SMOKABLE PAPER CONE CLOSING SYSTEM AND RELATED METHODS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to the provisional patent application identified by U.S. Ser. No. 63/680,763, filed Aug. 8, 2024, titled “SMOKABLE PAPER CONE CLOSING SYSTEM AND RELATED METHODS,” the entire contents of which is hereby expressly incorporated herein by reference.

BACKGROUND

In recent years, the cannabis industry has seen a significant rise in the popularity of pre-rolled cannabis products, particularly pre-rolled cones filled with ground cannabis flower. Despite the high demand for pre-rolls, the current methods of manufacturing these products are largely manual and labor-intensive. Conventional production processes often require manual loading, filling, packing, crimping, and sealing of individual pre-formed cones. Current commercial practices for manufacturing pre-rolled cones predominantly rely on manual labor for the critical steps of filling, packing, crimping, and sealing. Workers typically use simple tools such as funnels, tamping rods, and basic vibration devices to fill pre-formed cones with measured quantities of ground cannabis material. The filled tubes are then often manually packed, crimped, and sealed. These processes, while effective at small scales, exhibit several deficiencies when scaled to meet commercial demand. Manual crimping and sealing processes are inherently inconsistent, resulting in poorly formed or insecure closures, diminishing product quality and shelf stability. To address these shortcomings, operators have increasingly sought semi- or fully automated systems capable of consistently and efficiently producing pre-rolled cones at commercial scale. Specifically, there is a need for systems capable of uniformly applying controlled force to form consistent crimps at the open ends of pre-rolled cones, and securely sealing the cones in a reliable, repeatable manner. Ideally, such systems would be compatible with cones of varying sizes, materials, scalable to different production volumes, and designed to integrate with existing filling equipment or downstream packaging stations.

Such systems must be capable of performing a variety of coordinated tasks, including accurate dosing of material into pre-formed blunt tubes, uniform application of packing force to ensure consistent draw resistance, and smooth handling of tubes before and after filling. Additionally, a need exists for systems that are compatible with blunt tubes of varying dimensions and materials, are design to comply with applicable industry regulations, and are capable of integration with additional downstream equipment for further processing or packaging.

Accordingly, there exists a need for an automated system and method capable of simultaneously crimping, sealing, and ejecting multiple pre-formed cannabis cones in a consistent and efficient manner. It is to such systems and methods that the presently disclosed inventive concepts are directed.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more implementations described herein and, together with the description, explain these implementations. The drawings are not intended to be drawn to scale, and certain features and certain views of the figures may be shown exaggerated, to scale or in schematic in the interest of clarity and conciseness. Not every component may be labeled in every drawing. Like reference numerals in the figures may represent and refer to the same or similar element or function. In the drawings:

FIG. 1A is a front view of an exemplary embodiment of a system for simultaneously crimping, sealing, and ejecting a plurality of pre-formed cones in accordance with the present disclosure.

FIG. 1B is an isometric view of the exemplary embodiment of FIG. 1A.

FIG. 2A is an isometric view of an exemplary embodiment of a pressing assembly of the system for simultaneously packing a plurality of pre-formed tubes.

FIG. 2B is a bottom view of the exemplary embodiment of FIG. 2A.

FIG. 2C is a side view of the exemplary embodiment of FIG. 2A.

FIG. 3A is a front view of an exemplary embodiment of a crimping assembly of the system for simultaneously packing a plurality of pre-formed tubes.

FIG. 3B is a top isometric view of the exemplary embodiment of FIG. 3A.

FIG. 3C is a bottom view of the exemplary embodiment of FIG. 3A in a disengaged position.

FIG. 3D is a bottom isometric view of the exemplary embodiment of FIG. 3A in a disengaged position.

FIG. 4A is a bottom view of the exemplary embodiment of FIG. 3A in an engaged position.

FIG. 4B is a bottom isometric view of the exemplary embodiment of FIG. 3A in an engaged position.

FIG. 5A is an isometric view of an exemplary embodiment of a modular carrier plate of the system for simultaneously packing a plurality of pre-formed tubes.

FIG. 5B is a bottom view of the exemplary embodiment of FIG. 5A.

FIG. 5C is a transparent isometric view of the exemplary embodiment of FIG. 5A.

FIG. 6A is a side view of the exemplary embodiment of FIG. 5A in a loaded state.

FIG. 6B is an isometric view of the exemplary embodiment of FIG. 6A.

FIG. 7-10 illustrates various steps of an exemplary method of simultaneously crimping, sealing, and ejecting a plurality of pre-formed cones, according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

Before explaining at least one embodiment of the inventive concept disclosed herein in detail, it is to be understood that the inventive concept is not limited in its application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. The inventive concept disclosed herein is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting in any way.

In the following detailed description of embodiments of the inventive concept, numerous specific details are set forth in order to provide a more thorough understanding of the inventive concept. It will be apparent to one of ordinary skill in the art, however, that the inventive concept within the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the instant disclosure.

