Dispensing unit for an aerosol precursor

Abstract

A unit for mixing and dispensing an aerosol precursor composition, and a container dispensed from the unit. The unit includes a plurality of bulk material filling stations having at least one first filling station with an aerosol former and at least one second filling station with a flavor material for producing an aerosol precursor. The unit also includes a bulk consumable package that arranges a plurality of containers configured to receive the aerosol precursor and a robot configured to remove the containers from the bulk consumable package and move the containers through at least two dimensions to stop at at least two of the plurality of bulk material filling stations.

Description

[0001] This application is a divisional application of the invention application filed by Lai Strategic Holdings Co., Ltd. on February 1, 2018, with Chinese national phase application number CN201880023762.X (PCT application number PCT / IB2018 / 050648) entitled "Dispensing Unit for Aerosol Precursors". Technical Field

[0002] This disclosure relates to custom aerosol precursor compositions and a machine configured to dispense containers having aerosol precursors. This disclosure also relates to containers for receiving aerosol precursors within a machine. Aerosol precursors may be of the type comprising materials that can be made from or derived from tobacco, or may otherwise comprise tobacco. When used with an aerosol delivery device (e.g., a smoking article), the precursor is intended to be able to form an inhalable substance for human consumption. Smoking articles may be of the type that utilize electrically generated heat to produce the inhalable substance. Background Technology

[0003] In recent years, numerous smoking devices have been proposed as improvements or alternatives to smoking products that require the combustion of tobacco. Many of these devices are reportedly designed to provide the sensation associated with smoking a cigarette, cigar, or pipe without delivering the large amounts of incomplete combustion and pyrolysis products produced by the combustion of tobacco. To this end, numerous cigarette products, flavor generators, and drug inhalers have been proposed that employ electrical energy to evaporate or heat volatile materials or attempt to provide the sensation of smoking a cigarette, cigar, or pipe without significantly burning the tobacco. For example, see the various alternative smoking products, aerosol delivery devices, and heat sources described in the background art of U.S. Patent No. 7,726,320 to Robinson et al. and U.S. Patent No. 8,881,737 to Collett et al., both of which are incorporated herein by reference. See also, for example, various types of smoking products, aerosol delivery devices, and electrically powered heat sources with reference to trademarks and commercial sources in U.S. Patent Publication No. 2015 / 0216232 to Bless et al., which are incorporated herein by reference in their entirety. In addition, various types of electro-aerosol and vapor delivery devices are disclosed in U.S. Patent Publication No. 2014 / 0096781 by Sears et al.; U.S. Patent Publication No. 2014 / 0283859 by Minskoff et al.; U.S. Patent Application Serial No. 14 / 282,768 filed by Sears et al. on May 20, 2014; U.S. Patent Application Serial No. 14 / 0335071 filed by Brinkley et al. on May 23, 2014; U.S. Patent Application Serial No. 14 / 327,776 filed by Ampolini et al. on July 10, 2014; and U.S. Patent Application Serial No. 14 / 465,167 filed by Worm et al. on August 21, 2014; all of which are incorporated herein by reference in their entirety.

[0004] Some of these alternative smoking products, namely aerosol delivery devices, can be reused by employing replaceable cartridges or refillable containers using aerosol precursors (such as tobacco juice, e-liquid, or e-juice). It is expected that personalized options for aerosol precursors used in these alternative smoking products will be available. Therefore, advancements in the generation, mixing, and dispensing of aerosol precursors will be anticipated. Summary of the Invention

[0005] This disclosure provides a unit for mixing and dispensing an aerosol precursor composition used by an aerosol delivery device such as an electronic cigarette. The aerosol precursor dispensed from this unit can typically be customized to a customer's preference for flavor and / or strength. The mixing and dispensing unit can be configured to dispense the composition in the form of a filled or partially filled container that holds the aerosol precursor composition until it is provided to a storage section of the aerosol delivery device. The container can be specifically designed to have at least one of child-protective and anti-tamper features. Methods of using the mixing and dispensing unit and methods of using the container are also described.

[0006] In one embodiment, this disclosure includes a unit for mixing and dispensing an aerosol precursor composition. The unit includes a plurality of bulk material filling stations, including at least one first filling station having an aerosol forming agent and at least one second filling station having a flavoring material for generating the aerosol precursor. The unit also includes bulk consumable packaging that staging a plurality of containers configured to receive the aerosol precursor. The unit further includes a robot configured to remove containers from the bulk consumable packaging and move the containers through at least two dimensions to stop at at least two of the plurality of bulk material filling stations.

[0007] The aforementioned mixing and distributing units may also include, individually, in combination, and in arrangement, one or more of the features stated below.

[0008] The unit also includes a capping station configured to remove the cap from the container before filling the container at at least two of the plurality of bulk material filling stations. The capping station may also be configured to attach the cap after the container has been at least partially filled with the aerosol precursor.

[0009] The unit may also include a test station configured to measure the amount of aerosol precursors within the container.

[0010] The unit may also include a marking station configured to provide identification based on a fragrance material. The marking station provides identification by applying a web to the container. The marking station may include a printhead for forming the identification.

[0011] Each bulk material filling station in this unit may include a pump. The pump may be integrated with a storage unit to form a bulk material package removable from the bulk material filling station. The pump may include a distribution chamber communicating with the storage unit, the distribution chamber being configured to hold a measured dose of the corresponding bulk material. An RFID antenna may be attached to a robot's platform, the RFID antenna being configured to read RFID tags on the bulk material packages. The pump may be configured to dispense a measured dose of the corresponding bulk material each time the pump is activated. The pump may be activated by pressing by a part of the robot or a container.

