Preroll forming system and method of using the same

Abstract

A system may include an unloading tray configured to receive filled paper preroll cones from a knock box. The unloading tray includes a mold defining apertures, each sized to receive a single cone. A tamping tool has a base and a plurality of rods depending therefrom, each being positioned on the base to align with a corresponding mold aperture. A fold plate includes a plurality of chamfers configured to fold a portion of each cone inwards, each chamfer being positioned to align with a corresponding mold aperture, and defining a hole sized to allow a tamping tool rod to pass therethrough. The tamping tool is positioned with the rods extending through the holes, and receives first and second downward forces, which are applied to the cones, causing the folded cone to close and to pass through the mold apertures, sealing the cones and expelling the cones from the unloading tray.

The following is claimed: 
     
         1 . A preroll joint forming system, comprising:
 an unloading tray configured to receive a plurality of filled paper preroll cones from a knock box into the unloading tray, the unloading tray includes a mold comprising a plurality of apertures, each aperture sized to receive and retain a single preroll cone, of the plurality of preroll cones;   a tamping tool comprising a base plate and a plurality of rods depending therefrom, wherein each of the plurality of rods is positioned on the base plate to align with a corresponding aperture of the mold, the tamping tool being configured to apply downward pressure to the preroll cones in each aperture of the mold;   a fold plate configured to rest on top of the mold and to fold at least a portion of each paper preroll cone inwards, towards a center axis, wherein the fold plate comprises a plurality of angled chamfers configured to effect the folding, wherein each of the chamfers is positioned to align with a corresponding aperture of the mold, and wherein each chamfer defines a hole sized to allow a rod of the tamping tool to pass therethrough;   wherein the tamping tool is positioned with the plurality of rods extending through the plurality of holes defined in the fold plate, and is configured to receive a first downward force and to apply the first downward force to the preroll cones causing the folded paper cone to close, and   wherein the tamping tool is configured to receive a second downward force and to apply the second downward force to the preroll cones, causing the preroll cones to pass through the apertures of the mold, thus sealing the preroll cones and expelling the preroll cones from the unloading tray.   
     
     
         2 . The system of  claim 1 , further comprising a crowning block configured to support the unloading tray, wherein the crowning block comprises one or more cavities defined therein, and wherein each of the one or more cavities is disposed so as to collect the preroll cones expelled from the unloading tray. 
     
     
         3 . The system of  claim 1 , further comprising a pneumatic press configured to apply the second downward force to the tamping tool. 
     
     
         4 . The system of  claim 1 , wherein the mold is formed from silicone. 
     
     
         5 . The system of  claim 1 , wherein the preroll cones received in the unloading tray are filled to a specific weight, and wherein a diameter of each aperture of the mold is determined based on the specific weight of the preroll cones. 
     
     
         6 . The system of  claim 1 , wherein the unloading tray further comprises a cover movable between:
 a closed position and an open position, wherein the cover prevents the filled preroll cones from passing from the knock box to the unloading tray, and an open position, wherein the preroll cones are permitted to pass from the knock box to the unloading tray.   
     
     
         7 . The system of  claim 1 , wherein the rods of the tamping tool are formed from polytetrafluoroethylene. 
     
     
         8 . The system of  claim 1 , wherein the apertures defined in the mold are disposed in a pattern based on a layout of the knock box. 
     
     
         9 . The system of  claim 1 , wherein the chamfers of the fold plate comprise an angled wall disposed at an angle of about 45 degrees, relative to a plane defined by the fold plate. 
     
     
         10 . The system of  claim 1 , wherein the preroll cones are filled with cannabis flower, and where the first downward force and second downward force are configured to compact the cannabis flower to a density that promotes a slow and even burn. 
     
     
         11 . A method of forming preroll joints, comprising:
 positioning an unloading tray beneath a knock box to receive a plurality of filled paper preroll cones from the knock box into the unloading tray, wherein each of the filled preroll cones is received in a corresponding aperture of a mold;   tamping each of the plurality of filled paper preroll cones using a tamping tool comprising a base plate and a plurality of rods depending therefrom, wherein each of the plurality of rods is positioned on the base plate to align with an aperture of the mold;   positioning a chamfered fold plate on top of the plurality of preroll cones to fold at least a portion of each paper preroll cone inwards, towards a center axis, wherein the fold plate comprises a plurality of angled chamfers to effect the folding, wherein each of the chamfers is positioned to align with a hole in the mold, and wherein each chamfer defines a hole sized to allow a rod of the tamping tool to pass therethrough;   placing the plurality of rods of the tamping tool through the plurality of holes defined in the fold plate to apply a first downward force, thereby causing the folded paper cone to close; and   pressing the tamping tool to apply a second downward force, the second downward force causing the preroll cones to pass through the apertures of the mold, thus sealing the preroll cones and expelling the preroll cones from the unloading tray.   
     
     
         12 . The method of  claim 11 , wherein the second downward force is applied by a pneumatic press. 
     
     
         13 . The method of  claim 12 , wherein the second downward force expels the sealed preroll cones into a cavity defined in a crowning block disposed under the unloading tray. 
     
     
         14 . The method of  claim 11 , further comprising inspecting the sealed preroll cones for defect. 
     
     
         15 . The method of  claim 11 , wherein the mold defines a plurality of apertures disposed in a pattern based on a layout of the knock box. 
     
     
         16 . The method of  claim 11 , wherein the paper preroll cones are filled to a specified weight, and wherein a size of each aperture in the mold is selected based on the specified weight. 
     
     
         17 . The method of  claim 11 , wherein the rods of the tamping tool are formed from polytetrafluoroethylene. 
     
     
         18 . The method of  claim 11 , wherein the chamfers of the fold plate comprise an angled wall disposed at an angle of about 45 degrees, relative to a plane defined by the fold plate. 
     
     
         19 . The method of  claim 11 , wherein the unloading tray further comprises a cover movable between:
 a closed position and an open position, wherein the cover prevents the filled preroll cones from passing from the knock box to the unloading tray, and   an open position, wherein the preroll cones are permitted to pass from the knock box to the unloading tray.   
     
     
         20 . The method of  claim 11 , wherein the preroll cones are filled with cannabis flower, and where the first downward force and second downward force compact the cannabis flower to a density that promotes a slow and even burn.