As used herein, the term “cone,” “cones,” “prerolls,” “preroll cone(s),” “pre-formed cones(s),” or any variation thereof, are intended to broadly encompass any hollow, elongate container or structure including, but not limited to, conical shapes, adapted to hold, contain, or dispense a variety of loose or particulate materials, such as, for example, herbs, cannabis, granules, or similar substances.

As used in the description herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” or any other variations thereof, are intended to cover a non-exclusive inclusion. For example, unless otherwise noted, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may also include other elements not expressly listed or inherent to such process, method, article, or apparatus.

Further, unless expressly stated to the contrary, “or” refers to an inclusive and not to an exclusive “or”. For example, a condition A or B is satisfied by one of the following: A is true (or present), and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

In addition, use of the “a” or “an” are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of the inventive concept. This description should be read to include one or more, and the singular also includes the plural unless it is obvious that it is meant otherwise. Further, use of the term “plurality” is meant to convey “more than one” unless expressly stated to the contrary.

As used herein, qualifiers like “substantially,” “about,” “approximately,” and combinations and variations thereof, are intended to include not only the exact amount or value that they qualify, but also some slight deviations therefrom, which may be due to computing tolerances, computing error, manufacturing tolerances, measurement error, wear and tear, stresses exerted on various parts, and combinations thereof, for example.

As used herein, any reference to “one embodiment,” “an embodiment,” “some embodiments,” “one example,” “for example,” or “an example” means that a particular element, feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment and may be used in conjunction with other embodiments. The appearance of the phrase “in some embodiments” or “one example” in various places in the specification is not necessarily all referring to the same embodiment, for example.

The use of ordinal number terminology (i.e., “first”, “second”, “third”, “fourth”, etc.) is solely for the purpose of differentiating between two or more items and, unless explicitly stated otherwise, is not meant to imply any sequence or order or importance to one item over another or any order of addition.

Finally, the use of the term “at least one” or “one or more” will be understood to include one as well as any quantity more than one. In addition, the use of the phrase “at least one of X, V, and Z” will be understood to include X alone, V alone, and Z alone, as well as any combination of X, V, and Z.

As discussed above, there exists a need for an automated system and method capable of simultaneously crimping and sealing multiple pre-formed cannabis cones in a consistent and efficient manner.

Referring now to the drawings, FIGS. 1A and 1B, shown therein are front and isometric views, respectively, of an exemplary embodiment of a pre-formed cone closing system 10 in its assembled configuration according to the instant disclosure.

The pre-formed cone closing system 10 comprises a top plate 14, one or more carrier support members 18, one or more linear guides 22, at least one pressing actuator 26, and a plurality of crimping actuators. The system further comprises a pressing assembly 30, a crimping assembly 40, and a modular carrier plate 60.

The top plate 14 defines a substantially planar body having an upper surface 15 and a lower surface 16. Similarly, the one or more carrier support members 18 includes an upper surface 19 and a lower surface 20. The upper surface 19 of the one or more carrier support members 18 is configured to support portions of the modular carrier plate 60, as will be discussed further below. The top plate 14 is superposed above the carrier support members 18, with the lower surface 16 of the top plate 14 facing and aligned parallel to the upper surface 19 of the carrier support members 18.

In certain embodiments, as shown in FIGS. 1A and 1B, the one or more carrier support members 18 are laterally separated by a predetermined distance and extending substantially parallel to one another along a horizontal axis. In such embodiments, the predetermined distance between the laterally separated carrier support members 18 defines a receiving space, which is dimensioned to accommodate the modular carrier plate 60 in a suspended manner, as will be discussed further below. In some embodiments, the carrier support members 18 may further include alignment features configured to facilitate the positioning of the modular carrier plate 60 on at least a portion of the upper surface 19 of the carrier support members 18.

One or more linear guides 22 extends between and connects the top plate 14 and the carrier support members 18. In certain embodiments, as shown in FIGS. 1A and 1B, the linear guides 22 may be secured at one end to the upper surface 19 of the carrier support members 18, while the opposite end is secured to the lower surface 16 of the top plate 14. The linear guides 22 are configured to provide guided, sliding engagement between the top plate 14 and the carrier support members 18, thereby maintain alignment and facilitating translational movement along the longitudinal axes of the linear guides 22. The attachment of the linear guides 22 to the respective surfaces of the top plate 14 and carrier support members 18 may be accomplished by any suitable fastening means, including, but not limited to mechanical fasteners, adhesives, or integral formation. Further, both the pressing assembly 30 and the crimping assembly 40 are slidably mounted to the of linear guides 22.

