MOLD FOR FORMING AN INHALATION DEVICE

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

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STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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TECHNICAL FIELD

The present invention relates to inhalation devices and in particular to a mold for forming an inhalation device and method for using the mold to form an inhalation device.

BACKGROUND

Having an inhalation device can make traveling more complicated and difficult than it already is. It is often challenging and unwieldy to carry an inhalation device, such as a pipe, while traveling given the number of other articles that a user may already be carrying. Also, in air travel, an inhalation device may be closely scrutinized by security and may be taken away by security leaving the user without an inhalation device.

Some people also want to be discrete in the office, at home, and in other public places. These users may find it difficult to have an inhalation device in a pocket, purse, or other bag without being discovered by others in the vicinity.

Users of inhalation devices that can be reused may inadvertently leave burning embers or other combustible residue inside the inhalation device. The inhalation device may be placed in a pocket, purse, or other bag or disposed of on the ground with a burning ember or other combustible residue. This can be dangerous for the person that has the inhalation device as well as the surrounding area. Especially in dry climates that are particularly susceptible to fires, this can present a fire hazard.

SUMMARY

Individuals use various tools for forming hollow articles with predetermined patterns or designs, including those to create different types of inhalation devices. The tools that are used for forming the hollow articles are often large, cumbersome, and difficult to work with. This makes it challenging for the user to quickly and efficiently form an inhalation device that is inexpensive to create, portable, and disposable. The teaching of the invention solves at least one of the problems associated with existing tools for forming hollow articles that may be used as inhalation devices to support the inhalation of smoke from burning organic materials.

In one embodiment, a mold for forming an inhalation device includes a form including a body having a first end and a second end opposite the first end. The body defines a channel and a longitudinal axis extending between the first end and the second end, in which the first end defines a first diameter and the second end defines a second diameter larger than the first diameter. The body tapers in diameter from the second end to the first end along the longitudinal axis. A mandrel is sized to at least partially fit within the channel to define a gap therebetween, the gap being sized to receive a malleable material.

In another embodiment, a mold for forming an inhalation device includes a mandrel. The mandrel includes a barrel form with a first end and a second end opposite the first end. The mandrel defines a longitudinal axis extending from the first end to the second end. A grasping element may be disposed at the first end and have a diameter. A coupling element may be disposed a distance from the grasping element at the first end, the coupling element may include a diameter smaller than the diameter of the grasping element. A shoulder extends away from the coupling element toward the second end, and the second end defines a distal most portion defining a planar distal most end. A form has a body that defines a channel. The channel has a plurality of different diameters and is sized to receive the barrel form of the mandrel. The form has a first end and a second end opposite the first end. The first end has a first aperture and the second end has a second aperture, the second aperture is sized to receive the barrel form of the mandrel and is larger than the first aperture. The first aperture is sized to receive a portion of the barrel form. The body of the form defines a longitudinal axis that extends between the first end and the second end. The first end defines a first diameter and the second end defines a second diameter larger than the first diameter. The body tapers in diameter from the second end to the first end along the longitudinal axis. The mandrel is sized to at least partially fit within the channel of the form. When the mandrel is received within the channel of the form, the form and the mandrel define a gap there between. The gap is sized to receive a malleable material.

In yet another embodiment, a method of forming an inhalation device, includes the steps of wrapping at least a portion of a mandrel with a malleable material. The mandrel wrapped with the malleable material is inserted into a form to form the inhalation device. The form has a channel sized and configured to receive the mandrel wrapped with the malleable material and defines a gap when the mandrel is received in the channel of the form wrapped with a malleable material. The form is removed from the mandrel and the inhalation device is removed from the form. The inhalation device has a channel, a first end and a second end, each of the first and second ends are open and the first end has a smaller diameter than the second end.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:

FIG. 1 is a perspective view of a form and a mandrel constructed in accordance with the principles of the present disclosure;

FIG. 2 is a perspective view of the second end of the form in accordance with the principles of the present disclosure;

FIG. 3 is a perspective view of the first end of the form in accordance with the principles of the present disclosure;

FIG. 4 is an overhead view of the first end of the form and the second end of the mandrel in accordance with the principles of the present disclosure;

