Methods for assembling cartridges for smoking articles and associated systems and apparatus

Abstract

The present disclosure relates to systems, apparatus and methods for assembling a cartridge for an aerosol delivery device. The cartridge can be assembled by coupling the base of the cartridge to a carriage transported via a track. The track transports the carriage between various substations where one or more parts are added to the base. The carriage can be lifted from the track by a lifter mechanism at each substation to perform assembly operations on the base. An inspection system can inspect the cartridge at various stages of completion at or between the various substations.

Description

[0001] This application is a divisional application of the invention patent application with application number 202010096547.1, application date May 18, 2016, and invention name “Method for assembling cigarette cartridges for smoking articles and associated systems and devices”. Technical Field

[0002] The present disclosure relates to a cartridge for an aerosol delivery device such as an electronic cigarette, and more particularly to a method for assembling a cartridge for an aerosol delivery device including an atomizer, and associated systems and apparatus. The atomizer may be configured to heat an aerosol precursor to form an inhalable substance for ingestion by a person, and the aerosol precursor may be made of tobacco or derived from tobacco or otherwise combined with tobacco. Background Art

[0003] Many smoking devices have been proposed in these years as improvements or replacements of smoking products that need to burn tobacco for use. Many devices in those devices are allegedly designed to provide the sensation associated with cigarettes, cigars or pipes, without delivering a considerable amount of incomplete combustion and pyrolysis products caused by the burning of tobacco. For this purpose, numerous smoking products, flavor generators and medicinal inhalers have been proposed, which utilize electrical energy to evaporate or heat volatile materials or attempt to provide the sensation of cigarettes, cigars or pipes to a great extent without burning tobacco. See, for example, the various alternative smoking articles, aerosol delivery devices, and heat generation sources set forth in the Background described in U.S. Pat. No. 8,881,737 to Collett et al., U.S. Patent Application Publication No. 2013 / 0255702 to Griffith Jr. et al., U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al., U.S. Patent Application Publication No. 2014 / 0096782 to Ampolini et al., and U.S. Patent Application No. 14 / 011,992 filed on August 28, 2013 to Davis et al., which are incorporated herein by reference in their entirety. And see, for example, the various embodiments of products and heating configurations described in the Background section of U.S. Pat. No. 5,388,594 to Counts et al. and U.S. Pat. No. 8,079,371 to Robinson et al., which are incorporated herein by reference in their entirety.

[0004] However, some electronic smoking articles or parts thereof may be difficult to manufacture. In this regard, for example, various components of electronic smoking articles may be relatively small and / or fragile. Therefore, it would be desirable to have an improvement in systems, devices and methods for manufacturing electronic smoking articles. Summary of the invention

[0005] The present disclosure relates to the assembly of a smoke cartridge for an aerosol delivery device configured to generate an aerosol, and the aerosol delivery device may be referred to as an electronic cigarette in some embodiments. In one aspect, an assembly substation is provided. The assembly substation may include a supply unit configured to provide a plurality of components, a first assembly unit configured to receive a first part of the component, and a second assembly unit configured to receive a second part of the component. The first assembly unit and the second assembly unit may be configured to assemble the first part of the component and the second part of the component into a plurality of smoke cartridges for an aerosol delivery device, respectively. The assembly substation may further include a feeder unit, which is configured to receive the component from the supply unit and alternately feed the first part of the component to the first assembly unit and the second part of the component to the second assembly unit.

[0006] In some embodiments, the feeder unit may include a rotating component configured to rotate between a first delivery position and a second delivery position, in which the rotating component is configured to deliver the first part of the component to the first assembly unit and in which the rotating component is configured to deliver the second part of the component to the second assembly unit. The rotating component may include a first engagement head and a second engagement head, each configured to receive one of the components from a supply unit. The first engagement head may be configured to receive one of the components from the supply unit while the second engagement head feeds one of the components to the second assembly unit. The second engagement head may be configured to receive one of the components from the supply unit while the first engagement head feeds one of the components to the first assembly unit.

[0007] In some embodiments, the supply unit may include a vibrating arrangement defining a path configured to arrange components in a serially aligned flow, and a singulator configured to singulate components from the serially aligned flow. The supply unit may further include an actuator configured to individually remove components from the serially aligned flow or realign components when the components are misaligned in a first direction. The path may define a gap configured to remove components from the serially aligned flow when the components are misaligned in a second direction.

[0008] In an additional aspect, an assembly method is provided. The assembly method may include providing a plurality of components via a supply unit, alternately feeding a first portion of the components from the supply unit to a first assembly unit and a second portion of the components to a second assembly unit, and assembling the first portion of the components with the first assembly unit and the second portion of the components with the second assembly unit into a plurality of cartridges for an aerosol delivery device.

[0009] In some embodiments, alternately feeding the first part of the component from the supply unit to the first assembly unit and feeding the second part of the component to the second assembly unit may include rotating a rotating component between a first delivery position in which the rotating component is configured to deliver the first part of the component to the first assembly unit and a second delivery position in which the rotating component is configured to deliver the second part of the component to the second assembly unit. Rotating the rotating component may include receiving one of the components from the supply unit in the first engagement head while the second engagement head feeds one of the components to the second assembly unit, and receiving one of the components from the supply unit in the second engagement head while the first engagement head feeds one of the components to the first assembly unit.

[0010] In some embodiments, providing the components via the supply unit may include directing the components along a path in a serially aligned flow and singling out the components from the serially aligned flow. The method may further include individually removing the components from the serially aligned flow or realigning the components when they are misaligned in the first direction. The method may further include removing the components from the serially aligned flow through a gap in the path when the components are misaligned in the second direction.

[0011] In an additional aspect, a system configured to assemble a plurality of cartridges for an aerosol delivery device is provided. The system may include a plurality of assembly substations that are collectively configured to assemble a substrate and a plurality of additional components together. The substrate may extend between an inner end and an attachment end, the inner end being configured to receive the additional components during assembly of the cartridge, the attachment end defining an inner surface that is configured to engage a control body during use of the aerosol delivery device. The system may further include a track extending between the assembly substations. In addition, the system may include a bracket that is configured to engage the track and cooperate with the track to move between the assembly substations. The bracket may include an engagement head that defines a plurality of sections, the plurality of sections being configured to engage the inner surface of the attachment end of the substrate via an interference fit to provide the assembly substation with access to the inner end of the substrate to attach the additional components to the substrate.

[0012] In some embodiments, the assembly substation may include a substrate loading substation. The substrate loading substation may be configured to rotationally align the substrate with the engagement head of the bracket and engage the substrate with the engagement head. The substrate loading substation may include an imaging device configured to detect the rotational orientation of the substrate based on an image of the attachment end of the substrate. The bracket may include a storage module configured to store cartridge identification and status information.

[0013] In some embodiments, the bracket may define one or more alignment apertures and the track may include one or more locking pins configured to engage the alignment apertures at one or more of the assembly substations to removably lock the bracket.

[0014] The track may further include a conveyor and a lifter mechanism. The lifter mechanism may include a locking pin and may be configured to lift the carriage from the conveyor. The carriage may include a static dissipative material. The carriage may further include a locator module including a ferromagnetic material.

[0015] In an additional aspect, a method of assembly is provided. The method of assembly may include providing a substrate and a plurality of additional components that are collectively configured to form a plurality of cartridges for an aerosol delivery device. The substrate may extend between an inner end and an attachment end, the inner end being configured to receive an additional component during the assembly of the cartridge, and the attachment end defining an inner surface that is configured to engage a control body during the use of the aerosol delivery device. The method may further include providing a plurality of assembly substations, tracks, and a bracket comprising a joint head defining a plurality of sections. The track may extend between the assembly substations, and the bracket may be configured to engage the track and cooperate with the track to move between the assembly substations. The method may additionally include engaging the inner surface of the attachment end of the substrate with the section of the joint head via an interference fit to provide access to the inner end of the substrate for the assembly substation. In addition, the method may include transporting the bracket between the assembly substations by means of the track and assembling the additional components with the inner end of the substrate at the assembly substation.

[0016] In some embodiments, engaging the substrate with the engagement head may include rotationally aligning the substrate with the engagement head. Rotationally aligning the substrate with the engagement head may include detecting a rotational orientation of the substrate based on an image of an attachment end of the substrate. In addition, the method may include storing cartridge identification and status information in a storage module coupled to the carriage. The method may also include locking the carriage at one or more locations in the substation by guiding one or more locking pins from a track into one or more alignment apertures defined in the carriage. Conveying the carriage by means of a track may include conveying the carriage by means of a conveyor, and wherein locking the carriage includes lifting the carriage from the conveyor.

[0017] In yet another aspect, an assembly substation is provided. The assembly substation may include a robot arm configured to insert a partially assembled cigarette cartridge into an external body. The partially assembled cigarette cartridge may include a substrate, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element. The negative heating terminal and the positive heating terminal may be coupled to the substrate. The heating element may be coupled to the negative heating terminal and the positive heating terminal. The robot arm may include an external body holder configured to receive an external body therein. The robot arm may be configured to guide an external body holder having an external body positioned therein above the partially assembled cigarette cartridge so that at least a portion of the negative heating terminal, the positive heating terminal, the heating element, and the liquid delivery element are received in the external body. The assembly substation may additionally include a suction system operably engaged with the external body holder of the robot arm. The external body holder may be configured to apply a negative pressure supplied by the suction system longitudinally through the external body to facilitate the insertion of the partially assembled cigarette cartridge into the external body.

[0018] In some embodiments, the assembly substation may further include a bending mechanism configured to receive the partially assembled cartridge therein so as to bend the liquid delivery element against the negative heating terminal and the positive heating terminal. The assembly substation may also include a substrate holder configured to at least partially wrap the reservoir substrate around the bending mechanism, and the bending mechanism may be configured to retract relative to the partially assembled cartridge after winding of the reservoir substrate so that the reservoir substrate is at least partially wrapped around the negative heating terminal and the positive heating terminal and in contact with the liquid delivery element.

[0019] In some embodiments, the outer body holder may include a piston. The piston may be in fluid communication with the suction system and configured to engage one end of the outer body to apply negative pressure through the outer body. The piston may be configured to press the outer body into engagement with the substrate. The outer body holder may be configured to receive the outer body therein while the bending mechanism receives a partially assembled cartridge therein.

[0020] In an additional aspect, an assembly method is provided. The assembly method may include providing a partially assembled cartridge, the partially assembled cartridge including a substrate, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element. The negative heating terminal and the positive heating terminal may be coupled to the substrate. The heating element may be coupled to the negative heating terminal and the positive heating terminal. The assembly method may further include inserting the partially assembled cartridge into the external body by engaging the external body with an external body gripper of a robot arm and guiding the external body over the partially assembled cartridge. In addition, the method may include applying a negative pressure supplied by a suction system operably coupled to the external body gripper of the robot arm to the external body to facilitate insertion of the partially assembled cartridge into the external body.

[0021] In some embodiments, the assembly method may further include inserting the partially assembled cartridge into a bending mechanism to bend the liquid delivery element against the negative heating terminal and the positive heating terminal. The assembly method may also include at least partially wrapping the reservoir substrate around the bending mechanism. In addition, the assembly method may include retracting the bending mechanism relative to the partially assembled cartridge after winding the reservoir substrate so that the reservoir substrate is at least partially wrapped around the negative heating terminal and the positive heating terminal and in contact with the liquid delivery element.

[0022] In some embodiments, applying negative pressure to the outer body may include engaging one end of the outer body with a piston of the outer body holder. The piston may be in fluid communication with the suction system and configured to apply negative pressure through the outer body. The assembly method may further include pressing the outer body into engagement with the substrate with the piston.

[0023] The present invention includes but is not limited to the following examples.

[0024] Embodiment 1: An assembly substation, comprising:

[0025] a supply unit configured to provide a plurality of components;

[0026] a first assembly unit and a second assembly unit, the first assembly unit being configured to receive the first part of the assembly, the second assembly unit being configured to receive the second part of the assembly, the first assembly unit and the second assembly unit being respectively configured to assemble the first part of the assembly and the second part of the assembly into a plurality of cartridges for an aerosol delivery device; and

[0027] A feeder unit is configured to receive the component from the supply unit and alternately feed the first part of the component to the first assembly unit and the second part of the component to the second assembly unit.

[0028] Embodiment 2: An assembly substation according to any preceding or subsequent embodiment, wherein the feeder unit comprises a rotating component, the rotating component being configured to rotate between a first delivery position and a second delivery position, wherein in the first delivery position the rotating component is configured to deliver the first part of the component to the first assembly unit, and in the second delivery position the rotating component is configured to deliver the second part of the component to the second assembly unit.

[0029] Embodiment 3: The assembly substation according to any preceding or subsequent embodiment, wherein the rotating component comprises a first engagement head and a second engagement head respectively configured to receive one of the components from the supply unit,

[0030] the first engagement head being configured to receive one of the components from the supply unit while the second engagement head is feeding one of the components to the second assembly unit,

[0031] The second engagement head is configured to receive one of the components from the supply unit while the first engagement head feeds one of the components to the first assembly unit.

[0032] Embodiment 4: An assembly substation according to any preceding or subsequent embodiment, wherein the supply unit comprises a vibrating arrangement defining a path configured to arrange the components in a serially aligned flow, and a singulator configured to singulate the components from the serially aligned flow.

[0033] Embodiment 5: The assembly substation according to any preceding or subsequent embodiment, wherein the supply unit further comprises an actuator configured to individually remove the components from the serial alignment flow or realign the components when the components are misaligned in the first direction.

[0034] Embodiment 6: The assembly substation of any preceding or subsequent embodiment, wherein the path defines a gap configured to remove the component from the serial alignment flow when the component is misaligned in a second direction.

[0035] Embodiment 7: An assembly method comprising:

[0036] providing a plurality of components via a supply unit;

[0037] alternately feeding a first portion of the assembly from the supply unit to a first assembly unit and a second portion of the assembly to a second assembly unit; and

[0038] The first portion of the assembly is assembled into a plurality of cartridges for an aerosol delivery device by the first assembly unit and the second portion of the assembly is assembled into a plurality of cartridges for an aerosol delivery device by the second assembly unit.

[0039] Embodiment 8: An assembly method according to any preceding or subsequent embodiment, wherein alternately feeding the first part of the component from the supply unit to the first assembly unit and feeding the second part of the component to the second assembly unit includes rotating a rotating component between a first delivery position and a second delivery position, wherein the rotating component is configured to deliver the first part of the component to the first assembly unit in the first delivery position and the rotating component is configured to deliver the second part of the component to the second assembly unit in the second delivery position.

[0040] Embodiment 9: An assembly method according to any preceding or subsequent embodiment, wherein rotating the rotating part includes receiving one of the components from a supply unit in the first bonding head while the second bonding head feeds one of the components to the second assembly unit and receiving one of the components from the supply unit in the second bonding head while the first bonding head feeds one of the components to the first assembly unit.

[0041] Embodiment 10: The assembly method according to any preceding or subsequent embodiment, wherein providing the components via the supply unit comprises guiding the components along a path in a serially aligned flow and singulating the components from the serially aligned flow.

[0042] Embodiment 11: The assembly method of any preceding or subsequent embodiment, further comprising individually removing the components from the serial alignment flow or realigning the components when the components are misaligned in the first direction.

[0043] Embodiment 12: The assembly method of any preceding or subsequent embodiment, further comprising removing the component from the serial alignment flow through a gap in the path when the component is misaligned in the second direction.

[0044] Embodiment 13: A system configured to assemble a plurality of cartridges for an aerosol delivery device, the system comprising:

[0045] a plurality of assembly substations collectively configured to assemble together a base and a plurality of additional components, the base extending between an inner end configured to receive the additional components during assembly of the cartridge and an attachment end defining an inner surface configured to engage a control body during use of the aerosol delivery device;

[0046] a track extending between the assembly substations; and

[0047] A bracket is configured to engage the track and cooperate with the track to move between the assembly substations, the bracket including an engagement head defining a plurality of segments, the plurality of segments being configured to engage the inner surface of the attachment end of the substrate via an interference fit to provide the assembly substation with access to the inner end of the substrate to attach the additional component to the substrate.

[0048] Embodiment 14: The system of any preceding or subsequent embodiment, wherein the assembly substation includes a substrate loading substation configured to rotationally align the substrate with the engagement head of the carrier and engage the substrate with the engagement head.

[0049] Embodiment 15: The system of any preceding or subsequent embodiment, wherein the substrate loading substation comprises an imaging device configured to detect a rotational orientation of the substrate based on an image of the attachment end of the substrate.

[0050] Embodiment 16: The system of any preceding or subsequent embodiment, wherein the cradle comprises a storage module configured to store cartridge identification and status information.

[0051] Embodiment 17: A system according to any preceding or subsequent embodiment, wherein the bracket defines one or more alignment apertures and the track includes one or more locking pins, wherein the one or more locking pins are configured to engage the alignment apertures at one or more of the assembly substations to removably lock the bracket.

[0052] Embodiment 18: The system of any preceding or subsequent embodiment, wherein the track further comprises a conveyor and a lifter mechanism comprising the locking pin and configured to lift the carriage from the conveyor.

[0053] Embodiment 19: The system of any preceding or subsequent embodiment, wherein the bracket comprises a static dissipative material.

[0054] Embodiment 20: The system of any preceding or subsequent embodiment, wherein the bracket further comprises a locator module, wherein the locator module comprises a ferromagnetic material.

[0055] Embodiment 21: An assembly method comprising:

[0056] providing a substrate and a plurality of additional components collectively configured to form a plurality of cartridges for an aerosol delivery device, the substrate extending between an inner end configured to receive the additional components during assembly of the cartridges and an attachment end defining an inner surface configured to engage a control body during use of the aerosol delivery device;

[0057] providing a plurality of assembly substations, a track extending between the assembly substations, and a carriage including an engagement head defining a plurality of sections, the track extending between the assembly substations, and the carriage configured to engage the track and cooperate with the track to move between the assembly substations;

[0058] engaging the inner surface of the attachment end of the substrate with the segment of the engagement head via an interference fit to provide the assembly substation with access to the inner end of the substrate;

[0059] transporting the brackets between the assembly substations by means of the rails; and

[0060] The additional component is assembled with the inner end of the substrate at the assembly substation.

[0061] Embodiment 22: The assembly method according to any preceding or subsequent embodiment, further comprising storing cartridge identification and status information in a storage module coupled to the bracket.

[0062] Embodiment 23: The assembly method of any preceding or subsequent embodiment, wherein engaging the substrate with the engagement head comprises rotationally aligning the substrate with the engagement head.

[0063] Embodiment 24: The assembly method of any preceding or subsequent embodiment, wherein rotationally aligning the substrate with the engagement head comprises detecting a rotational orientation of the substrate based on an image of the attachment end of the substrate.

[0064] Embodiment 25: The assembly method of any preceding or subsequent embodiment, further comprising locking the bracket at one or more of the substations by guiding one or more locking pins from the track into one or more alignment apertures defined in the bracket.

[0065] Embodiment 26: The assembly method of any preceding or subsequent embodiment, wherein transporting the bracket by means of the track includes transporting the bracket by means of a conveyor, and wherein locking the bracket includes lifting the bracket from the conveyor.

[0066] Embodiment 27: An assembly substation, comprising:

[0067] a robotic arm configured to insert a partially assembled cigarette cartridge into an external body, the partially assembled cigarette cartridge comprising a base, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element, the negative heating terminal and the positive heating terminal being coupled to the base, and the heating element being coupled to the negative heating terminal and the positive heating terminal, the robotic arm comprising an external body holder configured to receive the external body therein,

[0068] The robotic arm is configured to guide the outer body holder having the outer body positioned therein over the partially assembled cartridge such that the negative heating terminal, the positive heating terminal, the heating element, and at least a portion of the liquid delivery element are received in the outer body; and

[0069] A suction system is operably engaged with the outer body gripper of the robotic arm, the outer body gripper being configured to apply negative pressure supplied by the suction system longitudinally through the outer body to facilitate insertion of the partially assembled cigarette cartridge into the outer body.

[0070] Embodiment 28: The assembly substation according to any preceding or subsequent embodiment, further comprising a bending mechanism configured to receive the partially assembled cartridge therein so as to bend the liquid delivery element against the negative heating terminal and the positive heating terminal; and

[0071] a substrate holder configured to wrap a reservoir substrate at least partially around the bending mechanism,

[0072] The bending mechanism is configured to retract relative to the partially assembled cartridge following winding of the reservoir substrate such that the reservoir substrate is at least partially wrapped around the negative and positive heating terminals and in contact with the liquid delivery element.

[0073] Embodiment 29: The assembly substation of any preceding or subsequent embodiment, wherein the outer body holder is configured to receive the outer body therein while the bending mechanism receives the partially assembled cartridge therein.

[0074] Embodiment 30: The assembly substation of any preceding or subsequent embodiment, wherein the outer body gripper comprises a piston in fluid communication with the suction system and configured to engage an end of the outer body to apply the negative pressure through the outer body.

[0075] Embodiment 31: The assembly substation of any preceding or subsequent embodiment, wherein the piston is configured to press the outer body into engagement with the substrate.

[0076] Embodiment 32: An assembly method comprising:

[0077] Providing a partially assembled cigarette cartridge, the partially assembled cigarette cartridge comprising: a substrate, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element, the negative heating terminal and the positive heating terminal being coupled to the substrate, and the heating element being coupled to the negative heating terminal and the positive heating terminal;

[0078] inserting the partially assembled cartridge into the outer body by engaging the outer body with an outer body gripper of a robotic arm and guiding the outer body over the partially assembled cartridge; and

[0079] Negative pressure supplied by a suction system operably engaged with the outer body gripper of the robotic arm is applied to the outer body to facilitate insertion of the partially assembled cartridge into the outer body.

[0080] Embodiment 33: The assembly method according to any preceding or subsequent embodiment, further comprising inserting the partially assembled cartridge into a bending mechanism to bend the liquid delivery element against the negative heating terminal and the positive heating terminal;

[0081] wrapping a reservoir substrate at least partially around the bending mechanism; and

[0082] The bending mechanism is retracted relative to the partially assembled cartridge after winding of the reservoir substrate such that the reservoir substrate is at least partially wrapped around the negative and positive heating terminals and in contact with the liquid delivery element.

[0083] Embodiment 34: An assembly method according to any preceding or subsequent embodiment, wherein applying the negative pressure to the external body comprises engaging one end of the external body with a piston of the external body clamp, the piston being fluidically connected to the suction system and configured to apply the negative pressure through the external body.

[0084] Embodiment 35: The assembly method of any preceding or subsequent embodiment, further comprising pressing the outer body into engagement with the base with the piston.

[0085] These and other features, aspects and advantages of the present disclosure will be understood by reading the following detailed description together with the accompanying drawings briefly described below. The present invention includes any combination of two, three, four or more of the above-noted embodiments and any combination of two, three, four or more features or elements set forth in the present disclosure, regardless of whether such features or elements are explicitly combined in a specific embodiment described herein. The present disclosure is intended to be read as a whole so that any separable features or elements of the present invention disclosed in any of its various aspects and embodiments should be considered to be combinable, unless the context clearly specifies otherwise. BRIEF DESCRIPTION OF THE DRAWINGS

[0086] Having thus generally described the present disclosure, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0087] Figure 1 illustrates an aerosol delivery device including a cartridge and a control body according to an example embodiment of the present disclosure, the cartridge being illustrated in an exploded configuration and the control body being illustrated in an assembled configuration;

[0088] Figure 2 FIG. 1 illustrates an example embodiment of the present disclosure in an exploded configuration. Figure 1 The controlling entity;

[0089] Figure 3Schematically illustrates a system for producing a cartridge for an aerosol delivery device according to an example embodiment of the present disclosure, comprising a cartridge assembly subsystem, a cartridge filling subsystem, a cartridge cap sealing system, a cartridge marking subsystem, and an inspection subsystem;

[0090] Figure 4 Schematically illustrates an example embodiment according to the present disclosure Figure 3 The cigarette cartridge assembly subsystem;

[0091] Figure 5 Illustrated according to an example embodiment of the present disclosure Figure 4 A top perspective view of a bracket of a cartridge assembly subsystem;

[0092] Figure 6 Illustrated according to an example embodiment of the present disclosure Figure 5 A bottom perspective view of the bracket;

[0093] Figure 7 FIG. 1 illustrates an example embodiment according to the present disclosure Figure 5 A side view of a bracket and a substrate engaged with its first and second engagement heads;

[0094] Figure 8 FIG. 1 illustrates an example embodiment according to the present disclosure Figure 4 A perspective view of a base loading substation of a cartridge assembly subsystem;

[0095] Fig. 9 Illustrated according to an example embodiment of the present disclosure Figure 8 An enlarged view of a supply unit of a base load substation;

[0096] Fig.10 Illustrated according to an example embodiment of the present disclosure Fig. 9 An enlarged view of a single distributor of a supply unit;

[0097] Fig.11 FIG. 1 illustrates an example embodiment according to the present disclosure Figure 8 An enlarged perspective view of a feeder unit of a base load substation;

[0098] Fig.12 FIG. 1 illustrates an example embodiment according to the present disclosure Figure 8 An alternative enlarged perspective view of a feeder unit of a base load substation;

[0099] Fig.13 Illustrated according to an example embodiment of the present disclosure Figure 8 A first assembly unit and a second assembly unit of a base load substation;

[0100] Fig.14 Illustration of a machine tool in a desired rotational orientation relative to a machining direction according to an example embodiment of the present disclosure Figure 1 An enlarged view of the base of the cigarette cartridge;

[0101] Fig.15 FIG. 1 is a diagram illustrating an example embodiment according to the present disclosure Figure 8 The base load of the substation Figure 4 A view of the tracks of the cartridge assembly subsystem;

[0102] Fig.16 FIG. 1 is a diagram illustrating an example embodiment according to the present disclosure Figure 8 The base load of the substation Figure 4 An opposing view of the track of the cartridge assembly subsystem;

[0103] Fig.17 Illustrated according to an example embodiment of the present disclosure Figure 4 A perspective view of a control component terminal connection substation of a cigarette cartridge assembly substation;

[0104] Fig.18 Illustrated according to an example embodiment of the present disclosure Fig.17 An enlarged view of the control assembly terminals connecting the supply unit of the substation;

[0105] Fig.19 FIG. 1 illustrates an example embodiment according to the present disclosure. Fig.18 an enlarged view of a path defined by a vibratory bowl of a supply unit;

[0106] Fig. 20 Illustrated according to an example embodiment of the present disclosure Fig.18 View of a single distributor of the supply unit:

[0107] Fig.21 Illustrated according to an example embodiment of the present disclosure Fig. 20 A magnified view of the single-point switch and the terminals of the single-point control assembly;

[0108] Fig. 22 Illustrated according to an example embodiment of the present disclosure Fig.17 The control assembly terminal is connected to the first assembly unit and the second assembly unit of the substation;

[0109] Fig.23 Illustrated according to an example embodiment of the present disclosure Fig. 22 an enlarged view of a first engaging head of a first assembly unit;

[0110] Fig.24 FIG. 1 illustrates a method of coupling a substation close to a control assembly according to an example embodiment of the present disclosure. Figure 4 A perspective view of the track of the cartridge assembly subsystem;

[0111] Fig.25 Illustrated according to an example embodiment of the present disclosure Figure 1A perspective view of the base of the cartridge and the control assembly terminals partially engaged therewith:

[0112] Fig.26 Illustrated according to an example embodiment of the present disclosure Fig.17 The control components are connected to the presses of the substations;

[0113] Fig. 27 Illustrated according to an example embodiment of the present disclosure Figure 4 A perspective view of a negative heating terminal connection substation of a cigarette cartridge assembly substation;