[0012] The unit may use a container including child-protective features and anti-tamper features. Each container may include a bottle and a cap having a storage volume for holding the aerosol precursor. The cap may include a nozzle, an inner cover including an anti-tamper band, and an outer cover disposed on the inner cover. The outer cover forms a child-protective function that restricts the ability to remove the inner cover from the bottle. In a first state, the nozzle, inner cover, and outer cover can be removed from the bottle simultaneously. In a second state, the nozzle is substantially permanently fixed to the bottle. Further, the bottle may have a neck including external threads. The nozzle may be configured to be at least partially fitted within the neck, the nozzle having an orifice for dispensing the aerosol precursor from the bottle. The inner cover may also include internal threads for engaging with the external threads of the neck, and the anti-tamper band may be positioned within the inner cover. In the first state, the cap may engage with the bottle such that the nozzle is inserted into the neck with a first insertion distance I1, and the inner cover engages with the neck thread with a first thread distance T1. In the second state, the cap mates with the bottle such that the nozzle is inserted into the neck with a second insertion distance I2 greater than I1, and the inner cover is threaded into the neck with a second thread distance T2 greater than T1. In the third state, the nozzle can be inserted into the neck with a second insertion distance I2, and the inner cover is not threaded into the neck, allowing the aerosol precursor within the bottle to be dispensed through the nozzle orifice. In the fourth state, the cap is removed from the bottle to allow the storage volume to be at least partially filled with the aerosol precursor.

[0013] The nozzle may also include a stop for engaging with the inner cover, allowing the nozzle and inner cover to be removed from the bottle together. The bottle neck may also include a radial flange, and in a first state, the anti-jerk band is not activated, while in a second state, the anti-jerk band is activated by being positioned below the radial flange, such that when the inner cover is removed to reach a third state, the anti-jerk band is damaged as it passes the radial flange. The anti-jerk band may press against the radial flange in the first state. In the second state, the inner cover may abut against a bottle alignment stop formed on the neck, wherein if the sidewalls of the bottle and the cap are not cylindrical, the bottle alignment stop facilitates alignment of the respective sidewalls in the second state.

[0014] In one embodiment, the storage volume of the bottle is at least about 5 ml, and preferably at least about 15 ml.

[0015] The mixing and dispensing unit may also include multiple second bulk material filling stations, each containing a bulk material selected from nicotine, menthol, fruit flavorings, floral flavorings, and savory flavorings. The robot may include a container holder, a first-dimensional guide, and a second-dimensional guide. The user interface may be configured to receive selection information indicating which of the multiple bulk material stations the robot will stop at. A controller with a processor may be provided to control the robot to stop at the desired bulk material filling station and dispense the desired amount of bulk material from each station.

[0016] In other embodiments, this disclosure provides an automated method for manufacturing custom compositions of aerosol precursors. According to one embodiment, the method includes using a robot to remove a container, dispensing an aerosol forming agent into the container at a first location using a first pump, moving the container to a second location using the robot, dispensing at least one fragrance material into the container at the second location using the first pump, sealing the container, and mixing the aerosol forming agent with the at least one fragrance material.

[0017] Various methods for preparing custom compositions of aerosol precursors may individually or in combination include one or more of the following optional features.

[0018] The process of removing the container may include using a suction device to pull the container out of a bulk consumable package that contains multiple empty containers.

[0019] The step of dispensing a liquid aerosol forming agent may include activating a first pump integrated with a reservoir for the liquid aerosol forming agent. Activating the first pump may include pressing substantially vertically upward on a portion of the first pump. The pressing action may include: contacting the container holder with that portion of the first pump, the container holder having a container bottle held therein; and lifting the container holder relative to the first pump. Activating the first pump may also cause a drip shield on the first pump to shift together with the container holder.

[0020] The process of sealing the container may include attaching the cap to the bottle. The method may also include removing the cap from the bottle before dispensing the liquid aerosol forming agent into the container. The step of removing the cap may include holding the cap in place and rotating it relative to the bottle.

[0021] The mixing step may include using the same robot to move the container in a helical pattern along a plane and / or to rotate the container about an axis passing through it. Mixing may also include translating the container out of the plane.

[0022] The manufacturing method may also include measuring the amount of aerosol precursor within the container. Measuring the amount of aerosol precursor may include using a rangefinder to measure the distance between the instrument and the surface of the aerosol precursor. Such methods may involve moving the container to a waste bin if the amount of aerosol precursor is outside a predetermined range.

[0023] The manufacturing method may further include marking the container. Marking the container may include adding a film to the container. Marking may also include printing information onto the film. Marking the container may include printing information onto the container.

[0024] The manufacturing method may also include verifying at least one fragrance material before dispensing it into a container, wherein the verification step includes using RFID.

[0025] Additional embodiments of this disclosure provide a child-protected, child-resistant container. The container includes a bottle having a storage volume for holding liquid contents and a cap. The cap includes a nozzle, an inner cover including a child-resistant band, and an outer cover disposed on the inner cover, wherein the outer cover forms a child-protective feature, thereby restricting the ability to remove the inner cover from the bottle. In a first state, the nozzle, inner cover, and outer cover can be removed from the bottle simultaneously. In a second state, the nozzle is substantially permanently fixed to the bottle.