FIG. 5 is a top view of the first end of the form and the second end of the mandrel with the mandrel received within the form in accordance with the principles of the present disclosure;

FIG. 6 is a view of the mandrel at least partially disposed within the channel of the form in accordance with the principles of the present disclosure;

FIG. 7 is a view of the mandrel with a malleable material partially wrapped around the mandrel in accordance with the principles of the present disclosure;

FIG. 8 is a perspective view of the inhalation device made from a malleable material after being shaped by the mandrel and the form in accordance with the principles of the present disclosure;

FIG. 9 is a top view of the first end of the inhalation device in accordance with the principles of the present disclosure; and

FIG. 10 is a flow chart of an exemplary method of forming an inhalation device.

DETAILED DESCRIPTION

As used herein, relational terms, such as “first” and “second,” “over” and “under,” “front” and “rear,” “in, within, and around” and the like, may be used solely to distinguish one entity or element from another entity or element without necessarily requiring or implying any physical or logical relationship or order between such entities or elements.

Referring now to the drawings in which like reference designators refer to like elements, there is shown in FIG. 1 an exemplary mold for forming an inhalation device constructed in accordance with the principles of the present invention and designated generally as “10.” The mold 10 may include a form 12 and a mandrel 14. The mandrel 14 may be at least partially disposed or removably insertable within a portion of the form 12 when using the mold 10 to create an inhalation device. The sizes, shapes, and dimensions of the mold 10 may be customized to create different sized and shaped inhalation devices. An inhalation device can be used to deliver an organic material into the body via the lungs. A user can inhale smoke from the inhalation device derived from the burning of an organic material.

The form 12 includes a body 16 which may vary in size and shape. In one embodiment, the body 16 may have a frustoconical shape with a length between approximately 25.4 millimeters and 304.8 millimeters depending upon the size of the inhalation device that is being created using the mold 10. The body 16 has a first end 18 and a second end 20 opposite the first end 18. The first end 18 of the form 12 may define a first diameter 22 and the second end 20 of the form 12 may define a second diameter 24. As a non-limiting example, the second diameter 24 may be larger than the first diameter 22. For example, the second diameter 24 may be between 2.4-22.8 millimetersand the first diameter 22 may be between 2.4-15.24 millimeters. In an alternate embodiment, the second diameter 24 may be smaller than the first diameter 22 or the second diameter 24 may the same diameter as the first diameter 22. The parameters of the first diameter 22 and/or the second diameter 24 may depend upon the dimensions of the mandrel 14.

A longitudinal axis 26 extends between the first end 18 and the second end 20 of the form 12 passing through the center of diameters 22 and 24. In one embodiment, the longitudinal axis 26 may be between 25.4-152.4 millimeters in length. Along the longitudinal axis 26 of the body 16 of the form 12, the body 16 may taper in diameter from the second end 20 to the first end 18. This tapering may be gradual from the second end 20 to the first end 18 or it may occur in steps where the tapering is pronounced at each step. In an alternative embodiment, the body 16 may taper and become thinner from the first end 18 to the second end 20.

A channel 28, which is described in more detail below with respect to FIG. 2, may be defined within the body 16 of the form 12. The channel 28 may be a tubular enclosed passage within the form 12 and may have different dimensions depending upon the size and shape of the mandrel 14 which is sized to at least partially fit within the channel 28 of the form 12. The channel 28 of the form 12 may have a plurality of different diameters and may taper in diameter from the second end 20 to the first end 18.

The mandrel 14 includes a first end 30 and a second end 32 opposite the first end 30. The second end 32 may be sized to at least partially fit within the channel 28 of the form 12. In one embodiment, the first end 30 may have a larger diameter than the second end 32 and be too large to fit within the channel 28 while the second end 32 may have a smaller diameter than the channel 28 and be sized to fit within channel 28. In an alternate embodiment, the diameter of the first end 30 and the second end 32 may be smaller than the diameter of the channel 28 such that the first end 30 and the second end 32 may be sized to be received within the channel 28.