[0114] Fig.28 Illustrated according to an example embodiment of the present disclosure Fig.17 An enlarged view of the negative heating terminal connection substation supply unit;

[0115] Fig.29 Illustrated according to an example embodiment of the present disclosure Fig.28 An enlarged view of a single distributor of a supply unit;

[0116] Fig.30 Illustrated according to an example embodiment of the present disclosure Fig.17 An enlarged view of the negative heating terminal connection substation feeder unit;

[0117] Fig.31 Illustrated according to an example embodiment of the present disclosure Fig. 27 The negative heating terminal is connected to the first assembly unit and the second assembly unit of the substation;

[0118] Fig.32 Illustrated according to an example embodiment of the present disclosure Fig.31 An enlarged view of an end effector of a first assembly unit;

[0119] Fig.33 FIG. 1 illustrates a method of bonding a first negative heating terminal according to an example embodiment of the present disclosure. Fig.32 A magnified view of the end effector;

[0120] Fig.34 FIG. 1 shows a diagram of a substation connected close to a negative heating terminal according to an example embodiment of the present disclosure. Figure 4 Tracks for the cartridge assembly subsystem;

[0121] Fig.35 Illustrated according to an example embodiment of the present disclosure Figure 4 An inspection unit at the positive heating terminal assembly subsystem of the cigarette cartridge assembly substation;

[0122] Fig.36 Illustrated according to an example embodiment of the present disclosure Figure 4 A perspective view of a control component connection substation of a cigarette cartridge assembly substation;

[0123] Fig.37 FIG. 1 is a diagram illustrating an exemplary embodiment of the present invention. Fig.36 A control assembly is connected to a feeder unit of a substation;

[0124] Fig.38 FIG. 1 shows a schematic diagram of an actuator according to an example embodiment of the present disclosure. Fig.37 A magnified view of the vibratory bowl of the supply unit;

[0125] Fig.39 Illustration of a circuit diagram ... Fig.38 A magnified view of the vibrating bowl;

[0126] Fig.40 FIG. 1 shows a first receiving position according to an example embodiment of the present disclosure. Fig.37 The supply unit of the single distributor and Fig.36 an enlarged view of a feeder unit of a control assembly coupled to a substation;

[0127] Fig.41 Illustrated according to an example embodiment of the present disclosure Fig.40 An enlarged view of the single divider and the feeder unit, wherein the feeder unit is in a second receiving position;

[0128] Fig.42 Illustrated according to an example embodiment of the present disclosure Fig.36 A control assembly connects the first assembly unit and the second assembly unit of the substation;

[0129] Fig.43 Illustrated according to an example embodiment of the present disclosure Fig.42 a first end effector of a first assembly unit, wherein the pivoting gripper is in a generally horizontal configuration;

[0130] Fig.44 Illustrated according to an example embodiment of the present disclosure Fig.43 a first end effector of wherein the pivoting gripper is in a generally vertical configuration;

[0131] Fig.45 FIG. 1 is a diagram illustrating an example embodiment according to the present disclosure Fig.36 The control components of the substation are connected Figure 4 Tracks for the cartridge assembly subsystem;

[0132] Fig.46 FIG. 1 illustrates a method of processing a device close to a second processing portion according to an example embodiment of the present disclosure. Fig.45 Tracks;

[0133] Fig.47 Illustrated according to an example embodiment of the present disclosure Figure 4A perspective view of a flow guide connection substation of a cigarette cartridge assembly substation;

[0134] Fig.48 Illustrated according to an example embodiment of the present disclosure Fig.47 An enlarged view of the supply unit of the deflector connection substation;

[0135] Fig.49 Illustrated according to an example embodiment of the present disclosure Fig.48 Single distributor of the supply unit;

[0136] Fig.50 Illustrated according to an example embodiment of the present disclosure Fig.47 A perspective view of a feeder unit of a flow director connection substation;

[0137] Fig.51 Illustrated according to an example embodiment of the present disclosure Fig.47 A perspective view of a first assembly unit of a flow director connection substation;

[0138] Fig.52 Illustrated according to an example embodiment of the present disclosure Fig.51 a first end effector of a first assembly unit;

[0139] Fig.53 FIG. 1 is a diagram illustrating an example embodiment according to the present disclosure Fig.47 The deflector connects the substation Figure 4 A perspective view of the track of the cartridge assembly subsystem;

[0140] Fig.54 Illustrated according to an example embodiment of the present disclosure Figure 4 A perspective view of a heating element connection substation of a cigarette cartridge assembly substation;

[0141] Fig.55 Illustrated according to an example embodiment of the present disclosure Fig.54 A perspective view of a supply unit of a heating element coupling substation;

[0142] Fig.56 Illustrated according to an example embodiment of the present disclosure Fig.55 A side view of a supply unit;

[0143] Fig.57 Illustrated according to an example embodiment of the present disclosure Fig.54 A perspective view of a feeder unit, a first assembly unit, and a second assembly unit of a heating element coupling substation;

[0144] Fig.58 Illustrated according to an example embodiment of the present disclosure Fig.57 An enlarged view of an end effector of a second assembly unit;

[0145] Fig.59 Illustrated according to an example embodiment of the present disclosure Fig.57 an enlarged view of the engagement head and the gripper of the feeder unit;

[0146] Fig.60 FIG. 1 is a diagram illustrating an example embodiment according to the present disclosure Fig.55 The heating element of the connection substation Figure 4 A perspective view of the track of the cartridge assembly subsystem;

[0147] Fig.61 Illustrated according to an example embodiment of the present disclosure Fig.57 a terminal fixing mechanism and a laser of a first processing portion of a first assembly unit;

[0148] Fig.62 Illustrated according to an example embodiment of the present disclosure Fig.61 An enlarged partial view of a terminal actuator of a terminal fixing mechanism;

[0149] Fig.63 Illustrated according to an example embodiment of the present disclosure Figure 4 A perspective view of a reservoir and an external body connection substation of a cartridge assembly substation;

[0150] Fig.64 Illustrated according to an example embodiment of the present disclosure Fig.63 A perspective view of a reservoir and an external body coupling substation reservoir supply unit;

[0151] Fig.65 Illustrated according to an example embodiment of the present disclosure Fig.65 A side view of a single distributor of a reservoir supply unit;

[0152] Fig.66 Illustrated according to an example embodiment of the present disclosure Fig.63 A perspective view of a reservoir and an external body supply unit of an external body coupling substation;

[0153] Fig.67 Illustrated according to an example embodiment of the present disclosure Fig.66 A side view of a single distributor of an external main supply unit;

[0154] Fig.68 Illustrated according to an example embodiment of the present disclosure Fig.63 an initial external body feeder of a feeder unit of a reservoir and an external body coupling substation;

[0155] Fig.69 Illustrated according to an example embodiment of the present disclosure Fig.63 a first outer body and reservoir substrate feeder and first and second assembly units of a reservoir and outer body coupling substation;

[0156] Fig.70 Illustrated according to an example embodiment of the present disclosure Fig.69 A perspective view of a bending mechanism and an outer body holder of a first assembly unit;

[0157] Fig.71 Illustrated according to an example embodiment of the present disclosure Fig.63 a perspective view of a second outer body and a reservoir substrate feeder of a reservoir and outer body coupling substation;

[0158] Fig.72 Illustrated according to an example embodiment of the present disclosure Fig.70 An enlarged view of the bending mechanism;

[0159] Fig.73 illustrates a partial side view of an external body crimping and inspection substation according to an example embodiment of the present disclosure;

[0160] Fig.74 illustrates a perspective view of first and second crimper units of an external body crimping and inspection substation according to an example embodiment of the present disclosure;

[0161] Fig.75 The example embodiment according to the present disclosure is shown in Fig.74 an enlarged perspective view of a processing portion at each of the first and second crimper units;

[0162] Fig.76 Illustrated according to an example embodiment of the present disclosure Fig.73 an enlarged view of a processing portion of a first transfer unit of an outer body crimping and inspection substation;

[0163] Fig.77 Illustrated according to an example embodiment of the present disclosure Fig.73 A perspective view of an inspection and processing unit including an indexing table of an external body crimping and inspection substation;

[0164] Fig.78 Illustrated according to an example embodiment of the present disclosure Fig.77 An enlarged view of a first angle stopper of the indexing table;

[0165] Fig.79 Illustrated according to an example embodiment of the present disclosure Fig.77 An enlarged perspective view of a second angle stopper of the indexing table;

[0166] Fig.80 Illustrated according to an example embodiment of the present disclosure Fig.77 A side view of a third angle stopper of the indexing table;

[0167] Fig.81Illustrated according to an example embodiment of the present disclosure Fig.77 A side view of a fourth angle stopper of the indexing table;

[0168] Fig.82 Schematically illustrating a cartridge assembly method including alternately feeding components from a first supply unit to first and second assembly units according to an example embodiment of the present disclosure;

[0169] Fig.83 Schematically illustrating a cartridge assembly method including engaging an inner surface of a base of a cartridge with a bracket and conveying the cartridge on a track to a plurality of assembly substations via the bracket according to an example embodiment of the present disclosure;

[0170] Fig.84 Schematically illustrating a method of assembling a cartridge including applying negative pressure to an outer body of a cartridge to facilitate insertion of other components of the cartridge therein according to an example embodiment of the present disclosure;

[0171] Fig.85 A controller according to an example embodiment of the present disclosure is schematically illustrated. DETAILED DESCRIPTION

[0172] The present disclosure will now be described more fully below with reference to exemplary embodiments of the present disclosure. These exemplary embodiments are described so that the present disclosure will be thorough and complete, and these embodiments will fully convey the scope of the present disclosure to those skilled in the art. In fact, the present disclosure can be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein; in fact, these embodiments are provided so that the present disclosure will satisfy applicable statutory requirements. As used in this specification and in the appended claims, the singular forms "a", "the" and "the" include plural variations unless the context clearly dictates otherwise.

[0173] The present disclosure provides a description of a system for assembling an aerosol delivery device. An aerosol delivery device can use electrical energy to heat a material (preferably without burning the material to any significant extent) to form an inhalable substance; these products are most preferably sufficiently compact to be considered a "handheld" device. An aerosol delivery device can provide some or all of the sensations of smoking a cigarette, cigar, or tobacco pouch (e.g., inhalation and exhalation rituals, types of tastes or flavorings, sensory effects, physical sensations, rituals of use, visual cues such as those provided by visible aerosols, etc.) without burning any component of the product or device to any substantial extent. An aerosol delivery device does not produce smoke in the sense that an aerosol is produced from a byproduct of the combustion or pyrolysis of tobacco, but rather, the product or device most preferably produces vapor (including vapor within an aerosol that can be considered to be a visible aerosol that may be considered to be described as smoke-like) produced by the volatilization or gasification of certain components of the product or device, but in other embodiments the aerosol may not be visible. In a highly preferred embodiment, an aerosol delivery device can incorporate tobacco and / or components derived from tobacco. Thus, an aerosol delivery device may be characterized as an electronic smoking article, such as an electronic cigarette or "e-cigarette."

[0174] Although the system is generally described in terms of embodiments associated with an aerosol delivery device such as a so-called "electronic cigarette", it should be understood that the mechanisms, components, features, and methods can be embodied in many different forms and associated with a variety of articles. For example, the description provided herein can be used in conjunction with embodiments of traditional smoking articles (e.g., cigarettes, cigars, pipes, etc.), heat-not-burn cigarettes, and related packaging for any product disclosed herein. It should therefore be understood that the description of the mechanisms, components, features, and methods disclosed herein is discussed only in terms of embodiments associated with an aerosol delivery mechanism by way of example, and can be implemented and used in a variety of other products and methods.

[0175] Aerosol delivery devices of the present disclosure may also be characterized as steam-generated articles or pharmaceutical delivery articles. Therefore, such articles or devices may be adapted to provide one or more substances (e.g., flavoring agents and / or pharmaceutically active ingredients) in an inhalable form or state. For example, inhalable substances may be substantially in the form of vapor (i.e., substances in gas phase at a temperature below its critical point). Alternatively, inhalable substances may be in the form of aerosols (i.e., suspensions of fine solid particles or droplets in gas). For simple purposes, the term "aerosol" as used herein is intended to include steam, gas, and aerosols in a form or type suitable for human inhalation, whether visible or not and whether or not it may be considered to be a smoke-like form.

[0176] In use, the aerosol delivery device of the present disclosure may be subject to many of the physical actions that an individual employs when using a traditional type of smoking article (e.g., a cigarette, cigar, or pipe that is used by lighting and inhaling the tobacco. For example, a user of the aerosol delivery device of the present disclosure may hold the article in a manner very similar to a traditional type of smoking article, draw on one end of the article for inhaling the aerosol generated by the article, and puff at selected time intervals, etc.

[0177] The smoking article of the present disclosure generally includes several components provided in an outer shell or body. The overall design of the outer shell or body can be varied, and the format or configuration of the outer body that can define the overall size and shape of the smoking article can be varied. Generally, an elongated body similar to the shape of a cigarette or cigar can be formed by a single one-piece shell; or the elongated body can be formed by two or more detachable segments. For example, the smoking article may include an elongated shell or body, which may be generally tubular in shape, and therefore, similar to the shape of a conventional cigarette or cigar. In one embodiment, all components of the smoking article are contained in an outer body or shell. Alternatively, the smoking article may include two or more engaged and detachable shells. For example, the smoking article may have a control body at one end, the control body including a shell containing one or more reusable components (e.g., a rechargeable battery and various electronic devices for controlling the operation of the article), and the smoking article is attached to a shell containing a disposable part (e.g., a disposable flavored cigarette cartridge) in a detachable manner at the other end. In view of the further disclosure provided herein, more specific forms, configurations and arrangements of components within a single housing type unit or a multi-section separable housing type unit will be apparent.In addition, various smoking article designs and component arrangements can be understood after considering commercially available electronic smoking articles.

[0178] The aerosol delivery device of the present invention most preferably includes some combination of: a power source (i.e., an electrical power source), at least one control component (e.g., a means for activating, controlling, regulating and / or stopping the power used to generate heat, such as by controlling the flow of current from the power source to other components of the aerosol delivery device), a heater or heat-generating component (e.g., a resistive heating element or a component that is commonly referred to as part of a "atomizer"), and an aerosol precursor composition (e.g., a liquid that is typically capable of generating an aerosol upon application of sufficient heat, such as ingredients commonly referred to as "smoke juice," "e-liquid," and "e-juice"), and a mouth end region or tip for allowing drawing on the aerosol delivery device for aerosol inhalation (e.g., a defined airflow path that passes through the article so that the generated aerosol can be withdrawn therefrom after drawing).

[0179] The alignment of the components in the aerosol delivery device of the present invention can be varied. In a particular embodiment, the aerosol precursor composition may be located near the end of the aerosol delivery device, and the end may be configured to be positioned close to the user's mouth in order to maximize the aerosol delivery to the user. However, other configurations are not excluded. In general, the heating element may be positioned close enough to the aerosol precursor composition so that the heat from the heating element can volatilize the aerosol precursor (and one or more flavoring agents, medicaments, etc. that can also be provided for delivery to the user) and form an aerosol for delivery to the user. When the heating element heats the aerosol precursor component, an aerosol is formed, released or generated in a physical form suitable for inhalation by a consumer. It should be noted that the above terms are intended to be interchangeable, so that reference to release (release / releasing / releases / released) includes formation or generation (form or generate / forming or generating / forms or generates / formed or generated). Specifically, the inhalable substance is released in the form of vapor or aerosol or a mixture thereof, wherein these terms are also used interchangeably herein unless otherwise specified.

[0180] As described above, the aerosol delivery device may be incorporated with a battery or other power source (e.g., a capacitor) to provide current sufficient to provide various functionalities to the aerosol delivery device, such as powering the heater, powering the control system, powering the indicator, and the like. The power source may adopt various embodiments. Preferably, the power source is capable of delivering sufficient power to quickly heat the heating element to provide aerosol formation and to power the aerosol delivery device for the desired duration by use. The power source is preferably sized to conveniently fit within the aerosol delivery device so that the aerosol delivery device can be easily disposed of. In addition, the preferred power source is sufficiently lightweight so as not to detract from the desired smoking experience.

[0181] More specific formats, configurations, and arrangements of components within the aerosol delivery device of the present invention will be understood in light of the additional disclosure provided below. Additionally, the selection of various aerosol delivery device components may be understood after considering commercially available electronic aerosol delivery devices. Additionally, the arrangement of components within the aerosol delivery device may also be understood after considering commercially available electronic aerosol delivery devices.

[0182] exist Figure 1 An example embodiment of an aerosol delivery device 100 is illustrated in FIG. Figure 1A partially exploded view of an aerosol delivery device 100 including a cartridge 200 and a control body 300 is shown. The cartridge 200 and the control body 300 may be permanently or removably aligned in a functional relationship. Various mechanisms may connect the cartridge 200 to the control body 300 to obtain a threaded engagement, a press fit engagement, an interference fit, a magnetic engagement, or the like. In some embodiments, when the cartridge 200 and the control body 300 are in an assembled configuration, the aerosol delivery device 100 may be generally rod-shaped, generally tubular in shape, or generally cylindrical in shape.

[0183] In a specific embodiment, one or both of the cartridge 200 and the control body 300 may be referred to as disposable or reusable. For example, the control body 300 may have a replaceable battery or a rechargeable battery, and thus may be combined with any type of recharging technology, including connection to a typical AC outlet, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer such as via a universal serial bus (USB) cable. In addition, in some embodiments, the cartridge 200 may include a single-use cartridge, as disclosed in U.S. Patent Application Publication No. 2014 / 0060555 to Change et al., which is incorporated herein by reference in its entirety.

[0184] Figure 2 1 shows an exploded view of a control body 300 of an aerosol delivery device 100 according to an example embodiment of the present disclosure. As illustrated, the control body 300 may include a coupler 302, an outer body 304, a sealing member 306, an adhesive member 308 (e.g., 31 ), a flow sensor 310 (e.g., a puff sensor or a pressure switch), a control assembly 312, a spacer 314, a power source 316 (e.g., a rechargeable battery), a circuit board with an indicator 318 (e.g., a light emitting diode (LED)), a connector circuit 320, and an end cap 322. Examples of power sources are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0185] With respect to flow sensor 310, representative current regulation components and other current control components including various microcontrollers, sensors and switches for aerosol delivery devices are described in the following patents: U.S. Pat. No. 4,735,217 to Gerth et al., U.S. Pat. Nos. 4,922,901, 4,947,874 and 4,947,875 to Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat. No. 6,040,560 to Fleischhauer et al., U.S. Pat. No. 7,040,314 to Nguyen et al., and U.S. Pat. No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entirety. Reference is also made to the control scheme described in U.S. Application Publication No. 2014 / 0270727 to Ampolini et al., which is incorporated herein by reference in its entirety.

[0186] In one embodiment, the indicator 318 may include one or more light emitting diodes. The indicator 318 may communicate with the control assembly 312 via the connector circuit 320, and may be illuminated, for example, during a user's puffing on a cigarette cartridge connected to the coupler 302 as detected by the flow sensor 310. The end cap 322 may be adapted to make the illumination provided by the indicator 318 below it visible. Therefore, the indicator 318 may illuminate during use of the aerosol delivery device 100 to simulate the ignition end of a smoking article. However, in other embodiments, the indicator 318 may be provided in different numbers and may be in different shapes and may even be an opening in the outer body (e.g., for the release of sound when these indicators are present).

[0187] Still other components may be utilized in the aerosol delivery devices of the present disclosure. For example, U.S. Pat. No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Pat. No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouth end of the device to detect user lip activity associated with taking a puff and then trigger heating of a heating device; U.S. Pat. No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow into a heat load array in response to a pressure drop across a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses a socket in a smoking device that includes an identifier for detecting non-uniformity of infrared transmittance of an inserted component and a controller that performs a detection routine when the component is inserted into the socket; U.S. Pat. No. 6,040,560 to Fleischhauer et al. Describes a defined executable power cycle with multiple differential phases; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic light-guiding light-emitting component; U.S. Patent No. 5,954,979 to Counts et al. discloses a component for changing the resistance to draw through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a specific battery configuration for a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer-interfacing component for a smoking device to facilitate charging and allow computer control of the device; U.S. Patent No. 8,689,804 to Fernando et al. discloses an identification system for a smoking device; and Flick's WO 2010 / 003480 discloses a fluid flow sensing system for indicating puffs in an aerosol generating system; all of the foregoing disclosures are incorporated herein by reference in their entirety.Other examples of components related to electronic aerosol delivery articles and disclosing materials or components that can be used in the articles of the present invention include: U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to Morgan et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to White; U.S. Pat. No. 6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat. No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No. 7,513,253 to Kobayashi; U.S. Pat. No. 7,896,0 06; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon; U.S. Patent No. 8,794,231 to Thorens et al.; U.S. Patent No. 8,851,083 to Oglesby et al.; U.S. Patent Nos. 8,915,254 and 8,925,555 to Monsees et al.; U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490 to Hon; U.S. Patent Application Publication No. 2010 / 0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010 / 0307518 to Wang; U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al.; WO 2006 to Hon 2010 / 091593; and WO 2013 / 089551 to Foo, each of which is incorporated herein by reference in its entirety. In various embodiments, a variety of materials disclosed by the aforementioned documents can be incorporated into the present device, and all of the aforementioned disclosures are incorporated herein by reference in their entirety.

[0188] Return to Figure 1, a cartridge 200 is illustrated in an exploded configuration. As illustrated, according to an example embodiment of the present disclosure, the cartridge 200 may include a base shipping plug 202, a base 204, a control assembly terminal 206, an electronic control assembly 208, a flow guide 210, an atomizer 212, a reservoir substrate 214, an outer body 216, a label 218, a mouthpiece 220, and a mouthpiece shipping plug 222. The base 204 may be coupled to a first end of the outer body 216, and the mouthpiece 220 may be coupled to an opposite second end of the outer body to substantially or completely enclose the remaining components of the cartridge 200 therein. The base 204 may be configured to engage a coupler 302 of a control body 300. In some embodiments, the base 204 may include an anti-rotation feature that substantially prevents relative rotation between the cartridge and the control body, as disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety.

[0189] The base shipping plug 202 can be configured to engage and protect the base 204 prior to use of the cartridge 200. Similarly, the mouthpiece shipping plug 222 can be configured to engage and protect the mouthpiece 220 prior to use of the cartridge 200. The control assembly terminals 206, the electronic control assembly 208, the flow guide 210, the atomizer 212, and the reservoir substrate 214 can be substantially completely retained within the outer body 216. The label 218 can at least partially surround the outer body 216 and include information thereon, such as a product identifier.

[0190] The atomizer 212 may include a negative heating terminal 234 and a positive heating terminal 235, a liquid delivery element 238, and a heating element 240. In this regard, the reservoir substrate 214 can be configured to hold an aerosol precursor composition. Representative types of aerosol precursor components and formulations are also described in U.S. Patent No. 7,726,320 to Robinson et al. and U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., 2013 / 0213417 to Chong et al. and 2014 / 0060554 to Collett et al., 2015 / 0020823 to Lipowicz et al. and 2015 / 0020830 to Koller, and WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be employed include those that have been incorporated in the patent provided by RJ Reynolds Vapor Corporation. The aerosol precursors in the products provided by , BLU products provided by Lorillard Technology, MISTIC MENTHOL products provided by Mistic Ecigs, and VYPE products provided by CN Creative Co., Ltd. are also desirable. So-called "smoke juices" for electronic cigarettes that can be purchased from Johnson Creek Enterprises LLC are also desirable. Embodiments of effervescent materials can be used with aerosol precursors and are described, for example, in U.S. Patent Application Publication No. 2012 / 0055494 to Hunt et al., which is incorporated herein by reference. In addition, for example, the use of foaming materials is described in the following U.S. patents: U.S. Patent No. 4,639,368 to Niazi et al., U.S. Patent No. 5,178,878 to Wehling et al., U.S. Patent No. 5,223,264 to Wehling et al., U.S. Patent No. 6,974,590 to Pather et al., U.S. Patent No. 7,381,667 to Bergquist et al., U.S. Patent Publication No. 2006 / 0191548 to Strickland et al., U.S. Patent Publication No. 2009 / 0025741 to Crawford et al., U.S. Patent Publication No. 2010 / 0018539 to Brinkley et al., U.S. Patent Publication No. 2010 / 0170522 to Sun et al., and PCT WO 97 / 06786 to Johnson et al., all of which are incorporated herein by reference.

[0191] The reservoir substrate 214 may include a plurality of non-woven fiber layers formed into the shape of a tube surrounding the interior of the outer body 216 of the cartridge 200. Thus, for example, a liquid component may be adsorbed and retained by the reservoir substrate 214. The reservoir substrate 214 is in fluid connection with the liquid transport element 238. Thus, the liquid transport element 238 may be configured to transport liquid from the reservoir substrate 214 to the heating element 240 via capillary action or other liquid transport mechanisms.

[0192] As illustrated, the liquid delivery element 238 may be in direct contact with the heating element 240. Figure 1As further described in the claims, the heating element 240 may include a wire defining a plurality of coils wound around the liquid delivery element 238. In some embodiments, the heating element 240 may be formed by winding a wire around the liquid delivery element 238, as described in U.S. Patent Application Publication No. 2014 / 0157583 of Ward et al., which is incorporated herein by reference in its entirety. In addition, in some embodiments, the wire may define a variable coil spacing, as described in U.S. Patent Application Publication No. 2014 / 0270730 of DePiano et al., which is incorporated herein by reference in its entirety. Various embodiments of materials configured to generate heat when an electric current is applied therethrough may be used to form the heating element 240. Example materials from which a coil may be formed include Cantal (FeCrAl), nickel-chromium alloys, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), molybdenum disilicide doped with aluminum (Mo(Si,Al)2), graphite and graphite-based materials; and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0193] However, various other embodiments of the method may be used to form the heating element 240, and various other embodiments of the heating element may be used in the atomizer 212. For example, a stamped heating element may be used in the atomizer, as described in U.S. Patent Application Publication No. 2014 / 0270729 to DePiano et al., which is incorporated herein by reference in its entirety. With respect to the above, additional representative heating elements and materials that may be used therein are described in the following documents: U.S. Patent No. 5,060,671 to Counts et al., U.S. Patent No. 5,093,894 to Deevi et al., U.S. Patent No. 5,224,498 to Deevi et al., Sprinkel Jr., et al., U.S. Pat. No. 5,228,460, U.S. Pat. No. 5,322,075, Deevi et al., U.S. Pat. No. 5,353,813, Deevi et al., U.S. Pat. No. 5,468,936, Das et al., U.S. Pat. No. 5,498,850, Das et al., U.S. Pat. No. 5,659,656, Deevi et al., U.S. Pat. No. 5,498,855, Hajaligol et al., U.S. Pat. No. 5,530,225, Hajaligol et al., U.S. Pat. No. 5,665,262, Das et al., U.S. Pat. No. 5,573,692, and U.S. Pat. No. 5,591,368, Fleischhauer et al., the disclosures of which are incorporated herein by reference in their entirety. In addition, chemical heating may be employed in other embodiments. Various additional examples of heaters and materials used to form heaters are described in US Pat. No. 8,881,737 to Collett et al., which is incorporated herein by reference as noted above.

[0194] A variety of heater assemblies can be used in the aerosol delivery device of the present invention. In various embodiments, one or more micro-heaters or similar solid-state heaters can be used. Embodiments of micro-heaters that can be utilized are further described herein. Additional micro-heaters suitable for use in the device disclosed herein and atomizers incorporating micro-heaters are described in U.S. Pat. No. 8,881,737 to Collett et al., which is incorporated herein by reference in its entirety.

