Packaging apparatus, system, and method for forming filled cones

Abstract

The present apparatus and system relate to a machine and its components adapted to fill packages and can be utilized in accordance with a method. The machine advances packages via a conveyor through substations such as a cone trimmer, a product conveyor, a fill head, a folding station, and an injection station. The cone trimmer trims the packages to a desired length, the product conveyor deposits the product at the fill head, the fill head fills the product into the packages, the folding station folds the packages, and the injection station injects the packages.

Description

Technical Field

[0001] Incorporation by Reference This application incorporates by reference in its entirety for all purposes PCT / US19 / 26711, filed Apr. 10, 2019, by Mark W. Holderman and Gregory August Russell on behalf of the United States Patent and Trademark Office. This application incorporates by reference in its entirety for all purposes U.S. Patent Application No. 17 / 113,429, filed Dec. 7, 2020, by Mark W. Holderman and Gregory August Russell on behalf of the United States Patent and Trademark Office.

Background Art

[0002] Prior to the development of the present apparatus and system, paper cones were manually filled. By hand, products such as leaves were individually packed into a single cone, the leaves were mechanically pushed down, and the closed end was twisted. Alternatively, a number of cones can be placed within what is essentially a honeycomb structure having holes for accommodating the cones. Then, the crushed leaves were scattered over the holes containing the cones, and the leaves were packed into the cones using vibration or mechanical tamping.

[0003] Each of the above resulted in cones that were inaccurately and unevenly filled. Mechanical tamping often left the leaves overcompressed. The leaves at the bottom of the cone often became overpacked, and the leaves toward the top of the cone remained too loose. Mechanical pressure tended to tear the paper cones. Relying solely on vibration to fill the cones often left the leaves too loose.

[0004] These problems were often compounded by the type of microparticles being packed. Specifically, with plant materials that had a relatively high oil content, the crushed leaves tended to become sticky, resulting in a tendency for the leaves to clump together. The clumped leaves negatively impacted the effectiveness of the vibration method, as vibration alone was insufficient to break up the clumps. Similarly, the tamping method exacerbated the problem, simply resulting in tighter-packed clumps. In both cases, the clumps tended to remain in narrower parts of the cone, creating gaps or uneven packing of plant material within the cone.

[0005] Uneven filling can cause many problems. For example, it can affect the weight of the final product. If the clump is filled with looser plant material, the density of the clump may exceed the desired amount of plant material to fill the cone. The clump tends to burn at different rates, disrupting the natural and precise burning rate of a precisely and uniformly filled cone. If the clump creates gaps, the burning rate of the plant material can be negatively affected, as the lack of solid contact between plant material can lead to the plant material extinguishing. The density of the clump can disrupt the airflow through the plant material, potentially acting like a straw blockage.

[0006] When filling cones by hand or with a honeycomb-type filling device, it is also necessary to close each cone by hand. Using these methods, each cone had to be handled manually, the open end folded to seal the plant material and prevent the cone from falling. Often, the cones are simply closed by twisting the paper on top of the cone to completely close and seal the top of the cone. This manual process puts a strain on the human hand and limits the number of cones that can be filled in a given time. Also, because people tend to have different techniques for folding or twisting, the closures tend to be unevenly folded or twisted, and dexterity is further limited as the hands and fingers become more fatigued.

[0007] Further problems have been found when using automated systems for filling cones. Automating cone filling requires more processing of the products used to fill the cones, such as leaves. The products must be transported through the automated system, for example, through a series of hoppers and conveyors. In doing so, friction between the machine parts and the products (and simply between the products themselves) generates heat that raises the reference temperature of the products. In some cases (especially with products that have a higher oil or moisture content), the heating of the products can lead to the release of oil, moisture or resin from the products, resulting in stickiness which can further lead to agglomeration and residue buildup. Such undesirable properties can, for example, block or bind automated components, hinder the flow of products through the automated system, and all of this can lead to inaccurate filling of cones, resulting in wasted products or lost productivity. In one example, agglomeration of dry leaves leads to crosslinking of the products in a funnel hopper, which blocks the flow of products through the hopper and hinders the continuous packaging of cones. In another example, residue can accumulate in parts of the machine that the product frequently comes into contact with, such as the filling head, the area surrounding the filling head, and the conveyor. The stickiness of the product can also cause problems when using suction to clean parts of the machine. Sticky products tend to solidify in the internal structure of the vacuum, rapidly clogging the system and filters.

[0008] Traditionally, paper cones are manufactured manually or through a complex, semi-automated process. Manufacturing tolerances vary relative to the overall length of the cone, resulting in variations in cone length. This can lead to the cone becoming shorter than its ideal tip during the filling and sealing process, particularly because excess cone material may not adequately cover the distal end of the cone.

[0009] Automatic folding of paper cones can be uneven if not carefully controlled. Uneven folding hinders the uniformity of filling the cones, the uniformity of ignition, and the ability of the folded cones to maintain their folds. Therefore, when folding cones in an automated process, it is necessary to ensure uniformity and greater plastic deformation at the distal end of the cone. [Overview of the project]

[0010] This system provides a device that can be used in conjunction with a method for accurately and uniformly filling paper cones with free particles and for closing the cones to prevent the particles from escaping. Embodiments may be described herein in general terms as filling cones with crushed plant material such as crushed dried leaves, but it should be understood that any free particles that can fit inside the cone can be used as the cone filler without departing from the general scope of the device and system. For simplicity, all such free particles are referred to herein simply as “leaves” or “fine particles,” but the use of such terms herein does not in any way limit the device to packaging organic plant material. “Paper” is a common material used for cones, but it should be understood that the term is generally used herein for a relatively thin, flexible, flammable substrate and is not strictly limited to conventional paper. The term “cone” does not have to be a conventional cone with a point at one end, but may be any substantially cylindrical shape or a shape having a length longer than width (or diameter, the term “width” used when describing the width of an object with a circular cross-section), but preferably a conventional cone base or frustum shape.

[0011] This apparatus, system, and method overcomes the shortcomings of the aforementioned manual and automatic filling methods by ensuring that leaves are uniformly and consistently filled into the cones. The process is automated, enabling homogeneous packaging and uniformity of the final product. This facilitates the overall process of filling cones. This apparatus, system, and method includes several subcomponents that individually perform the filling function. Each subcomponent individually overcomes the various problems that occur when manually packaging corn leaves.

[0012] General systems for automatically filling cones are described in U.S. PCT Patent Application PCT / US19 / 26711 and U.S. Patent Application 17 / 113,429, each of which is incorporated herein in full and for all purposes as stated. This disclosure improves these systems through the implementation of alternative folding fingers used to fold the distal end of the cone together with the folding tip. This disclosure also relates to a filling head to facilitate the formation of a more uniformly folded package, and improvements to the fluid injection of the filled cone, as well as the addition of a cone trimmer.

[0013] For example, the folding fingers may consist of a pair of coplanar fingers that, by the action of an actuator, are separated and brought together along the folding edge in a scissor-like motion. At least one of the folding fingers may include a recess along at least a portion of the length of the blade (such as the front half, with the tip of the blade facing forward, or the middle third), and both may include a similar semicircular recess in each blade. The recesses are positioned so that, when the blades are joined together, they form a shape that, in one embodiment, is approximately the same size as the outer cross-section of the axial pin at the folding tip. The scissor motion allows a single actuator to move both fingers simultaneously, thereby ensuring that the fingers make contact with the cone and fold reliably in the same manner each time.