The one or more linear guides 22 may comprise various structural configurations including, but not limited to, cylindrical rods, linear rails, guide shafts, or any other elongated structural elements capable of supporting, guiding, or otherwise facilitating controlled sliding movement of associated components along the guides'longitudinal axis. In certain embodiments, the linear guides 22 may be configured as precision ground rods having a substantially circular cross-section, while in alternative embodiments, the guides may comprise profiled rails having non-circular cross-sections, such as rectangular, square, or other geometric configurations optimized for specific loading conditions and movement requirements.

Each of the one or more linear guides 22 extends along a predetermined length sufficient to accommodate the desired range of motion between the top plate 14 and the carrier support members 18. The linear guides 22 may be fabricated from materials exhibiting low friction characteristics and high wear resistance, including but not limited to hardened steel, stainless steel, aluminum alloys, or engineered polymers, depending upon the specific application requirements and environmental conditions. The configuration and arrangement of the linear guides 22 establishes a stable support framework, which provides enhanced rigidity against lateral or off-axis forces while maintaining alignment along the intended axis of motion during operational cycles.

The top plate 14 and the carrier support members 18 may be constructed from any suitable material exhibiting sufficient structural rigidity to provide dimensional stability under anticipated operational loads and service conditions, including but not limited to metals, metal alloys, composite materials, or engineered plastics having adequate strength-to-weight ratios for the intended application.

In certain embodiments, at least one pressing actuator 26 is operatively mounted on the upper surface 15 of the top plate 14. The pressing actuator 26 is configured to control the vertical displacement of the pressing assembly 30 relative to the top plate 14 along a predetermined vertical axis defined by the linear guides 22. The pressing actuator 26 may comprise various actuation mechanisms including, but not limited to, a pneumatic cylinder, hydraulic cylinder, electric linear actuator, servo motor with lead screw assembly, ball screw actuator, or any other suitable mechanical, electrical, or fluid-powered mechanism capable of imparting controlled bi-directional motion with predetermined force and speed characteristics tailored to operational requirements.

The vertical displacement capability facilitated by the pressing actuator 26 enables the pressing assembly 30 to move downward toward and upward away from the crimping assembly 40 and the carrier plate 60, thereby enabling precise application and withdrawal of compressive forces as required during operations. The pressing actuator 26 may be secured to the top plate 14 through various mounting configurations including, but not limited to, threaded fasteners, mounting brackets, flanged connections, or integral mounting features formed directly within the top plate structure.

The pressing actuator 26 may be operatively connected to automated control systems, manual control interfaces, or hybrid control arrangements configured to regulate operational parameters including, but not limited to, actuator speed, stroke length, maximum extension distance, applied force magnitude, dwell time at predetermined positions, and cycling frequency.

The system 10 further includes one or more crimping actuators 90 configured to control the vertical displacement of the crimping assembly 40, which is slidably mounted to the linear guides 22. In some embodiments, as shown in FIGS. 1A and 1B, the crimping actuators 90 are operatively mounted to the lower surface 20 of the carrier support members 18. In such embodiments, the crimping actuators 90 are configured to control the vertical displacement of the crimping assembly 40 relative to the carrier support members 18 along a predetermined vertical axis defined by the linear guides 22.

The one or more crimping actuators 90 are configured to enable precise, controlled movement of the crimping assembly 40 to perform crimping operations on a plurality of pre-formed cones 80 (as shown and described below with reference to FIGS. 6A and 6B) or similar articles.

The one or more crimping actuators 90 may comprise various actuation mechanisms including, but not limited to, a pneumatic cylinder, hydraulic cylinder, electric linear actuator, servo motor with lead screw assembly, ball screw actuator, or any other suitable mechanical, electrical, or fluid-powered mechanism capable of imparting controlled bi-directional vertical motion with predetermined force and speed characteristics tailored to operational requirements.

The vertical displacement capability facilitated by the crimping actuators 90 enables the crimping assembly 40 to move downward toward and upward away from the carrier plate 60. This enables effective engagement with the pre-formed cones 80 for crimping and subsequent release after the operation. The crimping actuators 90 may be secured to the carrier support members 18 through various mounting configurations including, but not limited to, threaded fasteners, mounting brackets, flanged connections, or integral mounting features formed directly within the carrier support member structure.

Furthermore, in some embodiments, as shown in FIGS. 1A and 1B, the crimping actuators 90 are arranged in pairs or multiples to provide balanced and synchronized vertical force distribution to the crimping assembly 40, thereby reducing uneven loading and enhancing the accuracy and repeatability of the crimping process.

The crimping actuators 90 may be operatively connected to automated control systems, manual control interfaces, or hybrid control arrangements configured to regulate operational parameters including, but not limited to, actuator speed, stroke length, maximum extension distance, applied force magnitude, dwell time at predetermined positions, and cycling frequency.

Referring now to FIGS. 2A-2C, shown therein is isometric, bottom, and side views, respectively, of the pressing assembly 30 of an exemplary embodiment of the pre-formed cone closing system 10 according to the instant disclosure. The pressing assembly 30 is slidably mounted to the one or more linear guides 22 and is configured to translate the downward actuation of the at least one pressing actuator 26 into simultaneous pressing action on multiple pre-formed cones 80.