A barrel form 34 may also be a part of the mandrel 14 with a first end 36 and a second end 38 opposite the first end. A longitudinal axis 40 is defined by the barrel form 34 and extends from the first end 36 to the second end 38 of the barrel form 34. The barrel form 34 may taper in diameter along the longitudinal axis 40 from the first end 36 to the second end 38. In an alternate embodiment, the diameter may remain the same along the longitudinal axis 40. When the mandrel 14 is within the channel 28 of the form 12, the longitudinal axis 40 of the barrel form 34 is aligned with the longitudinal axis 26 of the body 16 of the form 12.

Disposed at the second end 38, may be a shoulder 42 with a first end 44 and a second end 46 opposite the first end 44. The size of the shoulder 42 will correlate with the size of a feature on the inhalation device such as secondary bowl 82 (as shown in more detail in FIGS. 8 and 9). The shoulder 42 may be disposed at the second end 38 of the barrel form 34 and may be variable shapes and sizes and sized to be received within the channel 28. In one embodiment, the shoulder 42 may have a larger diameter than the barrel form 34 and taper in diameter from the second end 46 to the first end 44. The shoulder 42 may be sized to be removably coupled with the channel 28. In an alternate embodiment, the shoulder 42 may taper in diameter from the first end 44 to the second end 46 or it may have the same diameter throughout and not be tapered.

The mandrel 14 has a distal end 48 and the distal end 48 may have a planar surface which can be used to puncture through material used with the mold 10. In an alternative embodiment, the distal end 48 may have a rounded shape, a concave shape, or have a point that can facilitate the puncturing of the formed material.

The mandrel 14 may have a first portion 50 and a second portion 52 and the distal end 48 of the mandrel 14 may be a part of a first portion 50 and the shoulder 42 may be a part of the second portion 52. The diameter d1 of the second portion 52 may be larger than the diameter d2 of the first portion 50. The first portion 50, which may include the barrel form 34 and the shoulder 42, may be sized to be received within the channel 28 of the form 12. In one embodiment, the first portion 50 may be longer than the second portion 52.

The second portion 52 of the mandrel 14 may include a grasping element 54. The grasping element 54 can be placed in a user's hand and used to move the first portion 50 of the mandrel 14 at least partially within the channel 28 of the form 12. The grasping element 54 may be circular, square, or rectangle shaped. In one embodiment, the first end 30 of the mandrel 14 may be surrounded by the grasping element 54, and the grasping element 54 on the mandrel 14 may have a larger diameter d3 than the second diameter 24 of the channel 28 of the form 12. The surface of the grasping element 54 may be smooth or textured to make it easier to grasp. In one embodiment, the grasping element 54 may engage the second end 20 of the form 12 when the mandrel 14 is received within the channel 28.

The mandrel 14 may include a coupling element 56 which is configured to matably couple with a portion of the form 12 and is disposed a distance from the grasping element 54 at the first end 30 of the mandrel 14. The shoulder 42 may extend away from the coupling element 56 toward the second end 32, the second end 32 defining a distal most portion defining a planar distal most end 48. The coupling element 56 may be a flange or a collar that surrounds at least a portion of the mandrel 14 and has a wider circumference than the first portion 50 of the mandrel 14. In one embodiment, the coupling element 56 may be disposed a distance from the grasping element 54 and a diameter d4 of the coupling element 56 may be smaller than the diameter d3 of the grasping element 54. The different parts that make up the mandrel 14 and the form 12 may be multiple pieces affixed together or may be all integrated in one piece.

Now referring to FIG. 2, the channel 28 of the form 12 may define a plurality of different diameters which are sized to receive the barrel form 34 of the mandrel 14. In one embodiment, there are three different annular rings 58a, 58b, and 58c with annular ring 58a having diameter d5, annular ring 58b having diameter d6, and ring 58c having diameter d7. Each of these diameters d5-d7 may be different or the same. The annular rings 58a-58c are sized to create a specific feature of the inhalation device. As discussed in more detail below with respect to FIG. 8, in one embodiment, the annual ring 58a creates the opening of a primary bowl 80, the annular ring 58b creates the transition of the primary bowl 80 to the secondary bowl 82, and the annular ring 58c creates the transition from the secondary bowl 82 to the elongate body 34. In one embodiment, these diameters d5, d6, and d7 may taper along the longitudinal axis 26 of the channel 28 of the form 12. In an alternative embodiment, the channel 28 of the form 12 may have one annular ring 58a, two annual rings 58a, 58b, or more than three annual rings 58. The diameter of each of the annular rings 58a, 58b, 58c may be uniform in the channel 28 or may have variable sizes within the channel 28 and the annular rings 58a, 58b, 58c may be disposed at various locations in the channel 28.