[0014] A filling head is typically a hollow chamber into which leaves are deposited and then fed into a paper cone through an outlet. To limit the emergence of oil, moisture, or residue from the leaves, the filling head body is cooled during the filling process, and then the leaves are cooled. Because leaves tend to be light, a filling rod helps to evenly fill the cone with leaves. The filling rod can provide an air burst to the leaves being filled to facilitate filling within the cone. Air pressure tends to expel leaves from the cone and may expel leaves from the filling head undesirably. To limit leaf backsplash, prevent tearing of the cone, and control the pressure applied, the filling chamber may be provided with one or more gates that close off the inside of the chamber and essentially close off the inlet into which the leaves are deposited. An exhaust chimney is connected to the inside of the filling chamber, which provides a path for excess pressurized gas to leak out of the chamber. By extending the chimney (in one embodiment, about 10 to 20 inches from the filling chamber), leaves are prevented from escaping from the chamber. Therefore, in one embodiment, during operation, leaves are deposited into the chamber through the inlet and fall into a cooled filling chamber, with two gates closing the inlet. A filling rod is moved to allow the leaves to exit the filling chamber and fall into a paper cone. After or while the leaves are being deposited, the filling rod provides an air burst to the leaves in the cone. Some of the leaves may bounce back into the chamber and even into the chimney, but the length of the chimney prevents them from completely escaping the chamber. The leaves then return to the chamber and exit through the outlet to be deposited in the cone. The filling rod may be inserted into the outlet to substantially or completely block the outlet. The first gate is opened and a vacuum is applied to the chamber to remove any remaining leaves. The second gate is opened and the leaves are deposited again into the chamber to restart the process.

[0015] A fluid injection station injects a fluid, such as oil, into a leaf-filled cone. One potential problem is fluid cavitation, particularly when the fluid flow repeatedly moves forward and reverses within the flow path. This system prevents cavitation and bubbles in the injected fluid by controlling the fluid flow within the flow path. The system includes a fluid reservoir and a positive pressure flow circuit that draws fluid from the bottom of the reservoir and pressurizes the fluid into a hollow injector needle positioned within a needle cavity. The needle cavity is further connected to a negative pressure flow circuit that draws fluid from the needle into the needle cavity and deposits the fluid at the top of the reservoir through a negative pressure flow circuit. Its structure and associated directional flow paths ensure that the fluid in each flow path is controlled to flow in a single direction within each flow path, while the system allows both the discharge of fluid from the needle and the draw of fluid back into the needle, while preventing fluid cavitation and, more specifically, preventing or substantially limiting the injection of fluid with bubbles into the filled paper cone.

[0016] A cone trimmer, which may be positioned between the cone carousel and the filling head, facilitates the formation of more uniform cones. In one embodiment, the cone trimmer includes a conveyor having a plurality of holes, each holding a single cone. The conveyor moves the cones to a position above a cone lifter, which may be a plate attached to an actuator that raises and lowers the plate. A trimming head is positioned above the conveyor. The trimming head is adapted to trim the distal end of each cone. In one embodiment, the trimming head is a pair of scissors blades, and in another embodiment, a blade that is pulled through the cone. The trimming head is attached to one or more actuators that position the trimming head relative to the cone, for example, by raising and lowering the trimming head relative to the cone. In one embodiment, an encoder is connected to the actuator and a control system. The control system, such as a general-purpose computer, includes stored values, such as position values ​​corresponding to cones of various sizes. The stored values ​​may correspond to encoder positions, thereby the control system acts on an actuator (e.g., a servo) to move the encoder to a preset position, and then moves the trimming head to a known position relative to the cone position. The cone lifter lifts the cone by a set distance (a value which may be stored in the control system), so the distance from the tip of the cone to the trimmer head is known, and the trimmer head can be activated to trim the cone to that known distance, thereby forming a cone of known length. The encoder position can be adjusted for different sizes of cones, so that each cone can be trimmed to the same length for each size of cone. By trimming each cone, it is ensured that for a given common size of cone (e.g., 0.75g cone, 1.0g cone, 1.15g cone, etc.), the same length of the distal end of each cone is folded at the folding station (e.g., 10mm for a 1.0g cone, 8mm for a 0.75g cone, etc.). It also allows a single filling system to fit and fill cones of various different sizes in place.

[0017] In one embodiment, a vacuum filtration system is employed. In one embodiment, when the cone is folded, the folded tip is inserted into the distal end of the filled cone. The paper at the distal end is pressed against a pin at the folded tip while air is being injected into the filled cavity of the cone, and the distal end is vacuumed against the internal portion of the folded tip. The simultaneous application of air pressure and vacuum may cause the leaves to be sucked into the vacuum, potentially clogging the system. The vacuum filtration system sends the vacuumed air (and particulate matter) into a chamber containing a fluid such as water. The vacuumed air is sent into the chamber and into the fluid, and then captures the particulate matter. Periodically, an actuator is activated to open a valve, such as a plunger, at the base of the fluid-containing chamber. The fluid flows out of the chamber, taking in the particulate matter along with the fluid, the valve is closed, and the chamber is refilled with fluid. The waste liquid can then be transferred to a further filtration system of the kind known in the art that can be used to filter and recover particulate matter from the fluid.

[0018] The packaging of the cone can be completed using a folder subcomponent with air assistance. The folder subcomponent properly orients the cone. The folding fingers can precisely bend a portion of the cone, and the folding tip compresses and closes the bent portion of the cone. Alternatively, an iris folding system can be used instead of folding fingers to close the distal portion of the cone and press it against the folding tip. The folding tip may have an outer circumference configured to surround the distal end of the cone, particularly the distal rim of the distal end of the cone. It may also include a central portion such as an axial pin. In some embodiments, the folding tip is adapted to apply one or more of vacuum pressure and positive pressure to the cone. For example, suction may be applied circumferentially to the distal end of the cone by the folding tip, and air pressure may be injected into the cone through the axial pin of the folding tip. The release of the folding fingers or iris and the folding tip push down the distal end of the paper cone, folding the distal rim and at least a portion of the distal end into the cone itself and into the internal cavity of the cone, thereby folding the distal end of the cone. The folded portion covers at least substantially (in some embodiments, completely) the particles inside the cone. The use of vacuum and pneumatic application increases the rigidity of the paper cone just before the folding tip folds the distal end of the cone. This improves the uniformity of the folding, which enhances the plastic deformation of the distal end, resulting in a more reliable folding. [Brief explanation of the drawing]

