Compression and division of materials by gas

Abstract

The apparatus includes a stationary assembly and a reciprocating assembly. The stationary assembly includes a hopper, a first gas manifold, and a dispensing chamber, and the reciprocating assembly includes a channel assembly defining a channel conduit, a shield plate aligned perpendicularly thereto, and a second gas manifold. The reciprocating assembly is movable relative to the stationary assembly between a first position that allows the channel conduit to be filled with a bulk compressible material from the hopper, a second position that allows the compressible material to be forced from the channel conduit to the dispensing conduit and compressed in the dispensing chamber according to a first gas directed through the channel conduit by the first gas manifold, and a third position that allows the compressed material to be forced out of the dispensing conduit according to a second gas directed through the dispensing conduit by the second gas manifold.

Description

[Technical field]

[0001] The present disclosure relates to the division of compressible materials, and more particularly to the compression and division of materials to provide rapid, economical, and efficient division of materials to provide ("produce") portions of materials ("instances") having controllable density, weight, and volume. [Background technology]

[0002] Some products, including some consumer goods, include packaged portions ("portioned instances") of a compressible material (also referred to herein simply as "material"). In some cases, such portions may be produced ("provided," "manufactured," etc.) based on dividing ("dividing," "cutting," "severing," etc.) a relatively large ("bulk") body of material into multiple smaller portions and packaging the portions. Summary of the Invention

[0003] According to some exemplary embodiments, an apparatus configured to provide compressed pieces of material may include a stationary assembly and a reciprocating assembly. The stationary assembly may include a first hopper, a first gas manifold, and a dispensing vessel. The first hopper may be configured to hold a bulk compressible material. The first gas manifold may be configured to direct a first gas from a first gas source to a first manifold outlet. The dispensing vessel may define a dispensing vessel extending between a dispensing vessel inlet and a dispensing vessel outlet. The dispensing conduit may at least partially vertically overlap the first manifold outlet. The reciprocating assembly may include a first channel assembly and a second gas manifold. The first channel assembly may define a first channel conduit extending between a first channel conduit inlet and a first channel conduit outlet. The second gas manifold may be configured to direct a second gas from a second gas source to a second manifold outlet. The reciprocation includes a first position capable of at least partially filling the first channel conduit with bulk compressible material from the first hopper by exposing the first channel conduit inlet to the first hopper and covering the first channel conduit outlet with at least a first portion of the stationary assembly, and a first gas manifold directing a first gas through the first channel conduit inlet to push the bulk compressible material from the first channel conduit into the dispense conduit by exposing the first channel conduit inlet to the first manifold outlet and exposing the first channel conduit outlet to the dispense conduit inlet and covering the dispense conduit outlet; The device may be configured to be moved along a longitudinal axis relative to the fixed assembly between a second position where the bulk compressible material is compressed within the dispensing line to form a first piece of compressible material within the dispensing line, and a third position where the second manifold outlet is exposed to the dispensing line inlet and the dispensing line outlet is exposed to an exterior of the device, thereby cutting the first piece of compressed material within the dispensing line from the remaining compressible material in the first channel line and directing a second gas through the dispensing line inlet to the second gas manifold to push the first piece of compressed material out of the dispensing line.

[0004] The third position may be between the first and second positions along the longitudinal axis, such that the reciprocating assembly is configured to enable pushing and compressing the bulk compressible material based on the reciprocating assembly moving in a first direction along the longitudinal axis from the first position to the second position, shearing a first piece of compressed material, and pushing the first piece of compressed material out of the dispensing line based on the reciprocating assembly moving in an opposite second direction along the longitudinal axis from the second position to the third position, and to enable at least partial refilling of the first channel line with the bulk compressible material from the first hopper following pushing of the first piece of compressed material out of the dispensing line based on the reciprocating assembly moving in the second direction from the third position to the first position.

[0005] The dispensing vessel may be a bottom plate such that the dispensing conduit extends through a thickness of the bottom plate between a dispensing conduit inlet at a top surface of the bottom plate and a dispensing conduit outlet at a bottom surface of the bottom plate. The shuttle assembly may include an upper plate, a lower plate, and a cylindrical structure coupled between the upper plate and the lower plate. The top surface of the upper plate may be in sliding contact with the first hopper and the first gas manifold. The bottom surface of the lower plate may be in sliding contact with the top surface of the bottom plate. The lower plate may define a lower conduit extending through a thickness of the lower plate between an upper opening of the lower conduit and a bottom opening of the lower conduit. The bottom opening of the lower conduit may define a first channel conduit outlet at the bottom surface of the lower plate. The cylindrical structure may define an upper conduit extending through the cylindrical structure. The top opening of the upper conduit may define a first channel conduit inlet at the top surface of the upper plate. A bottom opening of the upper conduit may be exposed to an upper opening of the lower conduit, such that the upper and lower conduits collectively define a first channel conduit.

[0006] The second gas manifold may be coupled to a top surface of the bottom plate. The bottom plate may define a manifold conduit extending through a thickness of the bottom plate between a manifold conduit inlet at the top surface of the bottom plate and a manifold conduit outlet at a bottom surface of the bottom plate, the manifold conduit inlet being exposed to the second manifold outlet. The shuttle assembly may be configured to expose the manifold conduit outlet to the dispense conduit inlet such that the second manifold outlet is exposed to the dispense conduit inlet via the manifold conduit based on the shuttle assembly being in a third position.

[0007] The cylindrical structure may include a cylinder coupled to the upper plate at an upper end thereof such that an upper end opening of the cylinder defines an upper end opening of the upper conduit. The cylindrical structure may include a cylindrical sheath slidingly engaging a bottom end of the cylinder at an upper end of the cylindrical sheath and a bottom end of the cylindrical sheath slidingly engaging a bottom opening of the cylindrical sheath to define a bottom opening of the upper conduit. The cylindrical structure may include a spring configured to apply a spring force to urge the cylindrical sheath against the bottom plate. The cylindrical sheath may be configured to open a conduit extending between the cylindrical sheath and the bottom plate by being pushed away from the bottom plate by the first gas, thereby allowing the first gas to escape from the first channel conduit through the opened conduit in response to the first gas manifold directing the first gas to the first manifold outlet.

[0008] The dispensing container may be a bottom plate such that the dispense line extends through a thickness of the bottom plate between a dispense line inlet at a top surface of the bottom plate and a dispense line outlet at a bottom surface of the bottom plate. The shuttle assembly may include a first shielding plate that at least partially vertically overlaps the first channel assembly. The bottom plate may be between the first channel assembly and the first shielding plate. The first portion of the stationary assembly may include a portion of the bottom plate. The first shielding plate may be configured to cover the dispense line outlet based on the shuttle assembly being in the second position.

[0009] The apparatus may further include a servo mechanism configured to move the reciprocating assembly along the longitudinal axis between the first, second, and third positions. The apparatus may further include processing circuitry configured to control the servo mechanism to move the reciprocating assembly between the first, second, and third positions, to control the first gas source to selectively supply a first gas to the first gas manifold in response to the reciprocating assembly being in the second position, and to control the second gas source to selectively supply a second gas to the second gas manifold in response to the reciprocating assembly being in the third position.

[0010] The stationary assembly may include a second hopper. The second hopper may be configured to hold additional bulk compressible material. The second hopper may be adjacent to the first gas manifold along the longitudinal axis such that the first gas manifold is between the first and second hoppers along the longitudinal axis. The reciprocating assembly may include a second channel assembly defining a second channel conduit extending between a second channel conduit inlet and a second channel conduit outlet. The second channel assembly may be adjacent to the second gas manifold along the longitudinal axis such that the second gas manifold is between the first and second channel assemblies along the longitudinal axis. The reciprocating assembly may be configured to expose the second channel conduit inlet to the second hopper and cover the second channel conduit outlet with at least a second portion of the stationary assembly based on the reciprocating assembly being in the second position, thereby allowing at least partial filling of the second channel conduit with additional bulk compressible material from the second hopper. The reciprocating assembly may be configured to expose the second channel conduit inlet to the first manifold outlet, expose the second channel conduit outlet to the dispense conduit inlet, and cover the dispense conduit outlet based on the reciprocating assembly moving in a second direction from the second position to the first position, such that the first gas manifold directs the first gas through the second channel conduit inlet and extrudes the bulk compressible material from the second channel conduit into the dispense conduit, compressing the bulk compressible material within the dispense conduit to form a second piece of compressed material in the dispense conduit. The reciprocating assembly may be configured to expose the second manifold outlet to the dispensing line inlet and expose the dispensing line outlet to an exterior of the device based on the reciprocating assembly moving in a first direction from the first position to a third position, thereby cutting a second piece of compressed material in the dispensing line from a remaining compressible material in the second channel line, and the second gas manifold directs a second gas through the dispensing line inlet to push the second piece of compressed material out of the dispensing line.The reciprocating assembly may be configured to enable at least partial refilling of the second channel line with the bulk compressible material from the second hopper following expulsion of the second piece of compressed material from the dispensing line based on movement of the reciprocating assembly in the first direction from the third position to the second position.

[0011] The shuttle assembly may include an array of first channel assemblies each defining a separate first channel conduit of the array of first channel conduits. Each separate first channel conduit may extend between a separate first channel conduit inlet of the array of first channel conduit inlets and a separate first channel conduit outlet of the array of first channel conduit outlets. The array of first channel assemblies may include a first channel assembly. The shuttle assembly may include an array of second channel assemblies each defining a separate second channel conduit of the array of second channel conduits. The separate second channel conduits may extend between a separate second channel conduit inlet of the array of second channel conduit inlets and a separate second channel conduit outlet of the array of second channel conduit outlets. The array of second channel assemblies may include a second channel assembly. The dispense vessels may extend between distinct respective dispense line inlets of the array of dispense line inlets and distinct respective dispense line outlets of the array of dispense line outlets. The array of dispense lines includes the dispense lines. The shuttle assembly may be configured to move to a first position to expose the first array of channel line inlets to the first hopper, cover the first array of channel line outlets with at least a first portion of the stationary assembly, expose the second array of channel line outlets to the array of dispense line inlets, and expose the second array of channel line inlets to one or more first manifold outlets of the first gas manifold. The shuttle assembly may be configured to move to a second position to expose the array of first channel line outlets to the array of dispense line inlets, to expose the array of first channel line inlets to one or more first manifold outlets of the first gas manifold, to expose the array of second channel line inlets to the second hopper, and to cover the second channel line outlets with at least a second portion of the stationary assembly. The shuttle assembly may be configured to move to a third position to expose the array of dispense line inlets to one or more second manifold outlets of the second gas manifold, and to expose the array of dispense line outlets to an exterior of the apparatus.

[0012] The first gas manifold may include a plurality of first manifold conduits extending to respective distinct first manifold outlets of the plurality of first manifold outlets. The plurality of first manifold outlets may include one or more first manifold outlets. The second gas manifold may include a plurality of second manifold conduits extending to respective distinct second manifold outlets of the plurality of second manifold outlets. The plurality of second manifold outlets may include one or more second manifold outlets.

[0013] The apparatus may further include a servo mechanism configured to reversibly move the reciprocating assembly along the longitudinal axis between the first, second, and third positions. The apparatus may further include processing circuitry configured to control the servo mechanism to move the reciprocating assembly between the first, second, and third positions, to control a first gas source to selectively supply a first gas to a first gas manifold in response to the reciprocating assembly being in the first position, to control the first gas source to selectively supply the first gas to the first gas manifold in response to the reciprocating assembly being in the second position, and to control a second gas source to selectively supply a second gas to the second gas manifold in response to the reciprocating assembly being in the third position.

[0014] The first gas source and the second gas source may be the same gas source, such that the first gas and the second gas are the same type of gas.

[0015] According to some exemplary embodiments, a manufacturing system may include a conveyor belt comprising a loop of a plurality of plates, each plate having a cavity, and the above-described apparatus. The apparatus may overlie a portion of the conveyor belt to enable the conveyor belt to move to vertically align the cavities of each plate of the conveyor belt with the dispensing line outlets while the shuttle assembly is in the third position, and the second gas manifold to direct a second gas through the dispensing line inlets to force the compressed compressible material from the dispensing line into the cavities. The manufacturing system may include a packaging assembly configured to encapsulate the compressed compressible material in the cavities in a package. The conveyor belt may be configured to eject the package from the cavities based on the movement of the conveyor belt.

[0016] According to some exemplary embodiments, there is a method of operating an apparatus for providing a portion of compressible material. The apparatus includes a stationary assembly and a reciprocating assembly. The stationary assembly includes a dispensing vessel defining a first hopper, a first gas manifold, and a dispensing line. The reciprocating assembly includes a first channel assembly and a second gas manifold. The first channel assembly defines a first channel line. The method may include moving the reciprocating assembly relative to the stationary assembly along a longitudinal axis to a first position to expose a first channel line inlet of the first channel line to the first hopper and cover a first channel line outlet of the first channel line with at least a first portion of the stationary assembly to allow at least partial filling of the first channel line with a bulk of compressible material from the first hopper. The method may include moving the reciprocating assembly along a longitudinal axis from a first position to a second position relative to the fixed assembly to expose the first channel conduit inlet to a first manifold outlet of the first gas manifold, expose the first channel conduit outlet to a dispense conduit inlet of the dispense conduit, and cover a dispense conduit outlet of the dispense conduit. The method may include, in response to the reciprocating assembly being moved to the second position by controlling the first gas source, the first gas manifold directs a first gas through the first channel conduit inlet to force the compressible material from the first channel conduit into the dispense conduit and compress the compressible material in the dispense conduit to form a first piece of compressed material in the dispense conduit. The method may include moving the reciprocating assembly along a longitudinal axis from the second position to a third position relative to the fixed assembly to expose the second gas manifold to the dispense conduit inlet and expose the dispense conduit outlet to an exterior of the instrument. The method may include controlling a second gas source to supply a second gas in response to the reciprocating assembly being moved to a third position, and a second gas manifold directing the second gas through the dispensing line inlet to expel the first piece of compressed material from the dispensing line.

[0017] The third position may be between the first position and the second position along the longitudinal axis, such that moving the reciprocating assembly to the first position includes moving the reciprocating assembly in a first direction along the longitudinal axis from the first position through the third position to the second position, moving the reciprocating assembly to the second position includes moving the reciprocating assembly in an opposite second direction along the longitudinal axis from the third position to the first position, and moving the reciprocating assembly to the third position includes moving the reciprocating assembly in the second direction from the second position to the third position.

[0018] Moving the reciprocating assembly to the first position may include controlling a servo mechanism coupled to the reciprocating assembly such that the servo mechanism moves the reciprocating assembly along the longitudinal axis to the first position. Moving the reciprocating assembly to the second position may include controlling the servo mechanism such that the servo mechanism moves the reciprocating assembly in a first direction along the longitudinal axis to the second position. Moving the reciprocating assembly to a third position may include controlling a servo mechanism coupled to the reciprocating assembly such that the servo mechanism moves the reciprocating assembly in a second direction along the longitudinal axis to the third position.

[0019] The stationary assembly may include a second hopper. The second hopper may be adjacent to the first gas manifold along the longitudinal axis such that the first gas manifold is between the first and second hoppers along the longitudinal axis. The reciprocating assembly may include a second channel assembly defining a second channel conduit. The second channel assembly may be adjacent to the second gas manifold along the longitudinal axis such that the second gas manifold is between the first and second channel assemblies along the longitudinal axis. Moving the reciprocating assembly to the second position may expose a second channel conduit inlet of the second channel conduit to the second hopper and enable at least partial filling of the second channel conduit with the bulk compressible material from the second hopper. The method may further include moving the reciprocating assembly from the second position to the first position such that the second channel conduit inlet is exposed to the dispense conduit inlet and the second channel conduit outlet of the second channel conduit is exposed to the first manifold outlet. The method may further include, in response to the reciprocating assembly being moved from the second position to the first position by controlling the first gas source to provide a first gas such that the first gas manifold directs the first gas through the second channel conduit inlet to extrude the compressible material from the second channel conduit into the dispensing conduit, compressing the compressible material in the dispensing conduit to create a second piece of compressed material in the dispensing conduit. The method may further include, after the reciprocating assembly is moved from the first position to a third position and the second gas source is controlled to provide a second gas to create the second piece of compressed material in the dispensing conduit, the second gas manifold directs the second gas through the dispensing conduit inlet to extrude the second piece of compressed material from the dispensing conduit.

[0020] The first gas source and the second gas source may be the same gas source, such that the first gas source and the second gas source are the same type of gas, and controlling the first and second gases may be controlling the same gas source. [Brief description of the drawings]

[0021] Various features and advantages of the non-limiting embodiments herein will become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings, which are provided merely for illustrative purposes and should not be construed as limiting the scope of the claims. The accompanying drawings should not be considered to be drawn to scale unless explicitly noted. For purposes of clarity, various dimensions of the drawings may be exaggerated.

[0022] [Figure 1] FIG. 1 is a schematic perspective view of a manufacturing system including an apparatus according to some illustrative embodiments.