The channel 28 of the form 12 may define a receiving element 60. When the form 12 is at least partially received within the mandrel 14, the receiving element 60 may be disposed a distance from the grasping element 54 at the first end 30. The receiving element 60 may be annular in shape or may be shaped to be coupled with a portion of the mandrel 14. In one embodiment, the receiving element 60 may be configured to mateably couple with the coupling element 56 of the mandrel 14. The receiving element 60 may also be disposed in various locations within the channel 28.

A second aperture 62 may be disposed at the second end 20 of the body 16 of the form 12. The size of the second aperture 62 may depend upon the size of various portions of the mandrel 14. For example, in one embodiment, the second aperture 62 may be smaller than the grasping element 54 so the grasping element 54 does not fit within the channel 28. In an alternative embodiment, the second aperture 62 may be larger than the grasping element 54 so the grasping element 54 can fit within the channel 28. The second aperture 62 may be sized to receive the barrel form 34 of the mandrel 14.

Now referring to FIG. 3, the first end 18 of the form 12 may have a first aperture 64. The first aperture 64 may be sized to receive a portion of the mandrel 14, which includes the barrel form 34. The first aperture 64 and the second aperture 62 may each have different sizes. In one embodiment, the first aperture 64 may be smaller in size than the second aperture 62. Alternatively, the first aperture 64 may be larger than the second aperture 62 or the first aperture 64 may be the same size as the second aperture 62.

As shown in FIG. 4, the distal end 48 of the mandrel 14 may be sized to be received within the second aperture 62 of the form 12. The distal end 48 may be entirely received within the second aperture 62 or only a portion of the distal end 48 may be received within the first aperture 64. Now referring to FIG. 5, the distal end 48 of the mandrel 14 is shown received within the first aperture 64. The first aperture 64 may be sized to receive a portion of the mandrel 14, including a portion of the barrel form 34.

As shown in FIG. 6, at least a portion of the mandrel 14 may be sized to fit within the channel 28 of the form 12. When the mandrel 14 is received within the channel 28 of the form 12, there may be a gap 66 there between. The gap 66 may be sized to accommodate different sized material depending upon what is being used with the mold 10 and therefore the gap 66 may have variable sizes.

As shown in FIG. 7, the mandrel 14 may be wrapped with the malleable material 68 and then the wrapped mandrel 14 may be received within the channel 28 of the form 12. The malleable material 68 may be a material which can deform under compression into a different form. As a non-limiting example, the malleable material 68 may be a metal including gold, silver, iron, aluminum, copper, tin, or a plastic that is deformable. The materials can be initially manufactured as a malleable foil which can be folded and transported along with the mold 10. As seen in FIGS. 6 and 7, the gap 66 between the mandrel 14 and the form 12 within the channel 28 is sized to receive the malleable material 68 and an amount of pressure may be applied to the mandrel 14 during insertion into the form 12 so that the malleable material 68 is deformed into an inhalation device 70 (as shown in FIGS. 8 and 9). In one embodiment, the mandrel 14 is inserted into the form 12 using a twisting motion to allow the malleable material to wrap and form around the mandrel 14. Once the inhalation device 70 is formed, the mandrel 14 may be removed from the channel 28 of the form 12. In some embodiments, the distal end 48 of the mandrel 14 may be used to puncture a portion of the inhalation device 70. As a non-limiting example, the distal end 48 of the mandrel 14 may be sized to fit within the first aperture 64 of the form 12 such that the distal end 48 may be flush with the first aperture 64 or alternatively the distal end 48 may protrude from the first aperture 64 of the form 12 when the mandrel 14 is inserted within the form 12. When the malleable material 68 is wrapped around the mandrel 14 and the mandrel 14 is placed within the channel 28 of the form 12, the distal end 48 of the mandrel 14 may puncture any malleable material 68 covering the distal end 48, thereby creating an opening in the inhalation device 70. This opening may be used to provide an inhalation point, i.e., interface, for a user of the inhalation device 70.

