FIELD OF THE INVENTION
The invention described and contemplated herein relates to an apparatus for efficient filling and packing of particulate material, such as a particulate plant material, into elongated containers, such as elongated paper cones.
BACKGROUND
As with any product, it is important to package and deliver particulate products having measurable and consistent physical properties, as well as accurate and consistent quantities of the product in each package or container. Consistency of physical properties is often addressed during the production process performed to produce a particulate product. Accuracy and consistency of the quantities of particulate products provided in packaging or containers are often addressed during packaging processes (i.e., filling and packing), during which the quantity and density of the product loaded into the containers may be adjusted.
Production processes performed to convert raw plant materials to particulate plant products may vary depending on the raw plant material. Nonetheless, such production processes typically include one or more processing steps such as: harvesting, curing, dehydrating, physical modification (e.g., separation of components), and reducing to particulate form such as by chopping, grinding, shredding, etc. Once in final particulate form, particulate plant products are fed and packed into containers for one or more purposes including storage, shipping, and use.
Loading and packing some particulate materials, such as certain food and plant-derived products, into packaging and other containers for delivery to, and use by, customers, can be difficult due to their tendency to be relatively light weight and low density. The type and shape of the packaging or containers themselves may further complicate the efficient and consistent filling and packing. Particulate products such as smokable and/or inhalable particulate plant products, including, but not limited to, tobacco, cannabis, khat, sage, lavender, chamomile, peppermint, passionflower, damiana, marshmallow, rose petals, calendula, lobelia, mullein, other herbs, and combinations thereof, are known to present such difficulties. Filling and packing difficulties may be increased, for example, when filling elongated containers (whether tapered or not, but especially when tapered) with particulate plant products. These difficulties may be further increased when the containers are made of a flexible material such as plastic film or paper.
The filling and packing apparatus described and contemplated herein addresses the aforesaid challenges which occur when filling and packing particulate materials, and especially particulate plant derived products, into elongated containers made of flexible material.
SUMMARY OF THE INVENTION
An apparatus is provided for efficiently filling and packing a consistent quantity of particulate material into each of respective one of a plurality of elongated containers each of which has an open top end and a closed bottom end and a longitudinal axis extending therebetween. The apparatus generally comprises: a centrifuge assembly having a bottom disc and a top disc, as well as one or more stackable discs which are mounted in between the bottom and top discs of the centrifuge assembly, and also a motor connected to the centrifuge assembly for rotating the bottom disc, the top disc, and any of the one or more stackable discs mounted therebetween.
The centrifuge assembly is capable of providing centrifugal force for increasing velocity of particulate material provided to each of the plurality of containers, which increases compaction and density of the particulate material in each of the plurality of elongated containers. The centrifuge assembly has: a central conduit with an inlet for receiving particulate material and a central longitudinal axis which defines a rotational axis of the centrifuge assembly, and a bottom disc and a top disc which are each rotatably mounted on the central pipe via their respective central openings.
Each of the one or more stackable discs has: a disc periphery, at least one container holder which holds the plurality of elongated containers proximate to and evenly spaced around the disc periphery, and a central opening for rotatably mounting each of the one or more stackable discs on the central conduit of the centrifuge assembly, adjacent one another and in between the bottom disc and the top disc. The central conduit of the centrifuge assembly is in fluid communication with the central opening of each stackable disc mounted thereon.
Each of the one or more stackable discs also includes one or more internal passages, each of which is in fluid communication with both the central opening and the disc periphery, thereby providing at least a portion of a flow path for particulate material to flow therethrough, from the central conduit of the centrifuge assembly and the central opening of the stackable disc, to the disc periphery, and the open top ends of respective one or more of the plurality of elongated containers held by the at least one container.
Each container holder is capable of holding or allowing each of the plurality of elongated containers to move to an orientation in which the open top end of each elongated container is proximate the disc periphery for receiving particulate material, the longitudinal axis of each elongated container is aligned with and substantially parallel to the centrifugal force provided by the centrifuge assembly, and the closed bottom end of each elongated container is remote from the rotational axis of the centrifuge assembly.
The capacity of the apparatus may be controlled and varied by: increasing or reducing how many stackable discs are rotatably mounted on the centrifuge assembly, selecting and mounting one or more stackable discs capable of holding different desired quantities of elongated containers, varying the size of the elongated containers held on the one or more stackable discs, or a combination thereof.
In some embodiments, the internal passages of the one or more stackable discs may be branched and have two or more terminal passages each of which has an outlet in fluid communication with the disc periphery for providing particulate material to a corresponding one of the plurality of elongated containers. In some embodiments, the internal passages of one or more of the stackable discs may be spiral shaped and have a plurality of outlet openings, each of which is in fluid communication with the disc periphery for providing particulate material to a corresponding one of the plurality of elongated containers.
In some embodiments, the at least one container holder comprises a plurality of container holders, each of which is affixed to the stackable disc, proximate to and evenly spaced around the disc periphery. Each of the plurality of container holders is capable of pivotably holding a respective one of the plurality of elongated containers with its open top end proximate the disc periphery and aligned with a respective one of the one or more outlets of one of the one or more internal passages of the stackable disc, and allows the respective one of the plurality of elongated containers to be in, or move to, the orientation in which its longitudinal axis is aligned with and substantially parallel to the centrifugal force provided by the centrifuge assembly, which enables particulate material to flow and be compacted in the respective one of the plurality of elongated container.
In some embodiments, the apparatus further comprises a compressed gas material delivery assembly comprising a compressor which provides flowing compressed gas to the central conduit of the centrifuge assembly, via a conduit which is in direct or indirect fluid communication with the inlet of the central conduit of the centrifuge assembly, wherein the flowing compressed gas increases velocity of particulate material flowing along the flow path which increases compaction and density of the particulate material in each of the plurality of elongated containers.