[0195] The negative heating terminal 234 and the positive heating terminal 235 (e.g., positive and negative terminals) at the opposite ends of the heating element 240 are configured to form an electrical connection with the control body 300 when the cigarette cartridge 200 is connected thereto. In addition, when the control body 300 is coupled to the cigarette cartridge 200, the electronic control assembly 208 can be electrically connected to the control body through the control assembly terminal 206. The control body 300 can therefore use the electronic control assembly 208 to determine whether the cigarette cartridge 200 is authentic and / or perform other functions. In addition, various examples of electronic control components and the functions performed thereby are described in U.S. Patent Application Publication No. 2014 / 009678 to Sears et al., which is incorporated herein by reference in its entirety.

[0196] During use, a user can draw on the mouthpiece 220 of the cartridge 200 of the aerosol delivery device 100. This can pull air through an opening in the control body 300 or in the cartridge. For example, in one embodiment, the opening can be defined between the coupler 302 and the outer body 304 of the control body 300, as described in U.S. Patent Application Publication No. 2014 / 0261408 to DePiano et al.; the publication is incorporated herein by reference in its entirety. However, in other embodiments, the air flow can be received via other parts of the aerosol delivery device 100. As described above, in some embodiments, the cartridge 200 may include a flow guide 210. The flow guide 210 can be configured to guide the air flow received from the control body 300 to the heating element 240 of the atomizer 212.

[0197] A sensor in the aerosol delivery device 100 (e.g., a puff or flow sensor in the control body 300) can sense the puff. When a puff is sensed, the control body 300 can direct current to the heating element 240 through a circuit comprising a negative heating terminal 234 and a positive heating terminal 235. Thus, the heating element 240 can evaporate the aerosol precursor composition directed from the reservoir substrate 214 to the aerosolization zone by the liquid delivery element 238. Thus, the mouthpiece 220 can allow air and entrained vapor (i.e., components of the aerosol precursor composition in an inhalable form) to pass from the cartridge 200 to the consumer who draws on it.

[0198] Various other details regarding the components that may be included in the cartridge 200 are provided, for example, in U.S. Patent Application Publication No. 2014 / 0261495 to DePiano et al., which is incorporated herein by reference in its entirety. Figure 7 Figure 1 shows an enlarged exploded view of the base and control assembly terminals; Figure 8 An enlarged perspective view of the base and control assembly terminals in an assembled configuration is shown; Fig. 9An enlarged perspective view of the base, control assembly terminals, electronic control assembly, and heater terminals of the atomizer are shown in an assembled configuration; Fig.10 An enlarged perspective view of the base, atomizer, and control assembly are shown in an assembled configuration; Fig.11 The diagram shows Fig.10 An opposing perspective view of an assembly of Fig.12 An enlarged perspective view of the base, atomizer, flow guide, and reservoir substrate in an assembled configuration is shown; Fig.13 A perspective view of the base and outer body is shown in an assembled configuration; Fig.14 A perspective view of a cartridge in an assembled configuration is shown; Fig.15 The diagram shows Fig.14 A first partial perspective view of a cigarette cartridge and a connector for controlling a main body; Fig.16 The diagram shows Fig.14 The cigarette cartridges and their Fig.11 An opposite second partial perspective view of a connector; Fig.17 A perspective view of a cartridge including a base having an anti-rotation mechanism is shown; Fig.18 The figure shows a perspective view of a control body including a coupling having an anti-rotation mechanism; Fig.19 Graphics Fig.17 The cigarette cartridges and Fig.18 The alignment of the control subject; Fig. 20 The diagram includes Fig.17 The cigarette cartridges and their Fig.18 An aerosol delivery device of a control body and a modified view through the aerosol delivery device, illustrating the engagement of the anti-rotation mechanism of the cartridge with the anti-rotation mechanism of the connector body; Fig.21 A perspective view of a base having an anti-rotation mechanism is shown; Fig. 22 A perspective view of a coupling having an anti-rotation mechanism is shown; and Fig.23 The diagram shows the Fig.21 The base and its Fig. 22 Various other details regarding the components that the cartridge 200 may include are provided, for example, in U.S. Patent Application No. 14 / 286,552 to Brinkley et al., filed May 23, 2014, which is incorporated herein by reference in its entirety.

[0199] The various components of the aerosol delivery device according to the present disclosure can be selected from the components described and commercially available in the art. For example, reference is made to the reservoir and heater system for the controlled delivery of multiple atomizable materials in an electronic smoking article disclosed in U.S. Patent Application Publication No. 2014 / 0000638 to Sebastian et al., which is incorporated herein by reference in its entirety.

[0200] It should be further noted that Figure 1 The parts of the cartridge 200 described in the figure are optional. In this regard, for example, in some embodiments, the cartridge 200 may not include the deflector 210, the control component terminal 206 and / or the electronic control component 208.

[0201] In another embodiment, substantially all of the cartridge may be formed of one or more carbon materials, which may provide advantages in terms of biodegradability and the absence of wires. In this regard, the heating element may include carbon foam, the reservoir may include carbonized fabric, and graphite may be used to form an electrical connection with the battery and controller. Example embodiments of carbon-based cartridges are provided in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., which is incorporated herein by reference in its entirety.

[0202] As described above, the cigarette cartridge of an aerosol delivery device may include several components. Some components may be relatively small and / or relatively fragile. Therefore, precise manufacturing technology may be required to form an aerosol delivery device. In this regard, aerosol delivery devices are traditionally formed via manual assembly. However, there are certain disadvantages in assembling aerosol delivery devices using manual labor. In this regard, the quality of aerosol delivery devices produced via manual labor is only as good as the workers who perform the labor. In addition, even skilled workers may make mistakes from time to time. In addition, manual labor may be relatively expensive. Therefore, due to these problems and other problems associated with producing aerosol delivery devices via manual labor, it may be necessary to produce aerosol delivery devices in an automatic manner. Therefore, the automatic production of cigarette cartridges for aerosol delivery devices is discussed below, which can provide enhanced repeatability, lower cost and / or avoid other problems mentioned above.

[0203] In this regard, Figure 3 An embodiment of a system 400 for producing a cartridge (e.g., the cartridge 200 described above) for an aerosol delivery device (e.g., the aerosol delivery device 100 described above) is schematically illustrated. It should be noted that the aerosol delivery device 100 described above is provided by way of example. In this regard, the methods, systems, and apparatus described herein can be used to form various embodiments of cartridges that differ from the cartridges described above in one or more aspects.

[0204] As illustrated, the system 400 may include various subsystems that perform specific functions in the formation of the finished cartridge 200. It should be noted that although the subsystems are shown as separate from each other, the subsystems may overlap. For example, in some embodiments, a common device may perform two or more functions (e.g., assembly and filling or capping and labeling, etc.) rather than having a separate device perform a specific function.

[0205] In addition, various subsystems and parts thereof can be used separately. In this respect, although subsystems and parts thereof are generally described herein as being usable together, this is by way of example. Therefore, any of the subsystems or parts thereof described herein can be used by themselves or with some or all of the other subsystems and parts thereof described herein in any combination. In addition, although specific embodiments of parts of subsystems are disclosed below, these embodiments are provided for example purposes only. Therefore, in some embodiments, a subsystem may include fewer or additional parts. Therefore, each part of each subsystem and each part of the overall system are not required in all embodiments.

[0206] As illustrated, the subsystem may include a cartridge assembly subsystem 402 configured to form an unfilled cartridge 404 from components 406 (e.g., substrate 204, heating terminals 234, 235, etc.). A cartridge filling subsystem 408 may fill the unfilled cartridge 404 to produce a filled cartridge 410. A cartridge capping subsystem 412 may cap the filled cartridge 410 to produce a capped cartridge 414. A cartridge marking subsystem 416 may apply a label to the capped cartridge 414 to complete the finished cartridge 200.

[0207] The system 400 may further include an inspection subsystem 418. The inspection subsystem 418 may inspect the assembly 406, the unfilled cartridge 404, the filled cartridge 410, the capped cartridge 414, and / or the completed cartridge 200. Furthermore, in some embodiments, the cartridge may be inspected in an intermediate state of completion of one or more of the cartridge assembly subsystem 402, the cartridge filling subsystem 408, the cartridge capping subsystem 412, and the cartridge marking subsystem 416. Thus, the cartridge 200 and its components may be inspected before, during, and after its completion.

[0208] The system may further include at least one controller 417. The controller 417 may be configured to control the cartridge assembly subsystem 402, the cartridge filling subsystem 408, the cartridge capping system 412, and / or the cartridge marking subsystem 416. In this regard, in addition to otherwise directing the operations described herein, the controller may be configured to receive data from one or more of the sensors described herein and output instructions based thereon.

[0209] It should be noted that some or all of the system 400 may be automated. In this regard, as described below, robotic equipment may be employed in some embodiments of the system 400. The robotic equipment may be provided from a variety of robotic manufacturers, including, for example, DENSO Robotics of Long Beach, CA, FANUC of Rochester Hills, MI, Mitsubishi Electric Automation of Vernon Hills, IL, EPSON Robots of Carson, CA, and Siemens Automation Technology of Munich, Germany.

[0210] Figure 4 An example embodiment of a cartridge assembly subsystem 402 is schematically illustrated in FIG. It should be noted that the specific embodiments of the substations and their locations may differ from those described below and in FIG. Figure 4 Those embodiments described in. In addition, the specific operations adopted and their order may also vary. The equipment for assembling the cigarette cartridge may depend on the specific configuration of the final product cigarette cartridge. In this regard, the cigarette cartridge 200 described above and referenced below is discussed only for example purposes. In addition, although the description generally refers to the part of the cigarette cartridge assembly subsystem 402 as a substation, it should be understood that the various assembly operations discussed herein can be performed by a single device, device or substation, or distributed across multiple devices, devices and substations. Therefore, the description provided below is only for example purposes, and the equipment and operations adopted and their order may vary without departing from the scope of the present disclosure. In addition, it should be understood that the various substations and the operations performed at each of the substations should be regarded as individual creative aspects. In this regard, although individual substations and operations are generally described as parts of the system herein, each of the substations can be operated and / or combined with other substations independently of other substations discussed herein.

[0211] like Figure 4 As described in , the cartridge assembly subsystem 402 may include a substrate loading substation 502, a control component terminal connection substation 504, a negative heating terminal connection substation 506, a positive heating terminal connection substation 508, a control component connection substation 510, a deflector connection substation 512, a heating element connection substation 514, a reservoir and external body connection substation 516, and an external body crimping and inspection substation 518. As shown in Figure 4 As further described in , the controller 417 can be configured to control one or more of the substations 502 - 518 of the cartridge assembly subsystem 402 .

[0212] Briefly, the substrate load substation 502 can be configured to receive a substrate (e.g., substrate 204) and orient the substrate for assembly with various other components of the cigarette cartridge. The control component terminal connection substation 504, the negative heating terminal connection substation 506, and the positive heating terminal connection substation 508 can be configured to connect the control component terminal (e.g., control component terminal 206), the negative heating terminal (e.g., negative heating terminal 234), and the positive heating terminal (e.g., positive heating terminal 235) to the substrate 204, respectively. The control component connection substation 510 can be configured to connect the control component (e.g., electronic control component 208) to the control component terminal 206. The deflector connection substation 512 can be configured to connect the deflector (e.g., deflector 210) to the control component 208, the negative heating terminal 234, the positive heating terminal 235, and / or other components. The heating element coupling substation 514 can be configured to couple a heating element (e.g., heating element 240) to the negative heating terminal 234 and the positive heating terminal 235. The reservoir and external body coupling substation 516 can be configured to bend a liquid delivery element (e.g., liquid delivery element 238), wrap a reservoir (e.g., reservoir 214) around an atomizer (e.g., atomizer 212), and join an external body (e.g., external body 216) to the substrate 204. The external body crimping and inspection substation 518 can be configured to crimp the external body 216 to the substrate 204 and inspect the cartridge 200.

[0213] The cartridge assembly subsystem 402 can assemble a cartridge (e.g., cartridge 200) in a variety of ways. For example, in one embodiment, the cartridge 200 can be assembled generally from the base 204 upward. In other words, a component can be inserted into the base 204 or otherwise coupled to the base, or coupled to a component previously coupled to the base to build the cartridge 200 therefrom.

[0214] In this regard, as in Figure 4 , in one embodiment, the cartridge assembly subsystem 402 may include a conveyor system including a track 602 and at least one carriage 604, the carriage being configured to engage the track (e.g., by riding on the track) and cooperate with it to move between assembly substations 502. Preferably, multiple 604s may be employed so that each of the substations 502-518 of the cartridge assembly subsystem 402 can be operated simultaneously to assemble multiple cartridges 200 simultaneously. In addition, the carriage 604 can be returned to the initial starting point upstream of the substrate loading substation after the completion of the cartridge 200 so that the carriage can be reused to assemble multiple cartridges.

[0215] The bracket 604 can be configured to engage the base 204 so that the rest of the components of the cartridge 200 can be coupled thereto. In this regard, as discussed below, the base 204 can be engaged with the bracket 604 at the base loading substation 502. Additional components can then be directed generally downward into contact with the base 204 or components previously coupled thereto so that the cartridge 200 is built generally upward from the base as the various components are coupled thereto at the remaining substations 504-518.

[0216] Thus, the brackets 604 can be configured to grasp the base 204. In this regard, each bracket 604 can include at least one engagement head configured to engage the base 204. In some embodiments, each bracket 604 can include multiple engagement heads so that multiple cartridges can be assembled thereon to improve assembly speed and efficiency. For example, Figure 5 As shown in , in some embodiments, the brackets 604 can each include a main body portion 606 and two engaging heads 608a, 608b extending therefrom. Furthermore, each bracket 604 can be configured to assemble two cartridges thereon.

[0217] The engagement heads 608a, 608b can be configured to engage the respective substrates 204 in a secure manner that does not interfere with the attachment of other components to the substrate. In this regard, in some embodiments, the engagement heads 608a, 608b can be configured to engage the inner surface 242 (see FIG. 244 ) of the attachment end 244 of each substrate 204. Figure 1 ). Furthermore, the outer perimeter of each substrate 204 can be exposed to facilitate attachment of components thereto. In this regard, the components can be coupled to the inner ends 246 of the substrates 204 during assembly of the cartridge (see Figure 1 ), and thus engagement of the inner surface 242 of each base 204 with the bracket 604 can facilitate attachment of components thereto by providing substantially unimpeded access to the inner ends.

[0218] Specifically, Figure 5 , each engagement head 608a, 608b may include a collet 610a, 610b, wherein each collet includes a plurality of segments 612 separated by slots at its top portion. Collars 614a, 614b may extend around the segments 612 to prevent the collets 610a, 610b from dropping downward through the body portion 606. The segments 612 of each collet 610a, 610b may be configured to engage the inner surface 242 of the attachment end 244 of the base 204, for example, via an interference fit (see, e.g., Figure 1). In the illustrated embodiment, each chuck 610a, 610b includes four sections 612. However, as can be appreciated, in other embodiments the chucks 610a, 610b may include various other numbers of sections 612. The sections 612 of each chuck 610a, 610b may be configured to flex inwardly during engagement with the substrate 204, and then apply outward pressure against the inner surface 242 of the substrate to keep the substrate engaged therewith. For example, the inner surface 242 of each substrate 204 may define one or more ribs, and the sections 612 of the chucks 610a, 610b may engage the ribs so that the cooperation therebetween securely holds the substrate to the respective chucks. A cartridge comprising a substrate having these ribs is disclosed in U.S. Patent Application Publication No. 2014 / 0261495 to Novak et al., which is incorporated herein by reference in its entirety.

[0219] Figure 6 A bottom view of the bracket 604 is shown. As illustrated, the clamps 610a, 610b can extend to a bottom portion of the bracket 604. Clips 616a, 616b can secure each clamp 610a, 610b at opposing ends. In turn, the collars 614a, 614b and clips 616a, 616b cooperatively retain each clamp 610a, 610b in a fixed position relative to the body portion 606. As shown in FIG. Figure 6 In further description, the bracket 604 can define one or more alignment apertures 618a, 618b. As discussed below, the locking pin can be configured to engage the alignment apertures 618a, 618b to removably lock the bracket 604 at each of the assembly substations 502-518. As described, in one embodiment, the alignment apertures 618a, 618b can be defined by the chucks 610a, 610b. In this regard, when the alignment apertures 618a, 618b engage the locking pin, the chucks 610a, 610b can be directly aligned with the locking pin so that the partially assembled cigarette cartridges are accurately positioned and the cigarette cartridges can be accurately assembled. In some embodiments, the chucks 610a, 610b can be formed by polyetheretherketone (PEEK) of life science grade, which provides resilience for its section 612 and realizes the connection with the substrate as described above, and can be substantially hard to avoid the wear caused by repeated connection and separation with the substrate 204, which can also include plastic or other polymeric materials. However, the alignment apertures 618a, 618b can receive locking pins comprising metal or other relatively harder substances. Therefore, to prevent wear on the collets 610a, 610b at the alignment apertures 618a, 618b, in some embodiments, hardened rings 620a, 620b can be received within each collet at the alignment apertures 618a, 618b to avoid wear thereon.

[0220] like Figure 5As shown in FIG. 6 , each bracket 604 may further include one or more shock absorbers 622. In this regard, in some embodiments, the brackets 604 may be positioned adjacent to or in contact with each other at one or more locations along the track 602 so that the brackets are ready for use in the next substation. For example, Figure 4 As described in , in some embodiments, the track 602 may include a staging area 602a where the brackets 604 are temporarily collected. In some embodiments, the staging area 602a may be located upstream of the substrate loading substation 502 so that one or more of the brackets 604 can be temporarily collected before moving through the substations 502-518. In turn, the shock absorber 622 may protect the main body 606 of the bracket 604 and / or the cartridge assembly / subassembly carried thereby from damage due to contact between brackets.

[0221] As in Figure 5 Further described in, the bracket 604 may further include a storage module 624. The storage module 624 may be configured to store the cartridge identification and status information of each of the cartridges 200 (or partially assembled cartridges) connected to the bracket 604. In some embodiments, the storage module 624 may include a radio frequency identification (RFID) chip or other wireless transponder. In this regard, the storage module 624 may be used to track the information of each of the partially assembled cartridges on the bracket 604 during the assembly of the cartridge. The storage module 624 may include a unique identifier for each of the bracket 604 and / or the cartridges 200 to be assembled, and various other information may be stored and associated therewith. Furthermore, the storage module 624 may store information about each cartridge 200 during the assembly of the cartridge. Therefore, when each substation 502-518 completes the operation on the partially assembled cartridge, the data may be updated and written to the storage module 624. If the assembly step or post-assembly step check indicates that the assembly operation is not properly performed on one of the partially assembled cartridges or the partially assembled cartridge is determined to be different from the required specification, the operation or task at all substations downstream of the substation cannot be performed on the partially assembled cartridge to avoid potential damage to the downstream substations and waste of the use of additional components on the defective partially assembled cartridge. The information stored in the storage module 624 can also be used to determine where to place the completed cartridge 200 after removal from the bracket 604 (e.g., for filling and / or marking purposes). The storage module 624 can clear the data stored therein after the removal of the cartridge 200 is completed so that the cycle can be repeated during the assembly of a new cartridge on each bracket 604.

[0222] Figure 7The illustrated substrate load substation 502 is at the first substrate 204a and the first engagement head 608a after the engagement and the second substrate 204b and the second engagement head 608b after the opposing perspective view of the bracket 604, as discussed below. As described, the bracket 604 may further include a locator module 626. The locator module 626 can be used to detect the presence of the bracket 604 along the track 602 at each of the substations 502-518 when the bracket moves along the track, so that the substation knows when the bracket is available and is positioned to perform the cigarette cartridge assembly operation. In some embodiments, the locator module 626 may include ferromagnetic materials such as steel. In addition, in order to avoid interfering with the detection of the locator module 626, the main body 606 of the bracket 604 may include a non-ferromagnetic material. In some embodiments, the main body 606 of the bracket 604 may include an electrostatic dissipative material, such as polyoxymethylene sold by Wilmington, DE's EI du Pont de Nemours under the name DELRIN. In this regard, the use of static dissipative materials may prevent static charge from building up on carriage 604 due to movement along track 602. This static charge could potentially discharge and damage one of substations 502-518.

[0223] As in Figure 7 604. As further described in FIG. 604, in some embodiments, the bracket 604 may include a stop bar 628. The stop bar 628 may be configured to engage a stop pin at one or more locations along the track 602 to temporarily hold the bracket 604 in a desired position. For example, the stop pin may engage the stop bar 628 to temporarily stop the movement of the bracket 604 and allow lifting of the bracket.

[0224] Thus, the track 602 can be configured to transport the carriage 604 along it to the various assembly substations 502-518. In this regard, the empty cartridge 604 can first be directed to the substrate loading substation 502. The substrate loading substation 502 can be configured to rotationally align the substrate 204 with each engagement head 608a, 608b of the carriage 604 and engage the substrate with the engagement head.

[0225] In this regard, Figure 8A perspective view of a substrate loading substation 502 is shown. As illustrated, the substrate loading substation 502 may include a supply unit 702, a feeder unit 704, a first assembly unit 706a, and a second assembly unit 706b. Briefly, the supply unit 702 may be configured to provide a plurality of components (e.g., substrate 204). The feeder unit 704 may be configured to receive the substrate 204 from the supply unit 702 and alternately feed the substrate 204 to the first assembly unit 706a and the second assembly unit 706b. The first assembly unit 706a and the second assembly unit 706b may each be configured to, for example, assemble the components (e.g., substrate 204) into the cartridge 200 for the aerosol delivery device 100 by coupling the substrate 204 to the bracket 604 to allow subsequent coupling of other components thereto.

[0226] In this regard, Fig. 9 An enlarged view of the supply unit 702 is shown. As illustrated, the supply unit 702 can be configured to supply a plurality of substrates 204. In some embodiments, the supply unit 702 can include a vibration arrangement. For example, the vibration arrangement can include a vibration hopper 708, a vibration bowl 710, and a supply track 712. In some embodiments, the vibration hopper 708, the vibration bowl 710, and / or the supply track 712 can be manufactured by Performance Feeders, Inc. of Oldsmar, FL.

[0227] The substrate 204 may be loaded into the vibrating hopper 708. As the vibrating hopper 708 vibrates, the substrate 204 gradually travels under the gate 714 and drops into the vibrating bowl 710 to provide a substantially constant supply of substrate to the vibrating bowl. In this regard, the assembly level sensor 716 may detect the level of the substrate 204 within the vibrating bowl 710. In turn, the vibrating hopper 708 may be started and stopped based on the level of the substrate 204 within the vibrating bowl 710 detected by the assembly level sensor 716. The vibrating hopper 708 may thus maintain a substantially constant level of the substrate 204 within the vibrating bowl 710 as the substrate is delivered therefrom.

[0228] The vibratory bowl 710 can define a path 718 configured to arrange the substrates 204 in a serially aligned flow 720. In this regard, the vibratory motion of the vibratory bowl 710 can direct the substrates 204 upward along the path 718, which can narrow so that some substrates fall from it and remain on the path to become serially aligned. The vibratory bowl 710 can be configured to arrange the substrates 204 so that the attachment end 244 is oriented downward and the inner end 246 is oriented upward (see Figure 1 ).

[0229] However, some substrates 204 in the serial alignment stream 720 may be oriented upside down or otherwise oriented in a manner different from the desired orientation. In this regard, the supply unit 702 may further include an actuator 724 configured to individually remove or realign the substrates 204 in the serial alignment stream 720 when the substrates are misaligned in one direction. In one embodiment, the actuator 724 may include a nozzle 726 configured to direct an air flow at each substrate 204 that is misaligned to remove the substrate from the path 718 or to push the substrate into proper alignment. In some embodiments, the nozzle 726 may be oriented so as to impact only those substrates 204 that are misaligned with the air flow (i.e., if the substrate is misaligned, then the substrate will be impacted and removed or realigned by the air flow from the nozzle). In another embodiment, the supply unit 702 may further include an orientation sensor 722 (e.g., a camera) configured to determine the alignment of the substrates 204 on the path 718, and the actuator 724 may be actuated in response to the determination when a misaligned substrate is detected.

[0230] Thus, each of the substrates 204 in the serial alignment flow 720 can be properly oriented downstream of the actuator 724. The substrates 204 removed by the actuator 724 can be directed back into the vibratory bowl 710 so that the substrates 204 can return to the path 718. In some embodiments, the path can define a gap or other feature that is configured to remove the component from the serial alignment flow when the component is misaligned in the second direction. For example, this gap or other feature can be configured to allow a substrate resting on its outer circumference to roll off the path.

[0231] Thus, the serially aligned flow 720 of substrates 204 can be directed to the supply track 712, which can maintain the substrates in an upwardly extending orientation and single-file arrangement. In some embodiments, the supply track 712 can include a vibrating supply track to facilitate movement of the substrates 204 along it. As illustrated, the supply track 712 can include a full sensor 726, which is configured to detect whether the supply track is full of substrates 204. In this regard, when the full sensor 726 senses that the supply track 712 is full, the vibrating bowl 710 can be turned off. In addition, the supply track 712 can include a low level sensor 728, which is configured to detect when the supply track runs low on the substrates 204. In this regard, when the low level sensor 728 detects a low level of substrates 204 in the supply track 712, an indicator 730 (see Figure 8) by informing the operator that the substrate loading substation 502 is running low on the substrate 204 so that the operator can be informed that it is time to refill the vibratory hopper 708. In some embodiments, the full sensor 726 and the low level sensor 728 may include optical sensors including a transmitter and a receiver configured to detect the presence or absence of the substrate 204 therebetween.

[0232] In addition, if Fig.10 , the supply unit 702 may include a singulator 732 configured to singulate substrates 204 from the serial alignment stream 720. In this regard, the singulator 732 includes a stopper 734 (e.g., including first and second pins in the illustrated embodiment) and a vertical actuator 736. The vertical actuator 736 may be configured to raise the stopper 734 to an upper position and lower the stopper to a lower position. The vertical actuator 736 may default to a lower position so that the stopper 734 prevents the substrate 204 at the end of the serial alignment stream 720 from moving. However, the vertical actuator 736 may briefly raise the stopper 734 to an upper position to allow the substrate 204 at the end of the serial alignment stream to pass from below it. In turn, the substrate 204 passing below the stopper 734 may be delivered to the feeder unit 704. The vertical actuator 736 can return the stopper 734 to the lower position after the substrate 204 passes thereunder so as to block the remainder of the serial aligned stream 720. This cycle can be repeated to singulate each of the substrates 204 from the serial aligned stream 720 and deliver the individual substrates to the feeder unit 704.

[0233] Fig.11 and 12 The feeder unit 704 is shown. In some embodiments, the feeder unit 704 may include a rotating component 738, such as a rotating table. The first engagement head 740a and the second engagement head 740b may be coupled to the rotating component 738 and each configured to alternately receive one of the substrates 204 from the supply unit 702. In this regard, the first engagement head 740a may define a first recess 742a (see Fig.11 ) and the second engagement head 740b may define a second recess 742b (see Fig.11 As illustrated, in some embodiments, the rotating component 738 may include a first arm 744a and a second arm 744b. The first engagement head 740a may be coupled to the first arm 744a and the second engagement head 740b may be coupled to the second arm 742b.

[0234] Fig.12 The rotating member 738 is shown in the first receiving position and Fig.11The rotating component is shown in a second receiving position, between which the rotating component can be configured to swivel or rotate around a specific point. In the first receiving position, the first bonding head 740a is positioned close to the singulator 732. In turn, the first substrate 204a can be singulated from the serial alignment flow 720 and delivered to the first recess 742a in the first bonding head 740a. The substrate load sensor 745 (e.g., an optical sensor) can detect that the first substrate 204a has been delivered to the first bonding head 740a.