[0023] [Figure 2A] FIG. 2A is a perspective view of an apparatus including a fixed assembly and a reciprocating assembly in a first position relative to the fixed assembly, according to some exemplary embodiments.

[0024] [Figure 2B] FIG. 2B is a perspective view of an apparatus including a fixed assembly and a reciprocating assembly in a second position relative to the fixed assembly, according to some exemplary embodiments.

[0025] [Figure 2C] FIG. 2C is a perspective view of an apparatus including a fixed assembly and a reciprocating assembly in a third position relative to the fixed assembly, according to some exemplary embodiments.

[0026] [Figure 3A] FIG. 3A is a cross-sectional view of the device of FIG. 2A along line II', according to some exemplary embodiments. [Figure 3B] FIG. 3B is a cross-sectional view of the device of FIG. 2B along line II', according to some exemplary embodiments. [Figure 3C] FIG. 3C is a cross-sectional view of the device of FIG. 2C along line II', according to some exemplary embodiments.

[0027] [Figure 4A] FIG. 4A is an expanded view of region A of FIG. 3A, according to some exemplary embodiments. [Figure 4B] FIG. 4B is an expanded view of area A of FIG. 3B, according to some exemplary embodiments. [Figure 4C] FIG. 4C is an expanded view of area A of FIG. 3C, according to some exemplary embodiments.

[0028] [Figure 5A] FIG. 5A is an enlarged view of region B of FIG. 3A, according to some exemplary embodiments. [Figure 5B] FIG. 5B is an enlarged view of region B of FIG. 3B, according to some exemplary embodiments. [Figure 5C] FIG. 5C is an expanded view of region B of FIG. 3C, according to some exemplary embodiments.

[0029] [Figure 6A] FIG. 6A is a cross-sectional view of the device of FIG. 2A along line II-II', according to some exemplary embodiments. [Figure 6B] FIG. 6B is a cross-sectional view of the device of FIG. 2B along line II-II', according to some exemplary embodiments. [Figure 6C] FIG. 6C is a cross-sectional view of the device of FIG. 2C along line II-II', according to some exemplary embodiments.

[0030] [Figure 7A] FIG. 7A is a cross-sectional view of the device of FIG. 2A along line III-III', according to some exemplary embodiments. [Figure 7B] FIG. 7B is a cross-sectional view of the device of FIG. 2B along line III-III', according to some exemplary embodiments. [Figure 7C] FIG. 7C is a cross-sectional view of the device of FIG. 2C along line III-III', according to some exemplary embodiments.

[0031] [Figure 8A]FIG. 8A is a cross-sectional view of the device of FIG. 2A taken along line IV-IV', according to some illustrative embodiments. [Figure 8B] FIG. 8B is a cross-sectional view of the device of FIG. 2B along line IV-IV', according to some illustrative embodiments. [Figure 8C] FIG. 8C is a cross-sectional view of the device of FIG. 2C along line IV-IV', according to some exemplary embodiments.

[0032] [Figure 9A] FIG. 9A is a cross-sectional view of the device of FIG. 2A along line VV', according to some exemplary embodiments. [Figure 9B] FIG. 9B is a cross-sectional view of the device of FIG. 2B along line VV', according to some exemplary embodiments. [Figure 9C] FIG. 9C is a cross-sectional view of the device of FIG. 2C along line VV', according to some exemplary embodiments.

[0033] [Figure 10A] FIG. 10A is a perspective view of a device according to some exemplary embodiments. [Figure 10B] FIG. 10B is a perspective view of a device according to some exemplary embodiments. [Figure 10C] FIG. 10C is a perspective view of a device according to some exemplary embodiments.

[0034] [Figure 11] FIG. 11 is an expanded view of region B of FIG. 3B, according to some exemplary embodiments.

[0035] [Figure 12] FIG. 12 is a flow chart illustrating a method according to some example embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0036] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for purposes of describing the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited to only the exemplary embodiments set forth herein.

[0037] Thus, while exemplary embodiments are susceptible to various modifications and alternative forms, exemplary embodiments thereof have been shown by way of example in the drawings and will be described in detail herein. It is to be understood, however, that there is no intention to limit the exemplary embodiments to the particular forms disclosed, but on the contrary, the exemplary embodiments are intended to cover all modifications, equivalents, and alternatives falling within the scope of the exemplary embodiments. Like numbers refer to like elements throughout the description of the drawings.

[0038] When a component or layer is referred to as "on," "connected to," "coupled to," or "overlying" another component or layer, it is understood that it may be directly on, connected to, coupled to, or overlying the other component or layer, or there may be intervening components or layers. In contrast, when a component is referred to as "directly on," "directly connected to," or "directly coupled to" another component or layer, there are no intervening components or layers. Like numbers herein refer to like components. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0039] In this specification, the terms first, second, third, etc. may be used to describe various components, regions, layers, and / or sections, but it should be understood that these components, regions, layers, and / or sections should not be limited by these terms. These terms are used only to distinguish one component, region, layer, or section from another region, layer, or section. Thus, a first component, region, layer, or section described below may be referred to as a second component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0040] Spatially relative terms (e.g., "below," "lower," "lower side," "upper," "upper," etc.) may be used herein for ease of description to describe the relationship of a component or feature to other components or features as shown in the figures. It should be understood that the spatially relative terms are intended to encompass different orientations of the device during use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures were inverted, a component described as "below" or "below" the other component or feature would be oriented "above" the other component or feature. Thus, the term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptions used herein would be interpreted accordingly.

[0041] The terminology used herein is for the purpose of describing various exemplary embodiments only and is not intended to limit the exemplary embodiments. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. It is further understood that as used herein, the terms "comprise," "have," "comprise," and / or "comprise" specify the presence of stated features, integers, steps, operations, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, components, and groups thereof.

[0042] Exemplary embodiments are described herein with reference to cross-section illustrations that are schematic illustrations of idealized embodiments (and intermediate structures) of exemplary embodiments. As such, variations from the shapes of the illustrations are to be expected as a result, for example, of manufacturing techniques and / or tolerances. Thus, exemplary embodiments should not be construed as limited to the shapes of regions illustrated herein but are to include, for example, deviations in shapes that result from manufacturing.

[0043] Unless otherwise specified, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which the exemplary embodiments belong. Terms, including those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with the meaning in the context of the relevant art, and will be further understood not to be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0044] When the terms "about" or "substantially" are used herein in connection with a numerical value, it is intended that the associated numerical value includes a tolerance of ±10% around the stated numerical value. Furthermore, when ratios are referred to herein, it is intended that the ratios are based on weight, i.e., weight ratios. The expression "up to" includes the amount from zero to the upper limit expressed and all values ​​therebetween. Also, when a range is specified, the range includes all values ​​therebetween, such as in increments of 0.1%. Furthermore, when the terms "generally" and "substantially" are used in connection with a geometric shape, it is intended that precision of the geometric shape is not required, but that freedom of shape is within the scope of the present disclosure. Although the channels and / or conduits described herein may be illustrated and / or described as being cylindrical, other channel and / or conduit cross-sectional shapes are contemplated, such as square, rectangular, elliptical, triangular, etc.

[0045] FIG. 1 is a schematic perspective view of a manufacturing system including an apparatus according to some illustrative embodiments.

[0046] As shown in FIG. 1, the manufacturing system 1 includes a conveyor assembly 10 including an endless loop of plates 16. The conveyor assembly 10 is configured to be driven by one or more conveyor pulleys 12. Each separate plate 16 includes an array of one or more cavities 18, for example, a 4×3 array of 12 cavities 18 as shown in FIG. 1. The manufacturing system 1 further includes a bulk material source 80 of bulk compressible material 82, and an apparatus 100 configured to form one or more pieces of compressed material 11 from the bulk compressible material 82 and provide (e.g., eject, push, feed, etc.) the pieces 11 from the array 118-A of the array of dispensing lines 118-C to separate respective cavities 18 vertically aligned with separate dispensing lines 118-C of the array 118-A. As described herein, the pieces of compressed material 11 may be interchangeably referred to as “doses” of compressed material.

[0047] Manufacturing system 1 further includes bottom and top packaging assemblies 20 and 30 configured to provide respective bottom and top packaging material portions 21 and 31 that are joined together to form pouches 91 providing respective containers, and seals (e.g., "wraps," "encloses," etc.) the separate respective pieces of compressed material 11 provided by apparatus 100 to form separate respective packaging pieces 99 of compressed material. Manufacturing system 1 further includes a sealing and inspection assembly 40 including a sealing assembly 42 configured to complete the sealing of the provided pieces of compressed material 11 within the provided portions of packaging material 21 and 31 (e.g., complete the formation of pouches 91) and an inspection assembly 44 configured to monitor packaging pieces 99 to generate sensor data that can be processed to determine whether packaging pieces 99 are properly formed. The packaging strips 99 may be discharged from the cavities 18 at the discharge station 60, for example, based on the plate 16 moving around an endless loop such that the plate 16 is inverted and the packaging strips 99 are allowed to fall from the cavities 18 of the plate 16 according to gravity. As shown in FIG. 12, the discharge station 60 may include a chute configured to receive and guide the packaging strips 99 falling from the inverted plate 16, although example embodiments are not limited thereto.

[0048] In operation, the manufacturing system 1 may operate based on one or more pulleys 12 being driven by one or more drive motors 13 (which may be any known drive motor used to drive conveyor belt assemblies, any known servo mechanism, etc.) to move an endless loop of plates 16 of the conveyor assembly 10 around the pulleys 12. As shown, a given plate 16 may move sequentially between the bottom packaging assembly 20, the apparatus 100, the top packaging assembly 30, the sealing assembly 42, the inspection assembly 44, and the ejection station 60, and then back to the bottom packaging assembly 20, based on the endless loop being driven to move by the drive motor 13.

[0049] The bottom packaging assembly 20 may include a supply roll 22 of a sheet 24 of bottom packaging material (e.g., any known packaging material). The bottom packaging material is attached to a supply sheet 27. The sheet 24 / 27 may be fed from the supply roll 22 through a tension roller 26 to a return roll 28. The sheets 24 / 27 as fed from the supply roll 22 are attached to each other such that the supply sheet 27 resides between the sheet 24 of bottom packaging material and the tension roller 26 as the sheet 24 / 27 moves around the tension roller 26. As a result, the feeding of the sheet 24 / 27 around the tension roller 26 brings the sheet 24 of bottom packaging material into close proximity and / or contact with one or more plates 16 moving around the endless loop of the conveyor assembly 10. The tension roller 26 may, for example, apply tension to the composite adhesive sheet 24 / 27 moving around the tension roller 26 to cause the sheet 24 of bottom packaging material to be detached (e.g., peeled off) from the supply sheet 27. The supply sheet 27 contacts the tension roller 26 while the sheet 24 of bottom packaging material is separated from the tension roller 26 by the supply sheet 27, such that as the sheet 24 / 27 moves around the tension roller 26, the applied tension causes the sheet 24 of bottom packaging material to be detached (e.g., peeled off) from the supply sheet 27, and thus laid down on one or more plates 16 moving under the tension roller 26 as the supply sheet 27 returns to the return roll 28.

[0050] In some exemplary embodiments, the tension roller 26 is configured (e.g., based on a particular position of the tension roller 26 relative to the conveyor 10 and thus the plate 16) such that the tension roller 26 presses the sheet 24 of bottom packaging material into contact with the top surface of the one or more plates 16 as the composite adhesive sheet 24 / 27 moves around the tension roller 26. The sheet 24 of bottom packaging material may detach from the supply sheet 27 based on being pressed into contact with the one or more plates 16 by the tension roller 26. For example, in some exemplary embodiments, the sheet 24 may comprise an at least partially adhesive (e.g., at least lightly adhesive) material that detaches from the supply sheet 27 based on being pressed into contact with the one or more plates 16 by the tension roller 26 by at least lightly adhering to the portion (e.g., top surface) of the one or more plates 16 against which the tension roller 26 presses the sheet 24 into contact.

[0051] As a result of being disengaged from the supply sheet 27 and laid down on one or more plates 16, the sheet 24 of bottom packaging material is covered (e.g., by the tension roller 26) over the cavities 18 of the plate 16 as the plate 16 moves under the tension roller 26, so that the sheet 24 of bottom packaging material does not return to the return roll 28 with the supply sheet 27. The conveyor assembly 10 may operate to disengage the sheet 24 from the supply sheet 27 by the tension roller 26 to cover the cavities 18 of the plate 16 by moving the plate 16 relative to the bottom packaging assembly 20 at least partially vertically overlapping (e.g., vertically aligned or vertically overlapping) the tension roller 26. When the plate 16 is in (e.g., vertically aligned) the bottom packaging assembly 20, the cavities 18 are empty. In some exemplary embodiments, the return roll 28 may be connected to a driver that rotates the return roll 28 to feed the feed sheet 27 with the sheet 24 attached thereto from the feed roll 22 to the tension roller 26 to disengage the sheet 24 of bottom packaging material from the feed sheet 27. The feed rate of such sheets 24 / 27 may be matched to the speed of movement of the endless loop of the plate 16.

[0052] 2A-11, the apparatus 100, which will be described further below, may operate to compress a bulk compressible material 82, divide it into one or more pieces 11 of compressed material, and provide (e.g., discharge) the pieces 11 from the apparatus 100. The conveyor assembly 10 may operate to move a plate 16 from the bottom packaging assembly 20 to the apparatus 100 to a particular fixed position 90 relative to the manufacturing system 1. The cavities 18 of the plate 16 are aligned vertically (e.g., overlapping in the vertical direction V) with the respective dispensing line outlets 118-O of the array 118-A of the dispensing lines 118-C of the apparatus 100 based on the movement of the plate 16 to the position 90, as shown in FIG. 2A-11. The array 118-A of the dispensing lines 118-C may remain fixed in a position vertically aligned with the position 90 throughout the operation of the apparatus 100.

[0053] Based on plate 16 being in position 90, apparatus 100 may operate to provide (e.g., discharge, feed, etc.) one or more pieces of compressed material 11 via respective dispensing line outlets 118-O of array 118-A of dispensing lines 118-C to respective separate cavities 18 of plate 16 that are vertically aligned with dispensing line outlets 118-O. As the sheet 24 of bottom packaging material covers the cavities 18 of the plate 16 moved from the bottom packaging assembly 20 to position 90 so as to vertically overlap (e.g., vertically align in the vertical direction V) the array 118-A of the apparatus 100, each piece of compressed material 11 discharged from a given dispensing line 118-C of the array 118-A may, for example, push a separate portion 21 of the sheet 24 of bottom packaging material into a separate cavity 18 directly below the piece 11 of compressed material being discharged, based on the weight of the piece 11 pushing the portion 21 of the sheet 24 of bottom packaging material deep into the cavity 18.

[0054] The upper packaging assembly 30 may include a supply roll 32 of a sheet 34 of an upper packaging material (e.g., any known packaging material that may be the same or different than the lower packaging material) attached to a supply sheet 37. The sheet 34 / 37 may be fed from the supply roll 32 through a tension roller 36 to a return roll 38. The sheets 34 / 37 as fed from the supply roll 32 are attached to each other, and the feed sheet 37 resides between the sheet 34 of the upper packaging material and the tension roller 36 as the sheet 34 / 37 moves around the tension roller 36. As a result, the feeding of the sheet 34 / 37 around the tension roller 36 brings the sheet 34 of the upper packaging material close to and / or into contact with one or more plates 16 moving around the endless loop of the conveyor assembly 10. The tension roller 36 may, for example, detach the sheet 34 of the upper packaging material from the supply sheet 37 and lay it down on the plate 16 based on applying tension to the combined sheet 34 / 37 moving around the tension roller 36. As the supply sheet 37 contacts the tension roller 36, the sheet 34 of top packaging material is separated from the tension roller 36 by the supply sheet 37, and the applied tension causes the sheet 34 of top packaging material to detach (e.g., peel off) from the supply sheet 37 and, as a result, be laid down on one or more plates 16 moving below the tension roller 36 (e.g., be laid down on the sheet 24 of bottom packaging material which is laid down on one or more plates 16), while the supply sheet 37 returns to the return roll 38.

[0055] In some exemplary embodiments, the tension roller 36 is configured to contact and press the sheet 34 of top packaging material against the sheet 24 of bottom packaging material disposed on the top surface of one or more plates 16 (e.g., based on a particular position of the tension roller 36 relative to the conveyor 10 and thus the plates 16) as the composite affixed sheet 34 / 37 moves around the tension roller 36. The sheet 34 of top packaging material may detach from the supply sheet 37 based on being pressed against the sheet 24 by the tension roller 36. For example, in some exemplary embodiments, the sheet 34 may include an at least partially adhesive (e.g., at least lightly adhesive) material that detaches from the supply sheet 37 based on being pressed against the portion of the sheet 24 of bottom packaging material by the tension roller 36, such that the sheet 34 lightly adheres to a portion (e.g., a top surface) of the sheet 24 of bottom packaging material on the one or more plates 16 against which the tension roller 36 affixes the sheet 34, such that the sheet 34 detaches from the supply sheet 37 based on being pressed against the portion of the sheet 24 of bottom packaging material by the tension roller 36.