In another exemplary embodiment, an apparatus is provided for filling and packing particulate material into each of a plurality of elongated containers, each of which has an open top end and a closed bottom end, wherein the apparatus comprises: a source of particulate material; one or more conduits for directly or indirectly providing particulate material along a flow path from the source to each of the plurality of elongated containers; and a compressed gas material delivery assembly comprising a compressor which provides flowing compressed gas to the flow path which increases velocity of the particulate material and controllably increases compaction and density of the particulate material flowing into each of the one or more elongated containers.
In still another exemplary embodiment, a method is provided for filling and packing a plurality of elongated containers with a consistent quantity and density of particulate material which flows from a source, along flow path having one or more outlets and a flow direction at each of the one or more outlets, to the plurality of elongated containers, each of which has an open top end, a closed bottom end, and a longitudinal axis extending therebetween. More particularly, the method comprises: positioning each of the plurality of elongated containers in an orientation in which its open top end is proximate to and aligned with a corresponding outlet of the flow path for receiving flowing particulate material, its closed end is distal from the corresponding outlet of the flow path, and its longitudinal axis is aligned substantially along the flow direction at the corresponding outlet of the flow path; and (A) applying centrifugal force to particulate material flowing along the flow path which increases velocity of the particulate material and controllably increases compaction and density of the particulate material in each of the plurality of elongated containers, (B) providing a compressed gas to the flow path which increases velocity of particulate material flowing along the flow path and controllably increases compaction and density of the particulate material in each of the plurality of elongated containers, or (C) both (A) and (B).
BRIEF DESCRIPTION OF THE FIGURES
The present invention will be further explained with reference to the attached drawings, wherein like structures are referred to by like numerals and/or letters throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention.
FIG. 1 is a schematic front view of an exemplary embodiment of a filling apparatus which includes a centrifuge assembly, stackable discs held in the centrifuge assembly, a material feed tank, and a compressed gas material delivery assembly for moving particulate material from the tank to the centrifuge assembly and into elongate containers (e.g., tapered paper cones);
FIG. 1A is a schematic side view of an exemplary paper cone having a tapered profile and which is suitable for use with the filling apparatus of FIG. 1;
FIG. 2 is a schematic front view of the material feed tank and the compressed gas material delivery assembly of the filling apparatus of FIG. 1;
FIG. 3 is a schematic front view of an exemplary embodiment of a centrifuge assembly suitable for use in the filling apparatus of FIG. 1 and having top and bottom discs for holding stackable discs therebetween;
FIG. 4 is a schematic bottom view of an exemplary embodiment of a stackable disc for use with the centrifuge assembly of FIG. 3 and having a branched delivery pathway and a plurality of cone holder brackets evenly spaced around its periphery, each bracket shown holding a cone;
FIG. 5 is a schematic top view of the stackable disc of FIG. 4, but showing a fewer number of cone holder brackets and no cones;
FIG. 6 is a schematic elevational front view of an optional flanged cone slot which may be pivotably connected to a stackable disc and hold therein a tapered paper cone to be filled with compacted particulate material;
FIG. 7A is a schematic top view of an empty cone holder bracket and a flanged cone slot aligned therewith prior to assembly;
FIG. 7B is a schematic top view of the cone holder bracket and the flanged cone slot of FIG. 7A assembled together;
FIG. 8 is a schematic top view of the stackable disc of FIG. 5 showing each of the cone holder brackets holding a flanged cone slot;
FIG. 9 is a schematic front view of three of the stackable discs of FIG. 4, each having cones held in the cone holder brackets and being stacked with one another and ready for assembly with the filling apparatus as shown in FIG. 1;
FIG. 10 is a schematic front view of the stackable disc of FIG. 4 while not rotating;
FIG. 11 is a schematic bottom view of another exemplary embodiment of a stackable disc for use with the centrifuge assembly of FIG. 3 and having a spiral delivery pathway and a plurality of cone holder brackets, each of which is holding a cone;
FIG. 12 is a schematic front view of three of the stackable discs of FIG. 10, each having cones held in the cone holder brackets and being stacked with one another and ready for assembly with the filling apparatus as shown in FIG. 1;
FIG. 13 is a schematic front view of another exemplary embodiment of a stackable disc suitable for use with the centrifuge assembly of FIG. 3 and which includes a cone holder belt wrapped around and affixed to the circumferential side of the disc;
FIG. 14 shows the spiral delivery pathway of the stackable disc of FIG. 13 and the plurality ports which provide fluid communication between the pathway and the cones held by the belt;
FIG. 15A is a schematic top view of the cone holder belt prior to wrapping around the stackable disc of FIG. 13 and show the plurality of apertures of the belt for receiving and holding cones to be filled;
FIG. 15B is a schematic top view of the cone holder belt of FIG. 15A in which each aperture holds a cone to be filled;
FIG. 16 is a schematic front view of several of the stackable discs of FIG. 13 partially assembled with one another;
FIG. 17 is a schematic front view of another exemplary embodiment of a filling apparatus which includes a centrifuge assembly like that of FIG. 3 and a material feed tank which relies on gravity to move the particulate material from the tank to the centrifuge assembly and into cones;
FIG. 18 is a schematic front view of another exemplary embodiment of a filling apparatus which includes a material feed tank and a flowing gas material delivery assembly for moving particulate material from the tank and into cones which are moved relative to the tank for each cone to receive the particulate material;
FIG. 19 is a schematic front view of another exemplary embodiment of a filling apparatus which includes a flowing gas material delivery assembly with a movable nozzle, in which flowing gas moves particulate material through a conduit, to the nozzle, and into a topmost cone of a stack (tower) of cones held in a cone tower holder;
FIG. 20 is a schematic front view of an alternative material delivery assembly which includes a pressurized material tank which moves measured quantities of the particulate material from the tank, through a conduit, and to a nozzle, using pressure from the tank as well as a flowing gas stream;
FIG. 21 is a schematic front view of another exemplary embodiment of a filling apparatus which includes a material feed tank and a flowing gas material delivery assembly which uses gravity and flowing gas for moving particulate material from the tank, through a conduit and trigger valve, to a nozzle and into containers (e.g., cones) which may be moved relative to the nozzle for each to receive particulate material; and
FIG. 22 is a schematic diagram another alternative filling apparatus material delivery assembly which includes a material tank and a flowing gas stream which siphons the particulate material from the tank, through a conduit, to a nozzle, and into containers (e.g., cones) which may be moved relative to the nozzle for each to receive particulate material.