The pressing assembly 30 comprises a pressing plate 32, which is configured to be operatively coupled with the pressing actuator 26, and a plurality of pressing rods 35 extending away from the pressing plate 32. The pressing plate 32 defines a substantially planar body having an upper surface 32a and a lower surface 32b, as shown in FIG. 2C. In a retracted state, the pressing plate 32 is positioned such that its upper surface 32a is proximate to the lower surface 16 of the top plate 14.

In some embodiments, the upper surface 32a of the pressing plate 32 is configured to operatively engage with the pressing actuator 26 through direct mechanical coupling, such that actuation forces generated by the pressing actuator 26 are transmitted uniformly from the pressing actuator 26 to the pressing plate 32 during operation. This engagement may be achieved through various coupling mechanisms, including but not limited to threaded connections, bayonet-style attachments, magnetic coupling, or mechanical interlocking features that ensure reliable force transmission while maintaining proper alignment between the pressing actuator 26 and the pressing plate 32.

The lower surface 32b of the pressing plate 32 serves as the primary mounting interface for the plurality of pressing rods 35 that extend away from the lower surface 32b of the pressing plate 32 in a generally perpendicular orientation relative to the plane of the pressing plate 32. The plurality of pressing rods 35 are arranged in a predetermined geometric pattern on the lower surface 32b of the pressing plate 32, with spacing, size, and orientation selected to correspond to the layout of the plurality of pre-formed cones 80 positioned in the modular carrier plate 60, as will be discussed below. The plurality of pressing rods 35 may vary in length and diameter according to the specific pressing requirements and geometric constraints of the plurality of pre-formed cones 80. In some embodiments, the pressing rods 35 are uniformly sized with consistent diameter and length dimensions and are evenly spaced across the lower surface 32b to apply balanced pressure across all pre-formed cones 80 simultaneously. Each of the plurality of pressing rods 35 may be sized and shaped to be received within an internal diameter of a corresponding pre-formed cones 80, while providing a sufficient surface area for applying compression.

In some embodiments, each of the pressing rods 35 terminates at its distal end configured with specific geometric profiles to enhance pressing and/or crimping performance characteristics. The tip geometries may incorporate flat surfaces, rounded profiles, pointed configurations, or complex contoured shapes, with the selection depending upon the desired mechanical interaction with the pre-formed cones. Certain tips may be, for example, selected to facilitate crimping of pre-formed cones 80, incorporating features such as inwardly tapered profiles, concave depressions, circumferential ridges or ribbed surfaces designed to conform to the shape of the pre-formed cones 80 and apply localized deformation forces to securing the internal contents and/or modify the pre-formed cone 80 opening geometry.

The pressing rods 35 may be fabricated from materials selected for durability, compliance, or friction characteristics, including metals, polymeric materials, or composite constructions. Moreover, pressing rods may be removably mounted to or integrally formed with the pressing plate, allowing for modular replacement or customization based on operational needs.

In some embodiments, as shown in FIGS. 2A-2C, the pressing plate 32 may further include one or more linear motion bearings 36 positioned at predetermined locations along the pressing plate 32. Each of the linear motion bearings 36 is configured to cooperatively engage with a corresponding linear guide 22 to facilitate controlled guided linear movement along a vertical axis defined by the linear guides 22. The linear motion bearings 36 are dimensioned and configured to provide a close sliding fit with their respective linear guides 22 and permit free axial movement along the linear guide 22 axis.

The linear motion bearings 36 may be fixedly mounted to the pressing plate 32 through various attachment methods, including threaded fasteners, press-fit installations, adhesive bonding, or integral formation as part of the pressing plate 32.

Referring now to FIGS. 3A-3D, shown therein is front, top isometric, bottom, and bottom isometric views, respectively, of the crimping assembly 40 of an exemplary embodiment of the pre-formed cone closing system 10 according to the instant disclosure. The crimping assembly 40 is configured to cause a crimp to form in the upper unfilled portions of pre-formed cones 80 by facilitating the application of inward folding forces that fold the paper material of the pre-formed cones 80 toward the center of the pre-formed cones 80 to secure the pre-formed cone 80 opening.

The crimping assembly 40 comprises a substantially rigid crimping body 42 configured to be operatively coupled with the one or more crimping actuators 90. The crimping body 42 defines a substantially planar body having an upper surface 42a and a lower surface 42b. The crimping body further includes a plurality of crimping apertures 50 extending through the crimping body 42 from the upper surface 42a to the lower surface 42b. The crimping apertures 50 are arranged in a predetermined geometric pattern that corresponds with the spatial arrangement of the pressing rods 35 and the positional layout of the pre-formed cones 80 retained within the modular carrier plate 60, as will be discussed further below. In some embodiments, the crimping apertures 50 are arranged longitudinally in rows and laterally in columns, forming a grid-like configuration. The arrangement, orientation and dimensions of the crimping apertures 50 are selected to align the crimping apertures 50 with the corresponding features of modular carrier plate 60 retaining the pre-formed cones 80 and the pressing rods 35 of the pressing assembly 32.