[0056] As a result of the sheet 34 of top packaging material detaching from the supply sheet 37 and being laid down on the sheet 24 of bottom packaging material laid down on one or more plates 16, the sheet 34 of top packaging material is prevented from returning to the return roll 38 with the supply sheet 37 by covering the cavities 18 of the plate 16 (e.g., by the tension roller 36) as the plate 16 moves under the tension roller 36. The conveyor assembly 10 may be operable to move the plate 16 from the apparatus 100 to the top packaging assembly 30 so that the sheet 34 is at least partially vertically overlapping (e.g., vertically aligned or vertically overlapping in the vertical direction V) the tension roller 36, thereby causing the tension roller 36 to detach the sheet 34 from the supply sheet 37 and cover the cavities 18 of the plate 16. A plate 16 in the top packaging assembly 30 may include in one or more cavities 18 thereof strips 11 of compressible material laid over a portion 21 of a sheet of bottom packaging material 24 that is forced into the cavity 18 below the strips 11, such that an overlapping sheet 34 of top packaging material covers the strips 11 in each separate cavity 18, and overlaps the sheet of bottom packaging material 24 such that each separate strip 11 in a separate cavity 18 is covered by a separate portion 31 of the sheet of top packaging material 34. In some exemplary embodiments, a return roll 38 may be connected to a driver that rotates the return roll 38 to feed a supply sheet 37 with attached sheet 34 from the supply roll 32 to a tension roller 36 to disengage the sheet 34 of top packaging material from the supply sheet 37. The feed rate of such sheets 34 / 37 may be matched to the speed of movement of the endless loop of the plate 16.

[0057] The conveyor assembly 10 may operate to move the plate 16 from the upper packaging assembly 30 to the sealing / inspection assembly 40. The sealing assembly 42 may join the portions 31 of the sheet of upper packaging material 34 covering the respective cavities 18 of the plate 16 with the respective portions 21 of the sheet of lower packaging material 24 covering the pieces 11 in the respective cavities 18. Joining such a separate set of the portions 21, 31 of packaging material to each cavity 18 may also include separating the portions 21, 31 from the remainder of the respective sheets 24, 34 of packaging material to form a pouch 91 of the portions 21, 31 of packaging material joined together by any known means of joining packaging portions (e.g., fused together, stamped together, etc.) to contain and / or enclose the respective separate pieces 11 of compressible material in the respective cavities 18. The closure assembly 42 may be configured to remove the remnants of each sheet 24, 34 of packaging material laid on the plate 16 in the closure assembly 42 based on mechanically removing the remnants of each sheet 24, 34, such as via a mechanical manipulator device that actively grips and moves the remnants of the respective sheets 24, 34 from the plate 16, a shoulder that passively guides the remnants of the respective sheets 24, 34 to slide off the plate 16 as the plate moves relative to the closure assembly 42, a device that directs an air flow that pushes or pulls the remnants of the respective sheets 24, 34 from the plate 16, any combination thereof, etc. The inspection assembly 44 may scan and / or monitor some or all of the plate 16 to generate sensor data that may be processed (e.g., by a computing device) to determine whether the pouches 91 in the cavities 18 of the plate 16 are properly formed.

[0058] The conveyor assembly 10 operates to move the plate 16 from the sealing / inspection assembly 40 to the discharge station 60 around the endless loop such that packaging pieces 99 in the cavities 18 of the plate 16 are ejected from the cavities 18 as the plate 16 moves from the assembly 40 to the assembly 20 around the conveyor assembly 10 via the discharge station 60, for example, the packaging pieces 99 may fall out of the cavities 18 of the plate 16 as the plate is inverted at the discharge station 60 due to its movement around the endless loop. As a result, the compressed material pieces 11 may be packaged into individual packaging pieces 99 and ejected from the manufacturing system 1 at the discharge station 60.

[0059] 1 , the apparatus 100 may be a reciprocating manufacturing apparatus configured to form and provide (e.g., discharge) pieces of compressed material 11 based on one or more portions of the apparatus 100 reciprocating along a longitudinal axis L between various fixed positions relative to the manufacturing system 1. The apparatus 100 may be configured to compress and divide (e.g., cut, section, etc.) a bulk compressible material 82 provided from a bulk material source 80 into separate pieces 11 such that each piece 11 has a specific (or alternatively, predetermined) density, volume, and mass based on such movement. As a result, the manufacturing system 1 may be configured to provide pieces of compressible material 11 having precise and consistent volumes, densities, and masses, and thus more consistent packaging material products.

[0060] Although plate 16 is shown as including an array of multiple cavities 18, it will be understood that a given plate 16 may be limited to including a single cavity 18, and apparatus 100 may include array 118-A limited to a single dispense line 118-C that may vertically overlap a single cavity 18 upon the plate being moved to position 90.

[0061] 1 , the manufacturing system 1 may include first and second gas sources 90-1, 90-2 of one or more gases, one or more servo mechanisms 70, and one or more controllers 92. The controller 92 may be communicatively coupled to the servo mechanisms 70 and / or the gas sources 90-1, 90-2 (e.g., gas source valves included in the gas sources 90-1, 90-2) and may be configured to control operation of the apparatus 100 to form and provide compressed material pieces 11 based on compressing and splitting the bulk compressible material 82 by controlling the servo mechanisms 70 and / or the gas sources 90-1, 90-2. The servo mechanisms 70 may be fixed to one or more portions of the apparatus 100 and may be configured to operate the movement of one or more (e.g., reciprocating) portions between distinct positions relative to one or more other (e.g., fixed) portions of the apparatus 100 along the longitudinal axis L. The first and second gas sources 90-1, 90-2 may be configured to supply first and second gases 94-1, 94-2 to the apparatus 100 via separate respective gas lines 91-1, 91-2 (e.g., pipes, tubes, etc.) to enable compression and / or ejection of objects (e.g., small pieces, discrete volumes, etc.) of compressible material from the apparatus 100.

[0062] The controller 92 (also referred to herein as a computing device) may be included in, include, and / or be implemented by one or more objects of processing circuitry, such as hardware including logic circuitry, a hardware / software combination, such as a processor executing software, or a combination thereof. For example, the controller 92 may include, but is not limited to, a central processing unit (CPU), an application processor (AP), an arithmetic logic unit (ALU), a graphics processing unit (GPU), a digital signal processor, a microcomputer, a field programmable gate array (FPGA), a system on a chip (SoC), a programmable logic device, a microprocessor, or an application specific integrated circuit (ASIC), etc. In some exemplary embodiments, the controller 92 may include a non-transitory computer readable storage device, such as a solid state drive (SSD) that stores a program of instructions, and the controller 92 may include processing circuitry that may be configured to execute the program of instructions to perform the functions of the controller 92 and at least control the operation of the device 100.

[0063] In some exemplary embodiments, the controller 92 may be configured to control the operation of the manufacturing system 1 by controlling some or all of the assemblies and / or devices of the manufacturing system 1. For example, the controller 92 may be configured to control the drive motor 13, the drivers connected to the return rolls 28 and 38, the sealing / inspection assembly 40, some combination thereof, etc. The controller 92 may be configured to control and / or adjust the operation of the manufacturing system 1 (e.g., adjust the flow rate of the first gas 94-1 and / or the flow rate of the second gas 94-2, adjust the speed of the driver motor 13, adjust the movement of the servo mechanism 70, etc.) based on processing the sensor data generated by the inspection assembly 44.

[0064] The first gas source 90-1 may include a container that holds the first gas 94-1 and a gas flow control valve configured to adjustably control the release (e.g., supply) of the first gas 94-1 from the container. The first gas source 90-1 may be configured to supply the first gas 94-1 to the apparatus 100 (e.g., via a first gas line 91-1 that may be coupled to the gas flow control valve of the first gas source 90-1) to cause compression of the bulk body of compressible material 84 in at least a portion of the apparatus 100. The first gas 94-1 may be supplied at a pressure that exceeds the ambient pressure of the ambient environment surrounding the apparatus 100 ("positive pressure"). For example, the first gas source 90-1 may be configured to supply the first gas 94-1 to the apparatus 100 at a pressure of about 10 psig. The first gas 94-1 may be provided to compress the bulk body 84 of compressible material within the apparatus 100 such that the bulk body has a new, particular density. The first gas 94-1 may be provided to force at least a portion of the bulk body 84 of compressible material into a particular, fixed volume either before, during, or after compression of the compressible material. The controller 92 may control the flow of the first gas 94-1 (e.g., based on control of a gas flow control valve of the first gas source 90-1) (e.g., based on control of a gas flow control valve of the first gas source 90-1) to regulate, throttle, initiate, etc., the flow of the first gas 94-1 provided by the first gas source 90-1.

[0065] The amount of compression and / or the particular density of the compressed material of the particles 11 resulting from compression may be determined based on the supply and / or pressure of the first gas 94-1. This may be determined in the controller 92 based on accessing a look-up table (LUT) that correlates a density value of the compressed material of the particles 11 with a control signal and / or control position of a gas flow control valve of the first gas source 90-1 that causes compression of the compressible material to that density value. Such a look-up table may be created according to well-known empirical techniques of creating a look-up table based on experimental data (e.g., by compressing the particles of compressible material with the first gas 94-1 at various pressures and / or control positions of the gas flow control valve and correlating the resulting density value with the control position of the gas flow valve and / or control signal sent to the first gas source 90-1).

[0066] Each dispense line 118-C of array 118-A may have a fixed volume defined by the dimensions of the inner surface 118-S that defines dispense line 118-C. Apparatus 100 may section ("split") compacted body 86 of compressible material such that portions 86-2 of compacted body 86 within the fixed volume space of dispense line 118-C become discrete pieces of compressed material 11 having a specific volume defined by the fixed volume dimensions of dispense line 118-C. Apparatus 100 may cause pieces 11 to be severed from remaining portion 86-1 of compacted body 86 and then discharged from apparatus 100 via dispense line outlet 118-O. The size and shape (e.g., volume) of pieces 11 may be defined by the dimensions of the fixed volume space of dispensing line 118-C in which portion 86-2 of compressed body 86 is held, such that each formed piece 11 has the same or substantially the same volume (e.g., the same volume within manufacturing and / or material tolerances). Additionally, the density of each piece 11 may be based on the amount of compression of bulk body of compressible material 84 to form compressed body 86 present at least in part in dispensing line 118-C. The amount of compression may be controlled via control of the flow of first gas 94-1, such that the density of pieces 11 may be the same or substantially the same based on controlling the supply of first gas 94-1 to control the pressing and / or compression of bulk body of compressible material 84 in dispensing line 118-C.

[0067] The second gas source 90-2 may include a container that holds the second gas 94-2 and a gas flow control valve configured to adjustably control the release (e.g., supply) of the second gas 94-2 from the container. The second gas source 90-2 may be configured to supply the second gas 94-2 to the apparatus 100 (e.g., via a second gas line 91-2 that may be coupled to the gas flow control valve of the second gas source 90-2) to expel ("provide," "feed," "extrude," etc.) one or more portions of the compressed material (e.g., pieces 11) from a fixed volume space (e.g., dispensing line 118-C) of the apparatus 100 in which the pieces 11 were formed to an exterior of the apparatus 100. Thus, the second gas source 90-2 may be understood to be configured to supply the second gas 94-2 to the apparatus 100 to cause one or more pieces 11 to be expelled from the apparatus 100. The controller 92 may control the flow of the second gas 94-2 ("flow rate," "flow rate," some combination thereof, etc.) by controlling the second gas source 90-2 (e.g., based on control of a gas flow control valve of the second gas source 90-2) to adjust, throttle, initiate, etc., the flow of the second gas 94-2 supplied by the second gas source 90-2.

[0068] The timing of the flow of the first gas 94-1 and the second gas 94-2 may be determined in the controller 92. In some exemplary embodiments, the controller 92 may cause the flow of the first gas 94-1 and the second gas 94-2 to the apparatus 100 to be continuous during operation of the apparatus.

[0069] In some exemplary embodiments, the first and second gas sources 90-1 and 90-2 are the same gas source (common or same gas source) configured to supply a common or same gas via separate gas lines 91-1 and 91-2 and / or separate gas flow control valves, respectively, to compress the bulk body 84 of compressible material within the apparatus 100 and to discharge one or more pieces 11 of compressed material from the apparatus 100. The first and second gases 94-1 and 94-2 may be supplied to the apparatus 100 by a common gas source and / or different gas sources at a common pressure or at different pressures. As described herein, the first and second gases 94-1 and 94-2 may be any gas, including air. In some exemplary embodiments, including exemplary embodiments in which the first and second gas sources 90-1 and 90-2 are different gas sources, the first and second gases 94-1 and 94-2 may be different gases.

[0070] In some exemplary embodiments, the controller 92, servo mechanism 70, first gas source 90-1, and / or second gas source 90-2 may be considered to be part of the apparatus 100. In some exemplary embodiments, one or more characteristics of the pieces 11 formed by the apparatus 100 may be controlled (e.g., based on the controller 92 accessing a look-up table that associates control signals for one or more components of the manufacturing system 1 with one or more characteristics of the pieces 11) to provide a packaged product having one or more relatively consistent characteristics. For example, at least a portion of the apparatus 100 (e.g., the controller 92) may be configured to control the density, mass, and / or volume of the compressed pieces 11 of material provided by the apparatus 100 to provide a relatively consistent end product to the consumer, where each packaged piece 99 includes the same or substantially the same (e.g., the same within manufacturing and / or material tolerances) mass, volume, density, and / or shape of the compressed material. It will be understood that, as used herein, when components and / or characteristics are described as being "same," the components and / or characteristics may be substantially the same.

[0071] In some exemplary embodiments, based on the material to be divided for packaging the individual portions being a compressible material, at least the density and / or weight of the individual pieces 11 of the compressed material may be at least partially controlled (e.g., by at least a part of the apparatus 100 including the control device 92) based on compressing the bulk body 84 of the compressible material in the apparatus 100 to achieve a particular density of the compressed material, and then dividing (e.g., cutting, dividing, separating, etc.) the compressed bulk body into multiple portions (e.g., pieces 11 and remaining portion 86-1) so that each divided piece 11 has a relatively common density that is at least approximately the particular density.

[0072] In some exemplary embodiments, compressible materials as described herein have flowable properties (e.g., are "moist" and / or "wet") such that the material may have a relatively high viscosity and may be at least lightly adherent to various surfaces (e.g., may be "sticky"). Such materials may at least partially adhere to a portion of the apparatus 100, such as an inner surface of a channel through which the material is compressed. In some exemplary embodiments, the apparatus 100 according to some exemplary embodiments, including at least the exemplary embodiment shown in FIGS. 2A-11, is configured to enable compression and division of a bulk body 84 of compressible material, providing an improved apparatus for dividing a compressible material into pieces having a specific volume, density, and / or mass based on utilizing one or more gas supplies to at least partially compress the bulk body 84 of compressible material into a fixed volume dispensing line 118-C and ejecting divided pieces 11 of the compressed material from the dispensing line 118-C. The use of such a gas may allow for relatively simple, quick and easily adjustable control of material compression and ejection while reducing apparatus complexity, reducing maintenance requirements, and / or reducing the risk of disturbing a target density and / or volume of the material segments during ejection of the objects from the apparatus 100. In some exemplary embodiments, the bulk compressible material 82 that can be compressed and separated into compressed material pieces 11 may include tobacco.

[0073] 2A-11 are perspective views of one or more portions of an apparatus 100 including a stationary assembly 102 and a reciprocating assembly 104 configured to move along a longitudinal axis L relative to the stationary assembly, according to some exemplary embodiments.

[0074] FIG. 2A is a perspective view of an apparatus including a fixed assembly and a reciprocating assembly in a first position relative to the fixed assembly, according to some exemplary embodiments. FIG. 2B is a perspective view of an apparatus including a fixed assembly and a reciprocating assembly in a second position relative to the fixed assembly, according to some exemplary embodiments. FIG. 2C is a perspective view of an apparatus including a fixed assembly and a reciprocating assembly in a third position relative to the fixed assembly, according to some exemplary embodiments. FIGS. 3A, 3B, and 3C are cross-sectional views of the apparatus of FIGS. 2A, 2B, and 2C, respectively, along line I-I′, according to some exemplary embodiments. FIGS. 4A, 4B, and 4C are enlarged views of region A of FIGS. 3A, 3B, and 3C, respectively, according to some exemplary embodiments. FIGS. 5A, 5B, and 5C are enlarged views of region B of FIGS. 3A, 3B, and 3C, respectively, according to some exemplary embodiments. FIGS. 6A, 6B, and 6C are cross-sectional views of the apparatus of FIGS. 2A, 2B, and 2C, respectively, along line II-II′, according to some exemplary embodiments. 7A, 7B, and 7C are cross-sectional views of the devices of FIGS. 2A, 2B, and 2C along line III-III', respectively, according to some exemplary embodiments. FIGS. 8A, 8B, and 8C are cross-sectional views of the devices of FIGS. 2A, 2B, and 2C along line IV-IV', respectively, according to some exemplary embodiments. FIGS. 9A, 9B, and 9C are cross-sectional views of the devices of FIGS. 2A, 2B, and 2C along line V-V', respectively, according to some exemplary embodiments. FIGS. 10A, 10B, and 10C are perspective views of the devices according to some exemplary embodiments. FIG. 11 is an enlarged view of region B of FIG. 3B, according to some exemplary embodiments.

