skewers can also be supported in skewer holes 74 in the upper brace. The cannabis is introduced near the upper opening, for example, onto the frustoconical area 26 of the upper end of the mold or the funnel cap 70. Force is applied to the top plate 54 to drive it down along the guide rails 60, thereby driving the one or more plungers down into their aligned molds. (Figures 12, 14, 15).

[0065] When the packing is complete, the top plate 54 can be raised up high enough to remove the skewers from the plungers 14 (Figure 10). The molds 10, and their skirt/lower sleeve if any, can be removed from the base 52. If a double skirt is used and it is desired to handle the molds individually, then the double skirt can be replaced with a lower sleeve. The funnel cap can be replaced with a top cap 18. Each mold, with top cap and lower cap installed, can be handled separately.

[0066] In the embodiment of Figure 16, the mold is slid along base 52 to align plungers 14 with further empty cavities 24 before removing the mold from the apparatus. Base 52 includes a track 78 in which the mold is held during packing and along which the mold is slid to align further cavities of the mold with the plungers for packing thereof. [0067] If a filter is used, the filter can have a long passage therethrough to permit passage of the skewer or the skewer can be set against an end of the filter. In one embodiment, a filter is provided that can accommodate passage, and retain the centering of, the skewer through the length of the filter and is further configured receive and engage the cannabis packed there against. At the same time, air, for example smoke, can be drawn through the filter to diffuse and cool it without cannabis being transported with the smoke.

[0068] A new filter 28 (Figures 17 - 20) includes a hollow cylindrical outer housing 80 (Figure 17) with a first end 80a, which is the end that the user will place in their mouth, and an opposite end 80b, adjacent the cannabis core 21 (shown in phantom in Figure 17). The outer housing can be defined as having a length much longer than the diameter dso, forming a straw-like structure, and having a long axis xso extending from the first end to the opposite, cannabis end 80b. While the inner diameter through the housing is an open conduit, there is a constriction in the inner diameter of the hollow cylinder between the first end and the opposite, cannabis end. The constriction creates a ledge 80c with a surface facing toward the cannabis end. In one embodiment, for example, the inner diameter dso is smaller at the first end than at the cannabis end, and the constriction is where the inner diameter change occurs.

[0069] The filter further includes a baffle 82 positioned in the inner diameter between the ledge 80c and the cannabis end 80b. The baffle can substantially fill the inner diameter between the ledge and the cannabis end, but the baffled is configured to permit air flow through the inner diameter. The ledge stops 80c the baffle from migrating through the inner diameter towards the first end 80a. In one embodiment, the baffle includes axially extending filter medium substructures 82a that extend substantially parallel to the housing long axis. The filter medium substructures may each be solid but have open channels 84between them through which air can flow. In one embodiment, the filter substructures are planar structures, such as of sheet material such as paper, that are closely stacked with their planar side surfaces lying alongside each other in parallel and substantially parallel to the housing long axis. The planar structures can extend the full distance across the inner wall surfaces and the full length between the ledge and adjacent the cannabis end 80b. At least some of the planar filter substructures can be joined together, such as at their edges in order to act as a unitary member. In one embodiment, the baffle is an elongated pleated sheet of paper, such as hemp paper. As shown, the baffle 82 may be a separate structure inserted (see arrow in Figure 19) into the filter outer housing 80. Alternately, the baffle may be integral with the outer housing.

[0070] When the baffle is a pleated sheet of material, the baffle is positioned with the lengths 82b of the pleats extending substantially parallel to the long axis of the outer housing 80. The baffle can remain in place by friction and by abutment against the inner ledge 80c, by addition of an adhesive between the housing and the baffle or by forming the baffle integral with the housing.

[0071] With this filter construction, the skewer 12 can be readily inserted between two parallel planar members (Figure 18B), for example into a channel 84 formed by the pleat between two folded lengths. Because the planar members (aka filter medium substructures 82a) extend lengthwise through the inner diameter of the housing, the skewer can be pushed between the sheets, for example, between the same two sheets, from one end of the baffle to the other. Because the planar members are arranged lengthwise and stopped against the ledge, they hold in place and accommodate forces against their ends that are distributed in plane. In other words, filter medium substructures 82a are not pushed through by the skewer and can withstand the packing force of cannabis against the cannabis end and remain in place during use.

[0072] In one embodiment, the ends of the filter medium substructures 82a are all positioned a similar distance D from the cannabis end 80d of the outer housing. This means that once a skewer is inserted between two sheets, the skewer, when advanced, will not butt and catch against further ends filter medium substructures 82a. In one embodiment, the ends are spaced a small distance D from the cannabis end such that a small cup-shaped recess is created between the end of the housing and the baffle. The small cup-shaped recess holds the first amount of cannabis that is packed above the filter during packing. The baffle prevents the cannabis from falling through the housing, and allows for compression of the cannabis core against the baffle. This process "sets the cannabis in the tip” or cannabis end 80b of the housing.

