Pre-formed smokable tube filling device and methods

Abstract

A system and method for simultaneously packing a plurality of pre-formed tubes with a predetermined volume of material to a selectable pack density. The system includes a press assembly having a pressing plate with a plurality of pressing rods, an actuator configured to control compression force, a tube carrier assembly with tube receptacles and a release mechanism, and a modular material loading assembly with stackable layers for volume control and a slider for dispensing material. The material loading assembly is temporarily positioned above the tube carrier assembly to deliver material into the tubes, after which the pressing rods are actuated to compress the material. The system enables efficient and consistent packing of multiple tubes simultaneously. The method includes loading material, positioning components, actuating the press, and releasing the packed tubes in a repeatable cycle.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to the provisional patent application identified by U.S. Ser. No. 63 / 680,039, filed Aug. 6, 2024, titled “PRE-FORMED SMOKABLE TUBE FILLING DEVICE AND METHODS,” the entire contents of which is hereby expressly incorporated herein by reference.BACKGROUND

[0002] In recent years, the cannabis industry has seen a significant rise in the popularity of pre-rolled cannabis products, particularly a type commonly referred to as “blunts.” A blunt typically comprises a hollow cylindrical wrapper tube filled with ground cannabis flower or extract. Blunts are typically larger in size than conventional joints and are favored by consumers for their perceived potency and extended burn time.

[0003] Despite the high demand for blunt-style pre-rolls, the current methods of manufacturing these products are largely manual and labor-intensive. Conventional production processes often require manual loading, filling, and packing of individual pre-shaped blunt wrapper tubes. Current commercial practices for manufacturing pre-filled blunt tubes predominantly rely on manual labor for the critical steps of loading, filling, and packing. Workers typically use simple tools such as funnels, tamping rods, and basic vibration devices to fill pre-formed blunt tubes with measured quantities of ground cannabis material. The filled tubes are then manually packed to achieve desired density and draw characteristics. These processes, while effective at small scales, exhibit several deficiencies when scaled to meet commercial demand. Manual filling and packing processes are inherently inconsistent, resulting in variations in fill weight, material distribution, and packing density between individual units, which can lead to suboptimal product performance, reduced quality, and undesirable consumer experiences. To address these shortcomings, operators have increasingly sought automated systems capable of consistently and efficiently producing pre-filled blunt tubes at commercial scale.

[0004] Such systems must be capable of performing a variety of coordinated tasks, including accurate dosing of material into pre-formed blunt tubes, uniform application of packing force to ensure consistent draw resistance, and smooth handling of tubes before and after filling. Additionally, a need exists for systems that are compatible with blunt tubes of varying dimensions and materials, are designed to comply with applicable industry regulations, and are capable of integration with additional downstream equipment for further processing or packaging.

[0005] Accordingly, a need exists for an automated system and method that enable efficient, high-throughput production of pre-rolled blunts while maintaining uniform fill and pack across multiple units, simplifying loading and unloading of tubes, and increasing overall operational efficiency. It is to such systems and methods that the presently disclosed inventive concepts are directed.BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0006] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more implementations described herein and, together with the description, explain these implementations. The drawings are not intended to be drawn to scale, and certain features and certain views of the figures may be shown exaggerated, to scale or in schematic in the interest of clarity and conciseness. Not every component may be labeled in every drawing. Like reference numerals in the figures may represent and refer to the same or similar element or function. In the drawings:

[0007] FIG. 1A is a front view of an exemplary embodiment of a system for simultaneously packing a plurality of pre-formed tubes in accordance with the present disclosure.

[0008] FIG. 1B is an isometric view of the exemplary embodiment of FIG. 1A.

[0009] FIG. 2A is a front view of the exemplary embodiment of FIG. 1A in an unloaded state.

[0010] FIG. 2B is an isometric view of the exemplary embodiment of FIG. 2A.

[0011] FIG. 3 is an exploded view of an exemplary embodiment of a tube carrier assembly and a material loading assembly of the system for simultaneously packing a plurality of pre-formed tubes.

[0012] FIGS. 4-8 illustrates various steps of an exemplary method of simultaneously packing a plurality of pre-formed tubes, according to an embodiment of the present disclosure.DETAILED DESCRIPTION

[0013] Before explaining at least one embodiment of the inventive concept disclosed herein in detail, it is to be understood that the inventive concept is not limited in its application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. The inventive concept disclosed herein is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting in any way.

[0014] In the following detailed description of embodiments of the inventive concept, numerous specific details are set forth in order to provide a more thorough understanding of the inventive concept. It will be apparent to one of ordinary skill in the art, however, that the inventive concept within the disclosure may be practiced without these specific details. In other instances, well-known features have not been described in detail to avoid unnecessarily complicating the instant disclosure.