[0075] As shown in FIGS. 2A-11, the apparatus 100 may include a stationary assembly 102 (see, e.g., FIG. 2A) configured to be fixed in a predetermined position (e.g., fixed in a predetermined position relative to other assemblies 10, 20, 30, 40 of the manufacturing system 1) and a reciprocating assembly 104 (see, e.g., FIG. 2A) configured to move along a longitudinal axis L between various distinct positions (e.g., P1, P2, P3 as shown in at least FIGS. 2A-2C, respectively) relative to the stationary assembly 102. As shown in FIG. 1, the apparatus 100 may be connected to a servo mechanism 70. In some exemplary embodiments, the servo mechanism 70 may be connected to the reciprocating assembly 104, and the servo mechanism 70 may be configured to operate to move the reciprocating assembly 104 along the longitudinal axis L relative to the stationary assembly 102 between various positions. It will be understood that the servo mechanism 70 may be any known servo mechanism.

[0076] As described herein and shown at least in FIGS. 2A-2C, the reciprocating assembly 104 is configured to create separate bulk bodies 84 of compressible material within each separate channel conduit 120-C by moving along a longitudinal axis L relative to the stationary assembly 102 (e.g., in sliding engagement with one or more portions of the stationary assembly 102) between separate positions to receive the bulk compressible material 82 within the channel conduit 120-C of the reciprocating assembly 104 (see, e.g., FIG. 3A). It will be understood that a "bulk body" of compressible material may refer to a discrete, separate mass of bulk compressible material 82 within the separate channel conduit 120-C of the reciprocating assembly 104. The bulk bodies 84 may include uncompressed bulk compressible material, partially compressed compressible material, compressed compressible material, any combination thereof, and the like.

[0077] The shuttle assembly 104 is further configured to at least partially push the bulk body 84 of compressible material from the channel line 120-C holding the bulk body 84 into a respective separate dispensing line 118-C and compress the at least partially pushed compressible material to create a compressed body 86 of compressible material, each of which at least partially, and partially or completely fills a fixed volume space within the respective separate dispensing line 118-C (see, e.g., FIG. 3B ). The particular portions 86-2 of the compressed body 86 of compressed material within each separate dispensing line 118-C are compressed pieces of material 11 each having a particular volume defined by the respective fixed volume space of the respective dispensing line 118-C and a particular density defined by compression of the compressible material of the compressed body 86 at least partially present within the respective fixed volume space.

[0078] Shutting assembly 104 is further configured to separate (e.g., cut, divide, separate, etc.) portions 86-2 (e.g., pieces 11) of compressed material in dispensing line 118-C from remaining portions 86-1 of compacted body of material 86 (see, e.g., FIG. 3C). Shutting assembly 104 is further configured to discharge from dispensing line 118-C via respective dispensing line outlets 118-O into respective separate cavities 18 of plate 16 that are moved to position 90 vertically overlapping array 118-A of dispensing line 118-C such that each cavity 18 of plate 16 is vertically aligned (e.g., overlapping in vertical direction V) with a separate dispensing line 118-C of array 118-A (see, e.g., FIG. 3C).

[0079] As a result, the apparatus 100 can be configured to provide a more consistent product of compressed material for packaging by providing pieces of compressed material 11 having a more consistent volume and density (determined by the fixed volume of the fixed volume space and the amount of compression of the compressible material within the fixed volume space, respectively) to form packaging pieces 99.

[0080] As shown in FIGS. 2A-11, the stationary assembly 102 may include a first hopper 110-1 and a second hopper 110-2 (see, e.g., FIG. 2A), each of which is exposed to a bulk material source 80 and configured to receive and hold a bulk compressible material 82 within respective interior spaces defined by outer wall structures of the first and second hoppers 110-1, 110-2.

[0081] The stationary assembly 102 further includes a first gas manifold 112 (see, e.g., FIG. 2B) including one or more first manifold conduits 114-C (see, e.g., FIG. 2A) defined by one or more inner surfaces 114-S (see, e.g., FIG. 4B-4C) of the first gas manifold 112. The one or more first manifold conduits 114-C extend from one or more first manifold inlets 112-I (see, e.g., FIG. 4B-4C) to one or more corresponding first manifold outlets 112-O (see, e.g., FIG. 4B-4C). As shown, one or more first manifold inlets 112-I are coupled to a first gas line 91-1 (see, e.g., FIG. 2A), and the first gas manifold 112 is configured to direct a first gas 94-1 from a first gas source 90-1 via one or more first manifold lines 114-C (see, e.g., FIG. 4B) to one or more first manifold outlets 112-O.

[0082] Stationary assembly 102 further includes a dispense receptacle defining an array 118-A (see, e.g., FIG. 4B) of dispense lines 118-C (see, e.g., FIGS. 9A-9C, 10A-10C, 11), each extending between a dispense line inlet 118-I (see, e.g., FIG. 4B) and a dispense line outlet 118-O (see, e.g., FIG. 4B). Dispense lines 118-C may each at least partially vertically overlap (e.g., overlap in vertical direction V) with one or more first manifold outlets 112-O (see, e.g., FIGS. 3A-3C) based on the position of shuttle assembly 104. In FIGS. 2A-11, the dispense receptacle is bottom plate 118 (see, e.g., FIGS. 2A, 3A). 2A-11, bottom plate 118 includes an inner surface 118-S (see, e.g., FIG. 4B) that defines an array 118-A (see, e.g., FIG. 10C) of dispense lines 118-C, each separate dispense line 118-C extending between a separate dispense line inlet 118-I and a separate dispense line outlet 118-O (see, e.g., FIG. 10C). 2A-11, array 118-A of dispense lines 118-C are vertically aligned (e.g., overlap in vertical direction V) with position 90 of manufacturing system 1 and are configured to be vertically aligned with each separate cavity 18 of plate 16 when plate 16 is at position 90 (see, e.g., Figures 3C, 9A-9C, 10A-10C) such that pieces 11 located in dispense lines 118-C of array 118-A can be discharged into each separate cavity 18 of plate 16 at position 90 (see, e.g., Figures 3C, 5C).

[0083] As further shown, bottom plate 118 has a top surface 118u and an opposing bottom surface 118b (see, e.g., FIG. 5A), with dispense conduits 118-C defined by inner surface 118-S of bottom plate 118 extending through thickness 118T of bottom plate 118 (see, e.g., FIG. 4B) from respective dispense conduit inlets 118-I at top surface 118u to respective dispense outlets 118-O at bottom surface 118b (see, e.g., FIG. 4B). It will be understood that exemplary embodiments of dispense containers are not limited to bottom plate 118, but may include any other structure having one or more inner surfaces 118-S defining one or more dispense conduits 118-C.

[0084] 2A-11, the base plate 118 defines an array 118-A of multiple dispensing lines 118-C (e.g., a 4×3 array of 12 dispensing lines 118-C), although exemplary embodiments are not limited thereto, and in some exemplary embodiments, the dispensing container (e.g., the base plate 118) of the fixing assembly 102 may define an array 118-A that is limited to a single individual dispensing line 118-C.

[0085] It will be appreciated that each of the first hopper 110-1, the second hopper 110-2, the first gas manifold 112, and the dispensing vessel (e.g., bottom plate 118) are configured to be fixed in a predetermined position relative to the remainder of the manufacturing system 1 (e.g., relative to the conveyor assembly 10, the location 90, etc.) throughout operation of the apparatus 100 to compress and divide the bulk compressible material 82 into one or more pieces 11 of compressed material. It will be appreciated that in some exemplary embodiments, the fixture assembly 102 may omit one or more of the components of the fixture assembly 102 shown in FIGS. 2A-11. For example, in some exemplary embodiments, the fixture assembly 102 may not include the second hopper 110-2.

[0086] 2A-11, the reciprocating assembly 104 may include the first and second arrays 121-1 and 121-2 of the channel assembly 120 (see, e.g., FIG. 2A), the upper plate 122 (see, e.g., FIG. 2A), the lower plate 124 (see, e.g., FIG. 2A), the second gas manifold 140 (see, e.g., FIG. 2A), the shielding plates 126-1 and 126-2 (see, e.g., FIG. 2A), and a coupling structure 129 (see, e.g., FIG. 2A) coupling the shielding plates 126-1 and 126-2 to the lower plate 124. One or more structures of the reciprocating assembly 104 (e.g., the lower plate 124) may be connected to a servo mechanism 70 (see, e.g., FIG. 1), and the reciprocating assembly 104 may be configured to move relative to the stationary assembly 102 along the longitudinal axis L based on, for example, the operation of the servo mechanism 70. It will be appreciated that in some exemplary embodiments, the reciprocating assembly 104 may omit one or more components of the reciprocating assembly 104 shown in Figures 2A-11. For example, in some exemplary embodiments, the reciprocating assembly 104 may omit the second array 121-2 of the channel assembly 120 and may omit the second shield plate 126-2.

[0087] As shown in FIGS. 2A-11, the channel assemblies 120 of the first array 121-1 may be referred to as the first channel assembly 120-1 (see, e.g., FIG. 2A), and the channel assemblies of the second array 121-2 may be referred to as the second channel assembly 120-2 (see, e.g., FIG. 2A). Although the arrays 121-1, 121-2 are shown in FIGS. 2A-11 as each including a 4×3 array of twelve channel assemblies 120, it will be understood that each array 121-1, 121-2 may include any number of channel assemblies 120, including a single separate channel assembly 120. Additionally, it will be understood that in some exemplary embodiments, the second array 121-2 of the second channel assembly 120-2 is excluded from the device 100.

[0088] In some exemplary embodiments, each channel assembly 120 may be defined by one or more structures of the shuttle assembly 104. Each channel assembly 120 may include one or more inner surfaces 120-S (see, e.g., FIG. 4A) that define a channel conduit 120-C (see, e.g., FIG. 4A) that extends between a channel conduit inlet 120-I and a channel conduit outlet 120-O (see, e.g., FIG. 4A). It will be understood that the channel conduit 120-C of the first channel assembly 120-1 may be referred to as the "first channel conduit 120-C1" (see, e.g., FIG. 3A), the channel conduit inlet 120-I of the channel conduit 120-C may be referred to as the "first channel conduit inlet 120-I" (see, e.g., FIG. 3A), and the channel conduit outlet 120-O of the channel conduit 120-C of the first channel assembly 120-1 may be referred to as the "first channel conduit outlet 120-O1" (see, e.g., FIG. 3A). It will be further understood that the channel conduit 120-C of the second channel assembly 120-2 may be referred to as the "second channel conduit 120-C2" (see, e.g., FIG. 3A), the channel conduit inlet 120-I of the channel conduit 120-C of the second channel assembly 120-2 may be referred to as the "second channel conduit inlet 120-I2" (see, e.g., FIG. 3A), and the channel conduit outlet 120-O of the channel conduit 120-C of the second channel assembly 120-2 may be referred to as the "second channel conduit outlet 120-O2" (see, e.g., FIG. 3A).

[0089] As shown in Figures 2A-11, the first and second arrays 121-1 and 121-2 of channel assemblies have an arrangement and number of channel assemblies 120, and thus channel conduits 120-C, that are identical to the arrangement and number of dispense conduits 118-C in array 118-A and the arrangement and number of cavities 18 in each plate 16. As a result, as shown in Figures 2A-11, dispense conduits 118-C may be configured to be exposed by vertically aligning with respective separate first channel conduits 120-C1 based on the reciprocating assembly 104 being in a second position P2 (see, e.g., Figure 9B). As further shown in Figures 2A-11, dispense conduits 118-C may be configured to be exposed by vertically aligning with respective separate second channel conduits 120-C2 based on the reciprocating assembly 104 being in a first position P1 (see, e.g., Figure 9A). As further shown in Figures 1-11, dispensing conduits 118-C may be configured to vertically align with respective separate cavities 18 of plate 16 that have been moved to position 90 to vertically overlap array 118-A of apparatus 100 based on operation of conveyor assembly 10 and based on shuttle assembly 104 being in third position P3 (e.g., see Figures 9C, 3C).

[0090] 2A to 11, the reciprocating assembly 104 may include an upper plate 122 having an upper surface 122u in sliding contact with the hoppers 110-1, 110-2 and the first gas manifold 112 (see, for example, FIG. 3A). As shown in FIG. 2A to 11, the reciprocating assembly 104 may include a lower plate 124 having a bottom surface 124b in sliding contact with an upper surface 118u of the bottom plate 118 (see, for example, FIG. 3A).

[0091] As shown in Figures 2A-11, the lower plate 124 includes one or more inner surfaces 124-S (see, for example, Figure 4A) that define one or more lower conduits 124-C each extending through a thickness 124T (see, for example, Figure 4A) of the lower plate 124 between an upper opening 124-I (see, for example, Figure 4A) of the lower conduit 124-C and a bottom opening 124-O (see, for example, Figure 4A) of the lower conduit 124-C. As shown in Figures 2A-11, the bottom opening 124-O of each lower conduit 124-C defines a channel conduit outlet 120-O (see, for example, Figure 4A) of each respective channel conduit 120-C of each respective channel assembly 120 at a bottom surface 124b (see, for example, Figure 4A) of the lower plate 124.

[0092] 2A-11, each channel assembly 120 may include a cylindrical structure 420 (see, e.g., FIG. 4A). Each cylindrical structure 420 may be coupled at an upper end to the upper plate 122 and at a lower end to the lower plate 124. The cylindrical structure 420 includes one or more inner surfaces that define an upper conduit 420-C (see, e.g., FIG. 4A) that extends through the cylindrical structure 420 between an upper opening 420-I (see, e.g., FIG. 4A) at an upper end of the cylindrical structure 420 and a bottom opening 420-O (see, e.g., FIG. 4A) at a lower end of the cylindrical structure 420. 2A-11, the bottom end of each cylindrical structure 420 may be coupled to the lower plate 124 such that the upper conduit 420-C of the cylindrical structure 420 is exposed through its bottom opening 420-O to the separate lower conduit 124-C of the lower plate 124 through its upper opening 124-I (see, for example, FIG. 4A). Thus, in some exemplary embodiments, each separate channel assembly 120 is defined by a separate cylindrical structure 420 and a separate portion of the lower plate 124 to which the separate cylindrical structure 420 is coupled (see, for example, FIG. 4A), such that the channel conduit 120-C of the channel assembly 120 is collectively defined by the upper conduit 420-C of the cylindrical structure 420 and the lower conduit 124-C to which the upper conduit 420-C is exposed upon coupling of the cylindrical structure 420 to the lower plate 124 (see, for example, FIG. 4A). As a result, the upper opening 420-I of a given upper conduit 420-C may define a channel conduit inlet 120-I of a separate channel conduit 120-C of a separate channel assembly 120 at the upper surface 122u of the upper plate 122 (see, for example, FIG. 4), and the bottom opening 124-O of a lower conduit 124-C exposed to a given upper conduit 420-C may define a channel conduit outlet 120-O of a separate channel conduit 120-C of a separate channel assembly 120 at the bottom surface 124b of the lower plate 124 (see, for example, FIG. 4A).

[0093] As described herein, conduits and / or spaces that are "open" or "exposed" to one another will be understood to at least partially and collectively define conduits and / or spaces that are "open" or "exposed" to one another based on at least partial alignment of the conduits' and / or spaces' respective inlets and / or outlets with one another, thereby allowing for fluid (e.g., gas) flow by being "directly" or "indirectly" exposed to one another (e.g., with or without any intervening structures, conduits, and / or spaces, respectively). It will be understood that the terms "open" and "exposed" may be used interchangeably in reference to conduits, inlets, and / or outlets that are exposed to one another.

[0094] As further shown in FIGS. 2A-11, each of the predetermined cylindrical structures 420 may include a cylinder 130 (see, for example, FIG. 4A) whose upper end is coupled to the upper plate 122, such that the upper end opening 130-I of the cylinder 130 defines the upper end opening 420-I of the upper conduit 420-C, and thus the channel conduit inlet 120-I of the predetermined channel conduit 120-C (see, for example, FIG. 4A). As further shown in FIGS. 2A-11, the predetermined cylindrical structure 420 may further include a cylindrical sheath 132 (see, for example, FIG. 4A). The cylindrical sheath 132 may be slidably engaged at the upper end of the cylindrical sheath 132 with the bottom end of the cylinder 130, so that the bottom opening 130-O of the cylinder 130 is directly exposed to the upper opening 132-I of the cylindrical sheath 132 (see, for example, FIG. 4A). The cylindrical sheath 132 may be slidably engaged with the lower plate 124 at the bottom end of the cylindrical sheath 132, so that the bottom opening 132-O of the cylindrical sheath 132 defines the bottom opening 420-O of the upper conduit 420-C (see, for example, FIG. 4A). As shown in FIGS. 2A to 11, a given cylinder 130 may have an inner surface 130-S that at least partially defines the cylinder conduit 130-C, and the cylindrical sheath 132 may have an inner surface 132-S that at least partially defines the sheath conduit 132-C (see, for example, FIG. 4A). The sheath conduit 132-C is exposed to the cylinder conduit 130-C through the openings 130-O and 132-I that are exposed to each other, so that the conduits 130-C and 132-C collectively define the upper conduit 420-C.