[0026] Embodiments of child-protected anti-tamper containers may optionally include one or more of the following features, individually or in various combinations thereof. The bottle may have a neck including external threads. A nozzle may be configured to at least partially fit within the neck, and the nozzle has an orifice for dispensing liquid contents from the bottle. An inner cover may also include internal threads for engaging with the external threads of the neck, and an anti-tamper band may be positioned within the inner cover. In a first state, the cap may engage with the bottle such that the nozzle is inserted into the neck with a first insertion distance I1, and the inner cover is threaded into the neck with a first thread distance T1. In a second state, the cap may engage with the bottle such that the nozzle is inserted into the neck with a second insertion distance I2 greater than I1, and the inner cover is threaded into the neck with a second thread distance T2 greater than T1. In a third state, the nozzle may be inserted into the neck with a second insertion distance I2, and the inner cover is not threaded into the neck, such that the liquid contents of the bottle can be dispensed through the orifice of the nozzle. In a fourth state, the cap is removed from the bottle to allow the storage volume to be at least partially filled with liquid contents.

[0027] The nozzle may include a stop for engaging with the inner cover, allowing the nozzle to be removed from the bottle together with the inner cover. The neck may also include a radial flange. In a first state, the anti-tampering band is not activated. In a second state, the anti-tampering band is activated by being positioned below the radial flange, such that when the inner cover is removed to achieve a third state, the anti-tampering band is damaged as it passes the radial flange. The anti-tampering band may press against the radial flange in the first state.

[0028] In the second state, the inner cover can abut against the bottle alignment stop formed on the neck, wherein if the sidewall of the bottle and the sidewall of the cap are not cylindrical, the alignment stop facilitates alignment of the corresponding sidewall in the second state.

[0029] The storage volume of the bottle may be at least about 5 ml, and preferably at least about 15 ml.

[0030] Other embodiments of this disclosure include a method of filling a container with an aerosol precursor. One such method includes using a machine to separate a cap from a bottle, the cap including a nozzle, an inner cover, and an outer cover. The method further includes: at least partially filling the storage volume of the bottle with aerosol precursors from a plurality of filling stations, each station including a liquid component of the aerosol precursor; and attaching the cap to the bottle such that the nozzle is substantially permanently fixed to the bottle and an anti-tampering band formed in the inner cover is activated below a radial flange extending from the neck of the bottle.

[0031] The method of filling the container may also include one or more of the following features and elements, individually or in various combinations. The step of separating the cap from the bottle may at least include rotating the cap relative to the bottle. Separating the cap from the bottle may also include at least one action of pressing and squeezing the outer cover relative to the inner cover. Separating the cap from the bottle may include simultaneously removing the nozzle, inner cover, and outer cover from the bottle.

[0032] The step of attaching a cap to a bottle may include rotating the cap relative to the bottle.

[0033] The method of filling the container may also include rotating the cap relative to the bottle until the bottle is aligned with the stop and the cap is aligned with the stop.

[0034] The step of at least partially filling the storage volume may include dispensing a liquid aerosol forming agent into a container at a first position using a first pump, moving the container to a second position using a robot, and dispensing at least one liquid flavoring material into the container at the second position using a second pump. Dispensing the liquid aerosol forming agent may include activating the first pump, which is integrated with a storage portion for the liquid aerosol forming agent. Activating the first pump may include pressing substantially vertically upward on a portion of the first pump. The pressing action may include: contacting a container holder with a portion of the first pump, the container holder having a container bottle held therein; and lifting the container holder relative to the first pump.

[0035] The method of filling the container may further include verifying at least one fragrance material before dispensing at least one liquid fragrance material into the container, wherein the verification step includes using RFID. The method of filling the container may also include moving the container in a spiral pattern along a plane to mix the aerosol precursor liquid. Additional steps may also include: measuring the amount of aerosol precursor within the container; and if the amount of aerosol precursor is outside a predetermined range, moving the container to a waste bin.

[0036] This disclosure includes the following embodiments without limitation:

[0037] Example 1: A unit for mixing and dispensing an aerosol precursor composition, the unit comprising: a plurality of bulk material filling stations, including at least one first filling station having an aerosol forming agent and at least one second filling station having a flavoring material for generating an aerosol precursor; a bulk consumable package arranging a plurality of containers configured to receive the aerosol precursor; and a robot configured to remove containers from the bulk consumable package and move the containers through at least two dimensions to stop at at least two of the plurality of bulk material filling stations.

[0038] Example 2: The unit as described in any of the preceding embodiments further includes a capping station configured to remove the cap from the container before filling the container at at least two of the plurality of bulk material filling stations, and configured to attach the cap after filling the container with the aerosol precursor.

[0039] Example 3: The unit as described in any of the preceding embodiments further includes a test station configured to measure the amount of aerosol precursors in the container.

[0040] Example 4: The unit as described in any of the preceding embodiments further includes a marking station configured to provide identification based on a fragrance material.

[0041] Example 5: The unit as described in any of the preceding embodiments, wherein each bulk material filling station includes a pump.

[0042] Example 6: The unit as described in any of the preceding embodiments, wherein the pump and the storage unit are integrated to form a bulk material package that can be removed from the bulk material filling station.

[0043] Example 7: The unit as described in any of the preceding embodiments, wherein the pump includes a distribution chamber communicating with a storage section, the distribution chamber being configured to maintain a measured dose of the corresponding bulk material.

[0044] Example 8: The unit as described in any of the preceding embodiments further includes an RFID antenna attached to the robot's platform, the RFID antenna being configured to read RFID tags on bulk material packaging.