DETAILED DESCRIPTION
Particulate material products are typically loaded into any of a number of different kinds of containers for storage and delivery to customers, whether wholesalers, retailers, consumers, or others. Depending on the physical form of the particulate material products and the intended next phase of processing, storage, delivery or use, suitable containers for holding them include, without limitation, tanks, boxes, crates, cartons, cylinders, cones, etc. Furthermore, the containers may be made from one or more materials such as metal and metal alloys, plastics, wood, cardboard, paper, and others, and those materials may be flexible, ridged, opaque, translucent, transparent, or any combination thereof.
Some particulate material products are plant derived and, after processing, may be at least partially dehydrated and comprise particles having relatively large or small sizes and which tend to be irregular in shape. More particularly, particulate plant products are at least partially derived from raw plant materials which are typically harvested, at least partially dehydrated (cured), and reduced to particulate form, such as by chopping, grinding, shredding, before being fed (or loaded) and packed into containers. Exemplary particulate plant products include smokable or inhalable particulate plant products derived from plants such as, without limitation, tobacco, cannabis, khat, sage, lavender, chamomile, peppermint, passionflower, damiana, marshmallow, rose petals, calendula, lobelia, mullein, other herbs, and combinations thereof, (hereinafter collectively referred to as “inhalable particulate plant products” or “inhalable plant products”). Such products are also sometimes referred to as smokable products, combustible plant-based material, inhalation based consumer goods, combustible consumer products, and other terms, all of which are intended to be included and covered by the terms “inhalable particulate plant products” and “inhalable plant products,” which are used interchangeably herein. It is further noted that, unless otherwise clearly stated, the terms “particulate material,” “particulate plant material,” “inhalable particulate plant products” and “inhalable plant products” are used interchangeably herein.
When in their final form, such inhalable particulate plant products are typically light weight and low density, which sometimes makes filling and packing consistent quantities and densities of them into containers difficult. Not only is proper packing, or compaction, of the product important to ensuring consistent quantities of product are disposed in each container, proper compaction of inhalable particulate plant products is also important to providing the desired experience when the product is used (e.g., burned, smoked, etc.). Difficulty with quantity control and proper degree of compaction (i.e., achieving the desired degree of density) of inhalable particulate plant products in containers is further complicated when the containers are elongated, whether tapered or not, as well as when the containers are made of a flexible plastic or paper material.
The filling apparatus described and contemplated herein provides efficient and consistent filling and packing of particulate products, and especially at least partially dried particulate plant products, into elongated containers. Although the filling and packaging apparatus and its use are described below in connection with inhalable particulate plant products being efficiently loaded and packed into elongated paper cones, the filling and packing apparatus described and contemplated herein, as well as methods for its use, provide the advantages and benefits described below when applied to filling and packing virtually any particulate material into elongated or deep containers.
In one exemplary embodiment, the apparatus includes a centrifuge assembly and a compressed gas material delivery assembly. It is noted that, although the exemplary embodiment of the apparatus described below includes both a centrifuge assembly and a compressed gas material delivery assembly, it should be understood that either assembly, without the other, provides more efficient filling of particulate products into elongated containers as compared to current conventional filling apparatus and methods.
With reference now to FIGS. 1-10, in one exemplary embodiment, a filling apparatus 100 comprises a material feed tank 110 or other storage and holding apparatus, which holds particulate material (PM) until provided (fed), through a feed conduit 155, to one or more stackable discs 126, 128, 130 rotatably mounted and arranged in a centrifuge assembly 120, optionally, with the assistance of a compressed gas material delivery assembly 150. Generally, the centrifuge assembly 120 with one or more stackable discs 126, 128, 130 rotatably mounted and arranged, enables simultaneous efficient filling and packing (i.e., compaction) of consistent quantities of particulate plant material (PM) into a plurality of elongated containers (e.g., tapered paper cones, see FIG. 1A), as well as the ability to vary capacity (i.e., the number of containers filled). The ability to vary capacity is provided because each stackable disc 126, 128, 130 may be varied in size, in the number of containers held by each disc, or both.
Whereas filling apparatus currently used in the relevant art and industry tends to have enormous capacity (e.g., filling and packing 100s and even 1000s of cones with each batch operation of the apparatus), that capacity is not flexible and often not practical for operators who produce significantly smaller quantities of inhalable particulate plant products and filled elongate containers. The stackable disc 126, 128, 130 design and arrangement of the apparatus 100 described and contemplated herein provides the ability to handle small to medium quantities of particulate material and fill relatively small to medium quantities elongate containers, but also to easily scale up to relatively large quantities of particulate material and containers.
The compressed gas material delivery assembly 150 provides controlled and consistent delivery of the particulate plant material (PM) from the material feed tank 110. Furthermore, it is noted that compaction is improved (i.e., degree of compaction of inhalable particulate plant product is increased) in the filling apparatus 100 by both the centrifugal forces applied to the particulate product when the centrifuge assembly 120 is operated with one or more stackable discs 126, 128, 130 rotatably mounted and arranged therein, as well as by the force applied to the particulate product by flowing compressed gas provided by the compressed gas material delivery assembly 150.