[0095] In some exemplary embodiments, each given cylindrical structure 420 may further include a spring 402 (see, e.g., FIG. 4A ) that extends at least partially vertically (e.g., along a direction V) between the cylindrical sheath 132 and the upper plate 122 and is coupled to at least the cylindrical sheath 132 and configured to provide a spring force that urges the cylindrical sheath 132 downward in the vertical direction V toward the lower plate 124. In some exemplary embodiments, the cylindrical sheath 132 may be configured to be urged away from the lower plate 124 (e.g., upward in the vertical direction V), for example, along an annular track 404 (see, e.g., FIG. 4A ) defined by the outer surface of the cylinder 130, to open an annular channel 133-C (see, e.g., FIG. 4A-4B ) that extends between an outer surface 132-OS of the cylindrical sheath 132 (see, e.g., FIG. 4A-4B ) and an inner surface 124-IS of the lower plate 124 (see, e.g., FIG. 4A-4B ).

[0096] 2A-11, the reciprocating assembly 104 includes a second gas manifold 140 defined by one or more inner surfaces 140-S of the second gas manifold 140 and including one or more second manifold conduits 140-C (see, e.g., FIG. 5A) extending from one or more second manifold inlets 140-I to one or more corresponding second manifold outlets 140-O (see, e.g., FIG. 5A). As shown, the one or more second manifold inlets 140-I are coupled to a second gas conduit 91-2 (see, e.g., FIG. 2A), and the second gas manifold 140 is configured to direct a second gas 94-2 from a second gas source 90-2 through the one or more second manifold conduits 140-C (see, e.g., FIG. 5C, 7C, 8C, 9C, 11) to the one or more second manifold outlets 140-O.

[0097] In the exemplary embodiment shown in Figures 2A-11, the second gas manifold 140 is coupled to an upper surface 124u (see, e.g., Figure 5A) of a lower plate 124, the lower plate 124 including one or more inner surfaces 440-S (see, e.g., Figure 5A) that define manifold conduits 440-C (see, e.g., Figure 5A) that extend through a thickness 124T of the lower plate 124 between separate respective manifold conduit inlets 440-I (see, e.g., Figure 5A) at the upper surface 124u of the lower plate 124 and separate respective manifold conduit outlets 440-O (see, e.g., Figure 5A) at a bottom surface 124b of the lower plate 124. The one or more manifold conduits 440-C are exposed to one or more second manifold outlets 140-O (see, e.g., Figure 5A) via respective manifold conduit inlets 440-I.

[0098] As shown in Figures 2A-11, manifold line outlets 440-O may be exposed to separate respective dispense line inlets 118-I (see, e.g., Figures 5C, 9C, 10C, 11) depending on the relative position of reciprocating assembly 104 with respect to fixed assembly 102 (third position P3 as shown in Figures 2A-11), such that second manifold outlets 140-O may be exposed to dispense line inlets 118-I of array 118-A of dispense lines 118-C via manifold line 440-C. As shown in Figures 2A-11, each manifold line 440-C has a variable cross-sectional diameter (see, e.g., Figure 5A) along the length of the manifold line 440-C between manifold line inlet 440-I and manifold line outlet 440-O, such that the diameter of manifold line inlet 440-I is the same or substantially the same as the diameter of second manifold outlet 140-O to which manifold line inlet 440-I exposes, and the diameter of manifold line outlet 440-O may be the same or substantially the same as the diameter of one or more dispense line inlets 118-I to which manifold line outlet 440-O is exposed. Thus, a gas (e.g., second gas 94-2) that may be directed from second manifold outlet 140-O through manifold line 440-C to dispensing line 118-C may be made to flow through a cross-sectional area that is the same or substantially the same as dispensing line inlet 118-I, thereby enabling the gas (e.g., second gas 94-2) to have a relatively uniform distribution of gas impingement on the pieces of compressed material 11 held in dispensing line 118-C (e.g., see FIG. 5C ), reducing the risk of the pieces being destroyed due to uneven distribution of gas (e.g., second gas 94-2) on the top surface of the pieces 11, while enabling a relatively uniform pressure distribution on the pieces 11 and enabling the gas to push the pieces 11 out of dispensing line 118-C.

[0099] As shown in FIGS. 2A-11, the second gas manifold 140 may include multiple conduit substructures 141 (see, for example, FIG. 5A ), each having one or more second manifold inlets 140-I, second manifold conduits 140-C, and second manifold outlets 140-O, although exemplary embodiments are not limited thereto, and in some exemplary embodiments, the second gas manifold 140 may include a single structure having one or more second manifold inlets 140-I, second manifold conduits 140-C, and second manifold outlets 140-O.

[0100] 2A-11, the reciprocating assembly 104 includes first and second shielding plates 126-1 and 126-2 (see, for example, FIGS. 2A, 10A-10C) that are in sliding contact with the bottom surface 118b of the bottom plate 118 and at least partially overlap (e.g., are at least partially aligned in the vertical direction) with the first channel assembly 120-1 and the second channel assembly 120-2, respectively. As shown, the bottom plate 118 is between the first and second channel assemblies 120-1, 120-2 and the first and second shielding plates 126-1, 126-2. As shown, the first and second shielding plates 126-1, 126-2 are connected to the remainder of the reciprocating assembly 104 (e.g., the bottom plate 124) via one or more coupling structures 129 (see, e.g., FIG. 2A) such that the shielding plates 126-1, 126-2 are configured to maintain vertical alignment with the first and second channel assemblies 120-1 and 120-2, respectively, as the reciprocating assembly 104 moves relative to the fixed assembly 102 (e.g., relative to the bottom plate 118), thereby moving the first and second shielding plates 126 and 126-2 together with the first and second channel assemblies 120-1 and 120-2 along the longitudinal axis L.

[0101] 2A-11, the reciprocating assembly 104 is configured to move relative to the stationary assembly 102 along a longitudinal axis L to and between various positions to variously expose and isolate various portions of the stationary assembly 102 and the reciprocating assembly 104 relative to each other and to the first or second gas sources 90-1 or 90-2. With further reference to FIGS. 2A-11, the reciprocating assembly 104 is configured to be moved relative to the stationary assembly 102 along the longitudinal axis L (e.g., by servo mechanism 70 under control of controller 92) between a first position P1, a second position P2, and a third position P3.

[0102] 2A, 3A, 4A, 5A, 6A, 7A, 8A, 9A, and 10A show some or all of the apparatus 100 when the reciprocating assembly 104 is in a first position P1 relative to the fixed assembly 102. As shown in FIGS. 2A, 3A, 4A, 5A, 6A, 7A, 8A, 9A, and 10A, based on the reciprocating assembly 104 being in the first position P1, the first channel conduit inlet 120-I1 of the first channel assembly 120-1 is exposed to the first hopper 110-1 (e.g., to the interior of the first hopper 110-1), and the first channel conduit outlet 120-O1 of the first channel assembly 120-1 is covered by at least a portion of the fixed assembly 102 (e.g., the first portion 118u-1 of the upper surface 118u of the bottom plate 118) (see, e.g., FIG. 3A). As a result, the first channel pipes 120-C1 of the first channel assembly 120-1 are each sealed at the first channel pipe outlet 120-O1 and exposed to the first hopper 110-1 at the first channel pipe inlet 120-I1 based on the shuttle assembly 104 being in the first position P1, thereby allowing the bulk compressible material 82 to be supplied from the first hopper 110-1 into the first channel pipes 120-C1 to create separate respective bulk bodies 84 of compressible material in the separate first channel pipes 120-C1 (see, for example, Figures 3A, 4A). Thus, the reciprocating assembly 104 is configured to move along the longitudinal axis L to a first position P1 relative to the fixed assembly 102 to expose the first channel pipe inlet 120-I1 to the first hopper 110-1 and cover the first channel pipe outlet 120-O1 with at least a first portion of the fixed assembly 102 (e.g., a portion of the upper surface 118u), thereby enabling one or more first channel pipes 120-C1 of the first channel assembly 120-1 to be at least partially filled with bulk compressible material 82 from the first hopper 110-1 to form separate respective bulk bodies 84 of compressible material within the separate first channel pipes 120-C1.

[0103] 2B, 3B, 4B, 5B, 6B, 7B, 8B, 9B, and 10B show some or all of the apparatus 100 when the reciprocating assembly 104 is in a second position P2 relative to the stationary assembly 102. As shown in Figures 2B, 3B, 4B, 5B, 6B, 7B, 8B, 9B, and 10B, based on the reciprocating assembly 104 being in second position P2, first channel conduit inlet 120-I1 of first channel assembly 120-1 is exposed to one or more first manifold outlets 112-O, first channel conduit inlet 120-O1 of first channel assembly 120-1 is exposed to respective separate dispense conduit inlets 118-I of array 118-A of dispense conduit 118-C, and dispense conduit outlet 118-O of dispense conduit 118-C is covered by first shielding plate 126-1 (see, for example, Figures 3B, 4B). As a result, dispense lines 118-C may be exposed at respective dispense line inlets 118-I to respective first channel lines 120-C1 and receive at least a portion of respective separate bulk bodies of compressible material 84 from respective first channel lines 120-C1, while being sealed at respective dispense line outlets 118-O to prevent any received portion of bulk bodies of compressible material 84 from falling out of dispense line 118-C (see, e.g., FIGS. 3B, 4B). In FIGS. 2A-11, dispense line outlets 118-O are covered by first shielding plate 126-1 based on shuttle assembly 104 being in second position P2, but exemplary embodiments are not limited thereto, and first shielding plate 126-1 may not be present in apparatus 100 in some exemplary embodiments.

[0104] As shown in Figures 2B, 3B, 4B, 5B, 6B, 7B, 8B, 9B, and 10B, based on the reciprocating assembly 104 being in the second position P2, the first channel conduit outlets 120-O1 are exposed to respective separate dispensing lines 118-C, thereby allowing at least a portion of the bulk body of compressible material 84 held within the first channel conduits 120-C1 to move to the corresponding respective dispensing lines 118-C exposed to the respective first channel conduits 120-C1 (see, for example, Figures 3B, 4B).

[0105] 2B, 3B, 4B, 5B, 6B, 7B, 8B, 9B, and 10B, with the reciprocating assembly 104 in the second position P2, the first channel conduit inlet 120-I1 is exposed to one or more first manifold outlets 112-O. Thus, with the reciprocating assembly 104 in the second position P2, the first gas 94-1 is allowed to be supplied to the first channel conduit 120-C1 via the one or more first manifold outlets 112-O and the exposed first channel conduit inlet 120-I1 (see, for example, FIGS. 3B, 4B). A first gas 94-1 can be supplied into the first channel conduit 120-C1 via one or more first manifold outlets 112-O and the exposed first channel conduit inlet 120-I1 to 1) move at least a portion of the bulk body of compressible material 84 within the first channel conduit 120-C1 to fill the corresponding exposed dispensing conduit 118-C, and 2) compress the bulk body of compressible material 84 to form a compressed body of compressible material 86 (see, e.g., Figures 3B, 4B). As shown (see, e.g., FIGS. 3B, 4B), each compressed body 86 includes a first portion 86-1 that remains within a given first channel line 120-C1 and a second portion 86-2 that is located within a fixed volume space of the dispense line 118-C exposed to the given first channel line 120-C1 at the second position P2 and fills the exposed dispense line 118-C. As shown (see, e.g., FIGS. 3B, 4B), the first and second portions 86-1 and 86-2 are separate portions of the compressed body 86 of a uniform single piece of compressible material. The second portion 86-2 of the compressed body 86 of compressible material that extends at least partially into a respective first channel line 120-C1 separate from the dispense line 118-C may be understood to be a formed first piece 11 of compressed material (see, e.g., FIGS. 3B, 4B).

[0106] 2B, 3B, 4B, 5B, 6B, 7B, 8B, 9B, and 10B, a first gas 94-1 is provided into first channel conduit 120-C1 to move bulk body of compressible material 84 from first channel conduit 120-C1 into a respective separate exposed dispensing conduit 118-C and compress bulk body of compressible material 84 to form compressed body 86 that partially or completely fills exposed dispensing conduit 118-C. The increased pressure of the first gas 94-1 may push the cylindrical sheath 132 of the cylindrical structure 420 upward and away from the lower plate 124, against the spring force of the spring 402, opening the annular conduits 133-C of each cylindrical structure 420 and allowing the first gas 94-1 to escape from the first channel conduits 120-C1 through each annular conduit 133-C after displacing and compressing the compressible material held in the first channel conduits 120-C1 and the exposed dispensing conduits 118-C (see, for example, FIG. 4B). When the supply of first gas 94-1 to first channel duct 120-C1 via first channel duct inlet 120-I1 is terminated, the internal pressure of first channel duct 120-C1 may decrease, causing each spring 402 of cylindrical structure 420 to press cylindrical sheath 132 of cylindrical structure 420 downward toward bottom plate 124, closing annular duct 133-C.

[0107] In some demonstrative embodiments, the volume of each dispensing line 118-C may be fixed and the pressure of the first gas 94-1 supplied into first channel line 120-C1 may be controlled (e.g., based on the controller 92 controlling the supply of first gas 94-1 via control of the gas flow control valve of first gas source 90-1) such that the second portions of compressed material 86-2 positioned and filled in all of the volumetric space of each dispensing line 118-C may have a particular volume (e.g., defined by the combined volumes of the dispensing lines 118-C) and a particular density (defined at least in part by the pressure of the first gas 94-1 and thus the amount of compression of portions 86-2 of compressible material in dispensing lines 118-C).

[0108] Figures 2C, 3C, 4C, 5C, 6C, 7C, 8C, 9C, 10C, and 11 show part or all of apparatus 100 when reciprocating assembly 104 is in a third position P3 relative to fixed assembly 102, and plate 16 is moved to position 90 in which plate 16 vertically overlaps array 118-A of dispense lines 118-C, such that cavities 18 in plate 16 overlap (e.g., are vertically aligned) in the vertical direction V with each separate dispense line outlet 118-O of array 118-A of dispense lines 118-C (see, e.g., Figures 3C, 4C, 5C).

[0109] As shown in Figures 2C, 3C, 4C, 5C, 6C, 7C, 8C, 9C, 10C, and 11, based on the shuttle assembly 104 being in third position P3, dispense line inlets 118-I are exposed to one or more second manifold outlets 140-O, and dispense line outlets 118-O are exposed to the exterior of apparatus 100 (e.g., to respective separate vertically aligned cavities 18 of plate 16 that are moved to position 90 based on operation of conveyor assembly 10) (e.g., see Figures 3C, 4C, 5C).

[0110] 2B-2C, 3B-3C, 4B-4C, 5B-5C, 6B-6C, 7B-7C, 8B-8C, 9B-9C, 10B-10C, and 11, the shuttle assembly 104 holds a compressed body 86 of compressible material such that a first portion 86-1 of the compressed body 86 remains within a respective first channel conduit 120-C1 while a second portion 86-2 of the compressed body 86 is present within a respective dispensing conduit 118-C. Movement of shuttle assembly 104 from second position P2 to third position P3 results in second portion 86-2 being severed (e.g., "sectioned," "isolated," "separated," etc.) from first portion 86-1 of the "remainder" of compressible material that was located within dispense line 118-C and retained within first channel line 120-C1 that was exposed to dispense line 118-C when shuttle assembly 104 was in second position P2 (see, e.g., FIGS. 3C, 4C, 5C). Thus, it will be understood that the severing of portion 86-2 retained in dispense line 118-C from portion 86-1 retained in first channel line 120-C1 is due to movement of shuttle assembly 104 from second position P2 to third position P3 that separates first channel line 120-C1 from dispense line 118-C (see, e.g., FIGS. 3C, 4C, 5C). Based on such movement, the second portion 86-2 that is separated from the first portion 86-1 and remains within the dispensing line 118-C may be referred to as a separate first piece 11 of compressed material that is separated based on the movement of the reciprocating assembly 104 from the second position P2 to the third position P3 (see, e.g., Figures 3C, 4C, 5C).