[0235] After the first substrate 204a is received in the first engagement head 740a, the rotating member 738 can be rotated (eg, by rotating counterclockwise when viewed from above) to a first delivery position that corresponds to the second receiving position and Fig.11 As the rotating member 738 rotates, negative pressure may be applied to the first recess 742a. ​​Furthermore, the negative pressure may help hold the first substrate 204a on the rotating member 738 during the rotational movement of the rotating member. Thus, the first substrate 204a may be moved to the first delivery position.

[0236] Fig.13 A first assembly unit 706a and a second assembly unit 706b are shown. As illustrated, the first assembly unit 706a may include a first robotic arm 746a and a first end effector 748a coupled thereto. Similarly, the second assembly unit 706b may include a second robotic arm 746b and a second end effector 748b coupled thereto.

[0237] The first end effector 748a can be configured to engage the first substrate 204a and deliver the first substrate to the bracket 604 engaged with the track 602 via movement of the first robotic arm 748a. Thus, the first assembly unit 706a can be positioned so that the first robotic arm 746a is configured to move the first end effector 748a between the feeder unit 704 and the track 602. In this regard, when the rotating member 738 is in the first delivery position (see Fig.11 ), the first robotic arm 746a can guide the first end effector 748a to engage the first substrate 204a in the first engagement head 740a. In this regard, in some embodiments, the first end effector 748a can be configured to apply negative pressure to the inner end 246 of the first substrate 204a (see Figure 1 ) so that the first substrate becomes engaged therewith. In addition, the first engagement head 740a can stop applying negative pressure to the first recess 742a to facilitate the transfer of the first substrate 204a to the first end effector 748a when the rotating component 738 is in the first delivery position. In turn, the first robotic arm 746a can lift the first substrate 204a via the first end effector 748a.

[0238] like Fig.12 , the first assembly unit 706a may include a first rotational alignment imaging device 750a and the second assembly unit 706b may include a second rotational alignment imaging device 750b. In this regard, after the first robotic arm 746a and the first end effector 748a lift the first substrate 204a, the first robotic arm may move the first end effector so that the first substrate is positioned above the first rotational alignment imaging device 750a. In turn, the first rotational alignment imaging device 750a may detect the rotational orientation of the first substrate 204a based on an image of the attachment end 244 of the substrate. In turn, the first robotic arm 746a may rotate the end effector 748a so that the first substrate 204a defines a desired rotational orientation.

[0239] For example, Fig.14 An enlarged view of the substrate 204 is shown in a proper orientation relative to a machine direction 752, which corresponds to the direction of movement of the carriage 604 and the substrate at any given point thereon along the track 602. As illustrated, the substrate 204 can define a negative heating terminal aperture 248a configured to receive the negative heating terminal 234, a positive heating terminal aperture 248b configured to receive the positive heating terminal 235, and a control component terminal aperture 250 configured to receive the control component terminal 206. The negative heating terminal aperture 248a can be positioned downstream of the positive heating terminal aperture 248b, with the control component terminal aperture 250 positioned between the negative heating terminal aperture and the positive heating terminal aperture when the substrate 204 is properly oriented relative to the carriage 604.

[0240] Thus, the bracket 604 can be positioned to receive the first substrate 204a after it is rotationally aligned. Fig.15 An enlarged view of the track 602 is shown proximate to the substrate loading substation 502. As illustrated, the first assembly unit 706a can include a first processing section 754a and the second assembly unit 706b can include a second processing section 754b positioned proximate to the track 602. Specifically, each carrier 604 can be guided first through the first processing section 754a and then through the second processing section 754b. Figure 7 ) are performed at the first processing portion 754a, while the operations with the second substrate 204b and the second bonding head 608b (see Figure 7 ) related operations are performed in the second processing part 754b.

[0241] Thus, the carriage 604 can be guided along the track 602 into the substrate loading substation 502. The carriage 604 can then enter the first processing section 754a. Fig.16As shown in FIG. 1 , the carriage 604 may be directed past a carriage sensor 756a, which may include a light emitter and a detector and detect the presence of the carriage 604. Further, for example, upon detection of the carriage 604, the carriage may be removed from the staging area 602a (see FIG. Figure 4 ) releases additional carriages so that a continued flow of carriages can be directed along track 602.

[0242] like Fig.15 As shown in FIG. 1 , after passing the carriage sensor 756a, the carriage 604 can be guided past the initial locator sensor 758a, which is configured to detect the locator module 626 and verify the presence and position of the carriage. The initial stop 760a can then be stopped by aligning the initial stop pin 762a with the stop bar 628 (see FIG. 1 ) on the carriage 604. Figure 7 ) engages to stop the bracket 604. Then, when the downstream bracket is cleared, the bracket 604 can be released from the initial stopper 760a by retracting the initial stopper pin 762a.

[0243] Thus, the track 602 can move the carriage 604 until the carriage engages the lift stop 764a. Specifically, the stop bar 628 on the carriage (see Figure 7 ) can engage the lifting stop pin 766a. When the carriage 604 is stopped, the stop locator sensor 768a can detect the locator module 626 and verify the presence and position of the carriage. The track 602 can include a lifter mechanism 770a, which is configured to lift the carriage 604 after the stop locator sensor 768a verifies the presence and position of the carriage. In this regard, the track 602 can include a conveyor including two parallel conveyor belts 628, which can extend on opposite sides of the lifter mechanism 770a and move the carriage 604 along the track. Therefore, the lifter mechanism 770a can lift the carriage 604 from the conveyor belt 628. Example embodiments of conveyors and conveyor belts are available from MONTECH of Derendingen, Switzerland.

[0244] The lifter mechanism 770a may include a first locking pin 772a and a second locking pin 774a configured to engage the bracket 604. Specifically, the first locking pin 772a may be configured to engage the first clamp 610a (see Figure 6 ) defined by the first alignment aperture 618a, and the second locking pin 774a can be configured to engage the first alignment aperture 618a defined by the second clamp 610b (see Figure 6) is defined by the second alignment aperture 618b to removably lock the carriage 604 to the substrate loading substation 502. Therefore, the first engagement head 608a can be aligned with the first locking pin 772a and the second engagement head 608b can be aligned with the second locking pin 774a. Furthermore, the position of the engagement heads 608a, 608b is precisely controlled regardless of the overall tolerance of the carriage 604 because the clamps 610a, 610b are configured to engage the locking pins 772a, 774a and the substrates 204a, 204b. In this regard, when the carriage 604 is lifted and engaged by the lifter mechanism 770a, the first robot arm 746a can guide the first substrate 204a to engage with the first engagement head 608a, wherein the first substrate is properly rotationally oriented as described above. At this point, the first end effector 748a can stop applying negative pressure so that the first substrate 204a can be released therefrom and remain engaged with the first engagement head 608a. The robotic arm 748a may then return to its initial position proximate to the rotating component 738 .

[0245] After the robotic arm 748a completes the substrate bonding operation, the storage transceiver 776a can write a code to the storage module 624 indicating whether the first substrate 204a is properly coupled to the first bonding head 608a. In this regard, the component presence sensor 778a (e.g., including an optical transmitter and a receiver; see Fig.15 ) can detect whether the first substrate 204a is engaged with the first engagement head 608a after the movement of the first robotic arm 746a as described above. For example, the component presence sensor 778a can detect whether the substrate 204a is present while the tray 604 is lifted by the lifter mechanism 770a. In an instance in which the first substrate 204a is improperly engaged with the engagement head 608a, the substations downstream of the substrate loading substation 502 may not perform additional operations that would otherwise be performed on the first substrate 204a. In other words, the substations downstream of the substrate loading substation 502 may not attempt to connect additional components to the substrate that should be on the tray in view of the improper attachment or loss of the first substrate 204a, so as to avoid damage to the remaining substations and waste of components.

[0246] Subsequently, the lift mechanism 770a can release the carriage 604 by lowering the carriage back onto the conveyor belt 628. At this point, the carriage 604 can be directed to the second processing section 754b. The second processing section 754b can include the same components included in the first processing section 754a. For example, Fig.16, the second processing portion 754b may include a carriage sensor 756b, an initial locator sensor 758b, an initial stopper 760b including an initial stop pin 762b, a lift stopper 764b including a lift stop pin 766b, a stopper locator sensor 768b, and a lifter mechanism 770b including a first locking pin 772b and a second locking pin 774b. Thus, the second processing portion 754b may operate in substantially the same manner as the first processing portion 754a, and thus a description thereof will not be repeated. However, as can be appreciated, the carriage 604 may be lifted by the lifter mechanism 770b so that the second substrate 204b may engage with the second engagement head 608b.

[0247] In this regard, Fig.11 , while the first engagement head 740a is in the first delivery position, the second engagement head 740b is in the second receiving position where the second engagement head is positioned close to the singulator 732. In turn, one of the substrates 204 can be singulated from the serial alignment stream 720 and delivered to the second recess 742b in the second engagement head 740b. The substrate load sensor 745 can detect that the substrate 204 (e.g., the second substrate 204b) has been delivered to the second engagement head 740b. While the second engagement head 740b receives the second substrate 204b, the first engagement head 740a can feed the first substrate 204a received therein to the first assembly unit 706a in the manner described above. The rotating member 738 can then be rotated (e.g., by rotating counterclockwise when viewed from above) back to the first receiving position so that the first engagement head 740a can receive another substrate 204.

[0248] While the first engagement head 740a receives one of the substrates 204, the second engagement head 740b may feed the second substrate 204b received therein to the second assembly unit 706b. Thus, the rotating member 738 may rotate back and forth so that the substrates are individually delivered to the first assembly unit 706a and the second assembly unit 706b by the feeder unit 704. Thus, the first receiving position may correspond to the second delivery position and the second receiving position may correspond to the first delivery position.

[0249] Furthermore, the second assembly unit 706b can engage the second substrate 204b with the second engagement head 608b in the manner described above with respect to the first assembly unit 706a. In this regard, in brief, the second robotic arm 746b can engage the second substrate 204b via the second end effector 748b, lift and rotate the second substrate to the proper orientation based on the image provided by the second rotational alignment imaging device 750b, and engage the second substrate with the second engagement head 608b in the proper orientation while the lifter mechanism 770b engages the bracket 604. At this point, the second end effector 746b can stop applying negative pressure so that the second substrate 204b can be released therefrom and remain engaged with the second engagement head 608b. The second robotic arm 746b can return to an initial position close to the rotating component 738.

[0250] After the second robotic arm 746b completes the substrate engagement operation, the second storage transceiver 776b can write a code to the storage module 624 indicating whether the second substrate 204b is properly coupled to the second engagement head 608b. In this regard, the component presence sensor 778b (e.g., including an optical transmitter and a receiver; see Fig.15 ) can detect whether the second substrate 204b is engaged with the second engagement head 608b after the movement of the second robotic arm 746b as described above. For example, the component presence sensor 778b can detect whether the substrate 204b is present while the carrier 604 is lifted by the lifter mechanism 770b. In an example where the second substrate 204b is not properly engaged with the engagement head 608b, the substations downstream of the substrate loading substation 502 may not perform additional operations that would otherwise be performed on the second substrate in order to avoid damage to the remaining substations and waste of components.

[0251] The lift mechanism 770b can be lowered so that the track 602 can transport the carriage 604, including the first substrate 204a and the second substrate 204b coupled thereto downstream. The carriage 604 can be guided out of the substrate loading substation 502 by the track 602. Figure 4 As described in , in some embodiments, the carriage 604 can be guided to the control assembly terminal connection substation 504 after the substrate loading substation 502. It should be noted that some of the above operations can be performed simultaneously. In this regard, the substrates can be singulated while the carriage is guided and lifted along the track, etc. In addition, while the first substrate is being engaged with the carriage, the second substrate can be engaged with the bracket positioned downstream. Therefore, fast and efficient loading of substrates onto the carriage can be achieved.

[0252] Fig.17A perspective view of a control component terminal connection substation 504 is shown. As illustrated, the control component terminal connection substation 504 may include a supply unit 802, a first assembly unit 806a, and a second assembly unit 806b. In simple terms, the supply unit 802 may be configured to provide a plurality of components (e.g., control component terminals 206). The first assembly unit 806a and the second assembly unit 806b may each be configured to assemble the control component terminals 206 into a cartridge 200 for an aerosol delivery device 100 by engaging the control component terminals with the substrate 204.

[0253] In this regard, Fig.18 An enlarged view of a supply unit 802 is shown. As illustrated, the supply unit 802 can be configured to supply a plurality of control component terminals 206. In some embodiments, the supply unit 802 can include a vibration arrangement. For example, the vibration arrangement can include a vibration hopper 808, a vibration bowl 810, and a supply track 812. In some embodiments, the vibration hopper 808, the vibration bowl 810, and / or the supply track 812 can be manufactured by Performance Feeders, Inc. of Oldsmar, FL.

[0254] The control assembly terminals 206 may be loaded into the vibrating hopper 808. As the vibrating hopper 808 vibrates, the control assembly terminals 206 gradually travel under the gate 814 and drop into the vibrating bowl 810 to provide the vibrating bowl with a substantially constant supply of control assembly terminals. In this regard, the assembly level sensor 816 may detect the level of the control assembly terminals 206 within the vibrating bowl 810. In turn, the vibrating hopper 808 may be started and stopped based on the level of the control assembly terminals 206 within the vibrating bowl 810 detected by the assembly level sensor 816. Thus, the vibrating hopper 808 may maintain a substantially constant level of the control assembly terminals 206 within the vibrating bowl 810 while conveying the control assembly terminals therefrom.

[0255] The vibration bowl 810 may define a path 818 configured to arrange the control assembly terminals 206 in a series alignment flow 820 (see Fig. 20 In this regard, the vibratory motion of the vibratory bowl 810 can direct the control assembly terminals 206 upwardly along the path 818, which can narrow so that some of the control assembly terminals fall therefrom and the control assembly terminals that remain on the path become aligned in series.

[0256] like Fig.19, the vibration bowl 810 can be configured to horizontally arrange the control component terminals 206, wherein the upper ends 252 of the control component terminals extend outwardly away from the vibration bowl, the lower ends 254 of the control component terminals extend inwardly toward the vibration bowl, and the flanges 256 extend downwardly into the gap 818a defined by the path 818. However, some of the control component terminals 206 in the series alignment flow 820 may be oriented inverted or otherwise oriented in a manner different from the desired orientation. In this regard, as shown in FIG. Fig.18 , the supply unit 802 may further include an actuator 824 configured to individually remove or realign the control component terminals 206 in the serial alignment flow 820 when the control component terminals are misaligned in one direction. In one embodiment, the actuator 824 may include a nozzle 826 configured to direct the air flow at each control component terminal 206 that is misaligned to remove the control component terminal from the path 820 or to push the control component terminal to be properly aligned. In some embodiments, the nozzle 826 may be oriented so as to impact only those control component terminals 206 that are misaligned. In another embodiment, the supply unit 802 may further include an orientation sensor 822 (e.g., a camera) configured to determine the alignment of the control component terminals 206 on the path 818, and the actuator 824 may be actuated in response to the determination when the misaligned control component terminals are detected.

[0257] Thus, each of the control component terminals 206 in the serial alignment stream 820 can be properly oriented downstream of the actuator 824. The control component terminals 206 removed by the actuator 824 can be directed back into the vibration bowl 810 so that the control component terminals can return to the path 818. In some embodiments, the path can define a gap or other feature that is configured to remove the component from the serial alignment stream when the component is misaligned in the second direction. For example, the longitudinally oriented control component terminals 206 can fall through the gap 818a in the path 818 (see Fig.19 ).

[0258] Thus, the serially aligned flow 820 of the control assembly terminals 206 can be directed to the supply track 812, which can maintain the control assembly terminals in a horizontal orientation and a single-row arrangement. In some embodiments, the supply track 812 can include a vibrating supply track 812 to facilitate movement of the control assembly terminals 206 along it. Fig.18, the supply track 812 can include a full sensor 826 configured to detect whether the supply track is full of the control component terminals 206. In this regard, when the full sensor 826 senses that the supply track 812 is full, the vibratory bowl 810 can be turned off. In addition, the supply track 812 can include a low level sensor 828 configured to detect when the supply track runs low on the control component terminals 206. In this regard, when the low level sensor 828 detects a low level of the control component terminals 206 in the supply track 812, an indicator 830 (see Fig.17 ) to inform the operator that the control assembly connection substation 504 is running low on the control assembly terminals so that the operator can be informed that it is time to refill the vibratory hopper 808. In some embodiments, the full sensor 826 and the low level sensor 828 may include optical sensors that include a transmitter and a receiver configured to detect each control assembly terminal 206 passing by.

[0259] In addition, if Fig. 20 As shown in FIG. 8 , the supply unit 802 may include a single splitter 832 configured to single the control component terminal 206 from the series alignment flow 820. In this regard, the single splitter 832 may include a stopper 834 that prevents the series alignment flow 820 of the control component terminal 806 from advancing further. In addition, the single splitter 832 may include a horizontal actuator 836. Fig.21 , the horizontal actuator 836 can be configured to horizontally displace the terminal plunger 838 to separate one of the control assembly terminals 206 from the series alignment stream 820. In one embodiment, the terminal plunger 838 can extend between the flanges 256 below the control assembly terminal 206 to expose the upper end 252 of the control assembly terminal. In addition, the terminal presence sensor 845 (which can include a light emitter and a detector; see Fig. 20 ) can detect the presence of the singulated control assembly terminal 206. Therefore, the first assembly unit 806a can be prompted to grasp the upper end 252 of the control assembly terminal 206.

[0260] In this regard, Fig. 22 A perspective view of a first assembly unit 806a and a second assembly unit 806b is shown. As illustrated, the first assembly unit 806a may include a first robotic arm 846a and a first end effector 848a coupled thereto. Similarly, the second assembly unit 806b may include a second robotic arm 846b and a second end effector 848b coupled thereto.

[0261] The first end effector 848a can be configured to engage the control component terminal 206. Fig.23, in some embodiments, the first end effector 848a can include a first opposing portion 850 and a second opposing portion 852 configured to clamp the upper end 252 of the control assembly terminal 206 therebetween. Thus, the first end effector 848a can be configured to securely grasp each control assembly terminal 206.

[0262] In addition, the first end effector 848a can be configured to be in a horizontal configuration for grasping and removing the control component terminal 206 from the singulator 832 and a vertical configuration configured to insert the control component terminal into the first substrate 204a (see Fig.23 ) between the two. Fig. 22 The first end effector 848a is shown at an angle between the horizontal configuration and the vertical orientation during a transition between the horizontal configuration and the vertical orientation. Thus, the first robotic arm 846a and the first end effector 848a can prepare the control component terminal 206 for insertion into the substrate 204.

[0263] In this regard, the bracket 604 with the first substrate 204a and the second substrate 204b joined thereto may be guided through the control assembly terminal connection substation 504. Fig.24 As shown in FIG. 5 , the track 602 can guide each carrier 604 at the substrate loading substation 502 through the first processing section 854a of the first assembly unit 806a and the second processing section 854b of the second assembly unit 806b. Specifically, each carrier 604 can be first guided through the first processing section 854a and then through the second processing section 854b. Operations related to the first substrate 204a and the first control component terminal 206a are performed at the first processing section 854a, while operations related to the second substrate 204b and the second control component terminal 206b (see FIG. 5 ) are performed at the first processing section 854a. Fig.25 ) related operations are performed in the second processing part 854b.

[0264] Thus, the carriage 604 can be transported along the track 602 to the first processing section 854a. The carriage 604 can be directed past a carriage sensor 856a, which can include a light emitter and a detector and detect the presence of the carriage 604. After passing the carriage sensor 856a, the carriage 604 can be directed past an initial locator sensor 858a, which is configured to detect the locator module 626 and verify the presence and position of the carriage. The initial stop 860a can then be described above with respect to the initial stop 760a of the substrate loading substation 502 (see Fig.15 ) to stop the carriage 604 in the manner described above. Subsequently, when any downstream carriages are cleared, the carriage 604 can be released from the initial stop 860a. Thus, the track 602 can be raised to the stop 764a (see above) with respect to the base load substation 502. Fig.15 ) until the carriage engages the lift stop 864a. While the carriage 604 is stopped, a stop locator sensor (not shown; see, e.g., stop locator sensor 868b) can detect the locator module 626 and verify the presence and position of the carriage.

[0265] The track 602 may include a lift mechanism 870a (see Fig. 22 ), which is configured as the lift mechanism 770a described above with respect to the base load substation 502 (see Fig.15 ) in the manner described above, after the stop locator sensor 864a verifies the presence and position of the bracket, the bracket 604 is lifted. While the bracket 604 is lifted and engaged by the lifter mechanism 870a, the first robotic arm 846a can guide the first control component terminal 206a to engage with the first base 204a. Specifically, the lower end 254 of the first control component terminal 206a can engage with the control component terminal aperture 250 (see Fig.14 ) engagement. At this point, the first end effector 848a can release the first control assembly terminal 206a so that the first control assembly terminal can remain engaged with the first substrate 204a. The first robotic arm 846a can then return to the singulator 832 to engage the additional control assembly terminal for attachment with the first substrate on the subsequent bracket.

[0266] After the robotic arm 846a completes the substrate engagement operation, the storage transceiver 876a can write a code to the storage module 624 indicating whether the first control component terminal 206a is properly coupled to the first substrate 204a. In this regard, the component presence sensor 878a (e.g., including a light emitter and a receiver) can detect whether the first control component terminal 206a is engaged with the first substrate 204a after the movement of the first robotic arm 846a as described above. For example, the component presence sensor 878a can detect whether the first control component terminal 206a is present while the bracket 604 is lifted by the lifter mechanism 870a. In an instance in which the first control component terminal 206a is improperly engaged with the first substrate 204a, the substation downstream of the substrate loading substation 502 may not perform additional operations that would otherwise be performed on the first substrate 204a. In other words, given that the first control component terminal 206a is improperly attached to the substrate 204a or is missing, the substation downstream of the control component terminal connection substation 504 cannot attempt to connect additional components to it, so as to avoid damage to the remaining substations and waste of components. In this same aspect, the storage transceiver 876a can read the code on the storage module 624 to determine that the partially assembled cigarette cartridge is matched for further assembly before the control component terminal 206a is connected to the substrate 204a. Therefore, various storage transceivers disclosed herein can read the storage module before a specific operation is performed to determine whether the operation is performed, and write to the storage module after the operation to reflect whether the operation is properly completed.

[0267] Subsequently, the lifter mechanism 870a may release the carriage 604 by lowering the carriage back onto the conveyor belt 628 of the track 602. At this point, the carriage 604 may be directed by the track 602 to the second processing section 854b. The second processing section 854b may include the same components included in the first processing section 854a.

[0268] For example, if Fig.24 As shown in FIG. 8 , the second processing portion 854b may include a carriage sensor 856b, an initial locator sensor 858b, an initial stop 860b, a lift stop 864b, a stop locator sensor 868b, and a lift mechanism 870b (see FIG. 8 ). Fig. 22 ). Thus, the second processing portion 854b can operate in substantially the same manner as the first processing portion 854a, and thus a description thereof will not be repeated. However, as can be appreciated, the bracket 604 can be lifted by the lifter mechanism 870b so that the second control assembly terminal 206b can engage with the second substrate 204b, as shown. Fig.25 As shown in the figure.

[0269] After the second robotic arm 846b completes the control component terminal engagement operation, the second storage transceiver 876b can write a code to the storage module 624 indicating whether the second control component terminal 206b is properly engaged with the second substrate 204b. In this regard, the component presence sensor 878b (e.g., including an optical transmitter and a receiver) can detect whether the second control component terminal 206b is properly engaged with the second substrate 204b after the movement of the second robotic arm 846b as described above. For example, the component presence sensor 878b can detect whether the second control component terminal is present while the bracket 604 is lifted by the lifter mechanism 870b. In an instance where the second control component terminal 206b is not properly engaged with the second substrate 204b, additional operations that would otherwise be performed on the second substrate downstream of the second robotic arm 846b cannot be performed to avoid damage to the remaining substations and waste of components. In this same aspect, the memory transceiver 876b can read the code on the memory module 624 to determine that the partially assembled cartridge is mated for further assembly prior to coupling the control assembly terminals 206b to the base 204b.

[0270] The lift mechanism 870b can then be lowered so that the track 602 conveys the carriage 604, including the control assembly terminals 206a, 206b coupled to the downstream substrates 204a, 204b, respectively. Fig.25 As shown in FIG. 1 , the control component terminals 206a, 206b cannot be fully engaged with the substrates 204a, 204b by the robot arms 846a, 846b. Fig.26 As shown in FIG. 5 , the control component terminal connection substation 504 may further include a third processing portion 854c. The third processing portion 854c may include a lifting stopper 864c, a stopper locator sensor 868c (see FIG. 5 ). Fig. 22 ) and a lift mechanism 870c. The lift stop 864c can be configured to stop the bracket 604, the stop locator sensor 868c can be configured to detect the presence of the bracket, and the lift mechanism 870c can be configured to lift the bracket when detected.

[0271] The control component terminal connection substation 504 may further include a press 880. The press 880 may be configured to press the control component terminals 206a, 206b into full engagement with the substrate 204a, 204b while the bracket 604 is lifted by the lifter mechanism 870c. In this regard, since the control component terminals 206a, 206b are relatively short, the first assembly unit 806a and the second assembly unit 806b may not be able to use the robot arm 846a, 846b and the end effector 848a, 848b to fully insert the control component terminals, and therefore the press 880 can be used to fully engage the control component terminals. However, in other embodiments, the press cannot be used. After the operation of the press 880, the storage transceiver 876c can write a code to the storage module 624, and the code indicates whether the control component terminals 206a, 206b are properly pressed into the substrate 204a, 204a (e.g., based on the completion of the full downward stroke of the press 880).

[0272] It should be noted that the above operations can be performed simultaneously. In this regard, while the first robot arm 846a is coupling the first control component terminal 206a to the first substrate 204a, the second robot arm 846b can receive the second control component terminal 206b from the single splitter 832. Conversely, while the second robot arm 846b is coupling the second control component terminal 206b to the second substrate 204b, the first robot arm 846a can receive the first control component terminal 206a from the single splitter 832. In addition, the press 880 can press the control component terminals 206a, 206b into full engagement with the substrates 204a, 204b while other operations are in progress, for example, while the first robot arm 846a is coupling the first control component terminal 206a to the first substrate 204a and the second robot arm 846b is receiving the second control component terminal 206b from the single splitter 832. Therefore, a fast and efficient engagement of the control component terminals 206a, 206b with the substrates 204a, 204b can be achieved.

[0273] The negative heating terminal connection substation 506 and the positive heating terminal connection substation 508 can be positioned downstream of the control component terminal connection substation 504. For example, in one embodiment, the negative heating terminal connection substation 506 can be positioned downstream of the control component connection substation 506, and the positive heating terminal connection substation 508 can be positioned downstream of the negative heating terminal connection substation. The negative heating terminal connection substation 506 and the positive heating terminal connection substation 508 can be substantially similar. In this regard, although the description provided below is for the negative heating terminal connection substation 506, this description applies to both the negative heating terminal connection substation and the positive heating terminal connection substation 508, unless otherwise stated.

[0274] Fig. 27A perspective view of a negative heating terminal connection substation 506 is shown. As illustrated, the negative heating terminal connection substation 506 may include a supply unit 902, a feeder unit 904, a first assembly unit 906a, and a second assembly unit 906b. In simple terms, the supply unit 902 may be configured to provide a plurality of components (e.g., negative heating terminal 234). The feeder unit 904 may be configured to receive the negative heating terminal 234 from the supply unit and feed the negative heating terminal alternately to the first assembly unit 906a and the second assembly unit 906b. The first assembly unit 906a and the second assembly unit 906b may each be configured to assemble the negative heating terminal 234 into a cigarette cartridge 200 for an aerosol delivery device 100, for example, by engaging the negative heating terminal with the substrate 204.