At least a portion of the form 12 and the mandrel 14 may be rigid. For example, the form 12 and the mandrel 14 may be made from a thermoplastic including, but not limited to acrylonitrile butadiene styrene, polyethylene, polyamide, high impact polystyrene, and polypropylene. Alternatively, the form 12 and the mandrel 14 may be made from a metal including but not limited to stainless steel, a cobalt-based alloy, a titanium based alloy, and tantalum and composites. The materials that are used in the form 12 and the mandrel 14 are selected to withstand the pressure that is applied to each component when forming the malleable material 68 into an inhalation device 70.

Now referring to FIG. 8, in one embodiment the inhalation device 70 may have a generally frustoconical shape. As a non-limiting example, the inhalation device 70 may have a first end 72, a second end 74, and a longitudinal axis 76. The second end 74 may be sized to receive materials that are to be used in to inhalation device including medications, tobacco, and other organic materials so that they can be smoked using the inhalation device. The first end 72 is sized to fit within the mouth so it can be used to inhale any material placed within the second end 74. In one embodiment, the first end 72 may have a smaller diameter than the second end 74 and both the first end 72 and the second end 74 may be disposed along the longitudinal axis 76 which passes through the center of the diameters of the second end 74 and the first end 72. The first end 72 may be open to allow air to flow from the second end 74 to the first end 72.

The inhalation device 70 may further include a primary bowl 80 and a secondary bowl 82. Annular ring 58a may create the opening in the primary bowl 80, annular ring 58b may create the transition from the primary bowl 80 to the secondary bowl, and annular ring 58c may create the transition from the secondary bowl 82 to the elongate body 34. The primary bowl 80 and the secondary bowl 82 may be beneficial to assist with cooling as a user uses the inhalation device 70. As a non-limiting example, the primary bowl 80 may be packed with medication, tobacco, or another organic material and then the medication, tobacco, or organic material may be lit using a match or lighter. A user may inhale air from the first end 72 so that air is moved from the second end 74 to the first end 72. When air is inhaled it first moves through the primary bowl 80 and then moves to the secondary bowl 82. When the air moves from the primary bowl 80 to the secondary bowl 82, the secondary bowl 82 may be used to help cool the air before it moves through the remainder of the inhalation device 70 before it reaches the mouth of the user. Another benefit of the dual bowls is to catch any residual material from the primary bowl 80 in the secondary bowl 82. As a non-limiting example, when medication, tobacco, or another organic material is placed in the primary bowl 80 and then lit, the amount of medication, tobacco, or organic material will lessen in the primary bowl 80. The secondary bowl 82 may be used to catch any residual tobacco, medication, or other organic material so that it does not pass into the mouth of the user in the first end 72. In alternative embodiments, there may be a single bowl or more than two bowls to help with the cooling processes and also to catch additional material.

Now referring to FIG. 9, the inhalation device 70 may have a channel 78 which extends along the longitudinal axis 76 from the first end 72 to the second end 74. In one embodiment, the first end 72 may have a smaller diameter than the second end 74 and the first end 72 and the second end 74 may be hollow. In alternative embodiments, the first end 72 and the second end 74 may have different diameters or the same diameters and be partially open or closed. A method for forming an inhalation device is described with reference to FIG. 10. At block S100, at least a portion of a mandrel 14 may be wrapped with a malleable material 68. The mandrel 14 wrapped with the malleable material 68 may be inserted into a form 12 to form an inhalation device 70 (block S102), the form 12 having a channel 28 sized and configured to receive the mandrel 14 wrapped with the malleable material 68 and defining a gap 66 when the mandrel 14 is received in the channel 28 of the form 12 wrapped with a malleable material 68. The form 12 may be removed from the mandrel 14 and the inhalation device 70 may be removed from the form 12 (block S104). The inhalation device 70 has a channel 78, a first end 72 and a second end 74, each of the first end 72 and the second end 74 being open, the first end 72 having a smaller diameter than the second end 74.

It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention, which is limited only by the following claims.