[0111] As shown in Figures 2C, 3C, 4C, 5C, 6C, 7C, 8C, 9C, 10C, and 11, with reciprocating assembly 104 in third position P3, dispense line inlet 118-I is exposed to one or more second manifold outlets 140-O (see, e.g., Figures 3C, 4C, 5C), allowing second gas 94-2 to be supplied to dispense line 118-C via one or more second manifold outlets 140-O and dispense line inlet 118-I exposed thereto. A second gas 94-2 is supplied into dispensing line 118-C via one or more second manifold outlets 140-O and the dispense line inlets 118-I exposed thereto, such that the supplied second gas 94-2 creates a pressure gradient from dispense line inlet 118-I to the corresponding dispense line outlet 118-O, thereby pushing (e.g., expelling, supplying, providing, etc.) compressed pieces of material 11 (e.g., first pieces) held in dispensing line 118-C out of dispensing line 118-C via dispense line outlet 118-O (see, e.g., FIGS. 3C and 5C ). In some exemplary embodiments in which second manifold outlets 140-O are exposed to dispense line inlets 118-I through separate respective manifold lines 440-C, the variable diameter of manifold line 440-C may enable second gas 94-2 to be uniformly applied to the tops of each of the pieces 11 held in dispense line 118-C based on the diameter of manifold line outlets 440-O being the same or substantially the same (e.g., the same within manufacturing and / or material tolerances) as the diameter of the dispense line inlets 118-I to which manifold line outlets 440-O are respectively exposed based on the shuttle assembly 104 being in third position P3 (see, e.g., FIGS. 3C, 5C ).

[0112] 2A-11 generally, the reciprocating assembly 104 may be moved along the longitudinal axis L from a first position P1 to a second position P2 and then to a third position P3 to compress and divide the bulk compressible material 82 into one or more pieces 11 (e.g., first and / or second pieces) of compressed material having a particular volume, density and / or mass, and then discharge the one or more pieces 11 of compressed material from a dispensing line 118-C of the apparatus 100 (e.g., into separate respective vertically aligned cavities 18 of the plate 16 at position 90 based on the operation of the conveyor assembly 10). As shown, the reciprocating assembly 104 may first be moved to the first position P1 and / or be at the first position P1 such that a bulk body 84 of compressible material may be created within a first channel line 120-C1. The reciprocating assembly 104 is then moved from the first position P1 to the second position P2 such that the bulk body 84 is at least partially pushed into the corresponding exposed dispensing line 118-C, and the bulk body 84 may be compressed to form the compressed body 86 based on the first gas 94-1 being supplied into the first channel line 120-C1 via the first channel line inlet 120-I1. The reciprocating assembly 104 is then moved from the second position P2 to the third position P3 such that the portion 86-2 of the compressed body 86 that is located within and fills the fixed volume space of the dispensing line 118-C is the first piece of compressible material 11. With the portion 86-2 decoupled (e.g., separated, isolated, etc.) from the respective remaining portion 86-1 of the compressed body 86, the first piece 11 may be discharged from the apparatus 100 (e.g., into the cavity 18 of the vertically stacked plate 16) based on the second gas 94-2 being supplied into the dispensing line 118-C via the dispensing line inlet 118-I. The shuttle assembly 104 may then move from the third position P3 to the first position P1 to refill the bulk body 84 into the first channel line 120-C1, and the movement of the shuttle assembly 104 from the first to the second to third positions P1, P2, P3 may be repeated. Such a process may be performed iteratively.

[0113] It will be appreciated that the conveyor assembly 10 is operated while the reciprocating assembly 104 is moved between a plurality of positions such that when the reciprocating assembly 104 is in the third position P3, a plate 16 having a cavity 18 which has received a particle 11 of compressed material is moved away from position 90, and a new plate having a cavity 18 which does not have a particle 11 therein may be moved to position 90 based on the movement of the reciprocating assembly 104 before the reciprocating assembly 104 returns to the third position P3.

[0114] 2A-11, third position P3 is between first and second positions P1 and P2 along longitudinal axis L, thereby enabling reciprocating assembly 104 to 1) extrude and compress compressible material to form compressed body 86 based on reciprocating assembly 104 moving in first direction D1 along longitudinal axis L from first position P1 to second position P2, and 2) sever portion 86-2 of compressed material (e.g., first piece 11) retained within dispensing line 118-C from remaining portion 86-1 of compressed material within first channel line 120-C1 and release the compressed material from reciprocating assembly 104. 1) to allow the first piece of compressed material 11 to be pushed out of the dispensing line 118-C based on the reciprocating assembly 104 moving in the second opposite direction D2 from the second position P2 to the third position P3 along the longitudinal axis L, and 2) to allow at least partial refilling of the first channel line 120-C1 with the bulk compressible material 82 from the first hopper 110-1 after the first piece of compressed material 11 is pushed out of the dispensing line 118-C based on the reciprocating assembly 104 moving in the second direction D2 from the third position P3 to the first position P1. However, it will be understood that exemplary embodiments are not limited thereto, and that in some exemplary embodiments, the movement of the reciprocating assembly 103 from the first position P1 to the second position P2 and from the second position P2 to the third position P3 may be in a single direction (e.g., D1) along the longitudinal axis L, such that the second position P2 is between the first position P1 and the third position P3.

[0115] 1, the apparatus 100 may include a servo mechanism 70 configured to move the reciprocating assembly 104 along the longitudinal axis L between first, second, and third positions P1, P2, P3 relative to the stationary assembly 102. The apparatus 100 may further include a processing circuit (e.g., controller 92) configured to control the servo mechanism 70 to move the reciprocating assembly 104 between the first, second, and third positions P1, P2, P3 (e.g., based on generating control signals that control operation of the servo mechanism 70 via processing circuit control in a well-known manner that controls operation of the servo mechanism 70). The processing circuit may be configured to control the first gas source 90-1, e.g., based on generating control signals that control operation of one or more gas flow control valves of the first gas source 90-1 in a well-known manner that controls operation of the gas flow control valves via processing circuit control. The processing circuitry may thus be configured to selectively supply the first gas 94-1 to the first gas manifold 112 in response to the reciprocating assembly 104 being in the second position P2. The determination in the processing circuitry that the reciprocating assembly 104 is in the second position P2 may be based on the servo mechanism 70 being controlled to move the reciprocating assembly 104 to the second position and / or based on processing signals received from the servo mechanism 70 and / or one or more position sensor devices determining that the reciprocating assembly 104 is in the second position P2. The processing circuitry may be configured to control the second gas source 90-2 based on generating control signals that control operation of one or more gas flow control valves of the second gas source 90-2, for example, by well-known methods of controlling operation of a gas flow control valve via the processing circuitry control. The processing circuitry may thus be configured to selectively supply the second gas 94-2 to the second gas manifold 140 in response to the reciprocating assembly 104 being in the third position P3. The determination in the processing circuit that the reciprocating assembly 104 is in the third position P3 may be based on the servo mechanism 70 being controlled to move the reciprocating assembly 104 to the third position and / or based on processed signals received from the servo mechanism 70 and / or one or more position sensor devices that determine that the reciprocating assembly 104 is in the third position P3.In some exemplary embodiments, the control device 92 may continuously supply the first gas 94-1 and the second gas 94-2 to the apparatus 100 throughout the operation of the apparatus 100, regardless of the relative position of the reciprocating assembly 104 with respect to the fixed assembly 102.

[0116] As shown in FIGS. 2A-11, the first gas manifold 112 may include a plurality of first manifold inlets 112-I (see, e.g., FIG. 3A) connected to a respective set of one or more first manifold outlets 112-O (see, e.g., FIG. 3A) via a respective separate first manifold conduit 112-C (see, e.g., FIG. 3A). Each first manifold outlet 112-O is configured to be exposed to a respective set of one or more first channel conduit inlets 120-I1 when the reciprocating assembly 104 is in the second position P2 (see, e.g., FIG. 6B). However, exemplary embodiments are not limited thereto. For example, in some exemplary embodiments, the first gas manifold 112 may include a single first manifold inlet 112-I connected to a single first manifold outlet 112-O via a single first manifold conduit 112-C. In some exemplary embodiments, the first gas manifold 112 may include one or more first manifold inlets 112-I each connected to a plurality of first manifold outlets 112-O via a plurality of first manifold conduits 112-C connected in parallel to a given first manifold inlet 112-I. The plurality of first manifold outlets 112-O are configured to be exposed to a respective set of one or more first channel conduit inlets 120-I1 in response to the shuttle assembly 104 being in the second position P2.

[0117] As shown in FIGS. 2A-11, second gas manifold 140 may include multiple second manifold inlets 140-I (see, e.g., FIG. 7A) connected to separate respective second manifold outlets 140-O via separate respective second manifold conduits 140-C (see, e.g., FIG. 8A). Each second manifold outlet 140-O is configured to be exposed to a separate set of one or more dispense line inlets 118-I when shuttle assembly 104 is in third position P3 (see, e.g., FIG. 8C). However, exemplary embodiments are not limited thereto. For example, in some exemplary embodiments, second gas manifold 140 may include a single second manifold inlet 140-I connected to a single second manifold outlet 140-O via a single second manifold conduit 140-C. In some illustrative embodiments, second gas manifold 140 may include one or more second manifold inlets 140-I each connected to a plurality of second manifold outlets 140-O via a plurality of lines 140-C and / or 440-C connected in parallel to a given second manifold inlet 140-I. The plurality of second manifold outlets 140-O are configured to be exposed to a separate respective set of one or more dispense line inlets 118-I in response to shuttling assembly 104 being in third position P3.

[0118] It will be appreciated that in some exemplary embodiments, manifold line 440-C may not be present in apparatus 100 and second gas manifold 140 is configured such that one or more second manifold outlets 140-O are directly exposed to one or more dispense line inlets 118-I, i.e., without any intervening lines, in response to the shuttle assembly 104 being in third position P3.

[0119] 2A-11, the device 100 includes a second array 121-2 of second channel assemblies 120-2 (see, e.g., FIG. 2A). The second channel assembly 120-2, including separate respective second channel conduits 120-C2 having second channel conduit inlets 120-I2 and second channel conduit outlets 120-O2 (see, e.g., FIG. 3A), may be structurally identical to and have the same structural features as the first channel assembly 120-1. As such, a detailed description of similar structural features of the second channel assembly 120-2 will not be repeated, and it will be understood that the description of the structural features of the first channel assembly 120-1 may be applicable to the structural features of the second channel assembly 120-2.

[0120] As shown in FIGS. 2A-11, the stationary assembly 102 may include a second hopper 110-2 configured to hold an additional bulk compressible material 82 (see, e.g., FIG. 3B) relative to the bulk compressible material 82 held in the first hopper 110-1. In some exemplary embodiments, the first and second hoppers 110-1 and 110-2 are configured to receive the bulk compressible material 82 from the same bulk material source 80. In some exemplary embodiments, the first and second hoppers 110-1 and 110-2 are configured to receive the bulk compressible material from different bulk material sources 80. Although the second array 121-2 is shown in FIGS. 2A-11 as including an array of twelve second channel assemblies 120-2, exemplary embodiments are not limited thereto. In an exemplary embodiment in which the apparatus 100 includes a second array 121-2 of second channel assemblies 120-2, the second array 121-2 may include only a single second channel assembly 120-2 or any number of second channel assemblies 120-2.

[0121] As shown, the second channel assembly 120-2 is adjacent to the second gas manifold 140 along the longitudinal axis L in the shuttle assembly 104 (see, e.g., FIG. 2A ), such that the second gas manifold 140 is between the first and second channel assemblies 120-1 and 120-2 along the longitudinal axis L (see, e.g., FIG. 2A ). However, exemplary embodiments are not limited thereto. For example, in some exemplary embodiments, the second array 121-2 of the second channel assembly 120-2 may be between the first array 121-1 of the first channel assembly 120-1 and the second gas manifold 140 along the longitudinal axis L.

[0122] Referring to the operation of the apparatus 100 including both first and second channel assemblies 120-1 and 120-2 in addition to first and second hoppers 110-1 and 110-2 as shown in FIG. 2A-11, the reciprocating assembly 104 may be configured to provide first and second pieces 11 of compressible material based on alternating compression and division of the bulk body 84 of compressible material held in the first and second channel assemblies 120-1 and 120-2 (e.g., to form alternating first and second pieces 11 based on compression of the bulk body 84 held in the first channel assembly 120-1 or the second channel assembly 120-2) as the reciprocating assembly 104 reciprocates between the first, second, and third positions P1, P2, and P3 (e.g., the third position P3 is between the first and second positions P1 and P2).

[0123] As shown in Figures 2B, 3B, 4B, 5B, 6B, 7B, 8B, 9B, and 10B, the reciprocating assembly 104, including both the first and second channel assemblies 120-1 and 120-2, is configured, based on being in the second position P2, to expose the second channel conduit inlet 120-I2 to the second hopper 110-2 and cover the second channel conduit inlet 120-O2 with at least a second portion of the fixed assembly 102 (e.g., the second portion 118u-2 of the upper surface 118u of the bottom plate 118 as shown in Figure 2A-11), thereby allowing the second channel conduit 120-C2 of the second channel assembly 120-2 to be at least partially filled with additional bulk compressible material 82 from the second hopper 110-2 (e.g., see Figure 3B). Thus, second channel conduit 120-C2 may be filled with bulk compressible material 82 to form a respective bulk body 84 of bulk compressible material therein. At the same time, first channel conduit inlet 120-I1 of first channel assembly 120-1 may be exposed to first manifold outlet 112-O to allow pressing and compressing of bulk body 84 held within first channel conduit 120-C1 to form a compressed body 86 of compressible material that is partially present within dispense conduit 118-C exposed to first channel conduit 120-C1, as described above (e.g., see FIG. 3B ).

[0124] 2C, 3C, 4C, 5C, 6C, 7C, 8C, 9C, 10C, and 11, reciprocating assembly 104, including both first and second channel assemblies 120-1 and 120-2, is configured to separate (e.g., cut) portion 86-2 (e.g., first particle 11) of compressible material held in dispensing line 118-C from portion 86-1 held in channel line 120-C1 based on moving in second direction D2 from second position P2 to third position P3, isolating particle 11 in dispensing line 118-C, and further exposing dispensing line inlet 118-I to second manifold outlet 140-O, so that second gas 94-2 can be supplied via second manifold outlet 140-O to exhaust the formed and isolated particle 11 from dispensing line 118-C. Concurrent with the severing of first piece 11 of compressed material in dispense line 118-C, second channel assembly 120-2 may maintain a bulk body 84 of compressible material in its second channel line 120-C2 based on the movement of reciprocating assembly 104 from second position P2 to third position P3 in second direction D2 (see, e.g., FIG. 3C ). First piece 11 formed and isolated in dispense line 118-C based on the division of the compressed material initially held in first channel assembly 120-1 based on the movement of reciprocating assembly 104 from second position P2 to third position P3 is expelled from dispense line 118-C based on the supply of second gas 94-2 to dispense line inlet 118-I via second manifold outlet 140-O such that dispense line 118-C is emptied of compressible material and ready to receive additional compressible material.

[0125] 2A, 3A, 4A, 5A, 6A, 7A, 8A, 9A, and 10A, reciprocating assembly 104, including both first and second channel assemblies 120-1 and 120-2, is configured, based on moving in the second direction D2 from third position P3 to first position P1, to expose second channel conduit inlet 120-I2 to first manifold outlet 112-O, expose second channel conduit outlet 120-O2 to a separate respective dispense conduit inlet 118-I (which has been emptied of compressible material based on reciprocating assembly 104 previously being in third position P3), and cover dispense conduit outlet 118-O (e.g., with second shielding plate 126-2) (see, e.g., FIG. 3A ). This enables the first gas manifold 112 to direct the first gas 94-1 through the second channel inlet 120-I2 while the reciprocating assembly 104 is in the first position P1, forcing at least a portion of the compressible material of the bulk body 84 held within the second channel conduit 120-C2 (e.g., bulk body 84 as shown in Figures 3B-3C, 7B-7C, 8B-8C, 9B-9C) into a separate respective dispensing conduit 118-C and compressing the forced bulk body 84 of compressible material extending continuously between the dispensing conduit 118-C and the corresponding second channel conduit 120-C2 to form a separate compressed body 86 of compressible material. The portion 86-2 of the compressed body present within the fixed volume space of the dispensing line 118-C is a newly formed second piece 11 of compressed material (e.g., with respect to forming a compressed body 86 of compressible material formed based on supplying a first gas 94-1 and compressing a pressed bulk body 84 of compressible material extending continuously between the dispensing line 118-C and the corresponding first channel line 120-C1 (however, such compression occurs simultaneously with the reciprocating assembly 104 being in the first position P1).), and also as shown in FIGS. 3B and 4B , instead of first channel conduit 120-C1, second channel conduit 120-C2 is aligned with a separate respective dispensing conduit 118-C, and a compressed body of compressible material 86 is formed simultaneously with reciprocating assembly 104 in first position P1 based on compression of pressed bulk body of compressible material 84 extending continuously between dispensing conduit 118-C and the corresponding second channel conduit 120-C2). Thus, a new second piece 11 of compressed material may be formed in the dispensing line 118-C at the same time that the first channel conduit inlet 120-I1 of the first channel assembly 120-1 is exposed to the first hopper 110-1 (see, for example, FIG. 3A) based on the shuttle assembly 104 being in the first position P1, as described above, thereby enabling at least partial refilling of the bulk body 84 of compressible material in the first channel conduit 120-C1.