The crimping apertures 50 are sized and shaped to accommodate at least the upper unfiled portions of the pre-formed cones 80. Each of the crimping apertures 50 is configured to allow the pre-formed cone's 80 upper rim and adjacent sidewall portions to be inserted and manipulated. In some embodiments, the crimping apertures 50 may feature a tapered internal profile, with the wider portion of the aperture 50 located at the lower surface 42b of the crimping body—the surface facing the pre-formed cones 80—and narrowing towards the upper surface 42a of the crimping body 42. In that embodiment, the tapered configuration may facilitate initial guidance and insertion of the upper unfilled portion of the pre-formed cone 80 into the crimping aperture 50 and promote controlled inward folding and shaping of the paper material as it is crimped.

In various embodiments, an internal surface of the crimping apertures 50 may incorporate specialized surface treatments, textures, or geometric features designed to enhance the crimping process. These may include circumferential grooves or ridges to promote controlled folding patterns, polished surfaces to minimize friction and prevent paper damage, or specific surface coatings to reduce adhesion and facilitate easy release of the crimped products

The crimping body 42 may be fabricated from materials selected for their durability, dimensional stability, and compatibility with the processed materials, including but not limited to machined metals, injection-molded polymers, or composite materials that provide the necessary structural integrity over extended operational periods.

In some embodiments, as shown in FIGS. 3A-3D, the crimping body 42 may further include one or more linear motion bearings 46 positioned at predetermined locations along the crimping body 42. Each of the linear motion bearings 46 is configured to cooperatively engage with a corresponding linear guide 22 to facilitate controlled guided linear movement along a vertical axis defined by the linear guides 22. The linear motion bearings 46 are dimensioned and configured to provide a close sliding fit with their respective linear guides 22 and permit free axial movement along the linear guide 22 axis.

The linear motion bearings 46 may be fixedly mounted to the crimping body 42 through various attachment methods, including threaded fasteners, press-fit installations, adhesive bonding, or integral formation as part of the crimping body 42.

In certain embodiments, as shown in FIGS. 3C-4B, the crimping body 42 may further include a translatable sliding blade array 48 operatively coupled to one or more microactuators 44. Each of the one or more microactuators 44 having an extendable rod 45 that engages a surface of the sliding blade array 48 to impart lateral translation along the lower surface 42b of the crimping body 42. The rods 45 of the microactuators 44 provide controlled actuation force, enabling the sliding blade array 48 to move smoothly between a disengaged position and an engaged position, as will be discussed further below.

The sliding blade array 48 may be positioned on the lower surface 42b of the crimping body 42 in operational proximity to the plurality of crimping apertures 50. In some embodiments, the sliding blade array 48 may comprise a plurality of blades 49, arranged in parallel, that extend longitudinally across the crimping body 42. The plurality of blades 49 may be mechanically interconnected to form a unified structure that moves as a single unit. The sliding blade array 48 is configured to be selectively moved between an engaged position and a disengaged position.

In its disengaged position, as shown in FIGS. 3C and 3D, the microactuators 44 are maintained in their contracted state, and the sliding blade array 48 is positioned such that its blades 49 are disposed exterior to the perimeter boundaries of the crimping apertures 50. This configuration ensures that the blades 49 of the sliding blade array 48 do not occlude or obstruct the crimping apertures 50, allowing, for example, unobstructed passage of the pressing rods 35 through the crimping apertures 50.

FIGS. 4A and 4B depict bottom and bottom isometric views, respectively, of the of the crimping assembly 40 featuring the sliding blade array 48 in an engaged position. In the engaged position, the rods 45 of the microactuators 44 are extended, causing the sliding blade array 48 to be laterally translated across the lower surface 42b of the crimping body 42 into active alignment with each row of the crimping apertures 50. This alignment permits simultaneous engagement of the crimping apertures 50 contained within each row. In this configuration, each of the plurality of blades 49 of the sliding blade array 48 partially overlaps the corresponding crimping apertures 50. Such overlapping geometry enables the sliding blade array 48 to exert inward radial pressure on the upper unfilled portions of the pre-formed cones 80 retained within the modular carrier plate 60 during downward actuation of the crimping assembly 40. This action may facilitate the formation of uniform crimps along all pre-formed cones 80 arranged in the engaged rows, as will be described in greater detail below.

The blades 49 of the sliding blade array 48 may include specialized edge geometries, surface treatments, or angular orientations designed to optimize the paper folding characteristics and ensure consistent, high-quality crimp formation across all processed units.