[0045] Example 9: A unit as described in any of the preceding embodiments, wherein the pump is configured to dispense a measured dose of the corresponding bulk material each time the pump is activated.

[0046] Example 10: A unit as described in any of the preceding embodiments, wherein the pump is activated by pressing by a portion of a container or robot.

[0047] Example 11: A unit as described in any of the preceding embodiments, wherein each container includes child protection features and anti-tampering features.

[0048] Example 12: A unit as described in any of the preceding embodiments, wherein each container includes: a bottle and a cap having a storage volume for maintaining an aerosol precursor, the cap including: a nozzle; an inner cover including a tamper-evident strap; and an outer cover disposed on the inner cover, wherein the outer cover forms a child-protective feature thereby restricting the ability to remove the inner cover from the bottle, wherein in a first state, the nozzle, the inner cover, and the outer cover can be removed from the bottle simultaneously, and in a second state, the nozzle is substantially permanently fixed to the bottle.

[0049] Example 13: A unit as described in any of the preceding embodiments, wherein the bottle has a neck including external threads; a nozzle is configured to be at least partially fitted within the neck, the nozzle having an orifice for dispensing aerosol precursors from the bottle; the inner cover further includes: an internal thread for engaging with the external threads of the neck, and an anti-tampering band positioned within the inner cover.

[0050] Example 14: The unit as described in any of the preceding embodiments, wherein, in a first state, the cap engages with the bottle such that the nozzle is inserted into the neck at a first insertion distance I1, and the inner cover is threaded into the neck at a first thread distance T1; wherein, in a second state, the cap engages with the bottle such that the nozzle is inserted into the neck at a second insertion distance I2 greater than I1, and the inner cover is threaded into the neck at a second thread distance T2 greater than T1; and wherein, in a third state, the nozzle is inserted into the neck at a second insertion distance I2, and the inner cover is not threaded into the neck, such that the aerosol precursor in the bottle can be dispensed through the nozzle orifice.

[0051] Example 15: The unit as described in any of the preceding embodiments further includes a fourth state, wherein, in the fourth state, the cap is removed from the bottle to allow the storage volume to be at least partially filled using the aerosol precursor.

[0052] Example 16: The unit as described in any of the preceding embodiments, wherein the nozzle includes a stop for engaging with the inner cover, such that the nozzle and the inner cover are removed together from the bottle.

[0053] Example 17: The unit as described in any of the preceding embodiments, wherein the neck of the bottle further includes a radial flange, and wherein, in a first state, the anti-tampering strip is not activated, and wherein, in a second state, the anti-tampering strip is activated by being positioned below the radial flange such that when the inner cover is removed to reach a third state, the anti-tampering strip is damaged as it passes the radial flange.

[0054] Example 18: The unit as described in any of the preceding embodiments, wherein, in the second state, the inner cover abuts against the bottle alignment stop formed on the neck, wherein if the sidewall of the bottle and the sidewall of the cap are not cylindrical, the bottle alignment stop facilitates alignment of the corresponding sidewall in the second state.

[0055] Example 19: The unit as described in any of the preceding embodiments includes a plurality of second bulk material filling stations, each second bulk material filling station having a bulk material selected from nicotine, menthol, fruit flavorings, floral flavorings and savory flavorings.

[0056] Example 20: The unit as described in any of the preceding embodiments further includes a user interface configured to receive selection information indicating which of the plurality of bulk material stations the robot will stop at.

[0057] Example 21: The unit as described in any of the preceding embodiments further includes a controller having a processor for controlling the robot to stop at the desired bulk material filling station and dispensing the desired amount of bulk material from each bulk material filling station.

[0058] Example 22: An automated method for manufacturing a custom composition of an aerosol precursor, the method comprising: removing a container using a robot; dispensing an aerosol forming agent into the container at a first location using a first pump; moving the container to a second location using the robot; dispensing at least one fragrance material into the container at the second location using the first pump; sealing the container; and mixing the aerosol forming agent with at least one fragrance material.

[0059] Example 23: The method as described in any of the preceding embodiments, wherein the step of removing the container includes using a suction to pull the container out of a bulk consumable package comprising a plurality of empty containers.

[0060] Example 24: The method as described in any of the preceding embodiments, wherein the step of dispensing the liquid aerosol forming agent includes activating a first pump integrated with a storage unit for the liquid aerosol forming agent.

[0061] Example 25: The method as described in any of the preceding embodiments, wherein sealing the container includes attaching a cap to the bottle, and the method further includes removing the cap from the bottle before dispensing the liquid aerosol forming agent into the container.

[0062] Example 26: The method as described in any of the preceding embodiments, wherein mixing includes moving the container in a spiral pattern along a plane.

[0063] Example 27: The method as described in any of the preceding embodiments, wherein mixing further includes rotating the container about an axis passing through the container.

[0064] Example 28: The method as described in any of the preceding embodiments, wherein the same robot is used to move the container in a spiral pattern and to rotate the container.

[0065] Example 29: The method as described in any of the preceding embodiments further includes: measuring the amount of aerosol precursor in the container.

[0066] Example 30: The method as described in any of the preceding embodiments includes moving the container to a waste bin if the amount of the aerosol precursor is outside a predetermined range.

[0067] Example 31: The method as described in any of the preceding embodiments further includes verifying at least one fragrance material before dispensing it into a container, wherein the verification step includes using RFID.