[0015] As used herein, the term “tube,”“tubes,”“pre-formed tube(s),” or any variation thereof, are intended to broadly encompass any hollow, elongate container or structure including, but not limited to, cylindrical shapes, adapted to hold, contain, or dispense a variety of loose or particulate materials, such as, for example, herbs, cannabis, granules, or similar substances.

[0016] As used in the description herein, the terms “comprises,”“comprising,”“includes,”“including,”“has,”“having,” or any other variations thereof, are intended to cover a non-exclusive inclusion. For example, unless otherwise noted, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may also include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0017] Further, unless expressly stated to the contrary, “or” refers to an inclusive and not to an exclusive “or”. For example, a condition A or B is satisfied by one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

[0018] In addition, use of the “a” or “an” are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of the inventive concept. This description should be read to include one or more, and the singular also includes the plural unless it is obvious that it is meant otherwise. Further, use of the term “plurality” is meant to convey “more than one” unless expressly stated to the contrary.

[0019] As used herein, qualifiers like “substantially,”“about,”“approximately,” and combinations and variations thereof, are intended to include not only the exact amount or value that they qualify, but also some slight deviations therefrom, which may be due to computing tolerances, computing error, manufacturing tolerances, measurement error, wear and tear, stresses exerted on various parts, and combinations thereof, for example.

[0020] As used herein, any reference to “one embodiment,”“an embodiment,”“some embodiments,”“one example,”“for example,” or “an example” means that a particular element, feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment and may be used in conjunction with other embodiments. The appearance of the phrase “in some embodiments” or “one example” in various places in the specification is not necessarily all referring to the same embodiment, for example.

[0021] The use of ordinal number terminology (i.e., “first”, “second”, “third”, “fourth”, etc.) is solely for the purpose of differentiating between two or more items and, unless explicitly stated otherwise, is not meant to imply any sequence or order or importance to one item over another or any order of addition.

[0022] Finally, the use of the term “at least one” or “one or more” will be understood to include one as well as any quantity more than one. In addition, the use of the phrase “at least one of X, V, and Z” will be understood to include X alone, V alone, and Z alone, as well as any combination of X, V, and Z.

[0023] As discussed above, there exists a need for an automated system and method that enables efficient, high-throughput production of pre-rolled cannabis products while maintaining uniform fill and pack across multiple units.

[0024] Referring now to the drawings, FIGS. 1A and 1B, shown therein are front and isometric views, respectively, of an exemplary embodiment of a pre-formed tube fill and compression system 10 in its assembled configuration according to the instant disclosure.

[0025] The pre-formed tube fill and compression system 10 comprises a top plate 14, a base plate 18, a plurality of linear guides 22, at least one actuator 26. The system 10 further comprises a pressing assembly 30, a material loading assembly 40, and a tube carrier assembly 60.

[0026] The top plate 14 defines an upper surface 15 and a lower surface 16. Similarly, the base plate 18 defines an upper surface 19 and a lower surface 20. The top plate 14 and base plate 18 are interconnected by the plurality of linear guide 22 that extend vertically between the top plate 14 and the base plate 18, with each of the linear guides 22 having a first end 24 secured to the upper surface 19 of the base plate 18 and a second end 23 secured to the lower surface 16 of the top plate 14. The linear guides 22 are configured to provide guided, sliding engagement between the top plate 14 and the base plate 18, thereby maintaining alignment and facilitating translational movement along the longitudinal axes of the linear guides 22. The attachment of the linear guides 22 to the respective surfaces of the top plate 14 and the base plate 18 may be accomplished by any suitable fastening means, including, but not limited to mechanical fasteners, adhesives, or integral formation.

[0027] In some embodiments, as shown in FIG. 1B, the base plate 18 may also include one or more through-holes 13 disposed at opposing ends configured to receive a fastening element to secure the base plate 18 to an external surface for stable positioning on work surfaces.

[0028] The top plate 14 and the base plate 18 may be constructed from any suitable material exhibiting sufficient structural rigidity to provide dimensional stability under anticipated operational loads and service conditions, including but not limited to metals, metal alloys, composite materials, or engineered plastics having adequate strength-to-weight ratios for the intended application.

[0029] The plurality of linear guides 22 may comprise various structural configurations including, but not limited to, cylindrical rods, linear rails, guide shafts, or any other elongated structural elements capable of supporting, guiding, or otherwise facilitating controlled sliding movement of associated components along the guides' longitudinal axis. In certain embodiments, the linear guides 22 may be configured as precision ground rods having a substantially circular cross-section, while in alternative embodiments, the guides may comprise profiled rails having non-circular cross-sections, such as rectangular, square, or other geometric configurations optimized for specific loading conditions and movement requirements.