[0073] There may also be a thinner wall 86 close to the first end 80a of the filter housing. The thinner wall may be formed by a larger inner diameter close to the first end. This thinner wall may accommodate a portion of the pre-roll wrapper 46 folded up into the inner diameter.

[0074] The filter housing outer diameter is about the same as the cannabis core. The length may be 3cm - 30cm depending on the appearance desired. The side wall thickness of a filter may be 0.25mm to 4mm. The mold cavity and skewer are sized accordingly to accommodate and work with the housing size.

[0075] The filter housing can be produced from a rolled sheet material, such as cardstock such as hemp cardstock. As shown in Figure 20, a blank 88 can be formed from a square sheet of material can be prepared with a corner removed (at A) so that a narrower flap 92 extends from the main area 90 of the sheet. The sheet can be rolled starting with the narrower flap and then the larger main area rolls around the rolled flap. The narrower flap becomes rolled inside the other part 90 of the sheet and creates the ledge 80c along the edge 92a of flap 92 within the inner diameter of the rolled larger main area, while edge 90a forms end 80b of the housing. When the sheet is rolled, baffle 82 will reside in the distance between the ledge formed by edge 92a and edge 90a of the main portion. The length of baffle 82 along the pleats can be selected to fit between ledge 80c and end 80b, but leave space D to create the small cup for a small amount of cannabis to sit in the tip, on top of baffle for structural integrity of the cannabis core. The thinner end 86 may be formed by a small notch cut at B on the corner of the main area at a lower end of flap 92.

[0076] As noted above, the baffle may be integral to the filter housing. In such an embodiment, the blank 88 may include a flap of material that can be formed into the baffle and rolled within the main area 90 alongside the rolled flap 92.

[0077] In some embodiments, it may be useful to insert a mandrel within the housing as it is rolled. The mandrel can ensure the empty end of the housing maintains a suitable inner diameter during the construction process and then the mandrel can be removed. The baffle can be inserted later or can be in place at an end of the mandrel before rolling. In particular, the baffle may be positioned or secured at the end of the mandrel. A housing sheet material can be wrapped around the mandrel and the baffle.

[0078] In some embodiments, a second baffle can employed. This baffle is not needed, but may be useful for larger diameter pre-rolls or shorter tips. The second baffle can add additional cooling on larger cannabis cores. The second baffle can be added in the housing inner diameter at any position in the internal length of the filter.

[0079] The sheet material from the notches cut at A and B can be employed to construct baffle 82 or the second baffle, if desired.

[0080] The final pre-roll includes a solid cured cannabis core 21 possibly on top of the long specialty made paper filter 28. The solid cured cannabis core has a central vent hole 22 of varying diameter based on cannabis core diameter and length. The complete preroll is configured for an even, slow bum. That product configuration extends smoking time. The pre-roll can be rolled with infused flower, flower with cannabis considerate, and/or flower only.

[0081] The packing process and the central vent hole permit the solid cannabis core to t burn slowly and evenly.

[0082] It is to be understood that the mold assembly need not be used with any of the packing apparatus as disclosed and likewise the packing assembly may be employed with other forms of molds. Also, any pre-roll may or may have a filter and the filter described herein is only one possible filter that may be employed.

Clauses

A. A mold assembly for packing cannabis pre-rolls, comprising: mold parts connectable to define a mold with a cavity therein; a skewer sized to extend along a length of the cavity between the mold parts; a plunger sized to be inserted into the cavity and the plunger including a skewer channel passing up through the plunger, the plunger operable to be driven into the cavity and down over the skewer, while the skewer remains in place in the cavity; and a top cap configured to connect to a top end of the mold, the top cap including a plug extension protruding from an inner surface, the plug extension sized to protrude into the cavity.

B. The mold assembly of any of the clauses, further comprising: a releasable lock between the top cap and the mold parts.

C. The mold assembly of any of the clauses further comprising: a skewer hole extending through the plug extension. D. The mold assembly of any of the clauses, wherein the skewer has a twist along its length.

E. The mold assembly of any of the clauses, wherein the skewer is steel.

F. An apparatus for packing a biomass pre-roll, comprising: a base including a support area for holding a pre-roll mold in an upright position; guide rails coupled to the base and extending upwardly beside the support area; a top plate mounted to ride along the guide rails; and a first plunger mounted on an underside of the top plate, the plunger being elongate with a long axis extending substantially parallel to the guide rails and aligned with the support area.

G. The apparatus of any of the clauses, wherein the first plunger includes an open channel extending along the long axis to accommodate a packing skewer.

H. The apparatus of any of the clauses further comprising a hole in the top plate aligned with the open channel.

I. The apparatus of any of the clauses further comprising a skewer extending through the first plunger along which the first plunger is configured to slide.

J. The apparatus of any of the clauses further comprising a second plunger mounted on an underside of the top plate, the second plunger being spaced from and extending parallel to the first plunger.