[0068] Example 32: A child-protected anti-tamper container comprising: a bottle having a storage volume for containing liquid contents; and a cap including: a nozzle; an inner cover including an anti-tamper strap; and an outer cover disposed on the inner cover, wherein the outer cover forms a child-protective feature thereby restricting the ability to remove the inner cover from the bottle, wherein in a first state, the nozzle, the inner cover, and the outer cover can be removed from the bottle simultaneously, and in a second state, the nozzle is substantially permanently fixed to the bottle.

[0069] Example 33: A container as described in any of the preceding embodiments, wherein: the bottle has a neck including external threads; a nozzle is configured to be at least partially fitted within the neck, and the nozzle has an orifice for dispensing liquid contents from the bottle; the inner cover also includes an internal thread for engaging with the external threads of the neck, and an anti-tampering band is positioned inside the inner cover.

[0070] Example 34: A container as described in any of the preceding embodiments, wherein, in a first state, the cap engages with the bottle such that the nozzle is inserted into the neck at a first insertion distance I1, and the inner cover is threaded into the neck at a first thread distance T1; in a second state, the cap engages with the bottle such that the nozzle is inserted into the neck at a second insertion distance I2 greater than I1, and the inner cover is threaded into the neck at a second thread distance T2 greater than T1; and in a third state, the nozzle is inserted into the neck at a second insertion distance I2, and the inner cover is not threaded into the neck, such that the liquid contents of the bottle can be dispensed through the nozzle orifice.

[0071] Example 35: A method for filling a container using an aerosol precursor, the method comprising: separating a cap from a bottle using a machine, the cap including a nozzle, an inner cover, and an outer cover; filling at least partially the storage volume of the bottle using aerosol precursors from a plurality of filling stations, each station including a liquid component of the aerosol precursor; attaching the cap to the bottle such that the nozzle is substantially permanently fixed to the bottle, and an anti-tampering band formed in the inner cover is activated below a radial flange extending from the neck of the bottle.

[0072] Example 36: The method as described in any of the preceding embodiments, wherein separating the cap from the bottle includes simultaneously removing the nozzle, inner cover, and outer cover from the bottle.

[0073] These and other features, aspects, and advantages of this disclosure will become clear from the following detailed description and the accompanying drawings, which are briefly described below. This disclosure includes any combination of any two, three, four, or more of the embodiments set forth in this disclosure, as well as any combination of any two, three, four, or more features or elements, whether or not such features or elements are explicitly combined in the specific embodiments described herein. Unless expressly specified otherwise in the context, this disclosure is intended to be read holistically such that any divisible feature or element of this disclosure should be considered as intended to be combinable in its various aspects and in any embodiment. Attached Figure Description

[0074] The present disclosure has already been described in general terms above, and reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, in which:

[0075] Figure 1 An external view of a dispenser unit according to various embodiments of the present disclosure is shown.

[0076] Figure 2 A dispenser unit with an open cover is shown.

[0077] Figure 3 This is an internal cross-sectional view of the distributor unit according to various embodiments of the present disclosure.

[0078] Figure 4 This is a detailed view of a robot used within a dispenser unit according to an embodiment of the present disclosure.

[0079] Figures 5A-5E The steps for removing the container are shown.

[0080] Figure 6 The container is shown at the capping station.

[0081] Figure 7 This is a detailed view of the capping station according to one embodiment.

[0082] Figure 8 A container is shown at the first bulk material filling station.

[0083] Figure 9 A bulk material package for a first bulk material filling station is shown according to one embodiment.

[0084] Figure 10A-10D The steps of a filling process according to one embodiment are shown.

[0085] Figure 11 The container is shown at the second bulk material filling station.

[0086] Figure 12The container is shown at an optional third bulk material filling station.

[0087] Figure 13 The container is shown at the test station.

[0088] Figure 14A and 14B Details of a test station according to one embodiment are shown.

[0089] Figure 15 The container is shown returning to the capping station.

[0090] Figure 16 The container is shown at the marked workstation.

[0091] Figure 17 Details of a marking station according to one embodiment are shown.

[0092] Figure 18 This is a top sectional view of a dispenser unit according to one embodiment, which schematically illustrates the movement of a container provided by a robot to achieve mixing.

[0093] Figure 19 This is a detailed view of the discharge station according to one embodiment.

[0094] Figure 20 A cross-sectional view of a container in a pre-filled state according to one embodiment is shown.

[0095] Figure 21 It shows the state of being filled. Figure 20 A cross-sectional view of the container.

[0096] Figure 22 yes Figure 20 An exploded view of a portion of the container.

[0097] Figure 23 yes Figure 20 A detailed view of the interior of the nozzle of the container. Detailed Implementation

[0098] This disclosure will now be described more fully below with reference to exemplary embodiments. These embodiments are described in such a way that this disclosure will be exhaustive and complete, and will fully convey the scope of this disclosure to those skilled in the art. In fact, this disclosure may be implemented in many forms and should not be construed as limited to the embodiments set forth herein; rather, these aspects are set forth so that this disclosure will satisfy applicable legal requirements. Unless clearly stated otherwise herein, the singular forms “a,” “an,” and “the” as used in this specification and the appended claims include indications of the plural.