[0030] Each of the plurality of linear guides 22 extends along a predetermined length sufficient to accommodate the desired range of motion between the top plate 14 and the base plate 18. The linear guides 22 may be fabricated from materials exhibiting low friction characteristics and high wear resistance, including but not limited to hardened steel, stainless steel, aluminum alloys, or engineered polymers, depending upon the specific application requirements and environmental conditions. The configuration and arrangement of the plurality of linear guides 22 establish a stable support framework, which provides enhanced rigidity against lateral or off-axis forces while maintaining alignment along the intended axis of motion during operational cycles. In certain embodiments, as shown in FIG. 1B, the linear guides 22 may extend between corresponding regions along the peripheries of the upper surface 19 of the base plate 18 and the lower surface 16 of the top plate 14. The plurality of linear guides 22 are configured to interface with certain pressing components, as described further below, to facilitate smooth sliding movement for reliable and repeatable performance.

[0031] Mounted on the upper surface 15 of the top plate 14 is the least one actuator 26 that constitutes the primary force generation mechanism for the system 10. The actuator 26 includes a first end 29 and a second end 28. In some embodiments, as shown in FIGS. 1A and 1B, the top plate 14 may further comprise one or more actuator mounting features 25 on its upper surface 15, configured to support the actuator 26. The first end 29 of the actuators 26 is secured to the one or more actuator mounting features 25 on the upper surface 15 of the top plate 14.

[0032] The actuator 26 is configured to permit variable force generation for controlling pack density of material compressed by the pressing assembly 30, as will be discussed further below. The actuator 26 is configured to control the vertical displacement of the pressing assembly 30 relative to the top plate 14 along a predetermined vertical axis defined by the plurality of linear guides 22.

[0033] Furthermore, in some embodiments, as shown in FIGS. 1A and 1B, the at least one actuator 26 are arranged in pairs or multiples to provide balanced and synchronized vertical force distribution to the pressing assembly 30, thereby reducing uneven loading and enhancing the accuracy and uniformity of the pressing process.

[0034] The actuator 26 is operatively connected to automated control systems, manual control interfaces, or hybrid control arrangements configured to regulate operational parameters including, but not limited to, actuator speed, stroke length, maximum extension distance, applied force magnitude, dwell time at predetermined positions, and cycling frequency. Such control systems enable precise adjustment of the force applied by the actuator 26, allowing operators to select and maintain specific force parameters corresponding to desired compression forces, thereby enabling control over the pack density of compressed materials.

[0035] The actuator 26 may comprise various actuation mechanisms including, but not limited to, a pneumatic cylinder, hydraulic cylinder, electric linear actuator, servo motor with lead screw assembly, ball screw actuator, or any other suitable mechanical, electrical, or fluid-powered mechanism capable of imparting controlled bi-directional vertical motion with predetermined force and speed characteristics tailored to operational requirements.

[0036] In certain embodiments, the actuator 26 is a pneumatic actuator. In such embodiments, the actuator 26 may operate within a pressure range of approximately 20-200 PSI.

[0037] The force application capabilities of the system 10 may vary based on the material type disposed in the pre-formed tubes and desired compression characteristics. For fine ground loose material, for example, the system 10 may apply 20-40 PSI pressure. For medium ground loose material, for example, the system may apply 50-70 PSI pressure. For coarse ground loose material and dense fibers, the system may apply, for example, 70-200 PSI pressure.

[0038] In some embodiments, the base plate 18 may also include on its upper surface 19 a plurality of tube carrier alignment features 38, as shown in FIG. 2B, configured to receive and position the tube carrier assembly 60, which will be discussed in more detail below.

[0039] Referring now to FIGS. 2A and 2B, shown therein is front and isometric views, respectively, of an exemplary embodiment of a pre-formed tube fill and compression system 10 in its unloaded state, showing the pressing assembly 30 without the tube carrier assembly 60 or material loading assembly 40 installed. The pressing assembly 30 is configured to translate the downward actuation of the at least one actuator 26 into simultaneous pressing action on multiple pre-form tubes.

[0040] The pressing assembly 30 comprises a pressing plate 32, which is configured to be operatively coupled with the at least one actuator 26, and a plurality of pressing rods 35 extending away from the pressing plate 32. The pressing plate 32 defines a substantially planar body having an upper surface 33 and a lower surface 34. In a retracted state, the pressing plate 32 is positioned such that its upper surface 33 is proximate to the lower surface 16 of the top plate 14.

[0041] The upper surface 33 of the pressing plate 32 is configured to operatively engage with the actuator 26 through direct mechanical coupling, such that actuation forces generated by the actuator 26 are transmitted uniformly from the actuator 26 to the pressing plate 32 during operation. This engagement may be achieved through various coupling mechanisms, including but not limited to threaded connections, bayonet-style attachments, magnetic coupling, or mechanical interlocking features that ensure reliable force transmission while maintaining proper alignment between the actuator 26 and pressing plate 32.

[0042] In some embodiments, as shown in FIG. 2A, each of the at least one actuators 26 includes a piston rod 17 extending from the first end 29 of the actuator 26, with the piston rod 17 having a distal end 27 that extends downward through the top plate 14. The distal end 27 of the piston rod 17 connects to the upper surface 33 of the pressing plate 32 through mechanical coupling means, such as those described above.