Generally, the introduction of particulate material (PM), such as inhalable particulate plant products, from the material feed tank 110 to the centrifuge assembly 120 can be achieved using, for example without limitation, a conveyor belt, a gravity feed mechanism, an auger style system, a pressure and/or vacuum feed mechanism. In one exemplary embodiment shown in FIGS. 1 and 2, the compressed gas material delivery assembly 150 includes a compressor 152 (shown schematically in the drawings) and a conduit (i.e., one or more pipes or tubes) 154 which provides a flow path (see arrows F in FIGS. 1 and 2) for compressed gas from the compressor 152, past the material feed tank 110, and through the feed conduit 155. The compressor 152 provides compressed gas and should be selected having a size and capacity based on the desired or anticipated flow rate and phase (e.g., dense, dilute, etc.) of the gas and particulate material (PM). The pipes/conduits (154, 155), valves, and other components (not shown), as well as the channels 200, 210, and outlets 212, of each individual stackable disc 126, 128, 130, must also, of course be sized for the anticipated flow rate of particulate material (PM). Such determinations are well within the ability of persons of ordinary skill in the relevant art. The compressed gas provided by the compressor 152 should be inert to the particulate plant material (PM), such as without limitation, air or nitrogen.
The conduit 154 should be selected having a size and capacity based on the desired or anticipated flow rate and phase of the gas and particulate material (PM). Such determinations are well within the ability of persons of ordinary skill in the relevant art. The conduit 154 has an inlet 156, which is in fluid communication with the compressor 152, and an outlet 158, which is in fluid communication with an inlet 122 of the centrifuge assembly 120. The conduit 154 is also in fluid communication with an outlet 112 of the material feed tank 110 at a position intermediate the inlet 156 and outlet 158 of the conduit 154. The foregoing arrangement allows compressed gas to flow, in the direction of the arrows F shown in FIGS. 1 and 2, and entrain particulate material (PM) leaving the material delivery tank 110. As will be recognized, the compressed gas material delivery assembly 150 may include ancillary components such as, without limitation, one or more filters, humidifiers, dehumidifiers, baffles, valves, temperature monitoring devices or sensors, temperature control devices (e.g., heating elements, cooling elements, or both), etc.
FIG. 1A provides an elevational front view of an exemplary elongated container, i.e., tapered paper cone 20, which may be filled and packed with inhalable particulate plant material (PM) for storage, delivery, and use. As shown, the tapered cone 20 has an open top end 22 and a closed bottom end 24 and a tapered circumference 26 therebetween, as measured along its longitudinal axis 28. The compressed gas material delivery assembly 150 provides additional momentum and force to flowing particulate material (PM) being provided to the filling apparatus 100, which in turn causes particulate material (PM) to flow more forcefully into containers, especially elongate containers such as tapered cones 20 and to pack more densely into the containers, or cones 20, than currently used conveyor or gravity fed filling apparatus.
With reference now to FIGS. 1 and 3, a centrifuge assembly 120 in accordance with the presently described and contemplated invention and suitable for use in the filling apparatus 100 will now be described. The centrifuge assembly 120 includes a rotatable bottom disc 122 and a rotatable top disc 124 for holding and rotating stackable discs 126, 128, 130 therebetween, as will be described in further detail below. As will also be described below, each of the stackable discs 126, 128, 130 holds a plurality of tapered paper cones 20. The centrifuge assembly 120 further includes a central conduit, such as a pipe 132, with an inlet 133, which serves as the inlet 133 of the centrifuge assembly 120 for receiving particulate material (PM) from the material feed tank 110 via the compressed gas material delivery assembly 140 and distributing the particulate material (PM) to each of the cones 20. As explained in more detail below, each cone 20 may be held in a corresponding sleeve, such as a flanged cone slot (not shown, but see FIGS. 6, 7A, and 7B), each of which would be pivotably affixed to stackable discs 126, 128, 130 (see FIGS. 4, 5, and 8).
The centrifuge assembly 120 further includes a swivel bearing 134 which permits the central pipe 132 to remain stationary while the bottom and top discs 122, 124, as well as any stackable discs 126, 128, 130 mounted therebetween are rotated about a rotational axis RA of the centrifuge assembly 120 defined by the central longitudinal axis of the central pipe 132. A motor 136 provides the power to perform the aforesaid rotation. The size, power, capacity, shaft size, and other characteristics of the motor 136 are determinable by persons of ordinary skill based on the intended or expected size and capacity of the filling apparatus 100 and the centrifuge assembly 120.
A housing 50 may be provided to contain one or more components of the filling apparatus 100 such as, without limitation, the motor 136, the compressor 152, electronics, wiring, and control interfaces 138 for controlling the motor 136, the compressor 152, and possibly other components. The central pipe 132 extends into the housing and is connected with the motor 136. Pillow block bearings 140, 142 may be mounted adjacent the top and bottom discs 122, 124 for providing horizontal support to each of the top and bottom discs 122, 124. A pillow block bearing 144 may be mounted adjacent to the top of the housing 50 where the central pipe 132 enters the housing 50 for stabilizing the central pipe 132. The size and number of pillow block bearings 136, 138, 140 suitable for the centrifuge assembly 120 will be determined by the physical properties of the top and bottom discs 122, 124, (e.g., size, weight, etc.) with larger discs 122, 124 requiring larger pillow block bearings, or a greater number of pillow block bearings, or both.
With continued reference to FIGS. 1 and 3, the drive shaft (not shown per se) of the motor 136 extends through the housing and the pillow block bearing 144 which is mounted adjacent the housing 50, and is received and connected to the center of the bottom disc 122 for rotating the bottom disc 122. The bottom disc 122 includes a plurality of upwardly extending prongs, such as four prongs 160, 162, 164, 166, for purpose to be described below. The prongs 160, 162, 164, 166 should, but do not have to, be arranged symmetrically and evenly spaced about the center of the bottom disc 122. Each prong 160, 162, 164, 166 includes a plurality of openings 168 (see FIG. 3) which receive a locking pin (not shown per se) therethrough for securing the bottom and top discs 122, 124, as well as any stackable discs 126, 128, 130 mounted therebetween, for rotation by the motor 136 about the rotational axis RA with the bottom disc 122.
The top disc 124 has a plurality of bore holes, such as four bore holes 170, 172, 174, 176 shown more clearly in FIG. 3, each of which receives a corresponding one of the prongs 160, 162, 164, 166 of the bottom disc 122 therethrough. Furthermore, the top disc 124 is configured to receive particulate material (PM) from the outlet 158 of the conduit 154 of the compressed gas material delivery assembly 150. The conduit 154 extends through the pillow block bearing 142 and the swivel bearing 134 to communicate with the top disc 124.