[0126] In other words, as the reciprocating assembly moves from at least the third position P3 shown in FIG. 3C to at least the first position P1 shown in FIG. 3A , the second channel conduit 120-C2 is aligned with the separate respective dispensing conduit 118-C, and the bulk body of compressible material 84 held within the second channel conduit 120-C2 may be forced into the separate respective dispensing conduit 118-C and compressed (e.g., based on the first gas 94-1 being supplied via the first gas manifold 112 and through the second channel conduit inlet 120-I2) to form a compressed body of bulk material 86 at the same time that the first channel conduit 120-C1 receives additional bulk of compressible material 82 via the first hopper 110-1 to form a new bulk body of compressible material 84 held within the first channel conduit 120-C1.

[0127] In some exemplary embodiments, the reciprocating assembly 104, including both the first and second channel assemblies 120-1 and 120-2, after moving in first direction D1 from first position P1 to third position P3, reciprocating assembly 104 is in first position P1 to form a compressed body of compressible material 86 extending continuously between dispensing line 118-C and each of second channel lines 120-C2, and simultaneously exposing second manifold outlet 140-O to dispensing line inlet 118-I and exposing dispensing line inlet 118-O to the exterior of apparatus 100 (e.g., to separate respective cavities 18 of plate 16 at position 90) based on at least partially refilling bulk body of compressible material 84 within first channel line 120-C1, severing second piece of compressed material 11 within dispensing line 118-C from remaining compressible material 86-1 within second channel line 120-C2; Second gas manifold 140 directs second gas 94-2 through dispense line inlet 118-I and pushes (e.g., expels) the second piece of compressed material out of dispense line 118-C via dispense line outlet 118-O, thereby empties dispense line 118-C of compressible material and ready to receive additional compressed material while maintaining bulk body of compressible material 84 within first channel line 120-C1 (e.g., at least similar to the cutting and introduction of second gas 94-2 shown in FIG. 3C , except that second channel line 120-C2 holds remaining compressible material 86-1 instead of bulk body of compressible material 84, and first channel line 120-C1 holds bulk body of compressible material 84 instead of remaining compressible material 86-1).

[0128] 2B, 3B, 4B, 5B, 6B, 7B, 8B, 9B, and 10B, the reciprocating assembly 104 including the first and second channel assemblies 120-1 and 120-2 is configured to repeat the process of forming and discharging the compressible material into the first piece 11 using the first channel assembly 120-1 and repeat the process of forming and discharging the compressible material into the second piece 11 using the second channel assembly 120-2 based on the reciprocating motion of the reciprocating assembly 104 by enabling at least partial refilling of the bulk compressible material 82 from the second hopper 110-2 into the second channel line 120-C2 based on the second piece 11 being discharged from the dispensing line 118-C in response to the reciprocating assembly being at the third position P3 after moving in the first direction D1 from the third position P3 to the second position P2.

[0129] 2A-11 illustrate a single first channel line 120-C1, a single second channel line 120-C2, and a single dispense line 118-C as being filled with compressible material, it will be understood that this is for illustrative purposes only. In some exemplary embodiments, all first channel lines 120-C1 may be filled with bulk compressible material 82 from a first hopper 110-1 based on the shuttle assembly 104 being in a first position P1, all second channel lines 120-C2 may be filled with bulk compressible material 82 from a second hopper 110-2 based on the shuttle assembly 104 being in a second position P2, and all dispense lines 118-C may be filled with compressible material from either a first channel line 120-C1 or a second channel line 120-C2 to form a first or second piece of material 11 compressed therein.

[0130] 12 is a flow chart illustrating a method according to some exemplary embodiments. The method may be performed by any of the exemplary embodiments of the apparatus 100. The method may be performed based on the controller 92 according to any exemplary embodiment controlling the operation of any of the exemplary embodiments of the apparatus 100, for example, based on control of the servo mechanism 70 and one or more gas sources 90-1, 90-2, and may further be based on the controller controlling the operation of some or all of the manufacturing system 1 according to any exemplary embodiment.

[0131] As shown in FIG. 12, the method may be an iterative process, where operations in a given iteration may be influenced by operations in previous iterations.

[0132] In S1202, the reciprocating assembly 104 is moved along the longitudinal axis L (e.g., a specific movement of the reciprocating assembly 104 along the longitudinal axis L) to a first position P1 (e.g., see FIG. 3A) relative to the fixed assembly 102, thereby exposing the first channel pipe inlet 120-I1 of the first channel pipe 120-C1 of the first channel assembly 120-1 to the first hopper 110-1 and covering the first channel pipe outlet 120-O1 of the first channel pipe 120-C1 with at least a first portion of the fixed assembly (e.g., the first portion 118u-1 of the upper surface 118u of the bottom plate 118).

[0133] In S1204-1, the reciprocating assembly 104 is moved to a first position P1 whereby the first channel conduit inlet 120-I1 is exposed to the first hopper 110-1, and based on that, the bulk compressible material 82 may be fed (e.g., based on gravity) from the first hopper 110-1 to the first channel conduit 120-C1 to allow at least partial filling of the first channel conduit 120-C1 with the bulk compressible material 82 from the first hopper 110-1 and create separate bulk bodies 84 of compressible material in each first channel conduit 120-C1 (see, e.g., FIG. 3A). In some exemplary embodiments, the first iteration of the method shown in FIG. 12 may begin with the reciprocating assembly 104 moving to the first position P1 from a starting position, which may be any position relative to the fixed assembly 102, including the first position P1 itself. Movement of the reciprocating assembly 104 may be caused based on operation of a servo mechanism 70 connected to the reciprocating assembly 104, the operation of which may be controlled by a controller 92.

[0134] 12, in some exemplary embodiments, the shuttle assembly 104 includes one or more second channel assemblies 120-2 that define one or more second channel conduits 120-C2. The first gas manifold 112 resides between the first and second channel assemblies 120-1 and 120-2 along the longitudinal axis L. Thus, in some exemplary embodiments, by moving reciprocating assembly 104 to first position P1 in S1202, reciprocating assembly 104 being in first position P1 exposes second channel conduit inlet 120-I2 of second channel conduit 120-C2 to first manifold outlet 112-O of first gas manifold 112, exposes second channel conduit outlet 120-O2 of second channel conduit 120-C2 to a separate respective dispense conduit inlet 118-I of dispense conduit 118-C, and covers dispense conduit outlet 118-O of dispense conduit 118-C (e.g., covered by second shielding plate 126-2) such that first gas manifold 112 exposes second channel conduit inlet 120-I2 of second channel conduit 120-C2 to first manifold outlet 112-O of first gas manifold 112. (S1204-2) (see, for example, additional reference to FIG. 3A ; similar to the compressed body 86 shown in FIG. 3B , except that the reciprocating assembly 104 is at the first position P1 instead of the second position P2, and the compressed body 86 extends into the separate respective second channel conduits 120-C2 instead of the separate respective first channel conduits 120-C1, the second channel conduits 120-C2 shown in FIG. 3A may hold a bulk body 84 of compressible material to be pressed and compressed based on the first gas 94-1 being supplied thereto while the reciprocating assembly 104 is at the first position P1 to form a compressed body 86 extending between the dispensing conduit 118-C and the separate respective second channel conduits 120-C2).Operation S1204-2 includes controlling (e.g., by controller 92) first gas source 90-1 to supply first gas 94-1 from first gas source 90-1 to first gas manifold 112 to force any bulk bodies 84 of compressible material from second channel conduit 120-C2 at least partially into respective separate dispensing lines 118-C and compressing the bulk bodies 84 forced into dispensing lines 118-C to form compressed bodies 86 of compressible material, each at least partially within a separate dispensing line 118-C, filling the fixed volume space of dispensing line 118-C. Portions 86-2 within the fixed volume space of dispensing line 118-C are understood to be second pieces 11 of compressed material within dispensing line 118-C. Such control may include controlling a gas flow control valve of first gas source 90-1. It will be appreciated that operations S1204-1 and S1204-2 may occur simultaneously or approximately simultaneously based on the reciprocating assembly 104 being in the first position P1 relative to the stationary assembly 102.

[0135] In S1206, the reciprocating assembly 104 is moved (e.g., in a first direction D1) along the longitudinal axis L from a first position P1 to a third position P3 relative to the stationary assembly 102 (e.g., causing a particular movement of the reciprocating assembly 104 along the longitudinal axis L) (e.g., see FIG. 3C ). The movement of the reciprocating assembly 104 may be caused based on the operation of the servo mechanism 70 connected to the reciprocating assembly 104. This operation may be controlled by the controller 92.

[0136] In S1206, moving the reciprocating assembly 104 in a first direction D1 from a first position P1 to a third position P3 exposes the second manifold outlet 140-O to the dispense line inlet 118-I (e.g., directly or via one or more manifold lines 440-C) and further exposes the dispense line outlet 118-O to the outside of the device 100 (e.g., based on movement of the first or second shielding plate 126-1 or 126-2). In an exemplary embodiment in which the reciprocating assembly 104 includes a second channel assembly 120-2 having a second channel conduit 120-C2 exposed to the dispensing line 118-C based on the reciprocating assembly 104 being in the first position P1, such movement in the first direction D1 from the first position P1 to the third position P3 in S1206 may further sever the second piece of compressed material 11 in the dispensing line 118-C from the remaining compressible material (e.g., portion 86-1) present in the second channel conduit 120-C2 exposed to the dispensing line 118-C when the reciprocating assembly 104 was in the first position P1 in S1204-2.

[0137] In S1208, reciprocating assembly 104 is moved to a third position P3, and based on being in third position P3, dispense line inlet 118-I is exposed to one or more second manifold outlets 140-O, and dispense line outlet 118-O is exposed to the outside of apparatus 100 (e.g., based on movement of first and / or second shielding plates 126-1 or 126-2 exposing dispense line outlet 118-O) (e.g., see FIG. 3C). Thus, the reciprocating assembly 104 may be configured to allow the second gas manifold 140 to direct the second gas 94-2 through the exposed dispense line inlet 118-I to the second manifold outlet 140-O to emptie the compressed material dispensing line 118-C of the second gas 94-2, based on the reciprocating assembly 104 being in the third position P3. Operation S1208 may include controlling (e.g., by the controller 92) the second gas source 90-2 to supply the second gas 94-2 from the second gas source 90-2 to the second gas manifold 140. Such control may include controlling a gas flow control valve of the second gas source 90-2.

[0138] In S1210, the reciprocating assembly 104 is moved along the longitudinal axis L (e.g., a specific movement of the reciprocating assembly 104 along the longitudinal axis L is caused) from the third position P3 to the second position P2 (e.g., in the first direction D1) (see, e.g., FIG. 3B ) relative to the stationary assembly 102. The movement of the reciprocating assembly 104 is caused based on the operation of the servo mechanism 70 connected to the reciprocating assembly 104. This operation may be controlled by the controller 92. Moving the reciprocating assembly 104 from the third position P3 to the second position P2 exposes the first channel conduit inlet 120-I1 of the first channel assembly 120-1 to one or more first manifold outlets 112-O, exposes the first channel conduit outlet 120-O1 of the first channel assembly 120-1 to a separate respective dispense conduit inlet 118-I of the dispense conduit 118-C, and covers (e.g., by a first shielding plate 126-1) the dispense conduit outlet 118-O of the dispense conduit 118-C.

[0139] In S1212-1, the reciprocating assembly 104 is moved to the second position P2, and based on being at the second position P2, the first gas source 90-1 supplies the first gas 94-1 to the first gas manifold 112 and directs the first gas 94-1 to the first gas manifold 112 through the first channel conduit inlet 120-I1 to 1) at least partially compress the bulk body of compressible material 84 held within the first channel conduit 120-C1. 1) extrude the first gas source 90-1 from the first channel conduit 120-C1 into a respective separate dispensing line 118-C exposed to the first channel conduit 120-C1; and 2) compress the extruded bulk body 84 in the dispensing line 118-C to form a compressed body 86 of compressible material that is at least partially in each separate dispensing line 118-C and fills (e.g., completely fills) the fixed volume space of the separate dispensing line 118-C (see, e.g., FIG. 3B ). It will be understood that the portion 86-2 of the compressed body 86 that is in the dispensing line 118-C is the first piece 11 of compressed material in the dispensing line 118-C. Such control of the first gas source 90-1 may include controlling a gas flow control valve of the first gas source 90-1.

[0140] As shown in FIG. 12, in some exemplary embodiments in which the reciprocating assembly 104 includes one or more second channel assemblies 120-2 defining one or more second channel conduits 120-C2 and the first gas manifold 112 is between the first and second channel assemblies 120-1 and 120-2 along the longitudinal axis L, by moving the reciprocating assembly 104 to a second position P2 in S1210, the reciprocating assembly 104 being at the second position P2 may expose the second channel conduit inlet 120-I2 of the second channel assembly 120-2 to the second hopper 110-2, and may further cover the second channel conduit outlet 120-O2 of the second channel assembly 120-2 with at least a second portion of the fixed assembly 102 (e.g., the second portion 118u-2 of the upper surface 118u of the bottom plate 118) (see, e.g., FIG. 3B). As a result, in S1212-2, the reciprocating assembly 104 is moved to the second position P2, and in response to being at the second position P2, the bulk compressible material 82 may be fed (e.g., based on gravity) from the second hopper 110-2 to the second channel conduit 120-C2 to allow the second channel conduit 120-C2 to at least partially fill with the bulk compressible material 82 from the second hopper 110-2 to create a separate bulk body 84 of compressible material in each second channel conduit 120-C2 (see, e.g., FIG. 3B). It will be appreciated that operations S1212-1 and S1212-2 may occur simultaneously or nearly simultaneously based on the reciprocating assembly 104 being at the second position P2 relative to the fixed assembly 102.

[0141] In S1214, the reciprocating assembly 104 is moved (e.g., a particular movement of the reciprocating assembly 104 along the longitudinal axis L is caused) from the second position P2 to a third position P3 (e.g., in a second direction D2 opposite to the first direction D1) relative to the fixed assembly 102 along the longitudinal axis L (e.g., see FIG. 3C ). The movement of the reciprocating assembly 104 is caused based on the operation of a servo mechanism 70 connected to the reciprocating assembly 104. This operation may be controlled by the controller 92. It will be understood that the movements of the reciprocating assembly 104 described herein in connection with the method illustrated in FIG. 12 may be based on the operation of the same servo mechanism 70 or separate servo mechanisms 70 that cause separate respective movements of the reciprocating assembly 104.

[0142] In S1214, moving the reciprocating assembly 104 in the second direction D2 from the second position P2 to the third position P3 exposes the second manifold outlet 140-O to the dispense line inlet 118-I (e.g., directly or via one or more manifold lines 440-C) and further exposes the dispense line outlet 118-O to the outside of the apparatus 100 (e.g., based on movement of the first and / or second shielding plates 126-1 or 126-2) (e.g., see FIG. 3C). In S1214, such movement in the second direction D2 from the second position P2 to the third position P3 may further sever the first piece of compressed material 11 in the dispensing line 118-C from the remaining compressible material (e.g., portion 86-1) in the first channel line 120-C1 exposed to the dispensing line 118-C when the reciprocating assembly 104 was in the second position P2 in S1212-1 (e.g., see FIG. 3C ).

[0143] In S1216, the reciprocating assembly 104 is moved in a second direction D2 from the second position P2 to a third position P3, and based on being in the third position P3, the dispense line inlet 118-I is opened ("exposed") to one or more second manifold outlets 140-O, and the dispense line outlet 118-O is exposed to the outside of the apparatus 100 (e.g., based on exposing the dispense line outlet 118-O by moving the first and / or second shielding plates 126-1 or 126-2). Thus, based on the reciprocating assembly 104 being in the third position P3 (see, e.g., FIG. 3C ), the second manifold 140 may be configured to direct the second gas 94-2 through the dispense line inlet 118-I exposed to the second manifold outlet 140-O to empty the compressed material dispensing line 118-C by pushing the first pieces of compressed material 11 out of the exposed dispense line 118-C. Operation S1216 may include the second gas source 90-2 being controlled (e.g., by the controller 92) to supply the second gas 94-2 from the second gas source 90-2 to the second gas manifold 140. Such control may include controlling a gas flow control valve of the second gas source 90-2.

[0144] As shown in FIG. 12, the method may include moving the reciprocating assembly 104 along the longitudinal axis L in a second direction D2 from a third position P3 to a first position P1 relative to the fixed assembly 102 to expose the first channel conduit inlet 120-I1 to the first hopper 110-1 and cover the first channel conduit outlet 120-O1 with at least a first portion of the fixed assembly (e.g., a first portion 118u-1 of the upper surface 118u of the bottom plate 118) to enable at least partial refilling of the first channel conduit 120-C1 with the bulk compressible material 82 from the first hopper 110-1 to at least recreate (S1204-1) the bulk body 84 of the compressible material in the first channel conduit 120-C1 (see, for example, FIG. 3A).

[0145] The operations of FIG. 12 may then be operated iteratively in one or more process loops (e.g., iterative loops) to provide first and second pieces of compressed material 11, respectively, in operations S1216 and S1208 of each iterative loop.

[0146] In some exemplary embodiments, the shuttle assembly 104 does not include the optional second channel assembly 120-2, such that operations S1204-2 and S1212-2 may be omitted.