[0099] As described below, embodiments of this disclosure relate to aerosol precursor compositions, containers for and containing aerosol precursor compositions, apparatus for generating aerosol precursor compositions, and apparatus for dispensing one or more containers having a completed aerosol precursor composition therein. The related methods are also described and understood from the function of the articles and apparatus set forth below. An aerosol precursor (also interchangeably referred to as a precursor, aerosol precursor composition, and aerosol precursor formulation) is a consumable liquid composition conventionally used in conjunction with an aerosol delivery device. Aerosol delivery devices typically use electrical energy to heat the aerosol precursor to form an inhalable substance. Aerosol delivery devices can provide some or all of the sensations of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation habits, the type of taste or aroma, sensory effects, bodily sensations, usage habits, visual cues provided by visible aerosols, etc.) without significantly burning any component of the aforementioned articles or apparatus.

[0100] Aerosol delivery devices typically comprise a number of components. An aerosol delivery device typically includes a combination of the following: a power source (i.e., a power source); at least one controller (e.g., a device for actuating, controlling, regulating, and stopping the power used for heating by controlling the current flowing from the power source to other components of the article); a heater or heating element (e.g., a resistance heating element or component commonly referred to as an "atomizer"); an aerosol precursor composition (e.g., liquids that are generally capable of generating an aerosol when sufficient heat is applied, these liquids are commonly referred to as "vapor juice," "e-liquid," and "e-juice"); and a mouthpiece region or end portion that allows inhalation at the aerosol delivery device to draw in the aerosol (e.g., through a defined airflow passage of the article, such that the generated aerosol can be drawn out from the airflow passage upon inhalation). Various aerosol delivery device designs and component arrangements can be understood by considering the disclosed or commercially available electronic aerosol delivery devices, such as those representative products included in this disclosure above.

[0101] Go to Figure 1Embodiments of this disclosure relate to a dispenser unit 100. In one embodiment, the dispenser unit 100 is operated by a customer or store clerk to dispense a container containing a custom-mixed aerosol precursor composition, which may be available in various forms. At least, the custom-mixed aerosol precursor compositions dispensed from the dispenser unit 100 may be of at least two, at least three, at least five, preferably ten or more types. The upper limit of the number of available types may relate to the size of the dispenser unit 100 and any technical limitations of the equipment used in implementing the dispenser unit of this disclosure. If the aerosol precursor compositions differ in at least one aspect of flavor and strength, they are considered different types. Strength may refer to nicotine content or concentration. Strength may also refer to the concentration of flavor material within the aerosol precursor. Preferably, the custom-mixed aerosol precursor composition dispensed from the dispenser unit 100 is generated on-site within the dispenser unit 100 by combining initially separate components (e.g., aerosol precursor composition components, referred to herein as bulk materials). In one embodiment, the initially separated ingredients first come into contact within a container, which is then dispensed from dispenser unit 100 to the user (e.g., a customer or store clerk).

[0102] The dispenser unit 100 according to embodiments of this disclosure is intended to be relatively small in size, potentially able to be placed on a table or counter for operation by retail staff or appropriately screened customers. However, according to this disclosure, the scale of the dispenser unit 100 may be increased as desired. The dispenser unit 100 may include a user interface 102 disposed on or adjacent to the exterior of the dispenser unit in any easily located and easily operable location. The user interface 102 may be configured to allow the user to make a selection (e.g., provide selection information) resulting in the dispensing of a preferred aerosol precursor to the user. For example, the user may personalize the flavor and / or intensity (e.g., nicotine content) of their aerosol precursor by using multiple options and menus displayed on the user interface 102. The user interface 102 may be a touchscreen. Alternatively, the user interface 102 may include a display separate from an input device such as a keyboard.

[0103] The dispenser unit 100 may also include an opening 104 connected to a channel for discharging a filled container to a user. The opening 104 may include a door, cover, valve, drawer, or other structure that selectively opens when the filled container is ready to be retrieved or received by the user. The door may be opened manually by the user or automatically under the control of the dispenser unit 100.

[0104] like Figure 2As shown, the dispenser unit 100 may have an access door 106 to allow maintenance personnel or retailers access to the interior of the dispenser unit 100 to perform maintenance, updates, or resupply the dispenser unit 100 with at least the bulk materials and empty containers required for unit operation. The access door 106 is not limited to a hinged door and may include any other suitable closure. The access door 106 is shown at the front of the dispenser unit 100, but it may be placed in any other suitable location based on the expectation of providing access to the internal mechanisms of the dispenser unit 100. Therefore, the construction of the access door 106 may be influenced by the arrangement and packaging of the internal components and workstations within the dispenser unit 100. Although Figure 2 A single access door 106 is shown, but it should be well understood that the distributor unit 100 may include multiple individual access doors 106 to provide necessary internal access.

[0105] like Figure 1 As shown, the external portion of dispenser unit 100 may include various other ports, plugs, scanners, readers, and other devices operably accessible to a user. For example, dispenser unit 100 may include a reader 108 such as a scanner, sensor, camera, etc., for barcodes, QR codes, magnetic stripes, radio frequency identification (RFID), near field communication (NFC), and other optical and electromagnetic identification. In addition to or as an alternative to user interface 102, reader 108 may be used to provide information to dispenser unit 100. In one embodiment, dispenser unit 100 may be configured to identify a user via an identification card such as a driver's license or employee badge. Dispenser unit 100 may include a camera recording the user to help prevent theft or apprehend vandals. Dispenser unit 100 may have a reader for codes on coupons or other brochures. For example, a store may want to advertise aerosol precursor recipes favored by its employees. These recipes may be indicated by barcodes that can be scanned by a user to cause dispenser unit 100 to create the desired recipe. Users can store their preferences on key tags or other internal or external storage media such as memory, which can be read by the dispenser unit 100 to expedite the sale of customers' preferred aerosol precursors. In one example, a webpage or mobile application can be used to create a customer's recipe. The customer's smartphone can then be programmed to display a corresponding barcode, which can be read by a barcode reader operatively communicating with the dispenser unit 100. The customer's recipe can be included in the mobile application, enabling the application to access the product via various means, such as... Near-field wireless technologies such as Bluetooth transmit formula information to dispenser unit 100. A mobile application can be integrated with user profiles to facilitate other functions, such as storing purchase history and promoting reward programs, to wirelessly facilitate payments for aerosol precursors. Other readers can utilize credit card readers, cash receiving devices, or other devices for accepting payments known in the art to facilitate direct purchase of desired products from dispenser unit 100.