With reference now to FIGS. 1 and 4-10, the centrifuge assembly 120 includes one or more stackable discs 126, 128, 130 which are mounted and layered adjacent to one another and in between the bottom and top discs 122, 124 of the centrifuge assembly 120. As seen best in FIGS. 4, 5, and 8, each stackable disc 126 has a plurality of bore holes 180, 182, 184, 186 which are positioned symmetrically about a hollow central inlet (central opening) 178 and each of which is sized to receive a corresponding one of the prongs 160, 162, 164, 166 therethrough. In the foregoing configuration, when the bottom disc 122 is rotated by the motor 136, all of the stackable discs 126, 128, 130 and the top disc 124 are also rotated together about the rotational axis RA.
As shown schematically in FIG. 4, in some embodiments, each stackable disc 126 has internal branching bores or passages 200 which are in fluid communication with the hollow central inlet (central opening) 178 of the disc 126 and the central conduit or pipe 132, and have a plurality of outlets 203 each of which is aligned and in fluid communication with the disc periphery 127 and with the open top end 22 of a corresponding tapered cone 20, whereby particulate material (PM) is delivered to the open top end 22 of each of the tapered cones 20 pivotably held on the stackable disc 126, proximate to and evenly spaced around the disc periphery 127. It is noted that FIG. 4 generally shows four internal passages 200, each of which branches into two intermediate passages 201 and then into four terminal passages 202, each of which has an outlet 203 which is aligned with the open top end 22 of a corresponding tapered cone 20 to be filled. Nonetheless, it is within the scope of the present disclosure that a different number of passages 200 off of the central conduit or pipe 132 may be provided in each stackable disc 126, and each passage 200 may branch into a different number of intermediate and terminal passage branches 201, 202.
Each stackable disc 126, 128, 130 is configured to pivotably hold a plurality of tapered cones 20 to be filled and packed with particulate material (PM), such as inhalable plant derived particulate material. Each stackable disc 126 is configured to pivotable hold at least 4 tapered cones 20 (see FIG. 5) which are spaced equidistant about the circumference 126c of the stackable disc 126. Depending on the size of the stackable disc 126 and the size of the tapered cones (containers) 20 to be filled and packed, the stackable disc 126 may be configured to pivotably hold more, even many more, than 4 tapered cones 20.
Each tapered cone 20 is pivotably held by the stackable disc 126 such that when the stackable disc 126 is not rotating, as shown in FIG. 10 (such as when the centrifuge assembly 120 is not in operation), the tapered cone 20 hangs with its longitudinal axis 28 oriented perpendicular to the ground and parallel to the rotational axis RA of the centrifuge assembly 120. When the centrifuge assembly 120 is operated and the stackable disc 126 is rotating at a sufficient speed, as shown in FIGS. 1, 4, 8 and 9, each of the tapered cones 20 pivotably held by the stackable disc 126 is oriented with its longitudinal axis 28 being substantially parallel to the ground and the centrifugal force provided by the centrifuge assembly, as well as perpendicular to the rotational axis RA. Furthermore, centrifugal forces created when the stackable disc 126 is rotating assist the flow of particulate material (PM) into the open top end 22 of each tapered cone 20 and toward the closed bottom end 24 of each tapered cone, with more force than in the absence of centrifugal forces, or even when an agitating or vibrating device is used to encourage packing of particulate material in such elongated containers as tapered cones 20. Thus, the centrifugal forces provided by the centrifuge assembly 120 results in more efficient packing of the particulate material (PM), especially inhalable particulate plant material into each cone 20. The foregoing improved efficient filling and packing of the particulate material (PM) into tapered cones 20 provides better control of the quantity and density of the particulate material (PM) loaded into each cone 20.
In some embodiments, a plurality of flanged cone slots 30, such as that shown in FIG. 6, are each pivotably connected to a stackable disc 126 by a corresponding one of a plurality of cone holders 188 as shown in FIGS. 5, 6, 7A, and 7B. With reference to FIG. 6, an exemplary cone slot 30 is shown having an open top end 32 for inserting a tapered paper cone 20 (see FIG. 1A) therein as indicated by arrow I. The cone slot 30 also has a flange 33 extending downward from the open top end 22, as well as an opposite bottom end 24 which may be open or closed. Like the tapered paper cone 20, the flanged cone slot 30 is symmetrical about a longitudinal axis 38. When a tapered paper cone 20 is inserted and held in a flanged cone slot 30, their respective longitudinal axes 28, 38 are substantially aligned with one another.
It is recognized that various other designs for cone slots 30, as well as for cone holders 188, are possible and suitable for holding and pivotably connecting elongated containers, such as tapered paper cones 20, to one or more stackable discs 126, 128, 130, as shown in FIGS. 5-6, 7A and 7B. Accordingly, while flanged cone slots 30 are shown in FIGS. 5-6, 7A, and 7B, it should be understood that, even though not specifically shown, each flanged cone slot 30 would hold therein a tapered paper cone 20 to be filled with inhalable particulate plant product. Furthermore, for simplicity, other figures herein show cones 20 without any cone slot 30 or other sleeve or holder device, and the descriptions provided below may refer only to the tapered paper cones 20, with the understanding that cone slots 30 or other sleeve or holder devices may be used to hold the cones 20 or not, without departing from the intent and spirit of the presently described and contemplated filling apparatus 100 and stackable discs 126, 128, 130.