[0019] [Figure 1] This is a perspective view of one embodiment of the device and system, showing the overall relationships between the various subsystems of the device. [Figure 2A] This is a perspective view of one embodiment of a grinder hopper and wheel. [Figure 2B] This is an alternative perspective view of one embodiment of a grinder hopper and wheel. [Figure 3] This is a cross-sectional side view of one embodiment of a folder station having an unfolded cone. [Figure 4A] Perspective view of an embodiment of a folder tip having an axial pin. [Figure 4B] Plan view of an embodiment of a folder tip having an axial pin. [Figure 4C] Cross-sectional side view of an embodiment of a folder tip having an axial pin. [Figure 4D] Cross-sectional view of an embodiment of a folder tip having a vacuum chamber and a pneumatic chamber. [Figure 5A] Perspective view of an embodiment of a cone folded by an embodiment of a folder tip having an axial pin. [Figure 5B] Cross-sectional side view of the distal end of an embodiment of a filled cone having a fluid core folded by an embodiment of a folder tip having an axial pin. [Figure 6A] Perspective view of an iris folding station subassembly. [Figure 6B] Perspective view of the iris portion of an iris station subassembly. [Figure 7A] Perspective view of an embodiment of a hopper, conveyor, and feeder assembly. [Figure 7B] Side view of an embodiment of a hopper, conveyor, and feeder assembly. [Figure 8A] Perspective view of an embodiment of a hopper, conveyor, and feeder assembly, including a view of a portion of the assembly enlarged in FIG. 8B. [Figure 8B] Enlarged view of an embodiment of a hopper. [Figure 9A] Perspective view of an embodiment of a hopper, conveyor, and feeder assembly, including a view of a portion of the assembly enlarged in FIG. 9B. [Figure 9B] Enlarged view of an embodiment of a hopper. [Figure 10A] Perspective view of an embodiment of a hopper, conveyor, and feeder assembly, including a view of a portion of the assembly enlarged in FIG. 10B. [Figure 10B]This is an enlarged view of one embodiment of a feeder assembly. [Figure 11A] Figure 11B is a side view of one embodiment of a hopper, conveyor, and feeder assembly, including an enlarged view of a portion of the assembly. [Figure 11B] This is an enlarged side view showing a portion of the feeder assembly with plate 7020 removed. [Figure 11C] This is a perspective view of an alternative embodiment of a portion of a feeder assembly, including a cleaning brush. [Figure 12] This is a side view of a cone trimmer station with the trimmer head in the raised position and the cone lifter in the retracted position. [Figure 13] This is a side view of a cone trimmer station with the trimmer head in the lowered position and the cone lifter in the raised position. [Figure 14] This is a perspective view of one embodiment of a folding finger positioned relative to the folding tip. [Figure 15] This is an exaggerated plan view of one embodiment of a folding finger. [Figure 16A] This is a perspective view of one embodiment of a folding finger positioned in the closed position at an angle of approximately 90°. [Figure 16B] This is a perspective view of one embodiment of a folding finger positioned in the open position at an angle of approximately 90°. [Figure 17A] This is a front view of one embodiment of a filling station. [Figure 17B] This is a side cross-sectional view of one embodiment of a filling station along line A in Figure 17A, where the gate is in the filled position and closed. [Figure 17C] This is a side cross-sectional view of one embodiment of a filling station along line A in Figure 17A, with one gate closed and one gate open. [Figure 17D] This is a side cross-sectional view of one embodiment of a filling station along line A in Figure 17A, where the gate is in the opening filling position. [Figure 18A] This is a perspective view of one embodiment of a fluid injector station. [Figure 18B] This is a front cross-sectional view of one embodiment of a fluid injector station showing a positive pressure fluid flow path. [Figure 18C] This is a right-hand cross-sectional view of one embodiment of a fluid injector station showing a portion of the negative pressure fluid flow path. [Figure 18D] This is a rear cross-sectional view of one embodiment of a fluid injector station showing a portion of the negative pressure fluid flow path. [Figure 19] This is a cross-sectional view of one embodiment of the flow path of an injector needle and an injector station. [Figure 20A] This is a perspective view of one embodiment of a vacuum cleanout. [Figure 20B] This is a cross-sectional view along line D in Figure 20A of one embodiment of a vacuum cleanout. [Figure 21] This is a perspective view of one embodiment of a corn die and a cleaning brush. [Figure 22] This is a perspective view of an alternative embodiment of the device and system, illustrating the overall relationships between the various subsystems of the device. [Modes for carrying out the invention]

[0020] Throughout this specification, similar structures are identified by the same reference numerals where feasible. In some figures, components such as additional electrical connections and piping (e.g., vacuum and pneumatic piping) are omitted for clarity of the drawings. Furthermore, in some figures, repeating structures such as multiple actuators are omitted. In such cases, it should be understood that exemplary components are provided for illustrative purposes only, and similar components may be provided in other similar devices in the drawings. Unless otherwise specified, the term “or” means “either or both,” so that “A or B” includes A only, B only, and both A and B.

[0021] Figure 1 shows an overall representation of one embodiment of the packaging assembly 100. The embodiment may include a carousel 200, a cone conveyor 300, a hopper assembly 400, a leaf conveyor (not shown), a grinder hopper 401, a filling station 500, a weighing station 510, a folder station 600, and a quality control station 800. Furthermore, the packaging assembly may include a conveyor 806 and an injector station 700 (which may be integrated with the folder station or be a separate subassembly). The packaging assembly may also include a cone trimming station (not shown) and a vacuum cleanout (not shown). Various subassemblies can be mounted on the table 101.

[0022] The packaging assembly 100 also comprises several actuators. The actuators move the various components of the assembly into their appropriate positions. In one embodiment, the actuators are generally pneumatic actuators and electric motors, but those skilled in the art will understand that any actuator can be used. In non-limiting examples, continuous-speed motors, variable-speed motors, servo motors, hydraulic, or magnetic actuators can be used. In further examples, the actuator may be in the form of a simple valve or switch on which the control system operates to allow a hydraulic or pneumatic fluid to flow through the system and to provide the force required by the system. Vacuum pumps and vacuum tubes can also be utilized to control the airflow within the system.

[0023] Figure 22 is an overall diagram of an alternative embodiment of the apparatus and system, showing the subsystems in a linear arrangement rather than the circular arrangement shown in Figure 1. Figure 22 shows an overall embodiment of a packaging assembly 100, which includes a carousel 200 and a cone conveyor 300 that moves dies linearly through the system. It also includes a hopper assembly 400, a leaf conveyor 451, and a filling station and folder station downstream of the cone trimming station 1200.

[0024] An electrical control system can be used to monitor and control the operation of the system and packaging assembly. The electrical control system may include dedicated circuits, programmable computer hardware, firmware, software, controllers, or a combination thereof. The control system adjusts the operation of the device and system, particularly actuators, vacuum, and pneumatic adjustments, and further utilizes sensor data, pre-configured parameters stored in the control system, or a combination thereof. Generally, it is advantageous to use a control system of a self-contained, locally-oriented computer (equipped with accompanying input / output devices such as a display, keyboard, mouse, touchscreen, and voice command control) to reduce feedback between sensors, computers, and actuators, as well as command loop latency. However, parts of the control system may be organized in a distributed manner, with sub-control systems that operate parts of the packaging system while being networked with a main computer controller, or parts of the control system may be located further off-site and connected via the internet.