[0043] The lower surface 34 of the pressing plate 32 serves as the primary mounting interface for the plurality of pressing rods 35 that extend away from the lower surface 34 of the pressing plate 32 in a generally perpendicular orientation relative to the plane of the pressing plate 32. The plurality of pressing rods 35 are arranged in a predetermined geometric pattern on the lower surface 34 of the pressing plate 32, with spacing, size, and orientation selected to correspond to the layout of the plurality of pre-formed tubes positioned in the tube carrier assembly 60, as will be discussed below. The plurality of pressing rods 35 may vary in length and diameter according to the specific pressing requirements and geometric constraints of the pre-formed tubes. In some embodiments, the pressing rods 35 are uniformly sized with consistent diameter and length dimensions and are evenly spaced across the lower surface 34 to apply balanced pressure across all pre-formed tubes simultaneously. Each of the plurality of pressing rods 35 may be sized and shaped to be received within an internal diameter of a corresponding pre-formed tube, while providing a sufficient surface area for applying compression.

[0044] Each of the plurality of pressing rods 35 comprises a proximal end 39 that is secured to the lower surface 34 of the pressing plate 32 through one or more fastening methods, such as, for example, threaded connections, press-fit assemblies, or welded joints, and a distal end 37 that extends freely away from the lower surface 34 of the pressing plate 32 and is configured to engage with loose material positioned within the pre-formed tubes.

[0045] Each of the pressing rods 35 terminates at its distal end 37 configured with specific geometric profiles to enhance pressing performance characteristics. The distal end 37 geometries may incorporate flat surfaces, rounded profiles, pointed configurations, or complex contoured shapes, to facilitate smooth insertion into the pre-formed tubes and to minimize potential damage to the tube material.

[0046] The pressing rods 35 may be fabricated from materials selected for durability, compliance, or friction characteristics, including metals, polymeric materials, or composite constructions. Each of the plurality of pressing rods 35 are preferably fabricated from materials that are safe for contact with consumable products, such as, for example, stainless steel, aluminum, or other food-grade materials. Moreover, the pressing rods 35 may be removably mounted to or integrally formed with the pressing plate 32, allowing for modular replacement or customization based on operational needs.

[0047] In some embodiments, as shown in FIGS. 2A and 2B, the pressing plate 32 may further include linear motion bearings 36 positioned at predetermined locations along the pressing plate 32. Each of the linear motion bearings 36 is configured to cooperatively engage with corresponding linear guides 22 to facilitate controlled guided linear movement along a vertical axis defined by the linear guides 22. The linear motion bearings 36 are dimensioned and configured to provide a close sliding fit with their respective linear guides 22 and permit free axial movement along the linear guide 22 axis.

[0048] The linear motion bearings 36 are secured to the upper surface 33 of the pressing plate 32. The linear motion bearings 36 may be fixedly mounted to the pressing plate 32 through various attachment methods, including threaded fasteners, press-fit installations, adhesive bonding, or integral formation as part of the pressing plate 32.

[0049] Referring to FIG. 2B, in some embodiments, as shown in FIG. 2B, the upper surface 19 of the base plate 18 includes a plurality of tube carrier alignment features 38 configured to receive and position the tube carrier assembly 60. These tube carrier alignment features 38 may comprise, for example, recessed areas, raised bosses, or precision-machined receptacles designed to mate with portions of the tube carrier assembly 60, as will be discussed further below.

[0050] Referring now to FIG. 3, shown therein is an exploded view of the material loading assembly 40 and the tube carrier assembly 60, illustrating individual components.

[0051] The material loading assembly 40 is configured to deliver precise, predetermined quantities of loose material into pre-formed tubes. The material loading assembly 40 comprises a material loading base 41, one or more stackable material loading layers 44, and a material loading slider 47. The material loading assembly 40 demonstrates a modular design where one or more material loading layers 44 of various thickness can be stacked to achieve precise volumetric control.

[0052] The material loading base 41 defines an upper surface 42 and a lower surface 43. The material loading base 41 further includes a plurality of through-bores 48 that extend from the upper surface 42 to the lower surface 43. These through-bores 48 are arranged in a predetermined geometric pattern that corresponds with the positional layout of the pre-formed tubes contained in the tube carrier assembly 60, ensuring accurate material delivery. In some embodiments, the through-bores 48 arranged longitudinally in rows and laterally in columns, forming a grid-like configuration. The arrangement, orientation and dimensions of the through-bores 48 are selected to align the through-bores 48 with the corresponding features of the tube carrier assembly 60 retaining the pre-formed tubes. Each of the plurality of through-bores 48 may have, for example, a chamfered or radiused entry profiles, and a corresponding exit profiles to facilitate smooth material flow while preventing bridging or blockage of particulate materials.