In some embodiments, such as that shown in FIGS. 1 and 4-10, each stackable disc 126 has a plurality of cone holders 188, distributed evenly about the disc periphery 127 of the stackable disc 126 and each of which has a pair of opposing prongs 190, 194 configured to pivotably hold the open top end 22 of a corresponding tapered cone 20 therebetween (seen most clearly in FIGS. 5-8). As also shown in FIGS, 5-8, in some embodiments, each prong 190, 194 includes a mating feature 192, 196, each of which mates with a corresponding mating feature 198, 199 provided on opposite sides of each tapered cone 20 (or, alternatively, on opposite sides of the flange 33 of a flanged cone slot 30). As previously described, when several stackable discs 126, 128, 130 are used, they are stacked adjacent and one on top of another as shown in FIGS. 1 and 9, with central openings (e.g., see hollow central inlet 178 of stackable disc 126 shown in FIGS. 1, 4, 5, 8, and 9) aligned to receive, or define, the central conduit or pipe 132 of the centrifuge assembly 120 described above. As should be readily apparent, when two or more stackable discs 126, 128, 130 are stacked and mounted between the bottom and top discs 122, 124 of the centrifuge assembly 120, their bore holes (e.g., 180, 182, 184, 186 of stackable disc 126 shown in FIGS. 4, 5, and 8) are aligned with those of the other stackable discs so that a corresponding one of the prongs 160, 162, 164, 166 of the bottom disc 122 may be received therethrough, as described above, to enable rotation with the bottom disc 122.
It is noted that the stackable discs 126, 128, 130 are shown and generally function best when identical to one another in configuration, but may differ in several aspects, such as the number of cone holders, the size (e.g., diameter) of each disc 126, 128, 130, etc., as will be discernible by persons of ordinary skill in the relevant art. Additionally, it is contemplated that one or more stackable discs 126, 128, 130 may be permanently mounted between the bottom and top discs 122, 124 of the centrifuge assembly 120 without departing from the intent and spirit of the presently disclosed filling apparatus 110 in which filling and packing of particulate material (PM) is more efficiently and controllably achieved using centrifugal forces provided by operating the centrifuge assembly 120. It is noted that stackable discs 126, 128, 130 which are removable and interchangeable provide flexibility not provided by conventional filling apparatus and systems whereby the quantity of tapered cones 20 (or other containers) being filled by operation of the filing apparatus 110 is variable and can easily be modified or adjusted depending upon availability of particulate material product or market demand, and other practical considerations.
An alternate embodiment of a stackable disk 126′ is shown in FIGS. 11-12. Instead of a branching internal passage 200 for delivering and distributing particulate material (PM) to each of a plurality of tapered cones 20, the alternate stackable disc 126′ has a spiral shaped internal passage 210 with a plurality of outlet openings 212, each of which is aligned with a tapered cone 20 held by the disc 126′, so that particulate material is delivered to each cone 20. A plurality of stackable discs 126′, 128′, 130′ each having spiral shaped internal passages (210) are stacked adjacent and one on top of another as shown in FIG. 12, just like discs 126, 128, 130 having branched passages 200. In fact, it is possible to combine or mix stackable discs having different types of passages (e.g., branched 200, spiral 210, or other configurations) in the same stack for mounting between the bottom and top discs 122, 124 of the centrifuge assembly 120.
FIGS. 13-16 provide several views of another alternate embodiment of a stackable disc 326. FIG. 13 shows the stackable disc 326 which, instead of discrete cone holders (188), has a strip or belt element 388 wrapped and affixed around the circumferential side 327 of the disk 326 and holding a plurality of tapered cones 20. The disc 326 may have an internal spiral passage 210 as shown in FIG. 14, but could just as suitably have an internal branched passage 200 as shown for the disc 126 in FIG. 4.
With reference to FIGS. 13, 15A, 15B, and 16, the belt 388 includes a plurality of apertures 191 along its length (see FIG. 15A) each of which is configured to receive a tapered cone 20 therein. More particularly, each aperture 191 is sized to receive and retain the open top end 22 of a cone 20 (see FIG. 15B). When the belt 388 is wrapped and affixed around the circumferential side of the disk, the cone 20 is held on the disc 326 in an orientation where its longitudinal axis 28 is substantially parallel to the ground and perpendicular to the rotational axis RA of the centrifuge assembly 120, regardless of whether the disc 326 is rotating. FIG. 16 shows that stackable discs 326, 328, 330, 334 of the type having a belt 388 with apertures for receiving and retaining tapered cones 20 are stacked adjacent and one on top of another, just like the stackable discs 126, 128, 130 of FIGS. 1 and 9.
A method for filling and packing containers such as, but not limited to, elongated containers, with particulate material such as, but not limited to, inhalable particulate plant products, will now be generally described as contemplated herein. In some embodiments, such a method comprises the steps of: providing a flow path which extends from and is in fluid communication with a source of particulate material and is also in fluid communication with each of a plurality of outlets; aligning an open end of an elongated container with each of a corresponding one of the plurality of outlets, wherein each elongated container also has an opposite closed end; providing a stream of particulate material, such as without limitation inhalable particulate plant material; forming a flowing stream of particulate material which moves (i.e., causing the stream of particulate material to flow) along the flow path, from the source, to and through each of the plurality of outlets, and into each of the elongated containers; and continuing the flow of the particulate material until each of the elongated containers is filled with a consistent desired quantity and density of the particulate material in each of the elongated containers.
In one exemplary embodiment, the method for filling and packing containers with particulate material, as described above, further comprises increasing compaction of the particulate material in each of the elongated materials by providing a stream of compressed gas to the flow path either upstream of the source of particulate material, or downstream of the source of particulate material and upstream of the plurality of outlets. Without wishing to be bound by theory, it is believed that providing the stream of compressed gas to the flow path in the aforesaid manner generally increases velocity of the particulate material flowing along the flow path and into each of the elongated containers which, in turn, increases compaction and density of the particulate material in each container.
In another exemplary embodiment, wherein each of the elongated containers is further arranged and oriented with its open end positioned on the circumference of a planar circular pattern and its longitudinal axis essentially perpendicular to the circumference and coplanar with the circular pattern (see, e.g., FIGS. 1, 4, 9, and 16), the method for filling and packing containers with particulate material, as described above, further comprises increasing compaction of the particulate material in each of the elongated materials by applying centrifugal force to the elongated containers for a period of time sufficient to provide a desired consistent quantity and density of the particulate material in each container.