[0025] In one embodiment, a computer monitors sensors in the packaging assembly and adjusts the operation of the actuators in the packaging assembly. Simultaneously, the computer records data on the operation of the packaging assembly. For example, the computer records the time each actuator is activated. The computer system can further compile the number of operations for each actuator to determine whether a finished product should have been produced. For example, the computer identifies that the carousel actuator has been activated, followed by the activation of the nesting release finger. A feedback sensor on the nesting release finger notifies the computer that the cone has been successfully pulled out of the carousel, and the computer logs this data. The computer then records the activation of the cone conveyor, as well as the sensors and actuators of the weighing station (indicating that the product has been supplied to the cone). The computer system logs the activation of the packing rod actuator and the subsequent activation of the folding finger actuator (indicating that the filled cone is complete), and then the computer logs the die actuator (releasing the filled cone), followed by sensor feedback from the quality control sensor (weight of the cone, image of the cone, or simple confirmation that the cone is present). Next, the computer records whether the rejection actuator was activated to determine whether the cone was accepted or rejected. The computer also records subsequent activations of the actuators at the fluid injection station, including the operation of the fluid pump, to record whether the cone was filled with the fluid core and how much fluid was deposited inside the cone. Subsequent quality control data (and acceptance / rejection data) as described above may be recorded. In some embodiments, fluid filling occurs before any quality control. By coordinating the recording of data related to actuators and sensors, the computer system can track individual cones as they progress through the packaging system.

[0026] The computer control system may also be connected to a cooling or refrigeration unit. An example of a suitable cooling unit is an aluminum block containing or fixed to a reservoir. Several thermoelectric chips (TECs) may be mounted on the aluminum block, and when energized, the TECs cool the block, thereby cooling any refrigerant fluid in the reservoir within the block. Sensors can monitor the temperature of the coolant and provide feedback to the computer, which controls the temperature of the TECs and, consequently, the coolant. Other conventional refrigeration units will be obvious to those skilled in the art.

[0027] The refrigeration unit is connected to specific subcomponents of an assembly where it is desirable to maintain a constant temperature. These subcomponents are areas in the assembly or where the movement of products (leaves) through the assembly tends to generate heat that warms the products.

[0028] Generally, a packaging assembly consists of several different stations. Each station performs a specific task of assembling filled cones together. The packaging assembly shown in Figure 1 is configured in a circular arrangement so that the cones move counterclockwise through the system. However, it is conceivable that the cone conveyor could be arranged linearly with stations arranged along it, as shown in Figure 22. In the embodiment of Figure 1, cones from the carousel 200 are piled up on the cone conveyor 300, which moves the cones to the filling station 500, then to the folder station 600, and then to the quality control station 800. The cones can then proceed to the injector station 700.

[0029] Referring further to Figures 12, 13, and 22, in another embodiment, cones from the carousel 200 are piled on a cutting conveyor 1201 (which may have a structure similar to the structure of the carousel's plates). The cutting conveyor holds the cones 1000 in a vertical position and moves them toward a trimmer head 1202. The trimmer head may include a cutting part such as a blade or multiple scissor blades, generally indicated by 1203. A cone positioning system assists in positioning the cones. Although this embodiment is vertically oriented, it may be oriented horizontally. A cone lifter 1204 is positioned below the cutting conveyor. The cone lifter may consist of a piston 1206 and an actuator 1205 attached to a plate 1207. When the actuator 1205 is activated, the plate moves up and down. The plate contacts the proximal end of the cone, lifting the cone to the desired height, as shown in Figure 13. The trimmer head is mounted on an actuator 1208 that moves the head relative to the cone, for example, raising the head (Figure 12) and lowering it (Figure 13). The trimmer head may include position sensors, such as an encoder assembly (not shown), which provides feedback to the control system to precisely control the position and movement of the trimmer head. The control system includes stored values ​​for specific sized cones. By adjusting the operation of a cone lifter to contact the proximal end of the cone and lift the cone, and the height of the trimmer head relative to the cone and lifting plate 1207, the distance from the proximal end of the cone to the trimming blade 1203 is known for each stored cone value. Thus, cones sized differently can be precisely trimmed to the same length, regardless of the manufacturing tolerances of the sized cone in general.

[0030] Figures 2A and 2B show one embodiment of a grinder hopper assembly 450 that can be used. The grinder hopper assembly 450 includes a hopper 401 having a hopper inlet 402 and a hopper outlet 403. At the hopper outlet is a wheel 451 operated by a wheel actuator 452. The wheel may include a textured surface to function as a grinding wheel. In one embodiment, the hopper inlet 402 is funnel-shaped toward the hopper outlet 403, and the outlet is approximately the same width as the wheel 451. A portion of the wheel fits into the hopper outlet to substantially block the flow of leaves from the hopper, leaving a gap between the surface of the wheel and a portion of the hopper. A control system signals the wheel actuator to drive the wheel. When leaves are in the hopper, as the wheel rotates, the wheel pulls the leaves through the gap between the wheel and the hopper. If a textured wheel is used, the rotation of the textured wheel can grind the leaves as they are pushed between the surface of the wheel and the hopper at the hopper outlet. When the leaves exit the outlet, they may be piled up within the conveyor belt, or alternatively, directly piled up in a weighing station or other subassembly.

[0031] The grind hopper 401 is prone to heat buildup due to friction caused by the rotating wheel 451 and friction between products as the product moves through the hopper. This is particularly problematic in this subassembly because, when the product heats up, the fluid tends to coagulate and be released, leading to further accumulation of sticky residue in the hopper, on the wheel, and at the outlet. This accumulation restricts the free flow of product through the system. Furthermore, when the product coagulates, it tends to bridge within the hopper, thereby completely blocking the flow of product.

[0032] Therefore, both the hopper and the grinding wheel may be connected to a coolant flow circuit, which is connected to a refrigeration unit. For example, the hopper may be made of aluminum and include a sealed detour channel that allows coolant to flow from the refrigeration unit into the channel, out of the channel into the downstream part of the flow circuit, and finally back to the refrigeration unit. This allows the coolant to cool the hopper and maintain the hopper's temperature at approximately the temperature of the coolant within the coolant circuit. When product is supplied to the hopper, the cooled hopper cools the product and maintains its temperature to prevent the product from releasing fluid. The fluid circuit may also include a grinding wheel 451. Coolant can be supplied to the wheel via a hose together with a rotating union and then flow out and continue through the coolant circuit.

[0033] Figures 7A to 11B show one embodiment of a product conveyor system with a cooling circuit. This embodiment includes a hopper 7001, one or more conveyors (e.g., 7002), and a feeder 7004. The hopper may be formed in an hourglass shape with an upper chamber tapering towards a narrow neck and a lower chamber widening from the neck to a conveyor below the hopper. Generally, the upper chamber may be larger than the lower chamber. The hourglass shape helps prevent bridging of the product within the hopper. The conveyor may include a gate 7019 to control the amount of product leaving the hopper. As the conveyor 7002 moves below the hopper, the product may accumulate and be agitated at the gate 7019, thereby generating friction and heat. The hopper and conveyor may be connected to a cooling circuit to dissipate heat and keep the product cool.

[0034] Various parts of the product conveyor system can be connected to a cooling circuit. As shown in Figures 7A to 11B, the hopper 7001 may include cooling plates 7010, 7011, 7012, and 7013. In one embodiment, the cooling plates include internal paths through which a coolant fluid can flow. The cooling plates can be connected by hoses, e.g., 7014 and 7015, which can be connected to additional cooling plates and coolant reservoirs (not shown) to form a cooling circuit. Additional cooling plates may be provided in relation to the conveyor(s). For example, cooling plates 7016 and 7017 cool the conveyor belt 7002. In this way, the hopper and conveyor belt can keep the products cool as they move through the system.