[0106] In one embodiment, the dispenser unit 100 may include ports or plugs that allow a user to recharge the power unit of their aerosol delivery device while the dispenser unit prepares its personalized precursor.

[0107] Distributor unit 100 may also have one or more ports, plugs, or devices to facilitate non-user-accessible or user-facing operations on the distributor unit. These may include objects such as a power cord for supplying power to distributor unit 100, or an Ethernet port that allows the unit to network with a remote database on the World Wide Web or as part of operations at a retail location. For example, distributor unit 100 may connect to a store’s registered account, such that the unit dispenses the desired product only after the customer has paid for it or after the salesperson has verified the user’s age or other identifying characteristics.

[0108] Distributor unit 100 can store customer preferences to optimize the distribution process. Distributor unit 100 can be networked to other similar units, connected to the Internet, or equipped with read technology, allowing customers to receive their preferred options without having to return to the same unit or make a full selection on user interface 102 each time.

[0109] Figure 2 Distributor unit 100 with access door 106 open is shown. Discharge channel 110 may be attached to swing with access door 106. Removable waste bin 112 may also travel with access door 106. Waste bin 112 is configured to receive non-conforming products generated by distributor unit 100. Inner door 114 is also shown, optionally configured to conceal and protect moving parts within distributor unit 100. Raw material drawer 116 may be configured to slide out to facilitate refilling of the drawer with bulk material components from empty containers or aerosol precursors.

[0110] Figure 3This is a cross-sectional view of a dispenser unit 100 according to an embodiment of the present disclosure, showing the internal arrangement of stations, features, and components. The raw material drawer 116 may include bulk consumable packages 118 arranged in a plurality of containers 120 configured to be filled with a custom-mixed aerosol precursor composition. Containers 120 within the bulk consumable packages 118 may be empty or partially filled with components of the custom-mixed aerosol precursor composition. The bulk consumable packages 118 may take various forms, including trays, hoppers, or other configurations facilitating the removal of a container 120 from a group of containers. The raw material drawer 116 may have a plurality of additional compartments 122 configured to receive components for manufacturing the precursors. Each compartment 122 is configured to receive a bulk material package 124 to form a bulk material filling station 126 for the container 120.

[0111] There are no specific limitations on the aerosol precursors produced by the containers 120 accessing two or more bulk material filling stations 126. Several optional features of representative precursors are discussed below. Aerosol precursors consist of combinations or mixtures of various components (i.e., parts). The selection of specific aerosol precursor components and the relative amounts of those components can be changed based on user input at the user interface 102 in order to control the overall chemical composition of the mainstream aerosol produced by the atomizer of the aerosol delivery device. Of particular interest are aerosol precursors characterized by being typically liquid. For example, representative typically liquid aerosol precursors may be in the form of a liquid solution, a mixture of miscible components, or a liquid containing suspended or dispersed components. Typical aerosol precursors are capable of evaporating when exposed to high temperatures under the conditions experienced during the use of an aerosol delivery device having the features of this disclosure; thus, they are capable of producing vapors and aerosols that can be inhaled.

[0112] The aerosol precursor may contain a so-called "aerosol forming agent" component, which may be provided within one or more first filling stations 126a. Such materials have the ability to generate visible aerosols when evaporated due to exposure to high temperatures under the conditions experienced during normal use of an atomizer having the features of this disclosure. Such aerosol forming materials include various polyols or polyhydroxy alcohols (e.g., glycerol, propylene glycol, and mixtures thereof). Many embodiments of this disclosure contain aerosol precursor components that can be characterized as water, moisture, or an aqueous liquid. During normal use of certain aerosol delivery devices, water contained within those devices can evaporate to produce components of the generated aerosol. Therefore, for the purposes of this disclosure, water present in the aerosol precursor can be considered an aerosol forming material.

[0113] Various flavoring or aroma materials that alter the sensory characteristics or properties of the inhaled mainstream aerosol include a second major component of the aerosol precursor and may be provided within a second filling station 126b. Each second filling station 126b may provide a unique aroma material. Furthermore, the most popular flavorings may be provided at more than one second filling station 126b. Flavorings may be selectively added to the aerosol precursor to alter the taste, aroma, and sensory characteristics of the aerosol. Some flavorings may be provided from sources other than tobacco. Exemplary flavorings may be natural or inherently artificial and may be employed as concentrates or flavoring packets.

[0114] Exemplary flavoring agents include vanillin, ethyl vanillin, cheese, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors, including lime and lemon), floral spices, savory spices, maple, menthol, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, fennel, sage, cinnamon, sandalwood, jasmine, acerola, cocoa bean, licorice, and spices and spice packets traditionally used as flavorings and properties of cigarette, cigar, and pipe tobacco. Syrups such as high-fructose corn syrup may also be used. Certain flavoring agents may be included in the aerosol-forming material before formulating the final aerosol precursor mixture (e.g., certain water-soluble flavoring agents may be included in water, menthol may be included in propylene glycol, and certain compound spice packets may be included in propylene glycol).