[0053] Each of the one or more stackable material loading layers 44 defines a first face 45 and an opposing second face 46. The material loading layers 44 enable flexible volume control for different product requirements. Each of the material loading layers 44 further includes apertures 49 extending between the first face 45 and second face 46 of the material loading layers 44. The apertures 49 are arranged in a predetermined geometric pattern that corresponds with the positional layout of the through-bores 48 of the material loading base 41 and the positional layout of the pre-formed tubes contained in the tube carrier assembly 60. The arrangement, orientation and dimensions of the apertures 49 through-bores 48 are selected to align the apertures 49 with the through-bores 49 of the material loading base 41 and with the corresponding features of the tube carrier assembly 60 retaining the pre-formed tubes.

[0054] When multiple material loading layers 44 are stacked, the second face 46 of an upper material loading layer 44 contacts the first face 45 of the material loading layer 44 below it, axially aligning the apertures 49 of the material loading layers and the through-bores 48 of the material loading base 41 to define material retention channels, as will be discussed further below. The cumulative height of the material loading base 41 and the selected material loading layers 44 measured from the first face 45 of the topmost material loading layer 44 to the second face 46 of the bottom material loading layer 44, directly determines the volume of material that can be retained in each material retention channel.

[0055] The one or more stackable material loading layers 44 are available in multiple thickness configurations, with the thickness measured as the distance between the first face 45 and second face 46, such as, for example, 5 mm, 10 mm, 15 mm, or other suitable dimensions.

[0056] The one or more stackable material loading layers 44 provides a modular system that enables precise volumetric control. Volume consistency between identical configurations may be maintained, for example, within ±5% variation. The through-bores 48 may have diameters ranging from approximately 8-22 mm depending on tube size compatibility.

[0057] In some embodiments, as shown in FIG. 3, a plurality of material loading bolts 50 may be positioned on the upper surface 42 of the material loading base 41 and extend away from the material loading base 41 as alignment features. Each of the plurality of material loading bolts 50 may extend through corresponding receiving holes 51 in each of the material loading layers 44 disposed above the material loading base 41. The plurality of material loading bolts 50 may further include engagement features (not shown) that extend beyond the lower surface 43 of the material loading base 41, the engagement features configured to engage with complementary alignment holes 66 in the tube carrier assembly 60.

[0058] The material loading base 41 and the material loading layers 44 may be fabricated from materials selected for their durability, dimensional stability, and compatibility with the processed materials, including but not limited to machined metals, injection-molded polymers, or composite materials that provide the necessary structural integrity over extended operational periods.

[0059] The material loading slider 47 is configured as a translatable plate positioned adjacent to the lower surface 43 of the material loading base 41. The material loading slider 47 is configured to slide linearly relative to the material loading base 41. In a first position, the material loading slider 47 obstructs the lower openings of the through-bores 48 to restrict or block material flow. When translated to a second position, the material loading slider 47 allows passage through the through-bores 48, thereby permitting material flow. The material loading slider 47 may be formed from any suitable material that is safe for contact with consumable products and is configured to provide an effective seal or obstruction in the first position and unobstructed path in the second position. In some embodiments, the material loading slider 47 may further include an actuating handle 70 to facilitate manual operation by an operator.

[0060] Still referring to FIG. 3, the tube carrier assembly 60 is configured to retain, position, and discharge pre-formed tubes. The tube carrier assembly 60 comprises a tube carrier body 61 having an upper surface 62, a lower surface 63, and side walls 64 extending between the upper surface 62 and lower surface 63. The tube carrier assembly 60 further includes a tube carrier slider 67.

[0061] The tube carrier body 61 further defines a plurality of vertically oriented tube receptacles 65 that extend from the upper surface 62 towards the lower surface 63. In some embodiments, as shown in FIG. 3, the tube receptacles 65 are arranged longitudinally in rows and laterally in columns, forming a grid-like configuration. The arrangement, orientation, and dimensions of the tube receptacles 65 may be selected to align the tube receptacles 65 with the corresponding through bores 48 of the material loading base 41, the apertures 49 of the material loading layers 44, and the pressing rods 35 of the pressing assembly 30.

[0062] The tube receptacles 65 are dimensioned to accommodate the external diameter of the pre-formed tubes with suitable clearance to facilitate insertion, removal, and maintenance of proper alignment of the tubes during processing operations. The tube receptacles 65 may be configured to accommodate pre-formed tubes having inner diameters ranging, for example, from approximately 8 mm to 25 mm, with standard blunt tube compatibility, for example, approximately in the 10-20 mm range. The plurality of pressing rods 35 may be dimensioned, for example, with clearances smaller than the pre-formed tube inner diameter to ensure proper fit and compression. Pre-formed tube length compatibility may range, for example, from approximately 20 mm to 200 mm, with pressing rod 35 travel adjustable, for example, from approximately 10-150 mm.