[0035] A feeder 7004 is shown in Figures 10A to 11B. The feeder may include a channel 7018 for guiding products on the conveyor toward the end of the conveyor and preventing excess products from accumulating and spilling onto the conveyor. In the illustrated embodiment, the channel consists of a pair of plates 7020 and 7021. The feeder may also include a grinding wheel 451 and a dynamic gate 7022. In one embodiment, the surface of the conveyor 7002 may be a grinding wheel that rotates passing through the dynamic gate 7022. The dynamic gate may be formed of a gate plate 7023 and a link mechanism 7024 connected to a pin 7025 eccentrically mounted on a wheel 7026. The gate plate 7023 may also be connected to plates 7020 and 7021 by a pin 7030 so as to allow the gate plate to pivot relative to the plate. The wheel may be connected to an actuator 7027. The actuator is further connected to a machine controller such as a computer or microprocessor. The controller can control the operation of the dynamic gate by sending commands to the actuator to rotate the wheel. In one embodiment, the actuator is intermittently controlled to rotate the wheel 7026 clockwise to open the gate, and then rotate it counterclockwise to close the gate and press the leaves against the grinding wheel 451. In this way, the dynamic gate can be repeatedly pulsed against the grinding wheel, allowing the leaves to pass through and be ground simultaneously. Furthermore, the coarseness of the grinding of the product can be controlled by controlling how much the gate and wheel 7026 are rotated counterclockwise.

[0036] Additionally, the conveyor and dynamic gate may be controlled by a control system that receives feedback from the weighing station. The controller monitors the feedback from the weighing station and uses it to control the conveyor speed and the operation of the dynamic gate. When the weighing station indicates that the weight is low, the conveyor speed increases and the dynamic gate opens to provide a larger gap. As the weight increases, the conveyor speed decreases and the dynamic gate moves closer to the grinding wheel to finer grind the product and slow down the accumulation of the product to the weighing station. The control system stores a set weight of the product in memory (e.g., the amount of product needed to fill one cone). As the weight approaches the set weight, the controller reduces the conveyor speed and adjusts the spacing of the dynamic gate to more precisely control the accumulation of the product to the weighing station.

[0037] In some embodiments, the gate plate 7023 includes an internal fluid path connected to a cooling circuit, for example, by hoses 7028 and 7029. The cooling circuit helps maintain the product at a cool temperature, preferably 35°F to 55°F, during the packaging cycle. It has been found that using the cooling circuit of this system in conjunction with a coolant fluid in the range of 35°F to 40°F is sufficient to maintain a favorable temperature for the product during the packaging cycle. Lower temperatures risk the formation of ice crystals from ambient humidity, which can adversely affect the process, while higher temperatures tend to be ineffective in overcoming the heat generated in the system. The product may be supplied from a refrigerated container to a hopper 7001. The cooling circuit maintains the temperatures of the hopper, conveyor, dynamic gate, and grinding wheel, thereby controlling the temperature of the supplied product as it moves through the system so that it is deposited in the cone by dissipating heat that may be generated, for example, by friction.

[0038] Figure 11C shows an alternative embodiment of the supply system. For clarity, the dynamic gate has been removed. Even with a chiller, particulate matter can still accumulate on the conveyor. To prevent excessive accumulation of particulate matter, a cleaning brush 7031 can be positioned below the conveyor. In some embodiments, the brush 7031 is moved by an actuator (not shown) to rotate in the opposite direction to the movement of the conveyor. Thus, after the conveyor has deposited material into the filling head, the conveyor continues along its path, and the cleaning brush rotates in the opposite direction to the conveyor to brush and clean any remaining particulate matter from the conveyor.

[0039] Referring to Figures 17A to 17D, one embodiment of a filling station is shown. The product is supplied to the filling station 500 for filling a cone. In one embodiment, the filling station includes an inlet 1701, a filling chamber 1703 which converges at an outlet 1704, a filling rod 1705, and an exhaust port 1706 communicating with the filling chamber. The filling station may also include one or more gates to open and close sections of the filling chamber. For example, the filling station may include an inlet gate 1707 at the inlet before the discharge path and a discharge gate 1708 between the discharge path and the filling chamber. As shown in Figures 17B to 17D, the gates can be selectively opened and closed to allow the product to flow into the filling chamber with both gates open, the size of the filling chamber can be limited by closing both gates or gate 1708, and the discharge gate 1708 can be opened to allow suction force to be applied to the filling chamber to remove residual particles.

[0040] During filling, particulate matter is deposited within the filling chamber, and a filling rod reciprocates to selectively allow the particulate matter to pass through the outlet and enter a cone positioned below the outlet 1704. The filling rod may be a hollow tube capable of supplying pressurized gas to the cone during filling. When an air burst is applied, the air is pushed back into the filling chamber. To relieve the pressure, the air can exit the filling chamber through the exhaust port 1706. Particulate matter has been found to be similarly transported. To prevent leakage of particulate matter and control the airflow, the exhaust port is often equipped with an exhaust chimney 1709. In one embodiment, the chimney is approximately 10 to 20 inches long. Air passes through the chimney, but due to its length, no particulate matter is leaked. The transported particulate matter falls into the chamber and can then be further filled into the cone.

[0041] Since the particulate matter is handled during the filling process, heat can accumulate inside the filling chamber. To counteract this heat, in one embodiment, the structure forming the filling chamber 1703 is cooled, which then helps to keep the particulate product at a cool temperature.

[0042] Keeping the product at a cool temperature is further helpful when injecting the fluid core. After the product is filled into the cone, the filled cone is ready for fluid injection. To maintain the free flow of the fluid, it may be heated. Therefore, depending on the type of fluid used, the fluid may undergo a decarboxylation process. For example, before the heating and injection process is carried out at the fluid injection station, concentrated oil extracts may first be decarboxylated using techniques known in the industry (e.g., by heating the oil for a long period of time until foaming stops in the liquid). This step is necessary because certain extracted concentrated oils (e.g., crushed, abrasive, source, raw resin extracts) will release gas and foam when heated to a point where their viscosity is low enough for fluid injection. The bubbles can interfere with the pumping mechanism and fluid circuit by generating variable pressure during pumping (e.g., air pockets in the fluid line), potentially leading to inaccurate amounts of oil being injected. Therefore, by decarboxylating the oil first, the fluid injection station can ensure that the fluid is heated without interrupting the fluid flow and pumping process, thereby ensuring that the fluid is injected into the cone.

[0043] Referring to Figures 18A to 18D and Figure 19, one embodiment of a fluid injection station includes a plurality of unidirectional flow paths. Generally, the fluid injector station 1800 includes a reservoir 1801, an actuator 1802 and pump 1803 for the positive flow path, an actuator 1804 and pump 1805 for the negative flow path (however, in some embodiments, each actuator and pump is integrated into its own single pump unit), and a needle actuator 1806 for raising and lowering an injector needle 1811.

