Filling Tray and Press Plate for Bat Pipe Compaction
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Solution Overview
Problem
Existing methods for filling smoking devices like bat pipes are labor-intensive, time-consuming, and result in inconsistent quantities and compaction levels, making them unsuitable for large-scale production and consistent product delivery.
Innovation Solution
A filling tray and press plate system that aligns with the top open ends of multiple smoking devices, allowing for simultaneous filling and compression of smokable plant matter into the devices without removing them from their packaging, ensuring consistent and efficient filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual filling process is used, then ease of operation is maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The filling system is segmented into multiple independent filling stations arranged in a row, each capable of filling one bat pipe simultaneously. This segmentation allows parallel processing of multiple products, dramatically increasing productivity while maintaining the simplicity of manual operation at each station.
Solution Approach 2:
Multiple manual filling operations are merged into a single integrated system where multiple bat pipes are filled simultaneously in one continuous process. The combining of multiple filling functions into one apparatus achieves both high productivity and operational ease.
2Device complexity
If manual filling process is used, then device complexity is low, but manufacturing precision is poor resulting in inconsistent quantities and compaction levels
Solution Approach 1:
Each filling station is designed with specific local features including adjustable filling depth guides and compaction mechanisms tailored to the specific requirements of each bat pipe. This local customization ensures consistent filling precision while keeping each individual station relatively simple.
Solution Approach 2:
Physical intermediaries such as filling guides, depth stops, and compaction plates are introduced between the operator and the filling process. These intermediaries standardize the filling operation, ensuring consistent quantities and compaction levels without requiring complex automated control systems.
3Productivity
If multiple containers are filled manually, then labor intensity increases, but consistency in filling quantities improves
Solution Approach 1:
The system divides the filling task into multiple parallel segments, one for each bat pipe in the row. This allows simultaneous filling of multiple containers without increasing the complexity of individual operations, maintaining ease of operation while dramatically improving productivity.
Solution Approach 2:
The filling process continues without interruption as material is continuously fed through the filling stations. Multiple bat pipes are filled in a continuous sequence without stopping, eliminating the need to repeatedly pick up and place down individual containers, thus improving productivity while keeping operations simple and continuous.
4Loss of time
If manual filling is used, then handling operations are simple, but time consumption increases and waste occurs
Solution Approach 1:
Multiple handling operations (positioning, filling, compaction, sealing) are merged into a single integrated apparatus that processes multiple bat pipes simultaneously. This combining reduces total handling time and minimizes product waste while the modular design keeps device complexity manageable.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables rapid, cost-effective, and consistent filling of smoking devices with minimal handling, reducing waste and labor, while maintaining product integrity and quality.
Implementation Method 1
gravity assists in the loading process to maintain the smokable plant matter 22 in place in the plant storage chamber 14
Implementation Method 2
downward pressure is then applied which causes the pegs to pass through the holes in the filling tray and penetrate the openings in the containers to, thereby, compress and pack the smokable plant matter in each of the containers
Data Source
AI summary
The present invention provides an apparatus and method for speed filling of a containers, such as bat pipes, that reside in a shipping container. A filling tray includes holes that align with top open ends of the bat pipes. A frame on the filling tray aligns the top open ends of the bat pipes. Smokable plant matter is spread onto the top surface of the filling tray to introduce the smokable plant matter into the holes of the filling tray and further into the top open ends of the bat pipes. A press plate, with a matrix of corresponding pegs, is urged downwardly to compress smokable plant matter into the top open ends of each of the bat pipes. After being filling with smokable plant matter, the top open ends of the bat pies are sealed with caps.