Claims

1. A mold for forming an inhalation device comprising: a form including a body having a first end and a second end opposite the first end, the body defining a channel and a longitudinal axis extending between the first end and the second end, the first end defining a first diameter and the second end defining a second diameter larger than the first diameter, the body tapering in diameter from the second end to the first end along the longitudinal axis; anda mandrel sized to at least partially fit within the channel to define a gap therebetween, the gap being sized to receive a malleable material.
2. The mold of claim 1, wherein the mandrel includes a first end and a second end opposite the first end, the first end including a grasping element.
3. The mold of claim 2, wherein the grasping element engages the second end of the form when the mandrel is received within the channel.
4. The mold of claim 2, wherein the grasping element defines a diameter larger than the channel of the form.
5. The mold of claim 2, wherein the mandrel includes a coupling element configured to matably couple with a portion of the form and disposed a distance from the grasping element at the first end.
6. The mold of claim 5, wherein the form includes a receiving element configured to matably couple with the mandrel coupling element.
7. The mold of claim 1, wherein the mandrel includes a barrel form having a first end, a second end opposite the first end, and a longitudinal axis extending from the first end to the second end, the barrel form tapering in diameter along the longitudinal axis.
8. The mold of claim 7, wherein the longitudinal axis of the body of the form and the longitudinal axis of the barrel form of the mandrel are aligned when the mandrel is within the channel of the form.
9. The mold of claim 7, wherein the barrel form includes a shoulder at the second end, the shoulder sized to be removably coupled within the channel.
10. The mold of claim 1, wherein the first end of the mandrel defines a planar distal most end.
11. The mold of claim 1, wherein the first end of the form has a first aperture and the second end of the form has a second aperture.
12. The mold of claim 11, wherein the first aperture is sized to receive a portion of the mandrel.
13. The mold of claim 12, wherein the second aperture is larger than the first aperture.
14. The mold of claim 1, wherein the mandrel has a first portion and a second portion, the diameter of the second portion is larger than the diameter of the first portion, and the channel is sized to receive the first portion.
15. The mold of claim 14, wherein the first portion is longer than the second portion.
16. The mold of claim 1, wherein at least a portion of the mandrel and the form are rigid.
17. The mold of claim 1, wherein the channel of the form has a plurality of different diameters.
18. The mold of claim 1, wherein the channel of the form has at least three annular rings, each of the annular rings has a different diameter and each of the diameters is tapered along the longitudinal axis of the channel.
19. A mold for forming an inhalation device comprising: a mandrel including a barrel form having a first end and a second end opposite the first end, the mandrel defining a longitudinal axis extending from the first end to the second end;a grasping element at the first end and having a diameter;a coupling element disposed a distance from the grasping element at the first end, the coupling element including a diameter smaller than the diameter of the grasping element;a shoulder extending away from the coupling element toward the second end, the second end defining a distal most portion defining a planar distal most end;a form having a body and defining a channel, the channel having a plurality of different diameters and sized to receive the barrel form of the mandrel, the form having a first end and a second end opposite the first end, the first end having a first aperture and the second end having a second aperture, the second aperture sized to receive the barrel form of the mandrel and being larger than the first aperture, the first aperture sized to receive a portion of the barrel form;the body of the form defining a longitudinal axis extending between the first end and the second end, the first end defining a first diameter and the second end defining a second diameter larger than the first diameter, the body tapering in diameter from the second end to the first end along the longitudinal axis; andthe mandrel sized to at least partially fit within the channel of the form, when the mandrel is received within the channel of the form, the form and the mandrel define a gap there between, the gap being sized to receive a malleable material.
20. A method of forming an inhalation device, comprising: wrapping at least a portion of a mandrel with a malleable material;inserting the mandrel wrapped with the malleable material into a form to form the inhalation device, the form having a channel sized and configured to receive the mandrel wrapped with the malleable material and defining a gap when the mandrel is received in the channel of the form wrapped with a malleable material; andremoving the form from the mandrel and removing the inhalation device from the form, the inhalation device having a channel, a first end and a second end, each of the first and second ends being open, the first end having a smaller diameter than the second end.

MOLD FOR FORMING AN INHALATION DEVICE

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