The microactuators 44, shown in their extended operational states in FIGS. 4A and 4B, provide the requisite actuation force to translate the sliding blade array 48 from its disengaged position to the engaged position. The microactuators 44 drive the sliding blade array 48 laterally along the lower surface 42b of the crimping body 42, thereby moving the blades 49 of the sliding blade array 48 into and out of alignment with the crimping apertures 50 to enable or disable a crimping action. In certain embodiments, the sliding blade array 48 is configured to slide within channels or guides formed in the crimping body 42.

Referring now to FIGS. 5A-5C, shown therein is transparent side, bottom, and transparent isometric views, respectively, of the modular carrier plate 60 of an exemplary embodiment of the pre-formed cone closing system 10 according to the instant disclosure. The modular carrier plate 60 is configured to retain, position, and guide ejection of pre-formed cones 80.

The modular carrier plate 60 defines an upper surface 60a, a lower surface 60b, and a plurality of openings 70 extending from the upper surface 60a to the lower surface 60b. In some embodiments, the openings 70 are arranged longitudinally in rows and laterally in columns, forming a grid-like configuration. The arrangement, orientation, and dimensions of the openings 70 may be selected to align the openings 70 with the corresponding crimping apertures 50 of crimping assembly 40 and the pressing rods 35 of the pressing assembly 30. In some embodiments, as shown in FIGS. 5A-5C, the modular carrier plate 60 further includes alignment features 63 configured to engage with corresponding alignment features of the one or more carrier support members 18, thereby facilitating precise positioning and secure mating therebetween.

Each of the plurality of openings 70 have a tapered upper section 71 adjacent to the upper surface 60a and a lower section 72 adjacent to the lower surface 60b. The tapered upper section 71 has an inner surface 73 that tapers inward from the upper surface 71 toward the lower section 72, with the taper configured to correspond to the outer geometry of the pre-formed cones 80 for secure placement. The lower section 72 is configured to support and retain a portion of the pre-formed cones 80 received through the opening 70, maintaining alignment and stability during operations.

The lower section 72 of each opening 70 includes an inner surface 73 that extends to the lower surface 72 of the modular carrier plate 60. The lower section 72 is sized to provide controlled back-pressure during a pressing operation. The inner surface 73 of the lower section 72 further guides the pre-formed cones 80 during ejection and offers the necessary resistance to ensure proper compression by the pressing rods 35 before ejection.

The amount of back-pressure applied to each pre-formed cone 80 during sealing and ejection operations is at least partially determined by the relative size and geometry of the lower sections 72 of each opening 70. Specifically, the cross-sectional dimensions of the lower section 72 influences the degree of resistance encountered by the cone 80 as it is driven downward by the pressing assembly 30. A narrower or more constricted lower section 72 increases the contact area between the inner surface 73 of the opening 70 and the exterior surface of the cones 80, thereby generating greater frictional resistance and back-pressure. Conversely, a wider or more open lower section 72 reduces the degree of mechanical interference and results in lower back-pressure.

This back-pressure resists premature downward displacement of the cones 80, ensuring that adequate compressive force is applied by the pressing rods 35 before the cones 80 are ejected from the carrier plate 60. By controlling the resistance encountered within the lower section 72, the carrier plate 60 ensures that each of the cones 80 undergoes sufficient compression and sealing prior to release.

In certain embodiments, the lower section 72 of each opening 70 may further include deformable or compliant regions formed from resilient materials, such as, for example, flexible polymers, elastomers, or other compressible substances, that are configured to yield or deform under applier force. This deformation adjusts the resistance experienced by the cones 80 during sealing and ejection operations.

In some embodiments, the lower section 72 of each opening 70 may include one or more actuating mechanisms integrated within the structure of the carrier plate 60. These mechanisms may be configured to exert an opposing force against the downward movement of the cones 80 under compression. As the pressing rods 35 advance, the mechanism compresses, offering increasing resistance until a predetermined threshold is reached, at which point the cone 80 is released and ejected from the carrier plate 60.

Further, the modular carrier plate 60 is designed to be modular and interchangeable. Multiple carrier plates 60 having different opening 70 diameters can be provided to accommodate varying cone sizes, material types, and fill volumes. This modularity allows for highly versatile and configurable operation by selecting the appropriate carrier plate 60 for specific production requirements.

In certain embodiments, the system 10 may be configured to provide adjustable ejection pressure for the pre-formed cones 80, thereby enabling controlled release of the cones 80 through the modular carrier plate 60 following the crimping and sealing steps, as will be discussed further below. This adjustable exit pressure may be achieved through a variety of design features, including but not limited to modifications to the geometry of the openings 70—such as the diameter of the lower section 72 or the angle and length of the tapered upper portions 71 of the openings 70.