[0275] In this regard, Fig.28 An enlarged view of the supply unit 902 is shown. As illustrated, the supply unit 902 can be configured to supply a plurality of negative heating terminals 234. In some embodiments, the supply unit 902 can include a vibration arrangement. For example, the vibration arrangement can include a vibration hopper 908, a vibration bowl 910, and a supply track 912. In some embodiments, the vibration hopper 908, the vibration bowl 910, and / or the supply track 912 can be manufactured by Performance Feeders, Inc. of Oldsmar, FL.

[0276] The negative heating terminal 234 can be loaded into the vibrating hopper 908. As the vibrating hopper 908 vibrates, the negative heating terminal 234 gradually travels under the gate 914 and drops into the vibrating bowl 910 to provide the vibrating bowl with a substantially constant supply of the negative heating terminal. In this regard, the assembly level sensor 916 can detect the level of the negative heating terminal 234 within the vibrating bowl 910. In turn, the vibrating hopper 908 can be started and stopped based on the level of the negative heating terminal 234 within the vibrating bowl 910 detected by the assembly level sensor 916. Therefore, the vibrating hopper 908 can maintain a substantially constant level of the negative heating terminal 234 within the vibrating bowl 910 from which the negative heating terminal is delivered.

[0277] The vibratory bowl 910 may define a path 918 configured to arrange the negative heating terminal 234 in a series alignment flow 920 (see Fig.29 ). In this regard, the vibratory motion of the vibratory bowl 910 can direct the negative heating terminals 234 upward along the path 918, which can narrow so that some of the negative heating terminals fall therefrom and remain on the path become aligned in series.

[0278] like Fig.29As shown in FIG. 1 , the vibratory bowl 910 can be configured to vertically arrange the negative heating terminals 234, wherein the upper end 258 of the negative heating terminal extends downward and the lower end 260 of the negative heating terminal extends upward. However, some of the negative heating terminals 234 in the series alignment flow 920 may be oriented in a manner different from the desired orientation. In this regard, as Fig.28 , the supply unit 902 may further include an actuator 924 configured to remove or realign the negative heating terminals 234 in the series alignment flow 920 when the negative heating terminals are misaligned in one direction. In one embodiment, the actuator 924 may include a nozzle 926 configured to direct the air flow at each negative heating terminal 234 that is misaligned to remove the misaligned negative heating terminals from the path 918 or to push the misaligned negative heating terminals to be properly aligned. In some embodiments, the nozzle 926 may be oriented so as to impact only those negative heating terminals 234 that are misaligned. In another embodiment, the supply unit 902 may further include an orientation sensor 922 (e.g., a camera) configured to determine the alignment of the negative heating terminals 234 on the path 918, and the actuator 924 may be actuated in response to the determination when a misaligned negative heating terminal is detected.

[0279] Thus, each of the negative heating terminals 234 in the serial alignment flow 920 may be properly oriented downstream of the actuator 924. The negative heating terminals 234 removed by the actuator 924 may be directed back into the vibratory bowl 910 so that the negative heating terminals may return to the path 918. In some embodiments, the path may define a gap or other feature configured to remove the component from the serial alignment flow when the component is misaligned in the second direction.

[0280] Thus, the series alignment flow 920 of the negative heating terminals 234 can be directed to the supply track 912, which can maintain the negative heating terminals in a vertical orientation and a single-row arrangement. In some embodiments, the supply track 912 can include a vibrating supply track to facilitate movement of the negative heating terminals 234 along it. Fig.28 , the supply track 912 can include a full sensor 926 configured to detect whether the supply track is full of the negative heating terminal 234. In this regard, when the full sensor 926 senses that the supply track 912 is full, the vibrating bowl 910 can be turned off. In addition, the supply track 912 can include a low level sensor 928, which is configured to detect when the supply track runs low on the negative heating terminal 234. In this regard, when the low level sensor 928 detects a low level of the negative heating terminal 234 in the supply track 912, an indicator 930 (see Fig. 27) to inform the operator that the negative heating terminal connection substation 506 is running low on the negative heating terminal so that the operator can be informed that it is time to refill the vibrating hopper 908. In some embodiments, the full sensor 926 and the low level sensor 928 may include optical sensors that include a transmitter and a receiver configured to detect each negative heating terminal 234 passing by.

[0281] In addition, if Fig.29 , the supply unit 902 may include a single splitter 932 configured to single the negative heating terminal 234 from the series alignment flow 920. In this regard, the single splitter 932 may include a stopper 934 (e.g., including a pin) that prevents the series alignment flow 920 of the negative heating terminal 234 from advancing further. As illustrated, in one embodiment, the horizontal actuator 936 (see Fig.30 ) can be configured to horizontally move the stopper 934 between a retracted position and an extended position. The horizontal actuator 936 can default to an extended position so that the stopper 934 blocks the serial alignment flow 920 of the negative heater terminals 234 from moving. However, the horizontal actuator 936 can temporarily retract the stopper 934 to the retracted position to allow one of the negative heating terminals 234 to pass through the stopper. In turn, the second stopper 938 (e.g., comprising a plate) can block the outermost negative heating terminal 234 from further advancement so that the outermost negative heating terminal is positioned between the stopper 934 (i.e., the first stopper) and the second stopper 938 and is singulated from the serial alignment flow 920.

[0282] As illustrated, when the outermost negative heating terminal 234 is separated between the first stop 934 and the second stop 938, the biasing member 940 can engage the outermost negative heating terminal 234 to further separate the outermost negative heating terminal 234 from the remaining negative heating terminals. Specifically, the biasing member 940 can be configured to extend upward to engage the downwardly extending upper end 258 of the outermost negative heating terminal 234. In this regard, the biasing member 940 can define an angled surface 942 that engages the upper end 258 of the outermost negative heating terminal 234 and presses outward on the upper end when the biasing member 940 extends upward.

[0283] After the outermost negative heating terminal 234 is singulated, this negative heating terminal can be transferred to the feeder unit 904. Fig.30A perspective view of the feeder unit 904 is shown. In some embodiments, the feeder unit 904 may include a rotating component 944. The rotating component 944 may include a first engagement head 946a and a second engagement head 946b, respectively configured to receive one of the negative heating terminals 234 from the supply unit 902. In this regard, the first engagement head 946a may define a first clamp 948a and the second engagement head 946b may define a second clamp 948b. As illustrated, in some embodiments, the rotating component 944 may include a first arm 950a and a second arm 950b. The first engagement head 946a may be coupled to the first arm 950a and the second engagement head 946b may be coupled to the second arm 950b.

[0284] The rotating member 944 may be configured to be positioned in a first receiving position where the first engagement head 946a is positioned close to the feeder 902 and in a second receiving position where the second engagement head 946b is positioned close to the feeder (see Fig.29 and 30 ). Then, the first negative heating terminal 234a singulated from the serial alignment flow 920 can be grasped by the first gripper 948a of the first engagement head 946a in the first receiving position. In this regard, the terminal singulation sensor 952 (e.g., an optical sensor; see Fig.29 ) can detect that the negative heating terminal 234 has been separated.

[0285] The first clamp extender 954a can then extend the open first clamp 948a around the first negative heating terminal 234a. The first clamp 948a can then be closed to clamp onto the first heating terminal 234a. The second horizontal actuator 956 (see Fig.29 ) The second stop 938 can then be retracted so that the first clamp extender 954a can retract the first clamp 948a and the first negative heating terminal 234a engaged therewith.

[0286] The terminal load sensor 958 (e.g., an optical sensor) can detect whether the first clamp 948a properly clamps the first heating terminal 234a. The rotating member 944 can then rotate back to the first delivery position (e.g., by rotating clockwise when viewed from above) to the first delivery position, which corresponds to the second receiving position and Fig.30 In the description.

[0287] Fig.31 A first assembly unit 906a and a second assembly unit 906b are shown. As illustrated, the first assembly unit 906a may include a first robotic arm 960a and a first end effector 962a coupled thereto. Similarly, the second assembly unit 906b may include a second robotic arm 960b and a second end effector 962b coupled thereto.

[0288] The first end effector 962a can be configured to engage the first negative heating terminal 234a and deliver the first negative heating terminal to the first substrate 204a on the bracket 604 on the track 602 via movement of the first robotic arm 960a. Thus, the first assembly unit 906a can be positioned so that the first robotic arm 960a is configured to move the first end effector 962a between the feeder unit 904 and the track 602. In this regard, when the rotating component 944 is in the first delivery position (see Figure 29-31 ), the first robot arm 960a can guide the first end effector 962a to approach the first negative heating terminal 234a held by the first clamper 948a of the feeder unit 904.

[0289] Thus, the first end effector 962 can be configured to engage the first negative heating terminal 234a. Fig.32 As shown in , in some embodiments, the first end effector 962a may include a first opposing portion 964 and a second opposing portion 966, the first and second opposing portions being configured to clamp the first negative heating terminal 234a therebetween. Thus, the first end effector 962a may be configured to firmly grasp each first negative heating terminal 234a.

[0290] As described above, the single divider 932 can supply the first negative heating terminals 234a in an inverted manner, wherein its upper end 258 points downward, and this orientation can be maintained by the supply unit 904 so that the first end effector 962a receives the first negative heating terminals in this inverted orientation. Specifically, the first end effector 962a can grasp each first negative heating terminal 234a substantially at its middle between the upper end 258 and the lower end 260. The first end effector 962a can further be rotated one hundred and eighty degrees so that the lower end 260 of the first negative heating terminal 234a points downward, as shown in FIG. Fig.33 As shown in the figure.

[0291] Thus, the track 602 can move the bracket 604 so that the first substrate 204a is positioned for receiving the first negative heating terminal 234a. In this regard, the bracket 604 having the first substrate 204a and the second substrate 204b engaged therewith and the control component terminals 206a, 206b engaged with the substrates can be guided through the negative heating terminal connection substation 506. Fig.34As shown in FIG. 5 , the track 602 can guide each bracket 604 through the first processing section 968a of the first assembly unit 906a and the second processing section 968b of the second assembly unit 906b at the negative heating terminal connection substation 506. Specifically, each bracket 604 can be first guided through the first processing section 968a and then through the second processing section 968b. Operations related to the first substrate 204a and the first negative heating terminal 234a are performed at the first processing section 968a, while operations related to the second substrate 204b and the second negative heating terminal 234b (see, e.g., Fig.30 ) is performed at the second processing portion 968b.

[0292] Thus, the carriage 604 can be transported along the track 602 to the first processing section 968a. The carriage 604 can be directed past a carriage sensor 970a, which can include a light emitter and a detector and detect the presence of the carriage 604. After passing the carriage sensor 970a, the carriage 604 can be directed past an initial locator sensor 972a, which is configured to detect the locator module 626 and verify the presence and position of the carriage. The initial stop 974a can then be described above with respect to the initial stop 760a of the substrate loading substation 502 (see Fig.15 ) to stop the carriage 604 in the manner described above. Subsequently, when any downstream carriages are cleared, the carriage 604 can be released from the initial stop 974a. Thus, the track 602 can be raised to the stop 764a (see above) with respect to the substrate loading substation 502. Fig.15 ) The carriage 604 is moved in the manner described until the carriage engages the lift stop 976a. When the carriage 604 is stopped, the stop locator sensor 978a can detect the locator module 626 and verify the presence and position of the carriage.

[0293] Track 602 may include a lift mechanism 980a configured as lift mechanism 770a described above with respect to substrate loading substation 502 (see Fig.15 ) in the manner described above after the stop locator sensor 978a verifies the presence and position of the bracket. While the bracket 604 is being lifted and engaged by the lifter mechanism 980a, the first robotic arm 960a can lower the first end effector 962a so that the lower end 260 of the first negative heating terminal 234a extends into the negative heating terminal aperture 248a (see Fig.14 ).

[0294] In some embodiments, the first assembly unit 906a may include a first pusher 982a positioned proximate to the first end effector 962a. Fig.32, the first pusher 982a can be configured to extend downward to press against the first negative heating terminal 234a to fully insert the first negative heating terminal into the first substrate 204a. Before the first pusher 982a is extended, the first end effector 962a can release the first negative heating terminal 234a so that the first negative heating terminal can remain engaged with the first substrate 204. The first robotic arm 960a can then return to the singulator 932 to engage additional negative heating terminals for attachment with the first substrate on a subsequent bracket.

[0295] After the robotic arm 960a engages the first negative heating terminal 234a with the first substrate 204a, a storage transceiver (not shown; see, e.g., storage transceiver 984b) can write a code to the storage module 624 indicating whether the first negative heating terminal 234a is properly coupled to the first substrate 204a. In this regard, a component presence sensor 986a (e.g., including a light emitter and a receiver) can detect whether the first negative heating terminal 234a is engaged with the first substrate 204a after movement of the first robotic arm 960a as described above. For example, the component presence sensor 986a can detect whether the first negative heating terminal 234a is present while the bracket 604 is lifted by the lifter mechanism 980a. In an instance where the first negative heating terminal 234a is improperly engaged with the first substrate 204a, a substation downstream of the substrate load substation 502 may not perform additional operations that would otherwise be performed on the first substrate 204a. In other words, given that the first negative heating terminal 234a is improperly attached to the substrate 204a or is missing, the substations downstream of the negative heating terminal connection substation 506 may not attempt to connect additional components to it in order to avoid damage to the remaining substations and waste of components. In this same aspect, the storage transceiver can read the code on the storage module 624 to determine that the partially assembled cartridge is mated for further assembly before the negative heating terminal 234a is connected to the substrate 204a.

[0296] Subsequently, the lift mechanism 980a can release the carriage 604 by lowering the carriage back onto the conveyor belt 628. At this time, the carriage 604 can be guided along the track 602 to the second processing section 968b. The second processing section 968b can include the same components included in the first processing section 968a. For example, Fig.34As shown in , the second processing section 968b may include a carriage sensor 970b, an initial locator sensor 972b, an initial stop 974b, a lift stop 976b, a stop locator sensor 978b, and a lift mechanism 980b. Therefore, the second processing section 968b can operate in substantially the same manner as the first processing section 968a, and therefore its description will not be repeated. However, as can be appreciated, the carriage 604 can be lifted by the lift mechanism 980b so that the second negative heating terminal 234b can engage with the second substrate 204b.

[0297] In this regard, while the first negative heating terminal 234a is being delivered to the first assembly unit 906a for insertion into the first substrate 204a, the second negative heating terminal 234b can be singulated from the series alignment flow 920 of negative heating terminals. Specifically, referring to Fig.29 and 30 , the second horizontal actuator 956 may extend the second stop 938 to the default extended configuration, the biasing member 940 may be retracted, and the horizontal actuator 936 (i.e., the first horizontal actuator) may retract the first stop 934 to allow the negative heating terminal 234 (i.e., the second negative heating terminal 234b) to advance to the second stop 938. The first horizontal actuator 936 may then extend the first stop 934 to allow the second negative heating terminal 234b to be received between the first stop 934 and the second stop 938. The biasing member 940 may then extend to separate the second heating terminal 234b from the series alignment flow 920 of negative heating terminals.

[0298] Thus, the second gripper 948b of the feeder unit 904 can engage the second negative heating terminal 234b. In turn, the feeder unit 904 can be rotated (e.g., by rotating counterclockwise when viewed from above) and position the second negative heating terminal 234b proximate to the track 602. The second robotic arm 960b, the second end effector 962b, and the second pusher (not shown; see, for example, pusher 982a) can then engage the second negative heating terminal 234b in the negative heating terminal aperture 248b of the second substrate 204b in the manner described above.

[0299] After the second robot arm 960b completes the second negative heating terminal engagement operation, the second storage transceiver 984b can write a code to the storage module 624, the code indicating whether the second negative heating terminal 234b is properly engaged with the second substrate 204b. In this regard, the component presence sensor 986b (e.g., including a light emitter and a receiver) can detect whether the second negative heating terminal 234b is properly engaged with the second substrate 204b after the movement of the second robot arm 960b as described above. For example, the component presence sensor 986b can detect whether the second negative heating terminal 234b exists while the bracket 604 is lifted by the lifter mechanism 980b. In an instance where the second negative heating terminal 234b is not properly engaged with the second substrate 204b, additional operations that would otherwise be performed on the second substrate downstream of the second robot arm 960b cannot be performed to avoid damage to the remaining substations and waste of components. After the attachment of the second negative heating terminal 234b and the detection of its presence or absence, the lifter mechanism 980b can lower the carriage 604 so that the track 602 conveys the carriage, including the negative heating terminals 234a, 234b respectively coupled to the downstream substrates 204a, 204b. In this same aspect, the storage transceiver 984b can read the code on the storage module 624 to determine that the partially assembled cartridge is matched for further assembly before the negative heating terminal 234b is coupled to the substrate 204b.

[0300] It should be noted that the above operations can be performed simultaneously. In this regard, while the first bonding head 946a delivers the first negative heating terminal 234a to the first robot arm 960a, the second bonding head 946b can receive the second negative heating terminal 234b from the single divider 932. Conversely, while the second bonding head 946b delivers the second negative heating terminal 234b to the second robot arm 960b, the first bonding head 946a can receive the first negative heating terminal 234a from the single divider 932. In addition, while the first robot arm 960a connects the first negative heating terminal 234a to the first substrate 204a, the second robot arm 960b can receive the second negative heating terminal 234b from the rotating component 944. Conversely, while the second robot arm 960b connects the second negative heating terminal 235 to the second substrate 204b, the first robot arm 960a can receive the first negative heating terminal 234a from the rotating component 944. Therefore, quick and efficient bonding of the negative heating terminals 234a, 234b to the substrates 204a, 204b may be achieved.

[0301] As described above, the positive heating terminal coupling substation 508 may be substantially similar to the negative heating terminal coupling substation 506. Therefore, the description of the various components of the positive heating terminal coupling substation 508 will not be repeated. However, in some embodiments, the positive heating terminal coupling substation 508 may additionally include an inspection unit 988, which may be positioned downstream of its first and second assembly units, which may be substantially similar to the first assembly unit 906a and the second assembly unit 906b of the negative heating terminal coupling substation 506 described above.

[0302] like Fig.35 As shown in FIG. 1 , the inspection unit 988 may include an inspection locator sensor 990 that can detect the presence of the bracket 604. A first inspection stop 992 can temporarily stop the bracket at a position where the first substrate 204a is located close to an imaging device 994 (e.g., a digital camera). Thus, the imaging device 994 can capture the first control component terminal 206a, the first negative heating terminal 234a, and the first positive heating terminal (see, e.g., FIG. 1 ). Figure 1 After being released from the first inspection stop 992, the carriage 604 can travel downstream on the track 602 and engage the second inspection stop 996 where the second substrate 204b is positioned proximate to the imaging device 994. Thus, the imaging device 994 can capture the second control assembly terminal 206b, the second negative heating terminal 234b, and the second positive heating terminal (see, e.g. Figure 1 An image of the positive heating terminal 235).

[0303] In some embodiments, backlight 998 can be positioned across imaging device 994 so that terminal 206,234,235 is positioned between imaging device and backlight to improve the imaging of terminal. Therefore, the image captured by imaging device 994 can be analyzed to determine whether terminal 206,234,235 is lost or improperly engaged with substrate 204. For example, the height to which terminal 206,234,235 extends from substrate 204 can be determined and compared with the required height of terminal. The third storage transceiver 984c can write code to storage module 624, and the code indicates whether terminal 206,234,235 is properly engaged with substrate 204. In the example where terminal 206,234,235 is not properly engaged with substrate 204, the additional operation that would be performed on substrate downstream of positive heating terminal connection substation 508 cannot be performed to avoid damage to the remaining substations and waste of components.

[0304] The control assembly coupling substation 510 may be positioned downstream of the positive heating terminal coupling substation 508 . Fig.36A perspective view of a control assembly connection substation 510 is shown. As illustrated, the control assembly connection substation 510 may include a supply unit 1002, a feeder unit 1004, a first assembly unit 1006a, and a second assembly unit 1006b. In simple terms, the supply unit 1002 may be configured to provide a plurality of components (specifically, an electronic control assembly 208). The feeder unit 1004 may be configured to receive the electronic control assembly 208 from the supply unit and alternately feed the electronic control assembly 208 to the first assembly unit 1006a and the second assembly unit 1006b. The first assembly unit 1006a and the second assembly unit 1006b may each be configured to assemble the electronic control assembly 208 into a cigarette cartridge 200 for an aerosol delivery device 100 (e.g., by engaging the electronic control assembly with the control assembly terminal 206).

[0305] In this regard, Fig.37 An enlarged view of a supply unit 1002 is shown. As illustrated, the supply unit 1002 can be configured to supply a plurality of electronic control assemblies 208. In some embodiments, the supply unit 1002 can include a vibration arrangement. For example, the vibration arrangement can include a vibration bowl 1010 and a supply track 1012. In some embodiments, the vibration bowl 1010 and / or the supply track 1012 can be manufactured by Performance Feeders, Inc. of Oldsmar, FL. Additionally, in some embodiments, the vibration bowl 1010 and / or various other components of the control assembly coupling substation 510 can be coated with an antistatic coating configured to avoid damaging the electronic control assembly 208, which can include a circuit board.

[0306] The electronic control assemblies 208 may be loaded directly into the vibratory bowl 1010, or a vibratory hopper may supply the electronic control assemblies 208 to the vibratory bowl in the manner described above. The vibratory bowl 1010 may define a path 1018 configured to arrange the electronic control assemblies 208 in a serially aligned stream 1020. In this regard, the vibratory motion of the vibratory bowl 1010 may direct the electronic control assemblies 208 upwardly along the path 1018, which may narrow so that some of the electronic control assemblies from which they fall and remain on the path become serially aligned.

[0307] The vibratory bowl 1010 can be configured to arrange the electronic control components 208 generally horizontally, with the longitudinal ends of the electronic control components contacting each other. However, some of the electronic control components 208 in the series alignment flow 1020 can be oriented in a manner different from the desired orientation. In this regard, as Fig.38, the supply unit 1002 may further include an actuator 1024 configured to individually remove or realign the electronic control components 208 in the serial alignment flow 1020 when the electronic control components are misaligned in one direction. In one embodiment, the actuator 1024 may include a nozzle 1026 configured to direct an air flow at each electronic control component 208 that is misaligned to remove the electronic control component from the path 1020 or to push the electronic control component into proper alignment. In some embodiments, the nozzle 1026 may be oriented so as to impact only those electronic control components 208 that are misaligned with the air flow directed therefrom.

[0308] In another embodiment, the supply unit 1002 may further include an orientation sensor 1028 (e.g., a camera) configured to determine the alignment of the electronic control assembly 208 on the path 1018, and the actuator 1024 may be actuated in response to the determination when a misaligned electronic control assembly is detected. Fig.39 , each of the electronic control assemblies 208 can define a first longitudinal end 262 and a second longitudinal end 264. The first longitudinal end 262 can be oriented in a proper orientation downstream of the second longitudinal end 264 for the performance of additional operations on the electronic control assembly 208 as described below. Thus, electronic control assemblies that define a different orientation as detected by the orientation sensor 1028 can be removed from the path 1018 through the nozzle 1026.

[0309] In some embodiments, the electronic control assembly 208 may also be asymmetrical relative to the first major surface 266 and the second major surface 268. For example, Fig.39 , the first major surface 266 of the electronic control assembly 208 may include a chip (e.g., a memory chip) extending therefrom. Additionally, the opposing second major surface 268 of the electronic control assembly 208 may be substantially flat. Thus, the orientation sensor 1028 may additionally determine which major side of the electronic control assembly 208 is oriented away from the vibration bowl 1010, and any electronic control assembly oriented differently than the desired orientation (e.g., an orientation in which the first major surface 266 faces away from the vibration bowl) may be removed from the path 1018 by the nozzle 1026.

[0310] Alternatively or additionally, such as Fig.39, in some embodiments, the path 1018 may define a gap 1030 or other feature that is configured to remove the electronic control component 208 from the serial alignment flow 1020 when the electronic control component is misaligned in the second direction. For example, as described above, the first major surface 266 and the second major surface 268 of the electronic control component 208 may be asymmetrical. In this regard, the first major surface 266 of the electronic control component 208 may include a memory chip or other feature that defines a protrusion extending along a portion of the longitudinal length of the electronic control component. In turn, when the electronic control component 208 is oriented with the first major surface 268 of the electronic control component facing the vibration bowl 1010, the protrusion may enter the gap 1030. In turn, the gap 1030 may be configured to cause the electronic control component terminal 208 to fall from the path 1018 when its major surface is oriented oppositely relative to the desired orientation. In some embodiments, the gap 1030 may be positioned upstream of the actuator 1024 so as to allow the actuator to remove only those electronic control components that are improperly oriented longitudinally.

[0311] Thus, each of the electronic control components 208 in the serial alignment flow 1020 may be properly oriented downstream of the gap 1030 and the actuator 1024. The electronic control components 208 removed by the gap 1030 and the actuator 1024 may be directed back into the vibratory bowl 1010 so that the electronic control components may return to the path 1018. Thus, the removed electronic control components 208 may be directed back into the serial alignment flow 1020.

[0312] The serially aligned flow 1020 of the electronic control assemblies 208 can then be directed to the supply track 1012, which can maintain the electronic control assemblies in a horizontal orientation and a longitudinal single-file arrangement. In some embodiments, the supply track 1012 can include a vibrating supply track to facilitate movement of the electronic control assemblies 208 along it. Fig.37 , the supply track 1012 can include a full sensor 1032 configured to detect whether the supply track is full of the electronic control assembly 208. In this regard, when the full sensor 1032 senses that the supply track 1012 is full, the vibratory bowl 1010 can be turned off. In addition, the supply track 1012 can include a low level sensor 1034, which is configured to detect when the supply track is running low on the electronic control assembly 208. In this regard, when the low level sensor 1034 detects a low level of the electronic control assembly 208 in the supply track 1012, the indicator 1030 (see Fig.36) to inform the operator that the electronic control assembly coupling substation 510 is running low on the electronic control assembly so that the operator can be informed that it is time to refill the vibratory bowl 1010. In some embodiments, the full sensor 1032 and the low level sensor 1034 may include optical sensors including a transmitter and a receiver configured to detect the presence or absence of the electronic control assembly 208 positioned therebetween.

[0313] In addition, if Fig.40 , the supply unit 1002 may include a singulator 1036 configured to singulate the electronic control components 208 from the serial alignment stream 1020. In this regard, the singulator 1036 may include a stopper 1038 (e.g., including a pin) that prevents the serial alignment stream 1020 of the electronic control components 208 from advancing further. As illustrated, in one embodiment, the vertical actuator 1040 may be configured to vertically move the stopper 1038 between a retracted position and an extended position. The vertical actuator 1040 may default to the extended position so that the stopper 1038 prevents the serial alignment stream 1020 of the electronic control components 208 from moving. However, the vertical actuator 1040 may temporarily retract the stopper 1038 to the retracted position to allow one of the electronic control components 208 to pass the stopper. In turn, the outermost electronic control component 208 may be directed to the feeder unit 1004. Additionally, vertical actuator 1040 may move stop 1038 to an extended position after outermost electronic control assembly 208 passes thereunder to allow the electronic control assembly to be singulated from serial alignment stream 1020 and received by feeder unit 1004 .

[0314] Fig.40 A perspective view of the feeder unit 1004 is further illustrated. In some embodiments, the feeder unit 1004 may include a rotating component 1042. The rotating component 1042 may include a first engagement head 1044a and a second engagement head 1044b, respectively, configured to receive one of the electronic control components 208 from the supply unit 1002. In this regard, the first engagement head 1044a may define a first recess 1046a and the second engagement head 1044b may define a second recess 1046b. As illustrated, in some embodiments, the rotating component 1042 may include a first arm 1048a and a second arm 1048b. The first engagement head 1044a may be coupled to the first arm 1048a and the second engagement head 1044b may be coupled to the second arm 1048b.