[0044] The positive channel directs fluid from the reservoir towards the injector needle. In contrast, the negative channel draws fluid from the needle back to the reservoir through the negative channel. In one embodiment, the positive channel draws fluid from the bottom of the reservoir, while the negative channel deposits fluid towards the top of the reservoir. This allows fluid from the negative channel, which may contain bubbles due to cavitation caused by reversing the fluid flow at the needle, to deposit at the top of the reservoir and settle within the reservoir before reaching the positive channel. Thus, the system prevents the formation of bubbles in the fluid injected using the needle, particularly at the injection point where the fluid occupies the cavity within the needle.

[0045] Figure 18B shows an embodiment of the positive flow path. Actuator 1802 controls the operation of pump 1803 to flow fluid through the positive flow path 1808. The pump draws fluid from reservoir 1801 to port 1807 at the bottom of reservoir 1801. The pump pushes the fluid through the positive flow path toward outlet port 1809, where the fluid then enters the needle and, if necessary, exits the needle. In some embodiments, at least a portion of the needle (and in some embodiments, most of its length) is further surrounded by heater 1818 and nozzle 1819. The heater is connected to a control system to control the temperature of the needle and, consequently, the fluid at the injection point. The nozzle is shaped similarly to a folded tip. Thus, alignment of the hole at the distal end of the cone filled with particulate matter and the needle (coaxial with the nozzle) is facilitated by the nozzle fitting into the distal end of the cone and the raised rim portion of the distal end of the cone. It was found that by using a heater to maintain a fluid temperature of 100°F to 120°F, and optimally around 110°F, the optimal flow viscosity can be obtained for most injection fluids while preventing cavitation during the injection process.

[0046] As shown in Figure 19, the positive flow path 1808 terminates at a port 1809 that pours into a chamber 1810 housing the needle 1811. Gaskets 1812 and 1813 seal the chamber around the needle, preventing fluid from leaking out of the chamber while allowing the needle to reciprocate within the chamber 1810. The needle includes a shaft hole 1814, which is a path that runs through the entire needle shaft. The needle includes a path 1815 connecting the shaft hole and the needle outlet 1816, allowing fluid to flow from the chamber through the shaft hole, through the needle path, and out through the needle outlet. The direction of fluid flow in the positive and negative paths is indicated by arrows.

[0047] The negative path 1817 connects to the chamber 1810. As shown in Figures 18C and 18D, the negative path 1817 flows from the chamber to the reservoir 1801 and into the reservoir at the return port 1820. Negative pressure is applied to the negative path to draw the fluid out of the chamber. The suction created in the chamber generates negative pressure in the needle path 1815, drawing the fluid back to the needle and through the shaft hole 1814. Thus, by applying positive and negative pressure, the fluid flows out of the needle through the positive path and out of the negative path through the needle, without reversing the fluid flow in either the positive or negative path.

[0048] Without controlling the fluid flow, cavitation tends to occur in the shaft bore 1814 as the fluid is moved forward and reversed through the shaft bore 1814. In one embodiment, by applying suction to draw the fluid from the shaft bore into the chamber 1810, the majority of the turbulent fluid can be raised above the shaft bore, and the needle size is set and the pump actuator is synchronized so that new fluid from the positive flow path can be pumped into the needle. This limits the amount of fluid in the system being pushed back and forth to only the amount of fluid in the needle, most or all of which is discharged in a continuous injection cycle, thereby the fluid in the needle undergoes flow reversal only once or twice before being discharged. Once the fluid is injected, it is preferable to cool the fluid so that it does not supersaturate the product. By keeping the product cold during the filling stage, the product itself assists in cooling the fluid as it is injected into the center of the cone. Thus, the cold product helps to lower the temperature of the fluid during injection, increasing the viscosity of the fluid and maintaining the fluid as the central core within the cone. The filled cone can then be transported to a refrigeration chamber for further cooling of the fluid.

[0049] Figure 3 shows an overall embodiment of the folder station 600. The folder station may include a housing that accommodates the folding rod 602. The folder tip 604 is attached to (or integrated with) the distal end of the folding rod 602, while the proximal end of the folding rod 602 is associated with the folding rod actuator 610.

[0050] In one embodiment, two folding fingers are utilized. Referring to Figure 3, one embodiment includes folding fingers 642, 652 and folding finger actuators 643, 653. Each folding finger includes, for example, a substantially V-shaped groove (not shown) that together surrounds the distal end 1102 of the cone 1120 when the folding fingers are brought together.

[0051] To fold the cone, the die 310 containing the filled cone 1120 is oriented below the folding station 600, thereby axially aligning the folder tip 604 and the cone 1120. In one embodiment, a cone support 561 supports the proximal end of the filled cone 1120. The cone support may be integrated with or connected to a support actuator 562 that can rise (lift in some embodiments) to contact the filled cone 1120 when the cone conveyor is aligned with the folder tip. Lifting the filled cone 1120 can help ensure that the distal end 1102 of the cone protrudes from the die 310 for proper folding. In one embodiment, the cone support may be attached to the cone (by suction or mechanical clamp, for example). In one embodiment, folding finger actuators 643, 653 engage folding fingers 642, 652 with the distal end 1102 of the filled cone 1120, deforming the distal end 1102 of the cone in preparation for folding. The folding fingers converge at the distal end, compressing the paper at the distal end toward the central axis of the cone.

[0052] Referring to Figures 4A, 4B, and 4C, one embodiment of the folder tip 670 is shown, and referring to Figures 5A and 5B, both a perspective view of the filled and folded cone and a cross-sectional view of the distal end of the filled and folded cone 1120 are shown. In one embodiment, fingers 652, 642 work together to press the distal end of the cone against the central portion of the folding tip, such as an axial pin 671. The folding tip 670 is then pushed into the distal end of the filled cone 1120, with the axial pin 671 preventing the cone from completely enclosing the distal end. As the folding tip is retracted, an access hole 1122 is formed in the folded paper 1121 of the filled cone 1120, so that the folded distal end extends over and substantially covers the particles within the cone. Alternatively, the cone can be pushed up into the folding tip, or a combination of movements can achieve the same effect.

[0053] In one embodiment, the folded tip 670 includes an outer circumferential surface 672, an inner circumferential surface 673, an axial pin 671, and a contact edge 674, as shown in Figures 4A to 4C. Preferably, the cross-section of the folded tip is circular, and preferably, the diameter of the contact edge 674 is smaller than the maximum diameter of the distal end of the filled cone 1120. The outer circumferential surface 672 of the folded tip 670 may be conical, as shown in Figure 3, such that the angle α matches the angle of the surface of the die (e.g., die 310) that holds the cone. The inner surface 673 may also be conical. In one embodiment, the angle β of the inner surface is 80° to 85°. The inner circumferential surface is terminated by an axial pin and a contact edge, respectively. During the folding process, the folding tip may be positioned at the distal end of the filled cone 1120 such that the central portion, for example, the axial pin 671, is below the rim 1103 of the distal end 1102 of the filled cone 1120. When the fingers 642 and 652 assemble, the axial pin prevents the fingers from completely crushing the cone paper, and the cone paper is pressed against the axial pin. The folding tip 670 is pressed toward the filled cone 1120 such that the paper at the distal end of the cone slides upward on the axial pin and is bounded by the inner surface 673. The contact end 674 presses the cone paper into the leaves within the cone, crimping the cone paper to itself (see generally the fold lines 1130 of the folded portion of the cone (1121)) and into the cone, while the axial pin prevents the cone paper from completely covering the leaves, although the majority of the distal end is covered by the folded paper. In this way, a portion of the paper cone is pressed into the internal cavity of the cone so that its distal end folds over itself and over the leaves inside the cone, but a portion of the paper cone protrudes above the level of the leaves 1140 (and any fluid 1124 into which the filled cone is injected), creating a circumferential lip 1123 around the cone. Also in this way, the end of the cone folds and exhibits plastic deformation, thereby preventing the leaves from leaking out while leaving small holes 1122 at the end of the cone.Therefore, as shown in Figures 5A and 5B, the filled cone 1120 has a proximal end 1101 (mouth) and a distal end 1102 (tip), a circumferential lip 1123 of paper, a folded piece of paper 1121 inside the circumferential lip, and an access hole 1122 located approximately in the center of the folded piece of paper 1121 such that the rim 1103 of the filled cone 1120 folds toward the center of the cone's diameter.