[0063] In some embodiments, as shown in FIG. 3, alignment holes 66 may be incorporated in the upper surface 62 of the tube carrier body 61 at locations corresponding to the material loading bolts 50. These alignment holes 66 may extend partially or completely through the tube carrier body 61 depending on material loading bolt 50 configuration. The alignment holes 66 may be dimensioned to receive the material loading bolts 50, ensuring alignment between the material retention channels, formed by the through-bores 48 of the material loading base 41 and apertures 49 of the material loading layers 44, and the tube receptacles 65.

[0064] The tube carrier slider 67 is configured as a translatable plate positioned adjacent to the lower surface 63 of the tube carrier body 61. The tube carrier slider 67 is configured to slide linearly relative to the lower surface 63 of the tube carrier body 61. In a first position, the tube carrier slider 67 obstructs portions of the tube receptacles 65 proximate to the lower surface 63 of the tube carrier body 61, to prevent pre-formed tubes from being discharged from the tube carrier body 61. When translated to a second position, the tube carrier slider 67 allows the passage of pre-formed tubes through the tube receptacles 65 at the lower surface 63 of the tube carrier body 61. The tube carrier slider 67 may be formed from any suitable material that is safe for contact with consumable products and is configured to provide an effective seal or obstruction in the first position and unobstructed path in the second position.

[0065] In some embodiments, as shown in FIG. 3, the tube carrier assembly 60 may further include a tube carrier slider retainer 68. The tube carrier slider retainer 68 is configured to accommodate and maintain the tube carrier slider 67 in proper position relative to the tube carrier body 61 while allowing controlled translational movement for retaining and discharging operations. In such embodiments, the tube carrier slider retainer 68 may be positioned adjacent to one of the side walls 64 of the tube carrier body 61 and may include retention features such as, for example, mechanical clips, springs, or guide tracks that engage with corresponding features on the tube carrier slider 67.

[0066] The tube carrier slider 67 may further include an actuating handle 69 to facilitate manual operation by an operator. The tube carrier slider 67 may be manipulated via the actuating handle 69 to either retain the pre-formed tubes within the tube carrier body 61 during processing or release finished products. The actuating handle 69 is positioned to be accessible to an operator when the tube carrier assembly 60 is installed in the system 10, allowing convenient slider actuation without interference from other system components.

[0067] In some embodiments, as shown in FIG. 3, a plurality of tube carrier bolts 71 may be positioned on the lower surface 63 of the tube carrier body 61 and extend downward as an alignment feature. Each of the plurality of tube carrier bolts 71 may be configured to engage with the plurality of tube carrier alignment features 38 on the upper surface 19 of the base plate 18, ensuring proper positioning of the tube carrier assembly 60 relative to the pressing rods 35.

[0068] Turning now to FIGS. 4-8, there are illustrated various embodiments of the method of simultaneously packing a plurality of pre-formed tubes, as performed by the system disclosed herein.

[0069] In an initial pre-formed tube loading step of the method of simultaneously packing a plurality of pre-formed tubes 73, as shown in FIG. 4, the tube carrier assembly 60 is positioned to receive the plurality of pre-formed tubes 73 from the upper surface 62 of the tube carrier body 61. Each of the plurality of pre-formed tubes 73 are inserted into corresponding tube receptacles 65 and are maintained therein in a vertical orientation. During the pre-formed tube loading step, the tube carrier slider 67 is positioned in its retaining configuration. In this configuration, the tube carrier slider 67 obstructs the lower openings of the tube receptacles 65, providing a bottom support for the plurality of pre-formed tubes 73 and preventing them from falling through the tube carrier assembly 60 during operations.

[0070] Subsequently, the loaded tube carrier assembly 60 is positioned on the upper surface 19 of the base plate 18, as shown in FIGS. 5A and 5B. During this step, the pressing plate 32 and associated pressing rods 35 are in a retracted position, creating clearance for the loaded tube carrier assembly 60 to be installed on the base plate 18. The tube carrier assembly 60 is positioned on the upper surface 19 of the base plate 18 such that the plurality of tube receptacles 65 are aligned with the pressing rods 35 of the pressing plate 32 for subsequent compression operations. Although not shown in FIGS. 5A or 5B, the plurality of tube carrier bolts 71 of the tube carrier assembly 60 may engage with tube carrier alignment features 38 in the upper surface 19 of the base plate 18 to facilitate the positioning and alignment of the loaded tube carrier assembly 60 on the upper surface 19 of the base plate 18.

[0071] Thereafter, the material loading assembly 40, with the material loading slider 47 in its retaining configuration, is positioned atop the loaded tube carrier assembly 60, as shown in FIGS. 6A. In this step, the pressing plate 32 and associated pressing rods 35 remain in its retracted position to provide clearance for the material loading assembly 40 to be positioned atop the tube carrier assembly 60. The material loading assembly 40 is positioned such that the apertures 49 of the one or more material loading layers 44 are axially aligned with the through-bores 48 of the material loading base 41, which in turn are axially aligned with the plurality of tube receptacles 65 of the tube carrier assembly 60, thereby forming continuous channels from the one or more material loading layers 44 to the plurality of pre-formed tubes 73.