[0147] In some exemplary embodiments, the second position P2 is between the first position P1 and the third position P3. In some exemplary embodiments, at least operations S1206 and S1208 may be omitted, and operation S1210 may include moving the reciprocating assembly 104 in the first direction D1 from the first position P1 to the second position P2 without stopping at the third position P3 (e.g., in exemplary embodiments where the third position P3 is not between the first and second positions P1 and P2). Operation S1202 may include moving the reciprocating assembly 104 in the second direction D2 from the third position P3 to the first position P1 with or without stopping at the second position P2 for any period of time (e.g., in exemplary embodiments where the second position P2 is between the first and third positions P1 and P3). In some exemplary embodiments, the method shown in FIG. 12 is a single pass process from S1202 to S1216, such that a return from S1216 to S1202 does not occur.

[0148] In some exemplary embodiments, one or more components of the apparatus 100 may be omitted. For example, the shield plates 126-1 and / or 126-2 and / or the coupling structure 129 may be omitted from the apparatus 100. In another example, some or all of the second channel assembly 120-2 may be omitted from the apparatus 100, the second hopper 110-2 may be omitted, and all of the second channel assembly 120-2 may be omitted. In another example, the apparatus 100 may include only a single channel assembly 120. It will be understood that exemplary embodiments in which one or more components of the apparatus 100 are omitted are not limited to the examples provided above.

[0149] While exemplary embodiments are disclosed herein, it should be understood that other variations are possible. Such variations are not to be regarded as departures from the spirit and scope of the present disclosure, and all such modifications as would be apparent to one skilled in the art are intended to be included within the scope of the following claims.

Claims

1. 1. An apparatus configured to provide compacted pieces of material, comprising: a stationary assembly including a first hopper, a first gas manifold, and a dispensing vessel, the first hopper configured to hold a bulk compressible material, the first gas manifold configured to direct a first gas from a first gas source to a first manifold outlet, the dispensing vessel defining a dispensing line extending between a dispensing line inlet and a dispensing line outlet, the dispensing line at least partially vertically overlapping the first manifold outlet; a reciprocating assembly including a first channel assembly and a second gas manifold, the first channel assembly defining a first channel conduit extending between a first channel conduit inlet and a first channel conduit outlet, the second gas manifold configured to direct a second gas from a second gas source to a second manifold outlet; The reciprocating assembly is adapted to move relative to the fixed assembly. a first position exposing the first channel conduit inlet to the first hopper and covering the first channel conduit outlet with at least a first portion of the fixture assembly to enable the first channel conduit to be at least partially filled with a predetermined amount of the bulk compressible material from the first hopper and to form a first bulk body of compressible material within the first channel conduit; a second position exposing the first channel line inlet to the first manifold outlet, exposing the first channel line outlet to the dispense line inlet, and covering the dispense line outlet, thereby enabling the first gas manifold to direct a first gas through the first channel line inlet to extrude a portion of the first bulk body of compressible material from the first channel line into the dispense line and compress the portion of the first bulk body of compressible material within the dispense line to form a first piece of compressed material in the dispense line; a first position exposing the second manifold outlet to the dispense line inlet, a second position exposing the dispense line outlet to an exterior of the device, a third position enabling the second gas manifold to direct the second gas through the dispense line inlet to force the first piece of compressed material out of the dispense line.

2. 2. The apparatus of claim 1, The third position is between the first position and the second position along the longitudinal axis, such that the reciprocating assembly: enabling the pressing and compressing of the portion of the first bulk body of compressible material upon the reciprocating assembly moving in a first direction along the longitudinal axis from the first position to the second position; severing a first piece of the compressed material and permitting the first piece of the compressed material to be pushed out of the dispensing line based on the reciprocating assembly moving in an opposite second direction along the longitudinal axis from the second position to the third position; the apparatus being configured to enable at least partial refilling of the first channel line with an additional predetermined amount of the bulk compressible material from the first hopper after expulsion of the first piece of compressed material from the dispensing line based on movement of the reciprocating assembly in the second direction from the third position to the first position.

3. 2. The apparatus of claim 1, the dispensing vessel being a bottom plate, such that the dispensing line extends through a thickness of the bottom plate between the dispensing line inlet at a top surface of the bottom plate and the dispensing line outlet at a bottom surface of the bottom plate; The reciprocating assembly includes: an upper plate, an upper surface of which is in sliding contact with the first hopper and the first gas manifold; a lower plate, a bottom surface of the lower plate in sliding contact with the top surface of the bottom plate, the lower plate defining a lower conduit extending through a thickness of the lower plate between a top opening of the lower conduit and a bottom opening of the lower conduit, the bottom opening of the lower conduit defining the first channel conduit outlet at the bottom surface of the lower plate; and a cylindrical structure coupled between the upper plate and the lower plate and defining an upper conduit extending through the cylindrical structure, an upper opening of the upper conduit defining the first channel conduit inlet at the upper surface of the upper plate and a bottom opening of the upper conduit exposed to the upper opening of the lower conduit, such that the upper conduit and the lower conduit collectively define a first channel conduit.

4. 4. The apparatus according to claim 3, the second gas manifold is coupled to an upper surface of the bottom plate; the bottom plate defines a manifold conduit extending through a thickness of the bottom plate between a manifold conduit inlet at a top surface of the bottom plate and a manifold conduit outlet at the bottom surface of the bottom plate, the manifold conduit inlet being exposed to the second manifold outlet; The apparatus, wherein the reciprocating assembly is configured to expose the manifold line outlet to the dispense line inlet, such that the second manifold outlet is exposed to the dispense line inlet through the manifold line based on the reciprocating assembly being in the third position.

5. 4. The apparatus according to claim 3, The cylindrical structure is a cylinder having an upper end coupled to the upper plate such that an upper end opening of the cylinder defines the upper end opening of the upper pipe; a cylindrical sheath having an upper end that slides with a bottom end of the cylinder and a bottom end that slides with the lower plate, such that a bottom opening of the cylindrical sheath defines the bottom opening of the upper conduit; a spring configured to apply a spring force pressing the cylindrical sheath against the lower plate, the spring configured to allow the first gas to escape from the first channel conduit through the open conduit in response to the cylindrical sheath being pushed away from the lower plate by the first gas, opening a conduit extending between the cylindrical sheath and the lower plate, and the first gas manifold directing the first gas to the first manifold outlet.

6. 2. The apparatus of claim 1, the dispensing vessel being a bottom plate, such that the dispensing line extends through a thickness of the bottom plate between the dispensing line inlet at a top surface of the bottom plate and the dispensing line outlet at a bottom surface of the bottom plate; the reciprocating assembly includes a first shield plate at least partially vertically overlapping the first channel assembly; the bottom plate is between the first channel assembly and the first shield plate; the first portion of the fastening assembly includes a portion of the base plate; The apparatus, wherein the first shielding plate is configured to cover the dispense line outlet based on the shuttle assembly being in the second position.

7. 10. The apparatus of claim 1 further comprising: a servo mechanism configured to move the reciprocating assembly along a longitudinal axis between first, second, and third positions; controlling the servo mechanism to move the reciprocating assembly between the first, second, and third positions; controlling the first gas source to selectively supply the first gas to the first gas manifold in response to the reciprocating assembly being in the second position; and processing circuitry configured to control the second gas source such that, in response to the reciprocating assembly being in a third position, the second gas is selectively supplied to the second gas manifold.

8. 3. The apparatus according to claim 2, the stationary assembly includes a second hopper configured to hold additional bulk compressible material, the second hopper adjacent the first gas manifold along the longitudinal axis such that the first gas manifold is between the first and second hoppers along the longitudinal axis; the shuttle assembly includes a second channel assembly defining a second channel conduit extending between a second channel conduit inlet and a second channel conduit outlet, the second channel assembly being adjacent to the second gas manifold along the longitudinal axis such that the second gas manifold is between the first and second channel assemblies along the longitudinal axis; The reciprocating assembly includes: exposing the second channel conduit inlet to the second hopper and covering the second channel conduit outlet with at least a second portion of the stationary assembly to enable the second channel conduit outlet to be at least partially filled with a predetermined amount of the additional bulk compressible material from the second hopper to form a second bulk body of compressible material within the second channel conduit based on the shuttle assembly being in a second position; exposing the second channel line inlet to the first manifold outlet, exposing the second channel line outlet to the dispense line inlet, and covering the dispense line outlet upon movement of the shuttle assembly in the second direction from the second position to the first position, thereby enabling the first gas manifold to direct the first gas through the second channel line inlet to push a portion of the second bulk body of compressible material out of the second channel line and into the dispense line, compressing the portion of the second bulk body of compressible material in the dispense line to form a second piece of compressed material in the dispense line; exposing the second manifold outlet to the dispense line inlet and exposing the dispense line outlet to the exterior of the device to sever a second piece of the compressed material in the dispense line from a remaining compressible material in the second channel line based on the shuttle assembly moving in the first direction from the first position to the third position, and enabling the second gas manifold to direct the second gas through the dispense line inlet to force the second piece of compressed material out of the dispense line; the apparatus is configured to enable at least partial refilling of the second channel line with a bulk compressible material from the second hopper after pushing a second piece of the compressed material out of the dispensing line based on movement of the reciprocating assembly in the first direction from the third position to the second position.

9. 9. The apparatus of claim 8, the shuttle assembly includes an array of first channel assemblies each defining a separate first channel conduit of an array of first channel conduits, each separate first channel conduit extending between a separate first channel conduit inlet of an array of first channel conduit inlets and a separate first channel conduit outlet of an array of first channel conduit outlets, the array of first channel assemblies including the first channel assemblies; the shuttle assembly includes an array of second channel assemblies each defining a separate second channel conduit of an array of second channel conduits, each separate second channel conduit extending between a separate second channel conduit inlet of an array of second channel conduit inlets and a separate second channel conduit outlet of an array of second channel conduit outlets, the array of second channel assemblies including the second channel assemblies; the dispense vessel defines an array of dispense lines extending between a respective separate dispense line inlet of an array of dispense line inlets and a respective separate dispense line outlet of an array of dispense line outlets, the array of dispense lines including the dispense line; The shuttle assembly is moved to the first position to exposing the first array of channel inlets to the first hopper and covering the first array of channel outlets with at least the first portion of the stationary assembly; configured to expose the array of second channel line outlets to the array of dispense line inlets and to expose the array of second channel line inlets to one or more first manifold outlets of the first gas manifold; The shuttle assembly is moved to the second position to exposing the array of first channel line outlets to the array of dispense line inlets and exposing the array of first channel line inlets to the one or more first manifold outlets of the first gas manifold; configured to expose the second array of channel inlets to a second hopper and cover the second array of channel outlets with at least the second portion of the stationary assembly; the shuttle assembly is configured to move to the third position to expose the array of dispense line inlets to one or more second manifold outlets of the second gas manifold and to expose the array of dispense line outlets to the exterior of the apparatus.

10. 10. The apparatus of claim 9, the first gas manifold includes a plurality of first manifold conduits extending to respective distinct first manifold outlets of a plurality of first manifold outlets, the plurality of first manifold outlets including the one or more first manifold outlets; the second gas manifold includes a plurality of second manifold lines extending to distinct respective second manifold outlets of a plurality of second manifold outlets, the plurality of second manifold outlets including the one or more second manifold outlets.

11. 9. The apparatus of claim 8 further comprising: a servo mechanism configured to reversibly move the reciprocating assembly along the longitudinal axis between the first, second, and third positions; controlling the servo mechanism to move the reciprocating assembly between the first, second, and third positions; controlling the first gas source such that in response to the reciprocating assembly being in the first position, the first gas is selectively supplied to the first gas manifold; controlling the first gas source such that in response to the reciprocating assembly being in the second position, the first gas is selectively supplied to the first gas manifold; and processing circuitry configured to control the second gas source such that, in response to the reciprocating assembly being in the third position, the second gas is selectively supplied to the second gas manifold.

12. 2. The apparatus of claim 1, The apparatus, wherein the first gas source and the second gas source are the same gas source, such that the first gas and the second gas are the same type of gas.

13. 1. A manufacturing system comprising: a conveyor belt including a loop of plates, each plate including a cavity; 2. The apparatus of claim 1, wherein the apparatus is configured to overlie a section of the conveyor belt such that the conveyor belt moves such that the cavities in each plate of the conveyor belt are vertically aligned with the dispense line outlets simultaneously with the shuttle assembly being in the third position, and the second gas manifold directs the second gas through the dispense line inlets to force the compressed material out of the dispense lines and into the cavities; a packaging assembly configured to seal the compressed compressible material in the cavity within a wrapper; The conveyor belt is configured to eject the packaging material from the cavity based on movement of the conveyor belt.

14. 1. A method of operating an apparatus for providing segments of compressible material, comprising the steps of: The apparatus includes a stationary assembly and a reciprocating assembly, the stationary assembly including a first hopper, a first gas manifold, and a dispensing vessel defining a dispensing line, the reciprocating assembly including a first channel assembly and a second gas manifold, the first channel assembly defining a first channel line, moving the reciprocating assembly along a longitudinal axis relative to the stationary assembly to a first position to expose a first channel conduit inlet of a first channel conduit to a first hopper and cover a first channel conduit outlet of the first channel conduit with at least a first portion of the stationary assembly to at least partially fill the first channel conduit with a predetermined amount of bulk compressible material from the first hopper to form a first bulk body of compressible material within the first channel conduit; moving the shuttle assembly along a longitudinal axis from the first position to a second position relative to the stationary assembly to expose the first channel line inlet to a first manifold outlet of the first gas manifold, expose the first channel line outlet to a dispense line inlet of the dispense line, and cover a dispense line outlet of the dispense line; in response to moving the reciprocating assembly to the second position, controlling a first gas source to supply a first gas to the first gas manifold such that the first gas manifold directs the first gas through the first channel conduit inlet to force a portion of the first bulk body of compressible material from the first channel conduit into the dispensing line and compress the portion of the first bulk body of compressible material in the dispensing line to form a first piece of compressed material in the dispensing line; moving the shuttle assembly along the longitudinal axis from the second position to a third position relative to the stationary assembly to expose the second gas manifold to the dispense line inlet and to expose the dispense line outlet to an exterior of the apparatus; and in response to the reciprocating assembly being moved to the third position, controlling a second gas source to supply a second gas such that the second gas manifold directs the second gas through the dispensing line inlet to force a first piece of the compressed material out of the dispensing line.

15. 15. The method of claim 14, the third position being between the first position and the second position along the longitudinal axis, moving the reciprocating assembly to the first position includes moving the reciprocating assembly in a first direction along the longitudinal axis from the first position through the third position to the second position; moving the reciprocating assembly to the second position includes moving the reciprocating assembly in an opposite second direction along the longitudinal axis from the third position to the first position; The method, wherein moving the reciprocating assembly to the third position includes moving the reciprocating assembly from the second position to the third position in the second direction.

16. 16. The method of claim 15, moving the reciprocating assembly to the first position includes controlling a servo mechanism coupled to the reciprocating assembly such that the servo mechanism moves the reciprocating assembly along the longitudinal axis to the first position; moving the reciprocating assembly to the second position includes controlling the servo mechanism to move the reciprocating assembly in the first direction along the longitudinal axis to the second position; the method, wherein moving the reciprocating assembly to the third position includes controlling the servo mechanism coupled to the reciprocating assembly such that the servo mechanism moves the reciprocating assembly in the second direction along the longitudinal axis to the third position.

17. 15. The method of claim 14, the stationary assembly includes a second hopper, the second hopper adjacent to the first gas manifold along the longitudinal axis such that the first gas manifold is between the first and second hoppers along the longitudinal axis; the shuttle assembly includes a second channel assembly defining a second channel conduit, the second channel assembly being adjacent to the second gas manifold along the longitudinal axis such that the second gas manifold is between the first and second channel assemblies along the longitudinal axis; moving the shuttle assembly to the second position exposes a second channel inlet of the second channel to the second hopper, thereby enabling the second channel to be at least partially filled with a predetermined amount of additional bulk compressible material from the second hopper to form a second bulk body of compressible material within the second channel; the method further includes moving the shuttle assembly from the second position to the first position thereby exposing the second channel line inlet to the dispense line inlet and further exposing a second channel line outlet of the second channel line to the first manifold outlet; The method further includes, in response to the reciprocating assembly being moved from the second position to the first position, controlling the first gas source to supply the first gas such that the first gas manifold directs the first gas through the second channel conduit inlet to force a portion of the second bulk body of compressible material from the second channel conduit into the dispensing line and compress the portion of the second bulk body of compressible material in the dispensing line to create a second piece of compressed material in the dispensing line; The method further includes moving the reciprocating assembly from the first position to the third position and controlling the second gas source to supply the second gas such that a second chunk of the compressed material is created in the dispensing line, followed by the second gas manifold directing the second gas through the dispensing line inlet to force the second chunk of the compressed material out of the dispensing line.

18. 15. The method of claim 14, The method, wherein the first gas source and the second gas source are the same gas source, such that the first gas and the second gas are the same type of gas, and controlling the first and second gas sources controls the same gas source.

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