[0054] In one embodiment, the length of the unfolded cone is approximately 4 to 4.5 inches. Folding the distal end of the cone such that the folded portion is pressed and in contact with the leaves inside the cone is better suited to ensuring that the leaves inside the cone do not flow freely out of the cone when the cone is inverted (especially in folded cones having access holes 1122), and improves ignition of the distal end of the cone compared to leaving a gap between the leaves of the cone and the folded paper. Additionally, folding the cone such that the circumferential lip 1123 is extended by approximately 2 to 5 mm has been found to yield optimal results while maximizing the internal volume of the cone that can be filled with leaves.

[0055] In contrast to completely sealing the cone by a full button fold or by twisting the paper of a closed cone, folding the tip of the cone to create an access hole 1122 at the distal end of the cone and a circumferential lip 1123 of paper has been found to have several advantages. One advantage is that the hole provides an access point for the needle, which can then be inserted into the cone to fill the cone with a fluid core without penetrating the layers of cone paper. Attempting to penetrate the layers of paper has been found to often result in the displacement of the leaves within the cone or uneven compression of the leaves that negatively affects the combustion of the cone. The hole ensures that the needle does not respond to excessive resistance from the paper and can penetrate the length of the cone through the leaves without unnecessarily compressing the leaves or pushing the paper towards the tip of the cone and displacing the leaves.

[0056] Furthermore, the holes allow for an airflow through the cone when igniting the filled cone. When a flame approaches the filled cone, air may be drawn through the cone by creating a vacuum at the smaller diameter end of the cone, thereby drawing the flame into the cone and bringing it into contact with the leaves and core. This helps ignite the center of the cone where the fluid core may be deposited. Without holes, it is difficult to create a vacuum within the unignited cone when the tip is closed due to the complete folding or twisting of the paper. When the flame contacts the completely closed tip, it has been found that the flame ignites the paper and then moves or progresses along the sides of the cone, burning the paper rather than the leaves. The leaves will eventually ignite, but the progress of the flame tended to cause uneven ignition of the leaves (e.g., igniting nearby leaves as it progresses, rather than uniformly igniting across the diameter of the cone), contributing to the uneven burning rate of the filled cone. This also means that the leaves along the outside of the cone (closer to the paper) ignite first, leaving the fluid-filled core unignited. By adding holes to the tip of the folded cone, when a vacuum is applied to the cone (drawing in air flowing in from the distal end and out through the proximal end), the flame is drawn directly to the center of the cone and the fluid core, ensuring ignition of the core and the leaves located in the center (especially if the fluid is flammable oil). As a result, the folded paper burns away first (in front of the cone paper that surrounds and holds the leaves), which helps to contain the leaves as the cone burns, leading to more uniform ignition and gradual combustion of the leaves. It has been found that by providing a folded tip having the aforementioned structure, a more reliable and uniform fold is created at the end of the filled cone, while at the same time providing airflow holes in the paper cone.

[0057] Additionally, it was found that even with access holes, the leaves inside the cone do not ignite consistently and uniformly, posing a risk of flames traveling along the length of the cone. However, by forming a circumferential lip of paper, when flames are drawn into the cone through the access holes, the more flammable circumferential lip of paper ignites simultaneously. That is, the circumferential lip of paper provides a mass of material that is more flammable than the leaves, and this mass of material surrounds the distal end of the cone so that the paper ignites around the distal end, forming a strong, uniform cherry at the distal end while preventing flames from traveling along the sides of the cone.

[0058] A further embodiment of a folding tip incorporating an air-assisted folding system is shown in Figure 4D. The interior of the folding tip is shown for illustrative purposes. Figure 4D shows a folding tip 2760 including a central portion such as an axial pin 2671. The folding tip includes a vacuum outlet 2010, one or more vacuum inlets 2011, a pneumatic inlet 2020, and a pneumatic outlet 2021. As shown in Figure 4D, the pneumatic outlet 2021 is formed at the tip of the axial pin 2671. The pneumatic outlet may be formed to discharge air from the side of the axial pin rather than directly downward from the bottom of the pin. The pneumatic inlet and pneumatic outlet may be connected by a chamber 2022 formed within the folding tip. Similarly, the vacuum inlets 2011 and vacuum outlets 2010 may be connected by a second separate chamber 2012 formed within the folding tip. One or more vacuum inlets 2011 may be formed as holes in the inner circumferential surface 2673. In one embodiment, the vacuum inlets are evenly and circumferentially spaced around the axial pin. Both the vacuum outlet and the pneumatic inlet are connected to a conventional pump (not shown) suitable for applying vacuum pressure or pneumatic pressure as needed. Lines 2030 and 2031 indicate the airflow paths for pneumatic and vacuum pressure, respectively. The pump is connected to a control system that thereby can operate the pump. As shown in the figure, the hollow chamber surrounding the axial pin widens outward near the inner surface. This widens to allow multiple passages to form on the inner surface, while the hollow chamber restricts the airflow, allowing for better suction near the tip.

[0059] The folding operation using air assist generally proceeds as follows: The folding tip is lowered into the distal end of the cone such that the rim of the cone is above the contact end 674. The folding finger compresses the distal end of the cone around an axial pin above the pressure outlet 2021. Vacuum is applied to draw air through the inlet 2011, which draws the paper at the distal end of the cone upward against the folding tip and circumferential surface 2673. Simultaneously, air pressure is applied through the outlet 2021 blowing into the interior of the cone, inflating the cone at least partially, thereby pushing the paper of the cone outward. The folding finger is retracted, driving the folding tip into the interior of the cone, thereby folding the distal end of the cone so that the distal end of the cone folds over itself and is held by plastic deformation over at least substantially all of the particles in the cone's package.