[0072] With the material loading assembly 40 so positioned, loose material is loaded into the material loading assembly 40 through the channels formed by the aligned apertures 49 of the one or more material loading layers 44 and the through-bores 48 of the material loading base 41. The material loading slider 47, in its retaining configuration, retains the loose material within the channels, thereby preventing discharge through the through-bores 48 of the material loading base 41. The quantity of loose material loaded into each channel and ultimately dispensed into each of the plurality of pre-formed tubes 73, may be selected by adding or removing one or more stackable material loading layers 44 from the material loading assembly 40.

[0073] The loose material is thereafter dispensed into the pre-formed tubes 73 by withdrawing the material loading slider 47 from the material loading base 41, as shown in FIG. 6B, thereby enabling the loose material to flow from the material loading assembly 40 into the plurality of pre-formed tubes 73 retained in the tube carrier body 61 below. This simultaneous filling operation ensures consistent material quantities across all tubes in the batch, contributing to uniform final product characteristics.

[0074] Once the loose material has been dispensed into the plurality of pre-formed tubes 73, the material loading assembly 40 is removed prior to a compression step, as shown in FIGS. 7A and 7B. The at least one pneumatic actuator 26 is then activated to move the pressing rods 35 downward into the plurality of pre-formed tubes 73 with a predetermined force to compress the loose material to a target packing density corresponding to the applied force. The tube carrier assembly 60 remains positioned on the upper surface 19 of the base plate 18, with the tube carrier slider 67 still in its retaining configuration. Following compression, the pressing rods 35 are retracted upwards to their original position.

[0075] The material loading and compression steps may be repeated as necessary until the plurality of pre-formed tubes 73 are filled to a desired weight, size, and / or pack density.

[0076] Finally, as shown in FIG. 8, upon completion of filling, the tube carrier assembly 60 is removed, and the tube carrier slider 67 is withdrawn from the tube carrier body 61 to release the completed plurality of pre-formed tubes 73 from the tube carrier assembly 60. The vertical dispensing orientation facilitates collection of the completed products in containers, conveyor systems, or other downstream processing equipment positioned below the tube carrier assembly 60.

[0077] Following product discharge, the tube carrier assembly 60 can be quickly reloaded with a new set of pre-formed tubes 73 to begin another processing cycle. The tube carrier slider 67 can be replaced to its inserted position, and the entire operational sequence can be repeated for continuous production operations.

[0078] It is to be understood that the steps disclosed herein may be performed simultaneously or in any desired order. For example, one or more of the steps disclosed herein may be omitted, one or more steps may be further divided in one or more sub-steps, and two or more steps or sub-steps may be combined in a single step, for example. Further, in some exemplary embodiments, one or more steps may be repeated one or more times, whether such repetition is carried out sequentially or interspersed by other steps or sub-steps. Additionally, one or more other steps or sub-steps may be carried out before, after, or between the steps disclosed herein, for example.

[0079] From the above description, it is clear that the inventive concept(s) disclosed herein are well adapted to carry out the objects and to attain the advantages mentioned herein, as well as those inherent in the inventive concept(s) disclosed herein. While the embodiments of the inventive concept(s) disclosed herein have been described for purposes of this disclosure, it will be understood that numerous changes may be made and readily suggested to those skilled in the art which are accomplished within the scope and spirit of the inventive concept(s) disclosed herein.

Claims

1. A system for simultaneously packing a plurality of pre-formed tubes, the system comprising:a base plate;a top plate;a plurality of linear guides extending between the top plate and the base plate;a press assembly, including:a pressing plate slidably mounted on the plurality of linear guides for translational movement between the base plate and the top plate;a plurality of pressing rods affixed to a surface of the pressing plate and extending axially therefrom, the plurality of pressing rods configured to be inserted into the plurality of pre-formed tubes to compress material disposed within the pre-formed tubes;at least one actuator operatively coupled to the pressing plate and configured to control vertical displacement and compression force of the pressing plate;a tube carrier assembly, including:a tube carrier body having a plurality of vertically oriented tube receptacles, each configured to receive a corresponding pre-formed tube;a tube carrier slider configured to selectively retain the plurality of pre-formed tubes within the plurality of vertically oriented tube receptacles in a first position, and to release the plurality of pre-formed tubes in a second position;a material loading assembly, including:a material loading base having a plurality of through-bores axially aligned with the plurality of vertically oriented tube receptacles;at least one stackable material loading layer removably positioned above the material loading base, each of the at least one stackable material loading layer having a plurality of apertures aligned with the plurality of through-bores of the material loading base to define material channels for temporarily retaining a predetermined volume of material;a material loading slider configured to selectively retain the predetermined volume of material within the material channels in a first position, and to release the predetermined volume of material in a second position;wherein the material loading assembly is removably positionable above the tube carrier assembly such that the material channels are aligned with the plurality of vertically oriented tube receptacles to enable material flow from the material channels through the plurality of through-bores into the plurality of pre-formed tubes; andwherein, upon actuation of the at least one actuator at a selected force parameter, the pressing plate is driven toward the tube carrier assembly to insert the plurality of pressing rods into the plurality of pre-formed tubes, thereby mechanically compressing material contained therein to a selectable pack density corresponding to the selected force parameter.