Additionally, alternative embodiments may incorporate compliant materials, flexible geometries, or spring-loaded retention features within the modular carrier plate 60 structure. These features may allow the openings 70 to deform, flex, or yield under a specified force threshold, enabling cone 80 release that is decoupled from the movement or position of the pressing rods 35. For example, a compliant liner or insert within the openings 70 may compress to allow passage of the cones 80 only when a predetermined internal pressure is reached, ensuring consistent exit conditions across multiple units.

In further embodiments, the modular carrier plate 60 may be formed from multiple interlocking sections, such as an upper section defining the tapered upper sections 71 and a lower section defining the lower sections 72 of the openings 70. These sections may be mechanically coupled during processing to form a unified cone-retention structure, and may be equipped with actuated release mechanisms configured to separate the sections at predetermined times, positions, or pressure thresholds. Such mechanisms may include mechanical linkages, pneumatic or hydraulic actuators, magnetic latches, or other automated means. In such embodiments, the separation of the carrier plate 60 sections mechanically releases the cones 80 from the retaining structure, enabling controlled ejection of the processed cones 80. This separation may be synchronized with the completion of a processing cycle or triggered based on a sensor input, enabling consistent, hands-free removal of cones 80 from the system 10. By decoupling the cone 80 ejection force from the actuation force of the pressing rods 35, and by incorporating adjustable release mechanisms, the system 10 may enables precise tuning of exit parameters to accommodate variations in cone geometry, material, and desired output characteristics—thereby increasing overall process consistency and efficiency.

In certain embodiments, as shown in FIGS. 5A-5C, the modular carrier tray 60 further includes laterally extending support shoulders 61 positioned at opposite longitudinal ends of the modular carrier tray 60. These support shoulders 61 extend outward from the carrier plate 60 and may define a stepped profile relative to the upper surface 60a. The support shoulders 61 may be configured to rest upon and be operatively supported by corresponding carrier support members 18. Each support shoulder 61 dimensioned to provide stable bearing contact with its respective carrier support member 18, with the longitudinal separation distance between the support shoulders 61 corresponding to the predetermined spacing between the one or more carrier support members 18. In this configuration, the carrier tray 60 may be suspended in the intermediate space formed between the one or more carrier support members 18. In some embodiments, the support shoulders 61 may be integrally formed with the modular carrier plate 60 and maintain a consistent height relative to the upper surface 60a of the modular carrier plate 60.

Referring now to FIGS. 6A and 6B, shown therein is side and isometric views, respectively, of the modular carrier plate 60 in its loaded state, containing a plurality of packed pre-formed cones 80, according to the present disclosure.

FIGS. 6A and 6B depict an intermediate stage between material packing and crimping, where the pre-formed cones 80 are held securely in place within the modular carrier plate 60 and aligned for engagement by the crimping assembly 40 and/or the pressing assembly 30.

In its loaded state, each of the plurality of pre-formed cones 80 are inserted into a corresponding opening 70 in the modular carrier plate 60, such that the pre-formed cones 80 are secured in a vertical orientation. As discussed above, the openings 70 of the modular carrier plate 60 are dimensioned to ensure that the pre-formed cones 80 are seated at a predetermined depth, with the packed material resting below the upper surface 60a of the carrier plate 60 and an upper portion 81 of the pre-formed cones 80—typically ranging from approximately 1 mm to 30 mm—protrudes above the upper surface 60a of the carrier plate 60. This exposed unfilled portion is what is engaged in the crimping operations.

Turning now to FIGS. 7-10, there are illustrated various embodiments of the method of simultaneously closing a plurality of pre-formed cones, as performed by the system disclosed herein.

In an initial pre-formed cone positioning step, the modular carrier plate 60, loaded with the plurality of pre-formed cones 80, is positioned such that at least a portion of the carrier plate 60 is supported on the upper surface 19 of the one or more carrier support members 18. The pre-formed cones 80 are arranged within the modular carrier plate 60 such that an upper portion of each cone 81 extends above the upper surface 60a of the modular carrier plate 60, as shown in FIG. 7.

Next, in an alignment step, the plurality of pre-formed cones 80 are aligned with the crimping apertures 50 of the crimping assembly 40. In some embodiments, alignment features 63 of the modular carrier plate 60 may engage with corresponding features on the one or more carrier support members 18, ensuring that the pre-formed cones 80 are positioned at predetermined locations and in axial alignment with both the crimping apertures 50 of the crimping assembly 40 and the pressing rods 35 of the pressing assembly 30.

At this step, both the pressing assembly 30 and the crimping assembly 40 are in their raised positions, with the pressing plate 32 positioned proximate the lower surface 16 of the top plate 14 and the crimping body 42 positioned at an intermediate height along the linear guides 22. The pre-formed cones 80 are shown in FIG. 7 in their initial configuration with the upper portions 81 of the pre-formed cones 80 extending above the upper surface 60a of the modular carrier plate 60.

Subsequently, in a crimping step, as shown in FIG. 8, the one or more crimping actuators 90 actuate to drive the crimping assembly 40 downward along the linear guides 22 until the lower surface 42b of the crimping body 42 contacts the upper surface 60a of the modular carrier plate 60 to cause the crimping of the pre-formed cones 80.