[0315] Fig.40 The rotating member 1042 is shown in a first receiving position, and Fig.41The rotating component is shown in the second receiving position, and the rotating component can be configured to rotate between the first receiving position and the second receiving position. In the first receiving position, the first engagement head 1044a is positioned close to the singulator 1036. In turn, the first electronic control component 208a can be singulated from the serial alignment flow 1020 and delivered to the first recess 1046a in the first engagement head 1044a. The singulation sensor 1050 (e.g., an optical sensor) can detect that the first electronic control component 208a has been singulated and delivered to the first engagement head 1044a.

[0316] After the first electronic control assembly 208a is received in the first engagement head 1044a, the rotating member 1042 can be rotated (e.g., by rotating clockwise when viewed from above) to a first delivery position that corresponds to the second receiving position and Fig.41 As the rotating member 1042 rotates, negative pressure may be applied to the first recess 1046a. Furthermore, the negative pressure may help maintain the first electronic control assembly 208a on the rotating member 1042 during the rotational movement of the rotating member. Thus, the first electronic control assembly 208a may be moved to the first delivery position.

[0317] Fig.42 A first assembly unit 1006a and a second assembly unit 1006b are shown. As illustrated, the first assembly unit 1006a may include a first robotic arm 1052a and a first end effector 1054a coupled thereto. Similarly, the second assembly unit 1006a may include a second robotic arm 1052b and a second end effector 1054b coupled thereto.

[0318] The first end effector 1054b can be configured to engage the first electronic control assembly 208a and deliver the first electronic control assembly to the first substrate 204a engaged with the bracket 604 on the track 602 via movement of the first robotic arm 1052a. Thus, the first assembly unit 1006a can be positioned so that the first robotic arm 1052a is configured to move the first end effector 1054a between the feeder unit 1004 and the track 602. In this regard, when the rotating component 1042 is in the first delivery position (see Fig.41 ), the first robotic arm 1052a may guide the first end effector 1054a to approach the first electronic control assembly 208a held by the first engagement head 1044a of the feeder unit 1004.

[0319] Thus, the first end effector 1054a can be configured to engage the first electronic control assembly 208a. Fig.43 and 44, in some embodiments, the first end effector 1054a may include a first opposing portion 1056 and a second opposing portion 1058 configured to clamp the first electronic control assembly 208a therebetween. Thus, the first opposing portion 1056 and the second opposing portion 1058 of the first end effector 1048a may securely grasp the first electronic control assembly 208a, and the first robotic arm 1052a may lift the first electronic control assembly from the rotating member 1042. In some embodiments, the first recess 1046a may stop applying the negative pressure while the first assembly unit 1006a lifts the first electronic control assembly 208a therefrom.

[0320] Thus, the track 602 can move the bracket 604 so that the first substrate 204a is positioned for receiving the first electronic control assembly 208a. In this regard, the bracket 604 with the substrate 204 engaged therewith, as well as the negative heating terminal 234, the positive heating terminal 235, and the control assembly terminal 206 engaged with the substrate can be guided through the control assembly connection substation 510. Fig.45 As shown in FIG. 5 , the track 602 can guide each carrier 604 through the first processing section 1060a of the first assembly unit 1006a and the second processing section 1060b of the second assembly unit 106b at the control assembly connection substation 510. Specifically, each carrier 604 can be guided first through the first processing section 1060a and then through the second processing section 1060b. Operations associated with the first substrate 204a and the first electronic control assembly 208a are performed at the first processing section 1060a, while operations associated with the second substrate 204b and the second electronic control assembly 208b (see FIG. 5 ) are performed at the first processing section 1060a. Fig.40 ) is performed at the second processing portion 1060b.

[0321] Thus, the carriage 604 can be transported along the track 502 to the first processing section 1060a. The carriage 604 can be directed past a carriage sensor 1062a, which can include a light emitter and a detector and detect the presence of the carriage 604. After passing the carriage sensor 1062a, the carriage 604 can be directed past an initial locator sensor 1064a, which is configured to detect the locator module 626 and verify the presence and position of the carriage. The initial stop 1066a can then be described above with respect to the initial stop 760a of the substrate loading substation 502 (see Fig.15 ) to stop the carriage 604 in the manner described above. Subsequently, when any downstream carriages are cleared, the carriage 604 can be released from the initial stop 1066a. Thus, the track 602 can be raised to the stop 764a (see above) with respect to the substrate loading substation 502. Fig.15) until the carriage engages the lift stop 1068a. When the carriage 604 is stopped, the stop locator sensor 1070a can detect the locator module 626 and verify the presence and position of the carriage.

[0322] The track 602 may include a lift mechanism 1072a configured as the lift mechanism 770a described above with respect to the substrate loading substation 502 (see Fig.15 ) in the manner described above after the stop locator sensor verifies the presence and position of the bracket. While the bracket 604 is being lifted and engaged by the lifter mechanism 1072a, the first robotic arm 1052a can lower the first end effector 1054a so that the first end 262 of the first electronic control assembly 208a engages the first control assembly terminal 206a.

[0323] In this regard, Fig.43 and 44 As shown in , the first end effector 1054a may further include a pivoting clamp 1074a. The pivoting clamp 1074a may be configured to apply negative pressure to the first electronic control assembly 208a. Therefore, when the first opposing portion 1056 and the second opposing portion 1058 are released, the pivoting clamp 1074a may remain engaged with the first electronic control assembly 208a.

[0324] like Fig.43 and 44 , the pivoting clamp 1074a can be configured to pivot downwardly so that the first electronic control assembly 208a transitions from a generally horizontal configuration to a generally vertical configuration. In turn, the first electronic control assembly 208a can be positioned between the negative heating terminal 234 and the positive heating terminal 235 that contact the control assembly terminal 206. In some embodiments, the assembly units 1006a, 1006b can include terminal spreaders 1076a, 1076b, respectively (see Fig.45 ), the terminal spreader can be configured to spread the negative heating terminal 234 and the positive heating terminal 235 apart from each other so as to facilitate the insertion of the electronic control component 208 therebetween.

[0325] After the electronic control assembly 208 is engaged with the control assembly terminal 206, the pivoting clamp 1074a can stop applying negative pressure to the first electronic control assembly 208a so that the first electronic control assembly remains engaged with the control assembly terminal 206a between the negative heating terminal 234a and the positive heating terminal 235a. The first robotic arm 1052a can then return to the feeder unit 1004 to engage an additional first electronic control assembly for attachment with the first substrate 204a on the subsequent bracket 604.

[0326] After the robotic arm 1060a engages the first electronic control assembly 208a with the first substrate 204a (e.g., via the control assembly terminals 206), the storage transceiver 1078a may write a code to the storage module 624 indicating whether the first electronic control assembly 208a is properly coupled to the first substrate 204a. In this regard, for example, the storage transceiver 1078a may store information to the storage module 624 indicating that the electronic control assembly 208a is improperly attached unless each of the movements of the assembly of the first assembly unit 1006a is successfully completed as detected by the various motion sensors associated therewith. In instances where the first electronic control assembly 208a is deemed improperly engaged with the first substrate 204a, substations downstream of the control assembly coupling substation 510 may not perform additional operations that would otherwise be performed on the first substrate 204a. In other words, given that the first electronic control component 208a is improperly attached to the substrate 204a or is lost, the substations downstream of the electronic control component connection substation 510 may not attempt to connect additional components to it in order to avoid damage to the remaining substations and waste of components. In this same aspect, the storage transceiver 1078a can read the code on the storage module 624 to determine that the partially assembled cartridge is mated for further assembly before the electronic control component 208a is connected to the control component terminal 206 connected to the first substrate 204a.

[0327] Subsequently, the lift mechanism 1072a can release the carriage 604 by lowering the carriage back onto the conveyor belt 628. At this time, the carriage 604 can be guided along the track 602 to the second processing section 1060b. Fig.46 As shown in FIG. 1 , the second processing section 1060b may include the same components included in the first processing section 1060a. For example, the second processing section 1060b may include a bracket sensor 1062b (see FIG. 1 ). Fig.42 ), initial locator sensor 1064b, initial stopper 1066b, lift stopper 1068b, stopper locator sensor 1070b, lifter mechanism 1072b, and storage transceiver 1078b. Thus, second processing portion 1060b may operate in substantially the same manner as first processing portion 1068a, and thus a description thereof will not be repeated.

[0328] In this regard, while the first electronic control component 208a is being delivered to the first assembly unit 1006a for bonding with the first substrate 204a, the second electronic control component 208b can be singulated from the serially aligned stream of electronic control components 1020 in the manner described above and received in the second recess 1046b in the second bonding head 1044b, as shown in FIG. Fig.41 Furthermore, when the rotating member 1042 is Fig.40When pivoted back to the first receiving position as shown in FIG. 1 , the second electronic control assembly 208b can be received by the second assembly unit 1006b, which can then engage the second electronic control assembly 208b with the second substrate 204b in the manner described above.

[0329] After the second electronic control assembly 208b is coupled to the second base 208b, the lift mechanism 1072b can lower the carriage 604 so that the track 602 transports the carriage downstream. Fig.46 , the inspection unit 1080 can be positioned downstream of the second assembly unit 1006b. The inspection unit 1080 can include an inspection locator sensor 1082 that can detect the presence of the bracket 604. The lifting stop 1084 can temporarily stop the bracket 604 at a position where the lift mechanism 1086 can lift the bracket 604 after the inspection locator sensor 1082 detects the bracket. Therefore, the first component presence sensor 1088a and the second component presence sensor 1088b (e.g., including a light transmitter and a receiver) can detect the presence of the electronic control components 208a, 208b. Therefore, the storage transceiver 1090 can write a code to the storage module 624, the code indicating whether the electronic control components 208a, 208b are properly attached to the corresponding substrates 204a, 204b. In instances where the electronic control assembly 208a, 208b is improperly engaged with the respective substrate 204a, 204b, the substation downstream of the control assembly coupling substation 510 may not perform additional operations that would otherwise be performed on the substrate. The lift mechanism 1086 may lower the carriage 604 so that the track 602 conveys the carriage, including the positive heating terminals 234 and the negative heating terminals 235, the control assembly terminals 206, and the electronic control assembly 208 coupled to the downstream substrates 204a, 204b, respectively.

[0330] It should be noted that the above operations can be performed simultaneously. In this regard, while the first bonding head 1044a delivers the first electronic control component 208a to the first robotic arm 1052a, the second bonding head 1044b can receive the second electronic control component 208b from the singulator 1036. Conversely, while the second bonding head 1044b delivers the second electronic control component 208b to the second robotic arm 1052b, the first bonding head 1044a can receive the first electronic control component 208a from the singulator 1036. In addition, while the first robotic arm 1052a couples the first electronic control component 208a to the first substrate 204a, the second robotic arm 1052b can receive the second electronic control component 208b from the second bonding head 1044a. Conversely, while the second robotic arm 1052b couples the second electronic control component 208b to the second substrate 204b, the first robotic arm 1052a can receive the first electronic control component 208a from the first bonding head 1044a. Thus, fast and efficient bonding of the electronic control components 208a, 208b to the substrates 204a, 204b may be achieved.

[0331] The deflector coupling substation 512 may be positioned downstream of the control assembly coupling substation 510 . Fig.47 A perspective view of a flow guide coupling substation 512 is shown. As described, the flow guide coupling substation 512 may include a supply unit 1102, a feeder unit 1104, a first assembly unit 1106a, and a second assembly unit 1106b. In simple terms, the supply unit 1102 may be configured to provide a plurality of components (specifically, the flow guide 210). The feeder unit 1104 may be configured to receive the flow guide 210 from the supply unit 1102 and feed the flow guide alternately to the first assembly unit 1106a and the second assembly unit 1106b. The first assembly unit 1106a and the second assembly unit 1106b may each be configured to assemble the flow guide 210 into the cigarette cartridge 200 for the aerosol delivery device 100, for example, by positioning the flow guide between the negative terminal 234 and the positive terminal 235 and engaging with the control component terminal 208.

[0332] In this regard, Fig.48 An enlarged view of a supply unit 1102 is shown. As illustrated, the supply unit 1102 can be configured to supply a plurality of flow directors 210. In some embodiments, the supply unit 1102 can include a vibration arrangement. For example, the vibration arrangement can include a vibration bowl 1110 and a supply track 1112. In some embodiments, the vibration bowl 1110 and / or the supply track 1112 can be manufactured by Performance Feeders, Inc. of Oldsmar, FL.

[0333] The deflector 210 may be loaded directly into the vibratory bowl 1110, or the vibratory hopper 1114 may supply the deflector 210 to the vibratory bowl in the manner described above. In this regard, the assembly level sensor 1116 may activate vibration of the vibratory hopper 1114 based on the level of the deflector 210 within the vibratory bowl 1110. The vibratory bowl 1110 may define a path 1118 configured to arrange the deflector 210 in a serial alignment flow 1120 (see Fig.49 ). In this regard, the vibratory motion of the vibratory bowl 1110 can direct the deflectors 210 upward along the path 1118, which can narrow so that some of the deflectors fall therefrom and the deflectors that remain on the path become aligned in series.

[0334] The vibratory bowl 1110 may be configured to arrange the deflectors 210 substantially vertically by the time the deflectors reach the supply track 1112. An actuator or gap (not shown) may be configured to individually remove or realign the deflectors 210 in the serial alignment stream 1120 when the deflectors are misaligned in one direction, as discussed above. The supply track 1112 may include a full sensor 1132 configured to detect whether the supply track is full of deflectors 210 and thereby shut down vibration of the vibratory bowl 1110, and a full sensor 1132 configured to detect when the supply track runs low on the deflectors 210 to activate the indicator 1130 (see Fig.47 ) to inform the operator that the deflector coupling substation 510 is running low on the deflector low level sensor 1134. In some embodiments, the full sensor 1132 and the low level sensor 1134 may include optical sensors that include a transmitter and a receiver configured to detect whether the deflector 210 is positioned therebetween.

[0335] In addition, if Fig.49 , the supply unit 1102 may include a single splitter 1136 configured to single-split the deflector 210 from the serially aligned flow 1120. In this regard, the single splitter 1136 may include a stopper 1138 (e.g., including a pin) that prevents the serially aligned flow 1120 of the deflector 210 from further advancement. As illustrated, in one embodiment, the vertical actuator 1140 may be configured to vertically move the stopper 1138 between a retracted position and an extended position. The vertical actuator 1140 may default to an extended position so that the stopper 1138 prevents the serially aligned flow 1120 of the deflector 210 from moving. In this regard, the stopper 1138 may extend to a longitudinal hole 210' (see FIG. 2 ) defined through the deflector 210. Figure 1 However, the vertical actuator 1140 may briefly retract the stopper 1138 to the retracted position to allow one of the deflectors 210 to pass the stopper. The vertical actuator 1140 may return the stopper 1138 to the extended position within the subsequent deflector 210 after the outermost deflector passes underneath it.

[0336] After the outermost deflector 210 is released from the stopper 1138, the deflector may contact the second stopper 1144. At this time, the second vertical actuator 1146 may extend the guide pin 1148 into the longitudinal hole 210' extending through the deflector 210. Therefore, when the horizontal actuator 1150 retracts the second stopper 1144, the deflector 210 may fall along the guide pin 1148. In this regard, the guide pin 1148 may guide the deflector 210 to the feeder unit 1104 so that the deflector is singulated from the series alignment flow 1120 and received by the feeder unit 1104.

[0337] like Fig.50 , the feeder unit 1104 may include a rotating component 1152 having a first engagement head 1154a including a first recess 1156a and a second engagement head 1154b including a second recess 1156b, each of the first engagement head and the second engagement head being configured to receive one of the flow guides 210 from the supply unit 1102. The rotating component 1152 may include a first arm 1158a to which the first engagement head 1154a is mounted and a second arm 1158b to which the second engagement head 1154b is mounted.

[0338] Fig.49 and 50 The rotating component 1152 is shown in a first receiving position in which the first engagement head 1154a is positioned close to the singulator 1136. The rotating component 1152 can be configured to rotate to a second receiving position in which the second engagement head 1154b is positioned close to the singulator 1136. The singulation sensor 1160 (e.g., an optical sensor) can detect that the flow guide 210 has been singulated and delivered to one of the engagement heads 1154a, 1154b. Therefore, the rotating component 1152 can rotate between the first receiving position (corresponding to the second delivery position) and the second receiving position (corresponding to the first delivery position) in the manner described above with respect to other rotating components described herein.

[0339] Therefore, the single-branch flow guide 210 can be delivered to the first assembly unit 1106a and the second assembly unit 1106b. Fig.51 The second assembly unit 1106b is shown. As illustrated, the second assembly unit 1106b may include a second robotic arm 1162b and a second end effector 1164b. Similarly, the first assembly unit 1106a may include a first robotic arm 1162a (see Fig.47 ) and the first end effector 1164a (see Fig.52 ). Thus, the first end effector 1154b may be configured to engage the first flow director 210a held in the first recess 1156a of the feeder unit 1104 (see Fig.49 ) and deliver the first guide to the first substrate 204a on the bracket 604 on the track 602 via the movement of the first robot arm 1162a. Fig.52 As shown in FIG. 1 , in some embodiments, the first end effector 1154a can include first opposing portions 1166 and second opposing portions 1168 configured to clamp the first flow director 210a therebetween.

[0340] Thus, the track 602 can move the bracket 604 so that the first base 204a is positioned for receiving the first flow director 210a, and similarly, the second base 204b is positioned for receiving the second flow director 210b. Fig.53 , the track 602 can guide each carriage 604 through the first processing section 1170a and the second processing section 1170b at the deflector coupling substation 512. The first processing section 1170a can include a carriage sensor (not shown; see, for example, carriage sensor 1172b), an initial locator sensor 1174a, an initial stop 1176a, a lift stop 1178a, a stop locator sensor 1180a, and a lift mechanism 1182a, which can function in the manner described above with respect to the same components at other substations.

[0341] In addition, the first processing portion 1170a can include a terminal spreader 1184. As illustrated, the terminal spreader 1184 can include a first spreader pin 1186a and a second spreader pin 1186b. In this regard, while the bracket 604 is stopped by the initial stop 1176a, the vertical actuator 1188 of the terminal spreader 1184 can lower the first spreader pin 1186a between the first negative heating terminal 234a and the first positive heating terminal 235a and lower the second spreader pin 1186b between the second negative heating terminal 234b and the second positive heating terminal 235b. In turn, the negative heating terminal 234 and the positive heating terminal 235 can be spread apart from each other so as to facilitate the first robotic arm 1162a to insert the deflector 210 therebetween and engage with the electronic control assembly 208.

[0342] In this regard, the first opposing portion 1166 and the second opposing portion 1168 of the first end effector 1164a (see Fig.52) can be configured to position the first current director 210a between the first negative heating terminal 234a and the first positive heating terminal 235a. In addition, each engagement head 1164 can include opposing first and second terminal clamps 1190 and 1192, which can be configured to move inward and outward in a direction perpendicular to the direction in which the first opposing portion 1166 and the second opposing portion 1168 move inward and outward. After the first current director 210a is positioned between the first negative heating terminal 234a and the first positive heating terminal 235a that are spread through the first opposing portion 1166 and the second opposing portion 1168, the terminal clamps 1190, 1192 can clamp the negative heating terminal and the positive heating terminal against the side of the first current director 208a so that the current director is firmly positioned therebetween.

[0343] While the bracket 604 is lifted by the lifter mechanism 1182a, the component presence sensor 1194a (e.g., including a light emitter and a receiver) can detect the presence of the flow guide 210a. In addition, the storage transceiver 1196a can write a code to the storage module 624 based on the signal from the component presence sensor 1194a, indicating whether the first flow guide 210a is properly connected to the first substrate 204a, so that the improperly assembled cigarette cartridge will not be subjected to further assembly operations downstream. In this same aspect, the storage transceiver 1196a can read the code on the storage module 624 to determine that the partially assembled cigarette cartridge before the flow guide 210a is connected to the substrate 204a is matched for further assembly.

[0344] Subsequently, the lift mechanism 1182a can lower the carriage 604 back onto the track 602. The carriage 604 can be directed downstream to the second processing section 1170b, where the second assembly unit 1106b can perform substantially the same operations discussed above with respect to the first assembly unit 1106a on the second substrate 204b, except that the terminal spreading is performed upstream at the terminal spreader 1184. In this regard, as shown in FIG. Fig.53 As shown in FIG. , the second processing portion 1170b may include a bracket sensor 1172b, an initial locator sensor 1174b, an initial stop 1176b, a lift stop 1178b, a stop locator sensor 1180b, a lift mechanism 1182b, a component presence sensor 1194b configured to detect whether the deflector 210b is properly attached, and a storage transceiver 1196b.

[0345] It should be noted that the above operations can be performed simultaneously. In this regard, while the first engagement head 1154a delivers the first flow guide 210a to the first robotic arm 1162a, the second engagement head 1154b can receive the second flow guide 210b from the singulator 1136. Conversely, while the second engagement head 1154b delivers the second flow guide 210b to the second robotic arm 1162b, the first engagement head 1154a can receive the first flow guide 210a from the singulator 1136. In addition, while the first robotic arm 1162a couples the first flow guide 210a to the first substrate 204a, the second robotic arm 1162b can receive the second flow guide 210b from the second engagement head 1154b. Conversely, while the second robotic arm 1162b couples the second flow guide 210b to the second substrate 204b, the first robotic arm 1162a can receive the first flow guide 210a from the first engagement head 1154a. Therefore, a quick and efficient engagement of the flow directors 210a, 210b with the substrates 204a, 204b may be achieved.

[0346] The heating element coupling substation 514 may be positioned downstream of the deflector coupling substation 512 . Fig.54 A perspective view of a heating element coupling substation 514 is shown. The heating element coupling substation 514 may include a supply unit 1202. As illustrated, the supply unit 1202 may include a reel 1204 configured to supply a substantially continuous heating element input 1206. In this regard, the substantially continuous heating element input 1206 may include a plurality of heating elements 240 wound around an elongated liquid delivery element 238, which may in turn be cut as described below to define a plurality of liquid delivery elements 238 having heating elements 240 coupled thereto. Examples of heating elements wound around liquid delivery elements are provided in U.S. Patent Application Publications No. 2014 / 0270730 to DePiano et al. and No. 2014 / 0157583 to Ward et al., which are incorporated herein by reference in their entirety.

[0347] The heating element coupling substation 514 may further include a housing 1208. The housing 1208 may be substantially closed and opaque to prevent the laser beam and / or other potentially harmful light from exiting therefrom. In this regard, as discussed below, welding, and in particular laser welding, may also be performed inside the housing 1208, in addition to various other operations discussed below.

[0348] Fig.55 A view of a portion of the supply unit 1202 within the housing 1208 is shown. Fig.55, the supply unit 1202 may further include a movable fixture 1210 configured to pull the substantially continuous heating element input 1206 from the reel 1204 into the housing 1206. The supply unit 1202 may additionally include a guide 1212 and a singulator 1214, which may include a cutter. In this regard, the substantially continuous heating element input 1206 may be directed through the guide 1212 (e.g., by passing through an aperture defined therethrough) and through the singulator 1214 to the feeder unit 1216.

[0349] like Fig.56 As shown in FIG. 1 , the feeder unit 1216 may include a first engagement head 1218a and a first gripper 1220a coupled to a first arm 1222a of a rotating member 1224. The rotating member 1224 is Fig.56 12 is shown in a first receiving position, where the first arm 1222a is positioned close to the supply unit 1202. Fig.57 As shown in FIG. 1 , the rotating member 1224 may further include a second arm 1222b including a second engagement head 1218b and a second gripper 1220b coupled thereto. Fig.57 The figure is shown in the second delivery position, which corresponds to Fig.56 The first receiving position described in .

[0350] The supply unit 1202 can be configured to pull the substantially continuous heating element input 1206 until a desired length thereof is received by the feeder unit 1216. In this regard, at least one imaging device can be configured to determine the length of the substantially continuous heating element input 1206 pulled from the spool 1202. Fig.56 , in one embodiment, the supply unit 1202 may include a first imaging device 1226a and the feeder unit may include a second imaging device 1226b. The first imaging device 1226a can determine the location of the heater zone defined by the heating element 240 (e.g., a portion of the heating element where multiple tightly wound coils are located), and the movable fixture 1210 can align the center of the heater zone with the second imaging device 1226b. In this position, the substantially continuous heating element input 1206 can extend through the first engaging head 1218a to the first clamp 1220a, which can be clamped to the end of the substantially continuous heating element input. The singulator 1214 can then cut the substantially continuous heating element input 1206 to singulate the first heating element 240 and the first liquid delivery element 238 that can be used in a single cartridge from it.

[0351] Therefore, the rotating member 1224 can be rotated from the first receiving position where the single heating element 240 and the liquid delivery element 238 are received to the first delivery position, which corresponds to the second receiving position where the second arm 1222b of the rotating member 1224 is positioned close to the supply unit 1202. Fig.55 , the stationary clamp 1228 can engage the substantially continuous heating element input 1206 so that the movable clamp 1210 can be released therefrom and moved to an initial position where the movable clamp can reengage the substantially continuous heating element input. In turn, the movable clamp 1210 can pull the substantially continuous heating element input 1206 from the reel 1204 and guide the substantially continuous heating element input through the second engagement head 1218b so that the second clamp 1220b can engage one end thereof. In turn, the singulator 1214 can singulate the second heating element 240 and the second liquid delivery element 238 from the substantially continuous heating element input 1206 in the manner described above.

[0352] like Fig.57 As shown in , the heating element coupling substation 514 may further include a first assembly unit 1230a and a second assembly unit 1230b. The first assembly unit 1230a may be configured to assemble the first heating element 240 and the first liquid delivery element 238 to the negative heating terminal 234a and the positive heating terminal 235a coupled to the first substrate 204a. Similarly, the second assembly unit 1230b may be configured to assemble the second heating element 240 and the second liquid delivery element 238 to the negative heating terminal 234b and the positive heating terminal 235b coupled to the second substrate 204b. In this regard, the first assembly unit 230a may include a first robot arm 1232a and the second assembly unit 230b may include a second robot arm 1232b. The first robot arm 1232a may include a first end effector 1234a and the second robot arm 1234a may include a second end effector 1234b (see Fig.58 ).

[0353] As explained, in Fig.58 , each end effector 1234a, 1234b may include a first opposing portion 1236 and a second opposing portion 1238. Each opposing portion 1236, 1238 may include a first fork 1240 and a second fork 1242. The first opposing portion 1236 and the second opposing portion 1238 of the end effector 1234a, 1234b may be configured to receive the singulated heating element 240 and the liquid delivery element 238 therebetween.

[0354] In this regard, Fig.59An enlarged view of the first engagement head 1218a is shown, which may be substantially similar to the second engagement head 1218b. As illustrated, the first engagement head 1218a may include a plurality of depressible buttons 1244. The buttons 1244 may be configured to be recessed into the first engagement head 1218a when engaged by the prongs 1240, 1242 of each of the opposing portions 1236, 1238 of the end effector 1234a. It should be noted that while gaps may be provided in the engagement heads 1218a, 1218b instead of depressible buttons 1244, the ends of the substantially continuous heating element input 1206 may undesirably enter these gaps and bind when directed into the engagement head, rather than traveling to the respective grippers 1220a, 1220b as intended during their individual divisions.

