Conical Smoking Shell Automation with Vacuum Mandrel

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Solution Overview

Problem

Conical smoking shells are typically handmade, leading to slow manufacturing processes and inconsistencies, necessitating the automation of manufacturing steps to improve efficiency and consistency.

Innovation Solution

A system and method involving a conical form mandrel with a vacuum system, motor, and a garage system to automate the wrapping and shaping of smokable material into conical shells, allowing for partial automation of the manufacturing process, including the use of a vacuum table and a garage carriage to handle and align the shells with blocking tips.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conical smoking shells are handmade, then customization and flexibility are maintained, but manufacturing speed and consistency deteriorate

Engineering Contradiction:

Improvemanufacturing speedVSAvoidmanual labor requirement

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The system allows the conical shell to be formed automatically through the interaction of the vacuum table, rotating mandrel, and smokable sheet material. The vacuum pressure and rotational motion work together to self-form the conical shape without requiring manual shaping operations at each station.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical shaping operations are replaced with a vacuum-based system combined with rotational motion. The vacuum table and mandrel create the conical form through controlled atmospheric pressure and mechanical rotation, eliminating the need for hand-rolling or manual forming tools.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If conical smoking shells are handmade, then flexibility in material selection is maintained, but manufacturing consistency and precision deteriorate

Engineering Contradiction:

Improveconsistency of shell formationVSAvoidautomation system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The vacuum table serves multiple functions: it holds the smokable sheet in place, applies uniform vacuum pressure for consistent formation, and works in conjunction with the rotating mandrel to create the conical shape. This multi-functional approach achieves precision without requiring separate devices for each operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The vacuum system provides controlled atmospheric pressure to form the conical shell consistently. The vacuum pressure uniformly draws the smokable sheet onto the mandrel, ensuring consistent thickness and shape across all produced shells, replacing variable manual pressure application.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Productivity

If automation is introduced to improve manufacturing speed, then productivity increases, but device complexity increases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidapparatus structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The vacuum table and rotating mandrel system combines multiple functions into a unified apparatus. The vacuum system and mechanical rotation work together in a single integrated setup to complete the conical shell formation, reducing the need for separate manual operations at multiple stations.

Inventive Principle:

Principle #5Merging (Combining)

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 the efficient and consistent production of custom conical smoking shells with automated steps, reducing manual labor and improving manufacturing speed while allowing for customization of materials and flavors.

Implementation Method 1

the conical form mandrel vacuum system pulling a partial vacuum on at least part of the external surface of the conical form mandrel; the partial vacuum on the external surface of the conical form mandrel connecting the selected sheet to the conical form mandrel

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

the motor rotating the conical form mandrel; rotation of the conical form mandrel causing the selected sheet to be wrapped about the conical form mandrel and forming a conical shell

Methodology Applied

Scientific EffectRotational motion:

Data Source

PatentUS11785980B1Method and apparatus for preparing a conically shaped smoking shell with blocking tip

Publication Date: 2023.10.17 LSR HC LLC

AI summary

In one embodiment is provided an apparatus which forms conically shaped smoking shells having blocking tips, the apparatus including: (i) a conical form mandrel having an exterior surface, an interior section, and a vacuum opening fluidly connecting the interior section with the exterior surface; (ii) a motor operably connected to the conical form mandrel which can rotate the conical form mandrel; (iii) a conical form mandrel vacuum system operably connected to the interior section of conical form mandrel; (iv) a vacuum table having an upper surface, a vertical elevation system operably connected to the upper surface, which vertical elevation system vertically positions the upper surface, and table heater supported by the vacuum table, and a table vacuum system operably connected to the upper surface; and (v) a garage system located next to the conical form mandrel, the garage system including a base and a garage carriage slidingly connected to the base, the garage carriage including first and second ends with an internal opening extending from the first to the second end, an a squeeze lock connected to the garage carriage and the apparatus is used to form conical smoking shells.