In still another exemplary embodiment, the method the method for filling and packing containers with particulate material, as described above, further comprises increasing compaction of the particulate material in each of the elongated materials by both providing a stream of compressed gas to the flow path and applying centrifugal force to the elongated containers, as described above, to provide a desired consistent quantity and density of the particulate material in each container.
In some embodiments, the filling apparatus 100 shown in any of FIGS. 1-16 may be used to perform the aforesaid method for filling and packing containers, such as elongated containers 20, with particulate material (PM), such as inhalable particulate plant products. In such embodiments, the source of particulate material (PM) is the material feed tank 110, and the flow path is formed and provided by a combination of the feed conduit 155, the central conduit 132 of the centrifuge assembly 120, and the branched or spiral internal passages 200, 210 of the stackable discs 126, 126′ (see FIGS. 4 and 11). In embodiments of the filling apparatus 100 including stackable discs 126 having branched internal passages 200 with intermediate and terminal passages 201, 202, the plurality of outlets in fluid communication with the flow path are positioned at the downstream ends of the terminal passages 203 (see FIG. 4). In embodiments of the filling apparatus 100 including a stackable discs 126′ having a spiral shaped internal passage 210, the plurality of outlets in fluid communication with the flow path are the outlet openings 212 provided along the spiral shaped internal passage 210 (see FIG. 11). Moreover, the flowing stream of the particulate material moves from the material feed tank 110, along the flow path (as described above), to and through each of the plurality of outlets, and into each of the elongated containers 20.
When the filling apparatus 100 described above and shown in FIGS. 1-16 is used to perform the method for filling and packing containers with particulate material, the step of increasing compaction of the particulate material in each of the elongated materials may be performed by either, or both, of the steps of providing a stream of compressed gas to the flow path and applying centrifugal force to the elongated containers, as described above, to provide a desired consistent quantity and density of the particulate material in each container. The step of providing a stream of compressed gas to the flow path may be performed by operating the compressed gas material delivery assembly 150. The step of applying centrifugal force to the elongated containers may be performed by operating the centrifuge assembly 120. Either of the stream of compressed gas or the centrifugal force will contribute to increasing compaction of the particulate material and providing a desired consistent quantity and density of particulate material in each container. Of course, operating both the compressed gas material delivery assembly 150 to provide the stream of compressed gas to the flow path and the centrifuge assembly 120 to apply centrifugal force will provide further improved control of quantity and density of the particulate material in each container.
FIG. 17 provides an alternative embodiment of the filing apparatus 400 which does not include a compressed gas material delivery assembly (150), but rather includes a centrifuge assembly 420 as described above, as well as a material feed tank 410 which holds particulate material (PM) and delivers the particulate material (PM) directly to the central conduit or pipe 43 of the centrifuge assembly 420 by gravity feed. Several stackable discs 426, 428, 430, each having a plurality of tapered cones 20 held thereon, are shown in FIG. 17 mounted between the bottom and top discs 422, 424 of the centrifuge assembly 420.
FIGS. 18-22 provide several alternative embodiments of the filling apparatus 500, 600, 700, 800, 900 which do not include a centrifuge assembly (120), but rather include a conduit or pipe which receives the particulate material (PM) and flowing or compressed gas. The gas entrains and facilitates moving the particulate material (PM) through the conduit more forcefully to fill containers (such as tapered cones 20) and pack the particulate material (PM) more tightly therein. This speeds the process of filling and packing the containers and provides more control and consistency with regard to the quantity and density of particulate material (PM) that is packed and provided in each container.
FIG. 18 provides a schematic diagram of an alternative embodiment of the filling apparatus 500 which does not include a centrifuge assembly (120), but rather includes a material feed tank 510 having an outlet 512 in fluid communication with a conduit or pipe 554 which receives the particulate material (PM) and delivers it to one or more containers, such as tapered cones 20. Compressed or flowing gas, such as air, nitrogen or another inert gas, is provided to the conduit 554 and flows past the outlet 512 of the material feed tank 510, whereby particulate material is entrained and flows in the direction of the arrows F in FIG. 18. The compressed or flowing gas increases the flow rate of particulate material (PM) through the conduit 554 and into cones 20 above that provided by gravity alone and enhances packing of the particulate material (PM) in each cone 20. The outlet of the conduit 554 may be provided with a nozzle 555 for additional control of the flow of particulate material (PM) from the conduit 554 to each tapered cone 20.
It has been noted that when particulate material, such as inhalable particulate plant product, is provided to a container made of a flexible material such as plastic film or paper, a problem sometimes arises wherein the open top end or edge of the container, such as tapered paper cones, may be displaced from its fully open configuration to a partially or fully bent or folded configuration which obstructs the particulate material from continuing to fill the container. To minimize or avoid this issue, it is recommended that the outlet (e.g., an outlet 203 of a terminal passage 202 of a branched passage 200 of a stackable disc 126, or an outlet 212 of a spiral passage 210 of a stackable disc 126′, or the outlet of a nozzle 555) from which particulate material is provided to the elongated container 20 should have a diameter which is from about 60% to about 80%, for example without limitation, from about 70% to about 75%, of the diameter of the open top end 22 of the elongated container 20. Otherwise stated, the outlet should be from about 20% to about 40% smaller than the diameter of the open top end 22 of the elongated container 20.
For example, without limitation, if the elongated container 20 to be filled has an open top end 22 of about 5 mm in diameter, a suitable diameter for the outlet (e.g., outlet 203 of a terminal passage 202, or outlet 212 of a spiral passage 210, or outlet of a nozzle 555) would be from about 3 mm to about 4 mm, or from about 1 mm to about 2 mm smaller than the open top end 22. In an exemplary embodiment, where tapered paper cones 20 having an open top end 22 of about 5 mm in diameters are to be used, each outlet from which the inhalable particulate product (PM) flows into a respective cone 20 would have a diameter of from about 3 mm to about 4 mm, or from about 3.5 mm to about 3.75 mm. For best results, the outlet should be oriented concentrically with the open top end 22 of the container 20.