[0355] Thus, the opposing portions 1236, 1238 of the first engagement head 1218a can depress the depressible button 1244 while extending around the singulated heating element 240 and the liquid delivery element 238 received in the first engagement head. The first engagement head 1218a can then clamp onto the singulated heating element 240 and the liquid delivery element 238. Thus, the first robotic arm 1234a can lift the singulated heating element 240 and the liquid delivery element 238 received in the first engagement head 1218a and deliver the singulated heating element and the liquid delivery element for assembly with the positive heating terminal 235 and the negative heating terminal 234a coupled to the first substrate 204a.

[0356] In this regard, Fig.60 , the first assembly unit 1230a may further include a first processing portion 1244a, and the second assembly unit 1230b may further include a second processing portion 1244b positioned along the track 602. Thus, the carriage 604 may be guided along the track 602 to the first processing portion 1244a. As illustrated, the first processing portion 1244a may include a carriage sensor 1246a, an initial locator sensor 1248a, an initial stopper 1250a, a lift stopper 1252a (see Fig.61 ), a stopper locator sensor (not shown; see, for example, the stopper locator sensor 1254b, and a lifter mechanism 1256a (see Fig.61 ), the above components may function in the manner described above with respect to the same components at other substations.

[0357] Additionally, the first processing portion 1244a may include a terminal securing mechanism 1258a and a laser 1260a. Fig.61The enlarged view of the terminal fixing mechanism 1258a is shown. As described, the terminal fixing mechanism 1258a may include a fixture 1262a. The fixture 1262a may include an opposing terminal actuator 1264a and an opposing substrate actuator 1266a connected thereto. Therefore, when the bracket 604 is lifted by the lifter mechanism 1256a, the fixture 1262a may act on the first substrate 204a and the negative heating terminal 234a and the positive heating terminal 235a connected thereto. In this regard, the substrate actuator 1266a may be clamped on the opposite side of the first substrate 204a so that the first substrate is located at the center therebetween. In addition, the terminal actuator 1264a may be clamped against the opposite side of the negative heating terminal 234a and the positive heating terminal 235a.

[0358] In this regard, Fig.62 An enlarged partial view of the terminal actuator 1264a is shown. As illustrated, the terminal actuator 1264a may include a protruding member 1268 and a recessed member 1270. The protruding member 1268 and the recessed member 1270 may be configured to clamp the negative heating terminal 234a and the positive heating terminal 235a therebetween. Specifically, the protruding member 1268 may define a first shoulder 1272a configured to engage the negative heating terminal 234a and a second shoulder 1272b configured to engage the positive heating terminal 235a. Similarly, the recessed member 1270 may define a first shoulder 1274a configured to engage the negative heating terminal 234a and a second shoulder 1274b configured to engage the positive heating terminal 235a. Therefore, the negative heating terminal 234a may be clamped between the first shoulder 1272a of the protruding member 1268 and the first shoulder 1274a of the recessed member 1270. Similarly, the positive heating terminal 235 a may be clamped between the second shoulder 1272 b of the protruding member 1268 and the second shoulder 1274 b of the recessed member 1270 .

[0359] During this clamping operation, the central portion 1272c of the protruding member 1268 can extend between the negative heating terminal 234a and the positive heating terminal 235a. In addition, the outer prongs 1274c defined by the recessed member 1270 can extend around the outside of the negative heating terminal 234a and the positive heating terminal 235a. Therefore, the central portion 1272c of the protruding member 1268 and the outer prongs 1274c of the recessed member 1270 can position the negative heating terminal 234a and the positive heating terminal 235a at a fixed spacing that corresponds to the desired spacing of the negative heating terminal and the positive heating terminal for the heating element 240 to be attached thereto.

[0360] In this regard, the robotic arm 1232a can position the end effector 1234a so that the heating element 240 and the liquid delivery element 238 are close to the negative heating terminal 234a and the positive heating terminal 235a. Specifically, the center of the heating portion of the heating element 240 can be aligned with the center of the negative heating terminal 234a and the positive heating terminal 235a via the movement of the robotic arm 1232a. In this regard, as shown in FIG. Fig.60 , the first processing portion 1244a may further include an imaging device 1270a configured to capture images of the negative heating terminal 234a and the positive heating terminal 235a and the heating element 240 so that the robotic arm 1232a can align the center of the heating element 240 with the center of the negative heating terminal 234a and the positive heating terminal 235a based on its image. Additional details regarding the alignment of the negative heating terminal and the positive heating terminal with the heating element are described in U.S. Patent Application No. 14 / 227,159 filed by Ampolini et al. on March 27, 2014, which is incorporated herein by reference in its entirety.

[0361] Once aligned, the laser 1260a can weld the heating element 240 to one of the negative heating element 234a and the positive heating element 235a. The laser 1260a can then weld the heating element 240 to the other of the negative heating element 234a and the positive heating element 235a. For example, the laser 1260a can weld the heating element 240 to the negative heating element 234a, and then move to the second position to weld the positive heating element 235a. In this regard, the laser 1260a and the imaging device 1270a can be mounted to a slide 1272a, which is configured to move the laser and the camera between the first and second welding positions. Therefore, the heating element 240 can be welded to the negative heating terminal 234a and the positive heating terminal 235a, and the heating terminal can then indirectly connect the liquid delivery element 238 to the negative heating terminal and the positive heating terminal due to the heating element wound around, or be attached to the liquid delivery element in another way.

[0362] like Fig.57As shown in , a vent 1275 may be provided inside the housing 1208. The vent 1275 may be used to remove smoke and gases associated with laser welding from the housing 1208. Additional details about the welding operation are provided in U.S. Patent Application No. 14 / 227,159 filed by Ampolini et al. on March 27, 2014, which is incorporated herein by reference in its entirety as described above. In addition, although the use of laser welding is described herein, it should be understood that the heating element may be attached to the negative heating terminal and the positive heating terminal in a variety of ways. For example, arc welding, metal inert gas welding (MIG), tungsten inert gas welding (TIG), plasma welding, etc. may be employed in other embodiments. More generally, the heating element may be attached to the heating terminal via other methods other than welding, such as via soldering and via mechanical connectors. It should therefore be understood that various other embodiments of connection methods and related equipment other than laser welding may be employed without departing from the scope of the present disclosure.

[0363] The component presence sensor 1278a (e.g., including a light emitter and a receiver) can detect whether the heating element 240 is properly connected to the negative heating terminal 234a and the positive heating terminal 235a. For example, the component presence sensor 1278a can detect that the bracket 604 is lifted by the lift mechanism 1256a (see Fig.61 ) is raised while the heating element 240 and / or the liquid delivery element are present. In turn, this information can be written by the storage transceiver 1276a to the storage module 624 so that no further operations can be performed on the partially assembled cartridge without detecting the heating element 240. In this same aspect, the storage transceiver 1276a can read the code on the storage module 624 to determine that the partially assembled cartridge is mated for further assembly before the heating element 240 is coupled to the negative heating terminal 234 and the positive heating terminal 235.

[0364] After welding at the first processing portion 1244a, the lifter mechanism 1256a (see Fig.61 ) can lower the carriage 604 back into engagement with the rails 602. The carriage 604 can be directed to a second processing section 1244b, which can contain substantially the same equipment as the first processing section. In this regard, Fig.60As shown in , the second processing portion 1244b may include a carriage sensor 1246b, an initial locator sensor 1248b, an initial stop 1250b, a lift stop 1252b, a stop locator sensor 1254b, and a lift mechanism 1256b, a terminal fixing mechanism 1258b, a laser 1260b, a storage transceiver (not shown; see storage transceiver 1276a), and a component presence sensor 1278b. Thus, the second processing portion 1244b can couple the second heating element 240 and the second liquid delivery element 238 to the second negative heating terminal 234b and the second positive heating terminal 235b.

[0365] It should be noted that the above operations can be performed simultaneously. In this regard, while the first joint head 1218a delivers the first heating element 240 and the first liquid delivery element 238 to the first robot arm 1232a, the second joint head 1218b can receive the second heating element and the second liquid delivery element from the supply unit 1202. On the contrary, while the second joint head 1218b delivers the second heating element 240 and the second liquid delivery element 238 to the second robot arm 1232b, the first joint head 1220a can receive the first heating element and the first liquid delivery element from the supply unit 1202. In addition, while the first robot arm 1232a connects the first heating element 240 and the first liquid delivery element 238 to the negative heating terminal 234a and the positive heating terminal 234b, the second robot arm 1232b can receive the second heating element and the second liquid delivery element from the second joint head 1218b. On the contrary, while the second robot arm 1232b connects the second heating element 240 and the liquid delivery element 238 to the negative heating terminal 234b and the positive heating terminal 235b, the first robot arm 1232a can receive the first heating element and the first liquid delivery element from the first engagement head 1220a. Therefore, a fast and efficient engagement of the heating element and the liquid delivery element with the negative heating terminal and the positive heating terminal can be achieved.

[0366] The reservoir and outer body coupling substation 516 may be positioned downstream of the heating element coupling substation 514 . Fig.63 A perspective view of a reservoir and external body coupling substation 516 is shown. As illustrated, the reservoir and external body coupling substation 516 may include a supply unit 1302. The supply unit 1302 may include a reservoir supply unit 1304 and an external body supply unit 1306.

[0367] As illustrated, the reservoir supply unit 1304 may include a first reel 1308a and a second reel 1308b each configured to respectively supply a substantially continuous reservoir substrate input 1310. Each reel 1308a, 1308b may supply the substantially continuous reservoir substrate input 1310 to a respective movable fixture 1312, one of which is Fig.64 Each movable fixture 1312 can be configured to pull a substantially continuous reservoir substrate input 1310 from a respective reel 1308a, 1308b. In turn, the substantially continuous reservoir substrate input 1310 can be directed to a singulator 1314. Fig.65 , the singulator 1314 may include a reservoir gripper 1316, which may include four prongs 1318. When the end of the generally continuous reservoir substrate input 1310 is directed downwardly into the reservoir gripper 1316, the prongs 1318 may grip against opposite sides thereof.

[0368] At this time Fig.64 The stationary clamp 1320 illustrated in FIG. 1 can clamp against the substantially continuous reservoir substrate input 1310, and the movable clamp 1312 can return to the starting position (e.g., by moving upward), where the movable clamp again grasps the substantially continuous reservoir substrate input. The cutter 1322 of the singulator 1314 can then cut the substantially continuous reservoir substrate input 1310 so that the reservoir clamp 1316 holds the singulated reservoir substrates 214 (see, e.g., Figure 1 ).

[0369] Vacuum gripper 1324 (see Fig.65 ) can then extend into contact with the reservoir substrate 214 held by the reservoir gripper 1316. In this regard, the vacuum gripper 1324 can apply negative pressure to the reservoir substrate 214 so that the reservoir substrate wraps around the curved outer nose 1326 defined by the vacuum gripper. The reservoir gripper 1316 can then release the reservoir substrate 214 and retract downward. In turn, the reservoir substrate 214 is positioned for receipt by the feeder unit 1328, as discussed below.

[0370] While the singulated reservoir substrate 214 is supplied by the reservoir supply unit 1304 in the manner described above, the external body supply unit 1306 can supply the external body 216 (see, e.g., Figure 1 ). In this regard, Fig.66, the external body supply unit 1306 can include a vibration arrangement. For example, the vibration arrangement can include a vibration bowl 1330 and a supply track 1332. In some embodiments, the vibration bowl 1330 and / or the supply track 1332 can be manufactured by Performance Feeders, Inc. of Oldsmar, FL. The external body 216 can be loaded directly into the vibration bowl 1330, or the vibration hopper 1334 can supply the external body 216 to the vibration bowl in the manner described above with respect to other vibration bowls and vibration hoppers described herein. In this regard, the assembly level sensor 1336 can activate vibration of the vibration hopper 1334 based on the level of the external body 216 within the vibration bowl 1330.

[0371] The vibration bowl 1330 can define a path 1338 configured to arrange the outer bodies 216 in the serial alignment flow 1340. In this regard, the vibratory motion of the vibration bowl 1330 can guide the outer bodies 216 upward along the path 1338, which can narrow so that some of the outer bodies from which they fall and remain on the path become aligned in series. The vibration bowl 1330 can be configured to arrange the outer bodies 216 generally vertically by the time the outer bodies reach the supply track 1332. An actuator or gap (not shown) can be configured to individually remove or realign the outer bodies in the serial alignment flow 1340 when the outer bodies are misaligned in one direction, as discussed above with respect to other components. The supply track 1332 can include a full sensor 1342 configured to detect whether the supply track is full of outer bodies 216 and thereby shut down the vibration of the vibration bowl 1330, and a full sensor 1342 configured to detect when the supply track 1332 runs low on the outer bodies 216 to activate an indicator 1346 (see Fig.63 ) to inform the operator that the reservoir and external body coupling substation 516 is running low on the external body 216 (not shown; see, e.g., full sensor 1342). In some embodiments, the full sensor 1342 and the low level sensor may include an optical sensor including a transmitter and a receiver configured to detect each external body 216 passing by. It should be noted that the indicator 1346 may alternatively or additionally be activated when one or both of the reels 1308a, 1308b are running low on the substantially continuous reservoir substrate input 1310.

[0372] In addition, if Fig.67, the outer body supply unit 1306 can include a singulator 1348 configured to singulate the outer body 216 from the serial aligned stream 1340. In this regard, the singulator 1348 can include a stopper 1350. As illustrated, in one embodiment, the stopper 1350 can include an end wall 1352 configured to prevent the serial aligned stream 1340 of the outer body 216 from further advancement. As illustrated, a horizontal slot 1354 can be defined through the end wall 1352. The singulation sensor 1356 can detect that the outermost one of the outer bodies 216 is positioned for singulation. In this regard, the stopper 1350 can include an upper cutout 1358, which can allow access to the outer body 216 at the end of the serial aligned stream 1340.

[0373] Thus, the feeder unit 1328 can receive one of the outer bodies 216. In this regard, as Fig.68 As shown in FIG. 1 , the feed unit 1328 may include an initial external body feed 1360. The initial external body feed 1360 may include a first engagement head 1362a and a second engagement head 1362b coupled to opposite ends of the beam 1364. Fig.67 and 68 As shown in FIG. 1 , each of the engagement heads 1362 a , 1362 b may include a first opposing portion 1366 and a second opposing portion 1368 configured to clamp the outer body 216 therebetween.

[0374] The crossbar 1364 can be configured to be raised, lowered, and laterally displaced between a first receiving position corresponding to a second delivery position and a second receiving position corresponding to the first delivery position. In this regard, the crossbar 1364 can be lowered so that the opposing portions 1366, 1368 of the first engagement head 1362a extend into the upper cutout 1358 in the stopper 1350 and clamp onto the outermost outer body 216 in the tandem alignment flow 1340. While the first engagement head 1362a engages the first outer body 216, the second outer body can be delivered to the second outer body and the reservoir substrate feeder 1370b, which Fig.71 After the first engagement head 1362a engages the first outer body 216, the crossbar may be raised upward, displaced laterally, and lowered to deliver the first outer body to the first outer body and reservoir substrate feeder 1370a, which is also described in Fig.69 At this time, the second engagement head 1362b is positioned close to the singulator 1348 and engages with the second outer body 216.

[0375] Thus, the initial external body feeder 1360 can alternately feed the external body 216 to the first external body and reservoir substrate feeder 1370a and the second external body and reservoir substrate feeder 1370b. While the first external body and reservoir substrate feeder 1370a receives the first external body 216 from the initial external body feeder 1360, the first external body and reservoir substrate feeder also receives the reservoir substrate 214 singulated from the substantially continuous reservoir input 1310 supplied by the first reel 1308a in the manner described above. Conversely, while the second external body and reservoir substrate feeder 1370b receives the second external body 216 from the initial external body feeder 1360, the second external body and reservoir substrate feeder also receives the reservoir substrate 214 singulated from the substantially continuous reservoir input 1310 supplied by the second reel 1308b in the manner described above.

[0376] In this regard, Fig.71 As shown in , the first outer body and reservoir substrate feeder 1370a and the second outer body and reservoir substrate feeder 1370b can each include a rotating member 1372, a first substrate clamp 1374' and a second substrate clamp 1374" positioned at opposite ends of the rotating member, and a first outer body support 1376' and a second outer body support 1376" positioned at opposite ends of the rotating member. As illustrated, the outer body supports 1376', 1376" can include upwardly extending pins. Therefore, the engaging heads 1362a, 1362b of the initial body feeder 1360 (see, for example Fig.68 ) can position and release the outer body 216 so that the outer body extenders 1376', 1376" extend at least partially through the outer body so that the outer body can be maintained in the appropriate position.

[0377] In addition, if Fig.70 , the substrate holders 1374', 1374" can each include a first opposing portion 1378' and a second opposing portion 1378" configured to receive the reservoir substrate 214 therebetween. In this regard, the distal end of each opposing portion 1378', 1378" can define a lip configured to engage a respective longitudinal end of the reservoir substrate 214. Thus, the reservoir substrate 214 can maintain a generally U-shaped configuration when removed from the curved outer nose 1326 of the vacuum holder 1324 (see, e.g., Fig.65). It should be noted that in order to facilitate the transfer of the reservoir substrate 214 from the vacuum clamp 1324 to one of the substrate clamps 1374', 1374", in some embodiments, the vacuum clamp can briefly apply positive pressure to the reservoir substrate when one of the substrate clamps is positioned to receive the reservoir substrate therefrom. In addition, in some embodiments, the substrate clamps 1374', 1374" can apply negative pressure to the reservoir substrate 214 to further improve its grip.

[0378] Once the first outer body and reservoir substrate feeder 1370a or the second outer body and reservoir substrate feeder 1370b receives the outer body 216 and the reservoir substrate 214, the rotating member 1372 can be rotated so that the reservoir substrate and the outer body are positioned for receipt by a corresponding one of the first assembly unit 1380a and the second assembly unit 1380b, such as Fig.69 In this regard, the first outer body and reservoir substrate feeder 1370a supplies the outer body 216 and the reservoir substrate 214 to the first assembly unit 1380a, and the second outer body and reservoir substrate feeder 1370b (see Fig.71 ) The outer body and the reservoir substrate are supplied to the second assembly unit 1380b.

[0379] In the illustrated embodiment, the second assembly unit 1380b is positioned upstream of the first assembly unit 1380a. Thus, the reservoir substrate 214 and the outer body 216 can be assembled to the second partially assembled cartridge including the second substrate 204b before the reservoir substrate and the outer body are assembled to the first partially assembled cartridge including the first substrate 204a. However, as can be appreciated, this order can be reversed in other embodiments.

[0380] Thus, the bracket 604 can be guided along the track 602 for receiving the reservoir substrate 214 and the outer body 216. In this regard, as shown in FIG. Fig.71 As shown in FIG. 1 , the track 602 can guide each bracket 604 through the first processing section 1382a of the first assembly unit 1380a and the second processing section 1382b of the second assembly unit 1380b at the reservoir and external body connection substation 516. The first processing section 1382a can include a bracket sensor 1384a, an initial locator sensor 1386a, an initial stop 1388a, a lift stop 1390a (see FIG. 1 ). Fig.70), a stop locator sensor 1392a, and a lift mechanism 1394a, which may function in the manner described above with respect to the same components at other substations. Similarly, the second processing portion 1382b may include a carriage sensor (not shown; see, e.g., carriage sensor 1384a), an initial locator sensor 1386b, an initial stop 1388b, a lift stop 1390b ​​(not shown; see, e.g., Fig.70 Thus, the carriage 604 may be guided along the track 602 to the second processing portion 1382b, where the second assembly unit 1380b assembles the reservoir substrate 214 and the outer body 216 to the second base 204b, and then guided to the first processing portion 1382a, where the first assembly unit 1380a assembles the reservoir substrate and the outer body to the first base 204a.

[0381] In this regard, Fig.69 As shown in , the first assembly unit 1380a may include a robot arm 1396. The second assembly unit 1380b may also include a robot arm 1396, which may be substantially similar to the robot arm of the first assembly unit 1380a. The robot arm 1396 may be configured to insert the partially assembled cigarette cartridge into the external body 216 (e.g., by guiding the external body above the partially assembled cigarette cartridge in the manner discussed below). In this regard, the bracket 604 can transport one or more (e.g., two as described above) partially assembled cigarette cartridges along the track 602 to the reservoir and the external body connection substation 516, and as described above, these partially assembled cigarette cartridges may include a substrate 204, a negative heating terminal 234, a positive heating terminal 235, a heating element 240, a liquid delivery element 238, a control component terminal 206, and an electronic control component 208. As further described above, the negative heating terminal 234 and the positive heating terminal 235 can be directly coupled to the substrate 204, and the heating element 240 can be directly coupled to the negative heating terminal and the positive heating terminal. The heating element 240 can be wrapped around the liquid delivery element 238 so that the liquid delivery element is indirectly coupled to the negative heating terminal 234, the positive heating terminal 235, and the substrate 204. In addition, the control component terminal 206 can be directly coupled to the substrate 204 and can engage the electronic control component 208.

[0382] like Fig.70 As shown in FIG. 1 , each robotic arm 1396 may include a bending mechanism 1398. The bending mechanism 1398 may be configured to receive a partially assembled cartridge therein so as to bend the liquid delivery element 238 against the negative heating terminal 234 and the positive heating terminal 235. In this regard, as shown in FIG. Fig.72As shown in , the bending mechanism 1398 may include a hollow tube extending above the partially assembled cartridge to press the end of the liquid delivery element 238 and the heating element 240 in the illustrated embodiment downward into contact with the negative heating terminal 234 and the positive heating terminal 235.

[0383] The substrate holder 1374' can wrap the reservoir substrate 214 at least partially around the bending mechanism 1398 while the liquid delivery element 238 and the heating element 240 are bent against the negative heating terminal 234 and the positive heating terminal 235. In this regard, as shown in FIG. Fig.70 As shown in , the opposing portions 1378', 1378" can be oriented toward each other and clamped around the bending mechanism 1398. The bending mechanism 1398 can be subsequently retracted relative to the partially assembled cartridge after winding of the reservoir substrate 214 (e.g., by moving upward in the illustrated orientation) so that the reservoir substrate is at least partially wrapped around the negative heating terminal 234 and the positive heating terminal 235 and in contact with the liquid delivery element 238.

[0384] like Fig.70 As shown in , each robotic arm 1396 may further include an external body gripper 1400. The external body gripper 1400 may include a first opposing portion 1402' and a second opposing portion 1402". The opposing portions 1402', 1402" of the external body gripper may be configured to move between a separated configuration as shown and in which the opposing portions are separated from each other and a retracted configuration in which the opposing portions are in contact with each other.

[0385] While the robotic arm 1396 is lowering the bending mechanism 1398 over the partially assembled cigarette cartridge, the external body clamp 1400 may also be lowered so that the first opposing portion 1402' and the second opposing portion 1402" extend around the external body 216 supported by the one of the external body supports 1376', 1376" positioned proximate to the track 602. Thus, the external body clamp 1440 may be configured to receive the external body 216 therein while the bending mechanism 1398 receives the partially assembled cigarette cartridge therein. Once lowered, the first opposing portion 1402' and the second opposing portion 1402" may be moved toward each other so that the external body clamp 1400 retains the external body 216 therein. Thus, when the robotic arm 1396 lifts the bending mechanism 1398 after the reservoir substrate 214 is wrapped around it, the external body clamp 1400 may lift the external body 216 from the one of the external body supports 1376', 1376" to which the external body is coupled.

[0386] In addition, the robot arm 1396 can guide the outer body holder 1400 with the outer body 216 positioned therein over the partially assembled cigarette cartridge. In this regard, the robot arm 1396 can be rotated (e.g., about 90 degrees) so that the bending mechanism 1398 is positioned away from the bracket 604 and thus does not contact the bracket, while the outer body holder 1400 extends downward toward the partially assembled cigarette cartridge. When the outer body 216 is guided over the partially assembled cigarette cartridge, the negative heating terminal 234, the positive heating terminal 235, the heating element 240 and the liquid delivery element 238, and at least a portion of the electronic control assembly 208 and the control assembly terminal 206 that include these components in embodiments are received in the outer body.

[0387] To facilitate insertion of the partially assembled cartridge into the outer body 216, the outer body holder 1400 may apply a negative pressure that passes longitudinally through the outer body via the outer body holder 1400. Fig.70 As shown in , the external body holder 1400 may further include a piston 1404. The piston 1404 may be configured to engage one end of the external body 216 and apply negative pressure through the external body when the first opposing portion 1402' and the second opposing portion 1402" of the external body holder 1400 are in a contracted configuration with the external body therein. In this regard, for example, the piston 1404 may be hollow and connected to a suction system 1405 configured to supply negative pressure. Applying negative pressure to the partially assembled cartridge through the external body 216 can help insert the partially assembled cartridge into the external body by pulling the reservoir substrate 214 into the external body during insertion. In turn, problems regarding the reservoir substrate 214 shifting from a desired position or not being fully inserted into the external body 216 can be avoided.

[0388] As the outer body 216 presses downward over the partially assembled cartridge, the opposing portions 1378', 1378" of the substrate clamp 1374' can release the reservoir substrate 214 and, in embodiments where the substrate clamp applies negative pressure to the reservoir substrate, cease applying negative pressure thereto. The rotating component 1372 of the outer body and reservoir substrate feeder 1370b can then be rotated (e.g., by rotating approximately one hundred eighty degrees) to deliver an additional outer body 216 as a partially assembled cartridge close to the robotic arm 1396 for attachment to the next bracket 604.

[0389] The piston 1404 can be further configured to press the outer body 216 into engagement with the base 204b. In this regard, the piston 1404 can press against the upper end of the outer body 216 (e.g., by being flush against the upper end of the outer body). In this regard, the piston 1404 can define one or more dimensions (e.g., diameter) that are substantially equal to the outer body 216. In turn, the outer body 216 can press the partially assembled cartridge into full engagement with the base 204b.

[0390] The component presence sensor 1406b (e.g., including a light emitter and a receiver) can detect whether the external body 216 is properly connected to the base 204b. For example, the component presence sensor 1406b can detect whether the external body 216 is present while the bracket 604 is lifted by the lifter mechanism 1394b. Then, this information can be written to the storage module 624 by the storage transceiver (not shown; see, for example, the storage transceiver 1408a) in the second processing part 1382b. Therefore, if the external body 216 is not properly assembled with the partially assembled cigarette cartridge, additional operations cannot be performed on the partially assembled cigarette cartridge to avoid damage to the assembly equipment and waste of additional components. In this same aspect, the storage transceiver can read the code on the storage module 624 to determine that the partially assembled cigarette cartridge is matched for further assembly before the external body 216 is connected to the base 204.

[0391] Once the outer body 216 is pressed onto the partially assembled cigarette cartridge, the lifter mechanism 1394b can lower the carriage back onto the track 602. The carriage 604 can then be guided to the first processing section 1382a, where substantially the same operation can be performed to connect the first outer body 216 to the first substrate 204a. Subsequently, as described above with respect to the second processing section 1382b, the component presence sensor 1406a (e.g., including a light transmitter and a receiver) can detect whether the outer body 216 is properly connected to the substrate 204a. Furthermore, this information can be written to the storage module 624 by the storage transceiver 1408a in the first processing section 1382a. Therefore, if the outer body 216 is not properly assembled with the partially assembled cigarette cartridge, additional operations cannot be performed on the partially assembled cigarette cartridge to avoid damage to the assembly equipment and waste of additional components. In this same aspect, the memory transceiver 1408a can read a code on the memory module 624 to determine that the partially assembled cartridge is mated for further assembly prior to coupling the outer body 216 to the base 204a.

[0392] It should be noted that the above operations can be performed simultaneously. In this regard, for each of the external body and reservoir substrate feeders 1370a, 1370b, while one of the substrate clamps 1374', 1374" receives the reservoir substrate 1314, another of the substrate clamps can wrap the reservoir substrate around the bending mechanism 1398. In addition, while one of the substrate clamps 1374', 1374" receives the reservoir substrate 1314, an associated one of the external body supports 1376', 1376" can receive the external body. Various other operations performed by the reservoir and external body coupling substation 516 can be performed simultaneously to reduce cycle time. Therefore, rapid and efficient engagement of the reservoir substrate and the external body with a partially assembled cartridge can be achieved.