[0060] When using air assist, the vacuum pressure typically draws small amounts of particulate matter from the filled cone. This can lead to significant particulate matter loss or vacuum blockage over time. To prevent clogging and allow for particulate matter recovery, a filtration system can be incorporated into the vacuum section of the folding section. Figures 20A and 20B show one embodiment of a vacuum filtration system, which includes a housing 2100, a fluid (such as water, indicated by the fluid level line 2113), fluid inlets 2101, 2102, a vacuum inlet 2103, a vacuum outlet 2104, a fluid holding chamber 2105, a fluid discharge chamber 2106, and a movable plug 2107 separating the fluid holding chamber from the discharge chamber. The plug 2107 may be attached to an actuator 2108, for example, by a rod 2109. The top of the plug 2114 is angled at approximately 40° to 50°, but may generally be approximately 45°. The top of the plug may be provided with a compressible O-ring (not shown) in a notch 2115 that forms a fluid-tight seal against the chamber wall 2110. The bottom of the plug 2116 is also conical, with an angle of approximately 50° to 60°, leading to a rounded tip 2117. The difference in angles ensures that particulate matter remains suspended in the fluid as the fluid flows from the fluid chamber to the discharge chamber. However, the steeper angle on the lower plug allows for different fluid flow rates, which helps to remove particulate matter from the plug. The vacuum inlet is connected to a vacuum diffuser 2111 having an outlet positioned above the fluid level. When a vacuum is applied to the folded tip, particulate matter can be drawn up, travel through the vacuum diffuser, and discharged into the fluid that captures the particulate matter. The plug may be operated periodically to discharge the fluid and remove any accumulation of particulate matter in the fluid. The discharged fluid can then exit through a drain 2112 and proceed to a regenerating filter (not shown), although the structure of regenerating filters is known in the art.

[0061] In one embodiment, the folding tip can be used in conjunction with folding fingers 652 and 642. In an alternative embodiment, an iris is used to apply closing pressure to the distal end of the cone. Figures 6A and 6B show a folding station subassembly that utilizes the iris 3001 and its components. The folding station includes a folding rod 3000, the iris 3001, and an iris actuator 3002 for opening and closing the iris. The folding rod terminates at a folding tip, for example, a folding tip 2670. The iris, folding rod, folding tip, vacuum, and pneumatic pressure work together to fold the distal end of the cone.

[0062] One method for folding the cone is as follows: The die 310 containing the filled and unfolded cone is axially aligned with the folding tip 2670. The relative vertical position of the cone to the iris is adjusted so that the iris is below the rim 1103 of the distal end 1102 of the cone. The folding tip 2670 is positioned so that at least a portion of the axial pin 2671 is below the rim 1103 of the distal end 1102 of the filled cone 1120 (i.e., the central portion of the tip is positioned within the internal cavity of the cone). The iris actuator acts to close the iris, thereby compressing the distal end of the cone toward the central axis of the cone and further pressing the distal end against the axial pin. It should be understood that the movement and positioning of the cone and the axial pin relative to the cone, as well as the closure of the iris to compress the cone, may be performed as discrete steps or simultaneously.

[0063] When the distal end of the cone is pressed against, for example, an axial pin, a vacuum is applied to the folded tip. The vacuum draws air in by pressing the distal end of the cone against the circumferential inner surface 2673 of the folded tip, and then (or simultaneously), a pneumatic pump is activated to apply air pressure to the internal cavity of the cone via the axial pin. When the cone is pressed against the axial pin by the iris with the axial pin inserted into the distal end of the cone, and when the cone is pressed against the inner circumferential surface and vacuum is applied, the air pressure outlet is inside the cone. The cone can be expanded by applying air pressure, and the outside of the cone can be further pressed against the die. It has been found that the combination of applying vacuum pressure with internal air pressure strengthens the paper at the distal end of the cone. With the cone strengthened, the folded tip is pushed down and enters the distal end of the cone, and the vacuum and air pressure are stopped. In practice, the iris can open just as a vacuum and air pressure are applied, and the folded tip can be pushed into the cavity when the iris opens or immediately afterward. Subsequently, the folded tip is pulled out of the cone, and the distal end of the cone remains folded, exhibiting plastic deformation.

[0064] Referring to Figures 14, 15, 16A, and 16B, as shown, an alternative embodiment of the folding station utilizes one or more sets of folding fingers. In this embodiment, the sets of fingers 1410, 1420 are positioned below the folding tip 670. In one embodiment, the folding fingers are offset from each other both vertically and angularly. Thus, one set of fingers closes around the distal end of the cone and around a portion of the folding tip at a first angle and in the upper vertical position, while a second set closes similarly but at a lower vertical position and at a second angle, offset from the first angle, for example, between 45° and 90°.

[0065] Figure 15 is an exaggerated block diagram of an example set of folding fingers 1410. The fingers include an actuator 1411 that simultaneously opens and closes fingers 1412, 1413 in a scissor-like action. Each finger may include recesses 1414, 1415 along a portion of its internal blade length. The recesses form a gap 1416 between the portion of the internal blade length of the finger when the finger is in the closed position. The rear of the blade length can be fully integrated to form a stopper. It has been found that when the distal end of a paper cone is compressed by the folding fingers without a gap, the friction caused by the tight pinch makes it difficult to fold the distal end accurately and can lead to tearing of the cone when the cone is pulled through the fingers. The gap allows for easier handling of the distal end of the paper by tip suction and allows the distal end to be pulled into the folding tip while maintaining proper positioning and crimping of the distal end by the folding fingers. Each folding finger may also include recesses 1417, 1418. In one embodiment, each recess is substantially semicircular so as to engage with the outer surface of the axial pin 671. As shown in Figures 16A and 16B, the fingers open and close at different vertical heights in substantially parallel planes.

[0066] Figure 21 shows a die clean-out station. After filling and folding the cone, the die 310 releases the filled cone. The die can then proceed to the die clean-out station 2000, where a brush 2001 connected to actuator 2002 removes any remaining particles from the die. The die actuator 2003 can close the die, and the brush actuator 2002 can push the brush into the die. In some embodiments, the actuators can also rotate the brush to further clean the inside of the die. The brush can then be removed from the die, and the die can be reused via the machine to help fill another cone.

[0067] While the present invention has been described in relation to various embodiments, it should be understood that such disclosures are not intended to be limiting. Various changes and modifications will be readily apparent to those skilled in the art. Accordingly, the appended claims are intended to be construed as encompassing all changes and modifications that fall within the spirit and scope of the invention.

Claims

1. A method for forming a folded cone-shaped package having an internal cavity at least partially defined by its circumferential distal end, The conical package is oriented so as to be aligned with the folded tip in the axial direction, Applying vacuum pressure to the upper part of the distal end of the package, The folded tip and the package are pushed together so that the distal rim of the distal end of the package is folded into the internal cavity, A method that includes this.

2. The vacuum pressure is continued to be applied to the upper part of the distal end of the package when the package and the folded tip are pressed together. The method according to claim 1, further comprising:

3. After oriented the conical package so as to be aligned with the folded tip in the axial direction, and before applying vacuum pressure to the upper part of the distal end, the folded tip is positioned such that a portion of the folded tip surrounds the distal rim and a portion of the distal end of the package. The method according to claim 1, further comprising:

4. Applying vacuum pressure through the folded tip so that a portion of the distal end of the package is pressed against the folded tip. The method according to claim 1, further comprising:

5. Applying vacuum pressure in the circumferential direction around the distal end of the package. The method according to claim 1, further comprising:

6. Applying vacuum pressure in the circumferential direction to the upper part of the distal end of the package. The method according to claim 3, further comprising:

7. After oriented the conical package so as to be aligned with the folded tip in the axial direction, mechanical pressure is applied to the outside of the distal end of the package so as to compress at least a portion of the distal end of the package toward the central axis of the package, The mechanical pressure is released, and then the vacuum pressure is applied to the upper part of the distal end. The method according to claim 1, further comprising:

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