Avoiding the aforesaid folding and obstruction problem may also be minimized or avoided by extending or inserting the outlet slightly into the container, i.e., about 2 to 10 mm past the edge of the open top end 22 of the container 20. Additionally, in an embodiment wherein the elongate container includes a flange (not shown per se) at its open top end 22 and the stackable disc 126 is provided with cone holders 188 (see, e.g., FIGS. 1, 2, 6-7), and the opposing prongs 190, 194 of the cone holder 188 pivotably hold the container 20 by its flange, the outlet may be configured as an extension or a nozzle 555 which may be configured to mate with the holder so as to position the outlet concentrically with the open top end 22 of the container 20, or extend the outlet slightly into the open top end 22 of the container 20, or both.
FIG. 19 provides a schematic diagram of another alternative embodiment of the filling apparatus 600 which includes a stacking device 625 and a retractable conduit or pipe 654 having an outlet nozzle 655 for controlling the delivery of particulate material (PM). More particularly, the stacking device 625 holds a plurality of stacked tapered cones 20 therein and, optionally, includes a top cone ejection mechanism 627. The conduit 654 conveys particulate material (PM) to the topmost tapered cone 20 held in the stacking device 625. Compressed or flowing gas, such as air, nitrogen or another inert gas, is provided to the conduit 654 and entrains particulate material (PM) so that both flow in the direction of the arrows F in FIG. 19. The outlet of the conduit 654 may be provided with a nozzle 655 for additional control of the flow of particulate material (PM). In operation, the nozzle 655 is extended to align with the open top end 22 of the topmost cone 20, particulate material (PM) is delivered through the nozzle 655 to the cone 20. When the topmost cone 20 contains the desired quantity of particulate material (PM), the nozzle 655 is retracted away from the cone 20 and the filled cone 20 is then ejected by the stacking device 625 and falls into a collection tank 631.
FIG. 20 provides a schematic diagram of still another alternative embodiment of the filling apparatus 700 which includes a pressurized material feed tank 710 having an outlet 712 in fluid communication with a delivery conduit or pipe 754 which receives the particulate material (PM) and delivers it to one or more containers, such as tapered cones (not shown in FIG. 20). The pressurized material feed tank 710 may include a capped fill port 711 for addition of particulate material (PM) to the tank 710, as well as a safety valve 713 for releasing pressure as desired or necessary for safety and proper operation of the tank 710.
Compressed gas, such as air, nitrogen or another inert gas, is provided to an upstream conduit 751 and an inline gas valve 752 directs a first portion of the compressed gas to the material feed tank 710 through a feed tank conduit 753 a second portion of the compressed gas to the delivery conduit 754. The flow of the compressed gas is generally shown by the arrows F in FIG. 20. The compressed gas provided to the material feed tank 710 provides downward pressure (see arrows P in FIG. 20) on particulate material (PM) therein which causes faster flow rate of particulate material (PM) out of the outlet 712 than by gravity alone.
The compressed gas provided to the delivery conduit 754 flows past the outlet 712 of the material feed tank 710, which entrains particulate material (PM) leaving the tank 710 and further increases the flow rate of the particulate material (PM) toward the outlet nozzle 755 and container (not shown) to be filled. The embodiment of the filling apparatus 700 shown in FIG. 20 may further include devices which provide additional control of the flow of particulate material (PM) to the container(s), which in turn provides more control and consistency of the quantity and density of particulate material product packed into each container. For example, a material metering valve 741 may be connected to and in fluid communication with the outlet 712 of the tank 710 and the delivery conduit 754 to control the quantity of particulate material (PM) which enters the delivery conduit 754. Additionally, a trigger valve 743 may be provided in the delivery conduit 754, downstream of the outlet 712 of the pressurized material feed tank 710 and upstream of the nozzle 755, for controlling the flow of particulate material (PM) exiting through the nozzle 755.
FIG. 21 provides a schematic diagram of another exemplary embodiment of a filling apparatus 800 which includes a material feed tank 810 and a conduit 854 for delivering particulate material (PM) to one or more containers, such as tapered cones (not shown in FIG. 21). Like the embodiment shown in FIG. 18 and described above, the filling apparatus 800 of FIG. 21 uses gravity and flowing or compressed gas for moving particulate material (PM) from the outlet 812 of the tank 810, through the conduit 854 to a nozzle 855, but also includes a trigger valve 843 for increased control of the flow rate through the nozzle 855. Containers, such as tapered cones (not shown), may be moved relative to the nozzle 855 for each cone to receive a controlled, consistent and metered quantity of particulate material (PM).
In the embodiment of FIG. 21, the compressed or flowing gas increases the flow rate of particulate material (PM) through the conduit 854 and into containers, such as tapered cones (not shown), greater than the flow rate provided by gravity alone and enhances packing of the particulate material (PM) in each container (cone). The outlet of the conduit 854 may be provided with a nozzle 855 for additional control of the flow of particulate material (PM) from the conduit 854 to each tapered cone 20.
FIG. 22 provides a schematic diagram of another alternative filling apparatus 900 which includes a material feed tank 910 having an outlet 912, and conduit 954 through which a flowing or compressed gas stream flows in the direction of the arrows F in FIG. 22. The flowing or compressed gas in the conduit 954 creates a siphon which moves the particulate material (PM) from the tank 810, in the direction of the arrows S, through the conduit 954 and through the nozzle 955. The particulate material (PM) exits the nozzle 955 and fills one or more containers, such as tapered cones (not shown) which may be moved relative to the nozzle 955 for each to receive particulate material (PM).
Many modifications and other embodiments of the invention described and contemplated herein will be apparent to persons of ordinary skill in the relevant art, in addition to those already mentioned above. All such modification and alternative embodiments are intended to be within the scope of the invention described and contemplated herein. Accordingly, the invention is not limited to the modifications or alternative embodiments described and suggested hereinabove.
Patent Application
20240351715