In certain embodiments, the crimping apertures 50 may feature a tapered internal profile, with the wider portion of the aperture 50 located at the lower surface 42b of the crimping body 42—the surface facing the pre-roll cones—and narrowing towards the upper surface 42a of the crimping body 42. In that embodiment, the tapered configuration may facilitate initial guidance and insertion of the upper portion 81 of the pre-formed cones 80 into the crimping aperture 50 and promote controlled inward folding and crimping as the crimping assembly 40 is actuated downward toward the carrier plate 60.

In other embodiments, prior to this step. There is linear actuation of the microactuators 44 of the crimping assembly 40, wherein the microactuators 44 transition from their contracted state to their extended state, causing the sliding blade array 48 to shift into its engaged position. In the engaged position, the sliding blade array 48 is translated laterally along the lower surface 42b of the crimping body 42b, such that the blades 49 of the sliding blade array 48 extend partially into the crimping apertures 50, thereby creating controlled obstructions aligned with the pre-formed cones 80.

As shown in FIG. 8, the one or more crimping actuators 90 then actuate to drive the crimping assembly 40 downward along the linear guides 22 until the lower surface 42b of the crimping body 42 contacts the upper surface 60a of the modular carrier plate 60. This downward motion forces the blades 49 of the sliding blade array 48 to engage with the upper portions 81 of the pre-formed cones 80. The engagement between the blades 49 and the upper portions 81 induce an inward folding action, causing the paper material of the pre-formed cones 80 to crimp and fold inward toward the center of each crimping aperture 50. The sliding blade array 48 thus creates a controlled deformation that prepares the pre-formed cones 80 for final sealing.

Following the crimping operation step, the crimping actuators 90 may actuate to retract the crimping assembly 40 by reversing direction to lift the crimping assembly 40 back to its raised position along the vertical linear guides 22, as shown in FIG. 9. The crimping body 42 moves upward until the lower surface 42b of the crimping body 42 is positioned above the upper surface 60a of the carrier plate 60.

In some embodiments, upon the return of the crimping assembly 40 to its raised position, the microactuators 44 are actuated so as to transition from their extended state back to their contracted state. The contraction of the microactuators 44 initiates a retraction of the sliding blade array 48, causing the blades 49 of the sliding blade array 48 to move from the engaged position into the disengaged position. In this disengaged position, the blades 49 of the sliding blade array 48 are withdrawn from the crimping apertures 50, thereby leaving the crimping apertures 50 unobstructed for the subsequent passage of the pressing rods 35. At this stage, as shown in FIG. 9, the pre-formed cones 80 that have undergone the crimping operation, exhibit a post-crimped configuration wherein the upper portions 81 of the pre-formed cones 80 are folded inward but not yet fully sealed against the packed material disposed therein.

Finally, a pressing and ejection step is conducted, as shown in FIG. 10. During these steps, the pressing actuator 26 is activated to advance the pressing assembly 30 downward along the linear guides 22. As the pressing assembly 30 is displaced vertically along the linear guides 22, the pressing rods 35 are guided through the now-unobstructed crimping apertures 50 and brought into direct contact with the upper, post-crimped portions 81 of the pre-formed cones 80. Continued actuation of the pressing assembly 30 causes the pressing rods 35 to apply a controlled compressive force onto the inwardly-folder paper portions of the pre-formed cones 80, thereby urging these sections downward and compressing them firmly against the material packed therein. This pressing action results in the creation of a secure seal at the upper portion 81 of each pre-formed cone 80.

In an ejection or displacement step, the pressing action continues until sufficient force is applied to overcome the back-pressure created by the lower section 72 of the carrier plate 60 openings 70. Once this threshold is exceeded, the finished pre-formed cones 80 are ejected downward through the openings 70 in the lower surface 60b of the carrier plate 60, where they can be collected for packaging.

It is to be understood that the steps disclosed herein may be performed simultaneously or in any desired order. For example, one or more of the steps disclosed herein may be omitted, one or more steps may be further divided in one or more sub-steps, and two or more steps or sub-steps may be combined in a single step, for example. Further, in some exemplary embodiments, one or more steps may be repeated one or more times, whether such repetition is carried out sequentially or interspersed by other steps or sub-steps. Additionally, one or more other steps or sub-steps may be carried out before, after, or between the steps disclosed herein, for example.

From the above description, it is clear that the inventive concept(s) disclosed herein are well adapted to carry out the objects and to attain the advantages mentioned herein, as well as those inherent in the inventive concept(s) disclosed herein. While the embodiments of the inventive concept(s) disclosed herein have been described for purposes of this disclosure, it will be understood that numerous changes may be made and readily suggested to those skilled in the art which are accomplished within the scope and spirit of the inventive concept(s) disclosed herein.