[0393] The outer body crimping and inspection substation 518 may be positioned downstream of the reservoir and outer body coupling substation 516 . Fig.73 Shown is a partial side view of the outer body crimping and inspection substation 518. As illustrated, the outer body crimping and inspection substation 518 may include a first crimper unit 1502a, a second crimper unit 1502b, a first transfer unit 1504, an inspection and handling unit 1506, and a second transfer unit 1508.

[0394] Fig.74 A perspective view of a first crimping unit 1502a and a second crimping unit 1502b is shown. As illustrated, the first crimping unit 1502a and the second crimping unit 1502b can each include a crimper 1510. The crimper 1510 can include a plurality of sections configured to extend around the outer body 216 and crimp the outer body to the substrate 204. In turn, the first crimping unit 1502a can crimp the outer body 216 to the first substrate 204a, while the second crimping unit 1502b can crimp the second outer body 216 to the second substrate 204b. Various details about the configuration of example embodiments of crimpers that can be employed in the first crimping unit 1502a and the second crimping unit 1502b are provided in U.S. Patent Application No. 14 / 227,159 filed by Ampolini et al. on March 27, 2014, which is incorporated herein by reference in its entirety.

[0395] As in Fig.74As further described in the first crimper unit 1502a and the second crimper unit 1502b can each include a processing portion 1512 configured to prepare each partially assembled cartridge on the bracket 604 for crimping while guiding the bracket along the track 602. In this regard, the processing portion 1512 can position the bracket 604 for crimping the first outer body 216 in the first crimper unit 1502a and position the bracket for crimping the second outer body in the second crimper unit 1502b, respectively.

[0396] In this regard, Fig.75 A perspective view of a processing portion 1512 included at each of the first crimper unit 1502a and the second crimper unit 1502b is shown. As illustrated, the processing portion 1512 may include a carriage sensor 1514, an initial locator sensor 1516, an initial stop 1518, a stop locator sensor 1520, a lift stop 1522, and a lift mechanism 1524, which may function in the manner described above with respect to the same components at other substations.

[0397] Thus, the bracket 604 can be lifted by the corresponding lifter mechanism 1524 at each of the first crimper unit 1502a and the second crimper unit 1502b. While lifting at the first crimper unit 1502a, the first outer body 216 can be crimped onto the first substrate 204a. Similarly, while lifting at the second crimper unit 1502b, the second outer body 216 can be crimped onto the second substrate 204b.

[0398] After each crimping operation, the component presence sensor 1526 (e.g., including a light transmitter and a receiver) can detect whether the partially assembled cigarette cartridge that has been crimped still exists. Then, the storage transceiver 1528 can write a code to the storage module 624, and the code indicates whether the partially assembled cigarette cartridge that has been subjected to the crimping operation exists, so that no additional operation can be performed on it when the cigarette cartridge is not detected. In this same aspect, the storage transceiver 1528 can read the code on the storage module 624 to determine that the partially assembled cigarette cartridge before the outer body 216 is crimped to the substrate 204 is matched for further assembly. Subsequently, the lifter mechanism 1524 can lower the carriage 604 to engage with the track 602 so that the carriage is guided downstream. In this regard, each carriage 604 can be guided from the first crimper unit 1502a to the second crimper unit 1502b to the first transfer unit 1504.

[0399] Fig.76An enlarged partial view of the first transfer unit 1504 is shown. As illustrated, the first transfer unit 1504 can include a processing portion 1530. The processing portion 1530 can position the bracket 604 for transfer of the partially assembled cigarette cartridge to the inspection and processing unit 1506. In this regard, the processing portion 1530 can include a bracket sensor (not shown; see e.g. Fig.75 The bracket sensor 1514 in FIG. 1 ), the initial locator sensor (not shown; see e.g. Fig.75 The first transfer unit 1504 may transfer the first and second partially assembled cartridges to the inspection and processing unit 1506.

[0400] In this regard, as in Fig.76 As further described in the first transfer unit 1504, the first transfer unit 1504 may include an end effector 1540. The end effector 1540 may include a first opposing portion 1542 and a second opposing portion 1544 configured to grasp the partially assembled cartridge. For example, the first opposing portion 1542 and the second opposing portion 1544 of the end effector 1540 may be configured to clamp against opposite sides of the base 204 and / or the outer body 204. In turn, the robotic arm 1546 of the first transfer unit 1504 may individually lift and remove the first and second partially assembled cartridges from the bracket 604, and transfer the partially assembled cartridges to the inspection and processing unit 1506.

[0401] The processing portion 1530 of the first transfer unit 1504 may further include a first component presence sensor 1548a and a second component presence sensor 1548b (e.g., including a light emitter and a receiver, respectively). The first component presence sensor 1548a can be configured to detect whether the first partially assembled cigarette cartridge is successfully removed from the bracket by the robot arm 1546 and the end effector 1540. Similarly, the second component presence sensor can be configured to determine whether the second partially assembled cigarette cartridge is removed by the robot arm 1546 and the end effector 1540. Furthermore, the storage transceiver 1542 can write a code to the storage module 624, the code indicating whether the partially assembled cigarette cartridge is successfully removed from the bracket 604. In this regard, when the partially assembled cigarette cartridge is successfully removed from the bracket 604, the track 602 can guide the bracket back to the assembly area 602a so that each of the substations 502-518 (see Figure 4However, in instances where one or both of the partially assembled cartridges are not successfully removed from the carriage 604, the carriage may be directed away from the track 602, or the operator may be alerted so that the carriage is no longer used with respect to the partially assembled cartridges still attached.

[0402] The first transfer unit 1504 can transfer the partially assembled cartridge to the inspection and processing unit 1506. Fig.77 As shown in, in one embodiment, the inspection and processing unit 1506 may include an inspection chute 1547. In this regard, partially assembled cartridges can be selected at various stages of assembly for review for quality control or other purposes. When a partially assembled cartridge is selected for review, after reaching the desired completion state, the storage module 624 can be programmed to indicate that these partially assembled cartridges should not be subjected to any further assembly in the same manner as discussed above for cartridges determined to be defective. In this regard, the various storage transceivers described above can read the storage module 624 and the code thereon can indicate that the corresponding substation does not perform further assembly operations on the partially assembled cartridges. Furthermore, the partially assembled cartridges can arrive at the first transfer unit 1504 in any of a variety of completion states, so that the partially assembled cartridges can be guided to the review chute 1547 and checked to ensure that each of the substations 502-518 of the cartridge assembly system 402 operates properly.

[0403] The first transfer unit 1504 can transfer the remaining part of the partially assembled cigarette cartridge that is not directed to the review chute 1547 to the indexing table 1550 of the inspection and processing unit 1506. As described, the indexing table 1550 may include a plurality of first clamps 1552a and second clamps 1552b extending radially therefrom. The first clamp 1552a can be configured to receive the first partially assembled cigarette cartridge and the second clamp 1552b can be configured to receive the second partially assembled cigarette cartridge. Furthermore, when the indexing table 1550 is indexed (e.g., by moving counterclockwise in the illustrated orientation), the partially assembled cigarette cartridge can be transported between multiple angle stops.

[0404] In this regard, the first transfer unit 1504 can deliver the partially assembled cartridge to the first angle stop 1554. Fig.78 As shown in FIG. 1 , the first angle stop 1554 may include a first rejection slot 1556. Thus, when the first transfer unit 1504 positions each partially assembled cartridge at the first angle stop 1554, the associated holder 1552a, 1552b to which the partially assembled cartridge is delivered may function in one of two ways. If the partially assembled cartridge is defective in one or more aspects, as recorded on the storage module 624, and as stored in the transceiver 1542 (see Fig.76) read, then the holders 1552a, 1552b to which the partially assembled cartridges are delivered may not be clamped thereon. Therefore, when the end effector 1540 releases the defective partially assembled cartridges, these cartridges may fall into the first rejection chute 1556 for disposal, further analysis or recycling of its components.

[0405] In contrast, when a partially assembled cartridge has not been determined to be defective, the associated clamp 1552a, 1552b to which the partially assembled cartridge is delivered can be clamped onto the cartridge so that the cartridge can be transported as the indexing table 1550 moves. In this regard, each clamp 1552a, 1552b may include a first opposing portion 1558 and a second opposing portion 1560 that are configured to clamp around the base 204 and / or outer body 216 of each partially assembled cartridge. Each clamp 1552a, 1552b can be actuated in response to the corresponding component presence sensor 1562a, 1562b detecting the presence of a partially assembled cartridge at the clamp that has not been previously determined to be defective as described above. It should be noted that in Fig.78 , the indexing table 1550 is illustrated as being slightly rotated counterclockwise from the first angular stop 1554 at which the grippers 1552a, 1552b receive the partially assembled cartridges from the first transfer unit 1504, so as to illustrate the first rejection chute 1556. In this regard, in the first angular stop 1554, the grippers 1552a, 1552b are positioned above the rejection chute 1556, rather than being displaced therefrom.

[0406] Once received in the holders 1552a, 1552b, the indexing table 1550 can be indexed so that the partially assembled cartridge is delivered to the second angular stop 1564. Fig.79 An enlarged view of the second angle stop 1564 is shown. As illustrated, the second angle stop 1564 may include a first air flow assembly 1566a and a second air flow assembly 1566b. Each air flow assembly 1566a, 1566b includes a first coupler 1568 and a second coupler 1570, one of which engages the base 204 and the other of which engages an end of the outer body 216 away from the base. In turn, each air flow assembly 1566a, 1566b can apply an air flow through the partially assembled cartridge in order to remove any contaminants and / or ensure that the pressure drop associated with the partially assembled cartridge meets specifications.

[0407] After the air flow assembly 1566 is released from the partially assembled cartridge, the indexing table 1550 can be indexed to the third angle stop 1572. Fig.80As shown in , the third angle stop 1572 may include a first imaging device 1574 (e.g., a camera) configured to inspect the exterior of the partially assembled cartridge. In this regard, the first imaging device 1574 can capture an image of the end of the partially assembled cartridge opposite to the substrate so that the image includes the heating element 240, the liquid delivery element 238, and the reservoir substrate 214 within the outer body 216. Then, the position of one or more of these components can be compared with their desired position. In addition, the third angle stop 1572 may include a second imaging device 1576 (e.g., a camera) configured to inspect the exterior of the partially assembled cartridge. In this regard, the second imaging device 1576 can capture images of the sides of the outer body 216 and the substrate 204 to ensure that the outer body 216 is properly crimped to the substrate and to ensure that the reservoir substrate 214 is not exposed at the joint therebetween.

[0408] The indexing table 1550 can then be indexed to the fourth angle stop 1578. Fig.81 As shown in , the fourth angle stop 1578 may include a first electrical tester 1580a and a second electrical tester 1580b. The electrical testers 1580a, 1580b may be configured to ensure that the heating element 240 is properly welded to the negative heating terminal 234 and the positive heating terminal 235. In addition, the electrical testers 1580a, 1580b can test the partially assembled cartridge to ensure that the control assembly terminal 206, the negative heating terminal 234, and the positive heating terminal 235 are not grounded to the external body 216. In addition, in some embodiments, the electrical testers 1580a, 1580b can upload code to the electronic control assembly 208, which code can, for example, control a heating profile that specifies how to direct current to the heating element 240 when a puff is detected on an associated control body.

[0409] The indexing table 1550 can then be indexed to the fifth angle stop 1582. Fig.77 , the fifth angle stop 1582 may include a second rejection chute 1584. In this regard, when the partially assembled cartridge fails one of the tests at the second angle stop 1564, the third angle stop 1572, or the fourth angle stop 1578 of the inspection and processing unit 1506, the grippers 1552a, 1552b may release the partially assembled cartridge over the second rejection chute 1584 for disposal, further analysis, or recycling of its components.

[0410] The indexing table 1550 can be further indexed to a sixth angular stop 1586, which corresponds to the position of the partially assembled cartridge close to the second transfer unit 1508. In this regard, as shown in FIG. Fig.73, the second transfer unit 1508 may include a robotic arm 1588 and an end effector 1590. The robotic arm 1588 may position the end effector 1590 so that the end effector can grasp the partially assembled cartridge and transfer the partially assembled cartridge to the unloading conveyor 1592. In turn, the unloading conveyor 1592 may transfer the partially assembled cartridge to the cartridge filling subsystem 408 for filling, then to the cartridge capping system 412 for capping, and to the cartridge marking subsystem 416 for marking (see Figure 3 ).

[0411] It should be noted that the inspection subsystem 418 can be distributed across various parts of the system 400 for producing a cartridge. In this regard, for example, the inspection subsystem 418 can include various component presence sensors and other sensors configured to detect the position, presence, and other properties of the components of the cartridge as described above.

[0412] In addition, an assembly method is provided. Fig.82 As illustrated in FIG. 1 , the method may include providing a plurality of components via a supply unit at operation 1602. Furthermore, the method may include alternately feeding a first portion of the components from the supply unit to a first assembly unit and a second portion of the components to a second assembly unit at operation 1604. The method may further include assembling the first portion of the components with the first assembly unit and the second portion of the components with the second assembly unit into a plurality of cartridges for an aerosol delivery device at operation 1606.

[0413] In some embodiments, alternately feeding the first part of the component from the supply unit to the first assembly unit and feeding the second part of the component to the second assembly unit in operation 1604 may include rotating a rotating component between a first delivery position in which the rotating component is configured to deliver the first part of the component to the first assembly unit and a second delivery position in which the rotating component is configured to deliver the second part of the component to the second assembly unit. Rotating the rotating component may include receiving one of the components from the supply unit in the first engagement head while the second engagement head feeds one of the components to the second assembly unit, and receiving one of the components from the supply unit in the second engagement head while the first engagement head feeds one of the components to the first assembly unit.

[0414] Providing the components via the supply unit at operation 1602 may include directing the components along a path in a serially aligned stream and singling out the components from the serially aligned stream. The method may further include individually removing the components from the serially aligned stream or realigning the components when misaligned in a first direction. The method may further include removing the components from the serially aligned stream through a gap in the path when the components are misaligned in a second direction.

[0415] Fig.83 In the additional embodiment of the assembly method described in. As described, the method may include providing a substrate and a plurality of additional components that are collectively configured to form a plurality of cigarette cartridges for an aerosol delivery device in operation 1702, the substrate extending between an inner end and an attachment end, the inner end being configured to receive an additional component during the assembly of the cigarette cartridge, and the attachment end defining an inner surface that is configured to engage a control body during the use of the aerosol delivery device. In addition, the method may include providing a plurality of assembly substations, tracks, and a bracket including a joint head defining a plurality of sections in operation 1704, the track extending between the assembly substations, and the bracket being configured to engage the track and cooperate with it to move between the assembly substations. The method may further include engaging the inner surface of the attachment end of the substrate with the section of the joint head via an interference fit in operation 1706 to provide access to the inner end of the substrate for the assembly substation. The method may also include conveying the bracket between the assembly substations by means of a track in operation 1708. In addition, the method may include assembling the additional components with the inner end of the substrate at the assembly substation in operation 1710.

[0416] Engaging the substrate with the engagement head at operation 1706 may include rotationally aligning the substrate with the engagement head. Rotationally aligning the substrate with the engagement head includes detecting the rotational orientation of the substrate based on an image of the attachment end of the substrate. The method may further include storing cartridge identification and status information in a storage module coupled to the carriage. In addition, the method may include locking the carriage at one or more locations in the substation by guiding one or more locking pins from a track into one or more alignment apertures defined in the carriage. Conveying the carriage by means of a track at operation 1708 may include conveying the carriage by means of a conveyor, and wherein locking the carriage includes lifting the carriage from the conveyor.

[0417] Fig.84 Additional assembly methods are illustrated. As described, the method may include providing a partially assembled cartridge at operation 1802, comprising: a substrate, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element, wherein the negative heating terminal and the positive heating terminal are coupled to the substrate, and the heating element is coupled to the negative heating terminal and the positive heating terminal. The method may further include inserting the partially assembled cartridge into the external body by engaging the external body with an external body gripper of a robot arm and guiding the external body over the partially assembled cartridge at operation 1804. In addition, the method may include applying a negative pressure supplied by a suction system operably coupled to the external body gripper of the robot arm to the external body at operation 1806 to facilitate insertion of the partially assembled cartridge into the external body.

[0418] In some embodiments, the method may further include inserting the partially assembled cartridge into a bending mechanism to bend the liquid delivery element against the negative heating terminal and the positive heating terminal, at least partially winding the reservoir substrate around the bending mechanism, and retracting the bending mechanism relative to the partially assembled cartridge after winding the reservoir substrate so that the reservoir substrate is at least partially wound around the negative heating terminal and the positive heating terminal and in contact with the liquid delivery element. Applying negative pressure to the external body in operation 1806 may include engaging one end of the external body with a piston of the external body holder, the piston being in fluid communication with the suction system and configured to apply negative pressure through the external body. In addition, the method may include pressing the external body to engage with the substrate by means of the piston.

[0419] As described above, the system 400 may include a controller 417. The controller 417 may be configured to execute computer code for performing the operations described herein. Fig.85 As shown in , the controller 417 may include a processor 1902, which may be a microprocessor or controller for controlling its overall operation. In one embodiment, the processor 1902 may be configured to perform the functions described herein. The controller 417 may also include a memory device 204. The memory device 1904 may include a non-temporary and tangible memory, which may be, for example, a volatile and / or non-volatile memory. The memory device 1904 may be configured to store information, data, files, applications, instructions, or the like. For example, the memory device 1904 may be configured to buffer input data for processing by the processor 1902. Additionally or alternatively, the memory device 1904 may be configured to store instructions for execution by the processor 1902.

[0420] The controller 417 may also include a user interface 1906 that allows a user to interact with it. For example, the user interface 1906 may be in a variety of forms, such as buttons, keypads, dials, touch screens, audio input interfaces, visual / image capture input interfaces, input in the form of sensor data, etc. Furthermore, the user interface 1906 may be configured to output information to the user through a display, speaker, or other output device. The communication 1908 interface may be provided for transmitting and receiving data through, for example, a wired or wireless network 1910, such as a local area network (LAN), a metropolitan area network (MAN), and / or a wide area network (WAN), such as the Internet.

[0421] Various aspects, embodiments, implementation schemes or features of the described embodiments may be used individually or in any combination. Various aspects of the described embodiments may be implemented by a combination of software hardware or hardware and software. The described embodiments may also be embodied as computer-readable code on a computer-readable medium for controlling the operations described above. Specifically, the computer-readable code may be configured to perform each of the operations of the methods described herein, and the operations are embodied as computer-readable code on a computer-readable medium for controlling the operations described above. In this regard, a computer-readable storage medium as used herein refers to a non-temporary physical storage medium (e.g., a volatile or non-volatile memory device that can be read by a computer system. Examples of computer-readable media include read-only memory, random access memory, CD-ROM, DVD, magnetic tape, and optical data storage devices. Computer-readable media may also be distributed on network-coupled computer systems so that computer-readable codes are stored and executed in a distributed manner.

[0422] As described above, the controller 417 can be configured to execute computer code for performing the operations described above. In this regard, an embodiment of a non-transitory computer-readable medium for storing computer instructions executed by a processor in a controller (e.g., controller 417) configured to assemble a cartridge for an aerosol delivery device is provided. The non-transitory computer-readable medium may include: program code instructions for providing a plurality of components via a supply unit; program code instructions for alternately feeding a first portion of a component from a supply unit to a first assembly unit and a second portion of a component to a second assembly unit via a processor; and program code instructions for assembling a first portion of a component with a first assembly unit and a second portion of a component with a second assembly unit into a plurality of cartridges for an aerosol delivery device.

[0423] Program code instructions for alternately feeding a first portion of a component from a supply unit to a first assembly unit and a second portion of a component to a second assembly unit may include program code instructions for rotating a rotating component between a first delivery position and a second delivery position, wherein the rotating component is configured to deliver the first portion of the component to the first assembly unit and the rotating component is configured to deliver the second portion of the component to the second assembly unit. Program code instructions for rotating a rotating component may include program code instructions for receiving one of the components from a supply unit in a first joint head while a second joint head feeds one of the components to the second assembly unit and receiving one of the components from a supply unit in a second joint head while a first joint head feeds one of the components to the first assembly unit. Program code instructions for providing components via a supply unit may include program code instructions for guiding components along a path in a serial alignment flow and singling out components from a serial alignment flow. The non-transitory computer-readable medium may further include program code instructions for individually removing components from a serial alignment flow or realigning components when misaligned in a first direction. The non-transitory computer-readable medium may further include program code instructions for removing a component from the serially aligned flow through a gap in the path when the component is misaligned in the second direction.

[0424] In another embodiment, a non-transitory computer-readable medium for storing computer instructions executed by a processor in a controller (e.g., controller 417) configured to assemble a cartridge for an aerosol delivery device may include: program code instructions for providing a base and a plurality of additional components that are collectively configured to form a plurality of cartridges for an aerosol delivery device, the base extending between an inner end and an attachment end, the inner end being configured to receive the additional components during assembly of the cartridge, the attachment end defining an inner surface configured to engage a control body during use of the aerosol delivery device; Program code instructions for providing a plurality of assembly substations, tracks, and a bracket including a coupling head defining a plurality of sections, the tracks extending between the assembly substations, and the bracket being configured to engage the tracks and cooperate therewith to move between the assembly substations; program code instructions for engaging the inner surface of an attachment end of a substrate with the sections of the coupling head via an interference fit to provide the assembly substation with access to the inner end of the substrate; program code instructions for transporting the bracket between assembly substations by means of the tracks; and program code instructions for assembling additional components with the inner end of the substrate at an assembly substation via a processor.

[0425] The program code instructions for engaging the substrate with the engagement head may include program code instructions for rotationally aligning the substrate with the engagement head. The program code instructions for rotationally aligning the substrate with the engagement head may include program code instructions for detecting the rotational orientation of the substrate based on the image of the attachment end of the substrate. The non-transitory computer-readable medium may further include program code instructions for storing cartridge identification and status information in a storage module connected to the bracket. The non-transitory computer-readable medium may further include program code instructions for locking the bracket at one or more locations in the substation by guiding one or more locking pins from the track into one or more alignment apertures defined in the bracket. In some embodiments, the program code instructions for conveying the bracket by means of the track may include program code instructions for conveying the bracket by means of a conveyor, and wherein the program code instructions for locking the bracket may include program code instructions for lifting the bracket from the conveyor.

[0426] In another embodiment, a non-transitory computer-readable medium for storing computer instructions executed by a processor in a controller (e.g., controller 417) configured to assemble a cartridge for an aerosol delivery device may include: program code instructions for providing a partially assembled cartridge, the partially assembled cartridge comprising a base, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element, the negative heating terminal and the positive heating terminal being connected to the base, and the heating element being connected to the negative heating terminal and the positive heating terminal; program code instructions for inserting the partially assembled cartridge into an external body by engaging the external body with an external body clamp of a robotic arm and guiding the external body over the partially assembled cartridge; and program code instructions for applying, via the processor, a negative pressure supplied by a suction system operably engaged with the external body clamp of the robotic arm to facilitate insertion of the partially assembled cartridge into the external body.

[0427] In some embodiments, the non-transitory computer-readable medium may further include: program code instructions for inserting the partially assembled cigarette cartridge into a bending mechanism to bend the liquid delivery element against the negative heating terminal and the positive heating terminal; program code instructions for at least partially wrapping a reservoir substrate around the bending mechanism; and program code instructions for retracting the bending mechanism relative to the partially assembled cigarette cartridge after wrapping the reservoir substrate so that the reservoir substrate is at least partially wrapped around the negative heating terminal and the positive heating terminal and in contact with the liquid delivery element.

[0428] In some embodiments, the program code instructions for applying negative pressure to the external body may include program code instructions for engaging one end of the external body with a piston of an external body holder, the piston being in fluid communication with a suction system and configured to apply negative pressure through the external body. The non-transitory computer readable medium may further include program code instructions for pressing the external body into engagement with the substrate with the piston.

[0429] Many modifications and other embodiments of the present disclosure will occur to those skilled in the art to which the present disclosure relates, thanks to the teachings presented in the foregoing description and the related drawings. Therefore, it should be understood that the present disclosure should not be limited to the specific embodiments disclosed herein, and modifications and other embodiments thereof are intended to be included within the scope of the appended claims. Although specific terms are employed herein, the terms are used only in a general and descriptive sense and not for limiting purposes.

Claims

1. An assembly substation, comprising: a robotic arm configured to insert a partially assembled cigarette cartridge into an external body, the partially assembled cigarette cartridge comprising a base, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element, the negative heating terminal and the positive heating terminal being coupled to the base, and the heating element being coupled to the negative heating terminal and the positive heating terminal, the robotic arm comprising an external body holder configured to receive the external body therein, the robotic arm being configured to guide the outer body holder having the outer body positioned therein over the partially assembled cartridge such that the negative heating terminal, the positive heating terminal, the heating element, and at least a portion of the liquid delivery element are received in the outer body; as well as A suction system is operably engaged with the outer body gripper of the robotic arm, the outer body gripper being configured to apply negative pressure supplied by the suction system longitudinally through the outer body to facilitate insertion of the partially assembled cigarette cartridge into the outer body.

2. The assembly substation of claim 1 , further comprising a bending mechanism configured to receive the partially assembled cartridge therein so as to bend the liquid delivery element against the negative heating terminal and the positive heating terminal; and a substrate holder configured to wrap a reservoir substrate at least partially around the bending mechanism, The bending mechanism is configured to retract relative to the partially assembled cartridge following winding of the reservoir substrate such that the reservoir substrate is at least partially wrapped around the negative and positive heating terminals and in contact with the liquid delivery element.

3. The assembly substation of claim 2, wherein the outer body holder is configured to receive the outer body therein while the bending mechanism receives the partially assembled cartridge therein.

4. An assembly substation according to claim 2 or claim 3, wherein the external body clamp includes a piston, which is fluidly connected to the suction system and is configured to engage one end of the external body to apply the negative pressure through the external body.

5. The assembly substation of claim 4, wherein the piston is configured to press the outer body into engagement with the substrate.

6. An assembly method comprising: Providing a partially assembled cigarette cartridge, the partially assembled cigarette cartridge comprising: a substrate, a negative heating terminal, a positive heating terminal, a heating element, and a liquid delivery element, the negative heating terminal and the positive heating terminal being coupled to the substrate, and the heating element being coupled to the negative heating terminal and the positive heating terminal; inserting the partially assembled cartridge into the outer body by engaging the outer body with an outer body gripper of a robotic arm and guiding the outer body over the partially assembled cartridge; and Negative pressure supplied by a suction system operably engaged with the outer body gripper of the robotic arm is applied to the outer body to facilitate insertion of the partially assembled cartridge into the outer body.

7. The assembly method of claim 6, further comprising inserting the partially assembled cartridge into a bending mechanism to bend the liquid delivery element against the negative heating terminal and the positive heating terminal; wrapping a reservoir substrate at least partially around the bending mechanism; and The bending mechanism is retracted relative to the partially assembled cartridge after winding of the reservoir substrate such that the reservoir substrate is at least partially wrapped around the negative and positive heating terminals and in contact with the liquid delivery element.

8. The assembly method of claim 7, wherein applying the negative pressure to the external body comprises engaging one end of the external body with a piston of the external body holder, the piston being in fluid communication with the suction system and configured to apply the negative pressure through the external body.

9. The method of assembling according to claim 8, further comprising pressing the outer body into engagement with the base with the piston.

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