2. The system of claim 1, wherein the at least one actuator is selected from the group consisting of a pneumatic actuator, a hydraulic actuator, an electric linear actuator, a servo motor, a stepper motor, and a solenoid actuator.

3. The system of claim 1, wherein the at least one actuator is a pneumatic actuator configured to operate within a pressure range of about 20 psi to about 200 psi.

4. The system of claim 1, wherein the at least one actuator is a pneumatic actuator configured to operate within a pressure range of about 40 psi to about 100 psi.

5. The system of claim 1, wherein the at least one actuator comprises one or more pneumatic actuators providing pressure-controlled force distribution to the pressing plate.

6. The system of claim 1, wherein the at least one stackable material loading layer enables modular volume control by stacking layers of different thicknesses to achieve the predetermined material volume.

7. The system of claim 1, wherein the tube carrier slider and the material loading slider each include manually operable handles for user control.

8. The system of claim 1, wherein the plurality of vertically oriented tube receptacles accommodates pre-formed tubes having inner diameters ranging from about 8 mm to about 25 mm.

9. The system of claim 1, wherein the pressing plate further includes a plurality of linear motion bearings configured to operatively engage with the plurality of linear guides to facilitate guided linear movement of the pressing plate.

10. The system of claim 1, wherein the tube carrier assembly further includes a plurality of alignment holes in the tube carrier body configured to receive alignment features from the material loading assembly.

11. The system of claim 1, wherein the tube carrier assembly further includes a plurality of tube carrier bolts extending from the tube carrier body, the tube carrier bolts configured to engage with the base plate.

12. The system of claim 1, wherein the base plate includes a plurality of tube carrier alignment features configured to receive and position the tube carrier assembly.

13. The system of claim 1, wherein the tube carrier assembly further includes a tube carrier slider retainer configured to maintain the tube carrier slider in slidable position. 14 The system of claim 1, wherein the plurality of pressing rods further includes contoured distal ends configured for smooth insertion into the plurality of pre-formed tubes.

15. The system of claim 1, wherein the material loading assembly is configured to be removed prior to actuation of the at least one actuator.

16. The system of claim 1, wherein the plurality of linear guides comprises one or more linear guides.

17. The system of claim 1, wherein the at least one actuator is a pneumatic actuator, and the selected force parameter is controlled by adjusting pneumatic pressure supplied to the actuator to achieve the selectable pack density of the pre-formed tubes.

18. A method for simultaneously packing a plurality of pre-formed tubes, comprising the steps of:(a) loading a plurality of pre-formed tubes into a plurality of corresponding vertically oriented tube receptacles of a tube carrier assembly, the tube carrier assembly having a tube carrier slider in a first position to retain the plurality of pre-formed tubes within the corresponding vertically oriented tube receptacles;(b) positioning the tube carrier body such that a plurality of pressing rods of a pressing assembly are vertically aligned with the plurality of pre-formed tubes;(c) positioning a material loading assembly on top of the tube carrier body, the material loading assembly comprising a material loading base and at least one stackable material loading layer, each having axially aligned openings defining a plurality of material retention channels configured to temporarily retain a predetermined volume of material, the material retention channels aligned with the plurality of pre-formed tubes, and a material loading slider positioned in a first position to retain the predetermined volume of material within the material retention channels;(d) loading the plurality of material retention channels of the material loading assembly with the predetermined volume of material;(e) dispensing the material from the material loading assembly into the plurality of pre-formed tubes by moving the material loading slider from the first position to a second position to release the predetermined volume of material from the plurality of material retention channels into the plurality of pre-formed tubes;(f) removing the material loading assembly from the tube carrier body;(g) actuating at least one actuator at a force parameter to drive the plurality of pressing rods downward into the plurality of pre-formed tubes, thereby compressing the predetermined volume of material to a target pack density corresponding to the force parameter;(h) retracting the plurality of pressing rods; and(i) moving the tube carrier slider from the first position to a second position to release the plurality of pre-formed tubes from the plurality of vertically oriented tube receptacles.

19. The method of claim 18, further comprising repeating steps (c) through (h) until the predetermined volume of material is compressed to the target pack density within the plurality of pre-formed tubes.

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