K. A method for producing a biomass product for a pre-roll, the method comprising: assembling a mold to define a cavity within the mold; positioning a skewer in the cavity in a position with the skewer protruding from an open end of the cavity; threading the skewer through a lengthwise channel in a plunger; and driving the plunger into the cavity while introducing biomass material between the plunger and the open end of the cavity, such that the biomass is packed into the cavity around the skewer to produce the biomass product.

L. The method of any of the clauses, wherein the plunger is on a driving structure and driving includes forcing the driving structure down while the mold is held in a support area.

M. The method of claim 12, further comprising installing a top cap onto the mold with a portion of the top cap protruding into the cavity to hold the packed biomass in the cavity. N. The method of any of the clauses wherein installing the top cap includes threading the top cap over the skewer and securing the top cap to the mold while the skewer remains in the cavity.

O. The method of any of the clauses further comprising removing the skewer from the packed biomass to leave a vent hole in the biomass product.

P. A filter for a cannabis pre-roll, comprising: a cylindrical housing including an open inner diameter extending from a first end to an opposite end, a long axis defined between the first end and the opposite end; a ledge in the inner diameter; and a baffle in the cylindrical housing stopped against the ledge, the baffle including a plurality of planar filter media substructures positioned parallel to the long axis.

Q. The filter of any of the clauses, wherein the baffle is integral to the cylindrical housing.

R. The filter of any of the clauses, further comprising adhesive securing the baffle in the cylindrical housing.

[0083] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to those embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein, but is to be accorded the full scope consistent with the claims, wherein reference to an element in the singular, such as by use of the article "a" or "an" is not intended to mean "one and only one" unless specifically so stated, but rather "one or more". All structural and functional equivalents to the elements of the various embodiments described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are intended to be encompassed by the elements of the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 USC 112, sixth paragraph, unless the element is expressly recited using the phrase "means for" or "step for".

Claims

1 . A mold assembly for packing a biomass pre-roll, comprising: mold parts connectable to define a mold with a cavity therein, the cavity having an open end on a top end of the mold; a skewer sized to extend along a length of the cavity between the mold parts; a plunger sized to be inserted into the cavity and the plunger including a skewer channel passing up through the plunger, the plunger operable to be driven into the cavity and down over the skewer, while the skewer remains in place in the cavity; and a top cap configured to connect on the top end of the mold, the top cap including a plug extension protruding from an inner surface, the plug extension sized to protrude into the cavity.

2. The mold assembly of claim 1 , further comprising: a releasable lock between the top cap and the mold.

3. The mold assembly of claim 2, further comprising: a skewer hole extending through the plug extension.

4. The mold assembly of claim 1 , wherein the skewer has a twist along its length.

5. The mold assembly of claim 1 , wherein the skewer is steel.

6. The mold assembly of claim 1 , wherein the mold includes a second cavity similar to the cavity.

7. An apparatus for packing a biomass pre-roll, comprising: a base including a support area for holding a pre-roll mold in an upright position; guide rails coupled to the base and extending upwardly beside the support area;

24 a top plate mounted to ride along the guide rails; and a first plunger mounted on an underside of the top plate, the plunger being elongate with a long axis extending substantially parallel to the guide rails and aligned with the support area. The apparatus of claim 7, wherein the first plunger includes an open channel extending along the long axis to accommodate a packing skewer. The apparatus of claim 8 further comprising a hole in the top plate aligned with the open channel. The apparatus of claim 8 further comprising a skewer extending through the first plunger along which the first plunger is configured to slide. The apparatus of claim 7 further comprising a second plunger mounted on an underside of the top plate, the second plunger being spaced from and extending parallel to the first plunger. A method for producing a biomass product for a pre-roll, the method comprising: assembling a mold to define a cavity within the mold; positioning a skewer in the cavity in a position with the skewer protruding from an open end of the cavity; threading the skewer through a lengthwise channel in a plunger; and driving the plunger into the cavity while introducing biomass material between the plunger and the open end of the cavity, such that the biomass is packed into the cavity around the skewer to produce the biomass product. The method of claim 12, wherein the plunger is on a driving structure and driving includes forcing the driving structure down while the mold is held in a support area. The method of claim 12, further comprising installing a top cap onto the mold with a portion of the top cap protruding into the cavity to hold the packed biomass in the cavity.

15. The method of claim 14 wherein installing the top cap includes threading the top cap over the skewer and securing the top cap to the mold while the skewer remains in the cavity.

16. The method of claim 12 further comprising removing the skewer from the packed biomass to leave a vent hole in the biomass product.

17. A filter for a biomass pre-roll, comprising: a cylindrical housing including an open inner diameter extending from a first end to an opposite end, a long axis defined between the first end and the opposite end; a ledge in the inner diameter; and a baffle in the cylindrical housing stopped against the ledge, the baffle including a plurality of planar filter media substructures extending parallel to the long axis.

18. The filter of claim 17, wherein the baffle is integral to the cylindrical housing.

19. The filter of claim 17, further comprising adhesive securing the baffle in the cylindrical housing.