[0115] For an aerosol delivery device characterized as an electronic cigarette, the aerosol precursor composition most preferably incorporates tobacco or tobacco-derived components (referred to herein as "nicotine sources"). These nicotine sources may be present in one or more third filling stations 126c. The third filling station 126c may be referred to as a nicotine station. On one hand, tobacco may be provided as portions or pieces of tobacco, such as finely ground, pulverized, or powdered tobacco sheets. On the other hand, tobacco may be provided in the form of an extract, such as a spray-dried extract containing many water-soluble components of tobacco. Alternatively, the tobacco extract may be in the form of an extract with a relatively high nicotine content, which also contains small amounts of components derived from other tobacco extracts. On the other hand, tobacco-derived components may be provided in a relatively pure form, such as certain tobacco-derived flavorings. On one hand, components derived from tobacco and usable in a highly purified or substantially pure form are nicotine (e.g., pharmaceutical-grade nicotine).

[0116] The aerosol precursor may also include components having acidic or basic characteristics (e.g., organic acids, ammonium salts, or organic amines). For the purposes of this disclosure, these components may be included in the general description of the flavor material. For example, certain organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be included in the aerosol precursor formulation containing nicotine, wherein the amount of these organic acids (based on the total organic acid content) is preferably equimolar with nicotine. For example, the aerosol precursor may include about 0.1 to about 0.5 mol of levulinic acid per mol of nicotine, about 0.1 to about 0.5 mol of succinic acid per mol of nicotine, about 0.1 to about 0.5 mol of lactic acid per mol of nicotine, about 0.1 to about 0.5 mol of pyruvic acid per mol of nicotine, or various arrangements and combinations thereof, up to a concentration in which the total amount of organic acids present therein is equimolar with the total amount of nicotine present in the aerosol precursor.

[0117] As a non-limiting example, a representative aerosol precursor produced by dispenser unit 100 at the user's request may, by weight, be in the form of a mixture of the following: about 70% to about 90% glycerol, typically about 75% to about 85% glycerol; about 5% to about 20% water, typically about 10% to about 15% water; about 1% to about 10% propylene glycol, typically about 4% to about 8% propylene glycol; about 0.1% to about 6% nicotine, typically about 1.5% to about 5% nicotine; and optionally up to about 6% of flavoring agent, typically about 0.1% to about 5% flavoring agent. For example, by weight, a representative aerosol precursor may be in a formulation containing more than about 76% glycerol, about 14% water, about 7% propylene glycol, about 1% to about 2% nicotine, and less than about 1% flavoring material. For example, a representative aerosol precursor may have a formulation containing more than about 75% glycerol, about 14% water, about 7% propylene glycol, about 2.5% nicotine, and less than about 1% flavoring material. For example, based on weight, a representative aerosol precursor may have a formulation containing more than about 75% glycerol, about 5% water, about 8% propylene glycol, about 6% nicotine, and less than about 6% flavoring material.

[0118] The composition and structure of representative types of aerosol precursors are described and characterized in U.S. Patent No. 7,726,320 to Robinson et al., U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., U.S. Patent Publication No. 2013 / 0213417 to Chong et al., U.S. Patent Publication No. 2014 / 0060554 to Collett et al., U.S. Patent Publication No. 2015 / 0030823 to Lipowicz et al., and U.S. Patent Publication No. 2015 / 0020830 to Koller, and WO 2014 / 182736 to Bowen et al., the full text of which is incorporated herein by reference. Other aerosol precursors that may be used include those already included in products from RJ Reynolds Vapor Company. Products; Lorillard Technologies' BLU TM Products; Mistic Menthol products from Mistic Ecigs; and VYPE products from CN Creative Ltd. Also expected are so-called “tobacco juice” for electronic cigarettes, already available from Johnson Creek Enterprises LLC. Examples of effervescent materials can be used with aerosol precursors and are described, for example, in U.S. Patent Application Publication No. 2012 / 0055494 by Hunt et al., which is incorporated herein by reference. Furthermore, the use of effervescent materials is described, for example, in 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. 5,223,246 to Wehling et al.; U.S. Patent No. 6,974,590 to Pater et al.; and U.S. Patent No. 7,381,667 to Bergquist et al.; and 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.; and U.S. Patent Publication No. 2010 / 0170522 to Sun et al.; and PCT WO97 / 06786 to Johnson et al., all of which are incorporated herein by reference.

[0119] In addition to the bulk material filling station, the distributor unit 100 also includes a robot 130. For example... Figure 4As best shown, robot 130 may include a platform 132 (referred to as a container holder) for holding container 120 and translating the container through at least two dimensions. For example, platform 132 may be driven by a first actuator 134 to travel along the X-axis when guided on track 136. A second actuator 138 may drive platform 132 to travel along the Y-axis when guided on support 140. Actuators 134, 138 may be guided by controller 142, wherein a processor operatively communicates with actuators 134, 138 and user interface 102. Based on a preferred precursor composition and the inventory level at each bulk material filling station 126, controller 142 is configured to stop platform 132 at each appropriate bulk material filling station and extract an appropriate amount of each type of bulk material into container 120.

[0120] Figure 3 A stand 132 of robot 130 is shown, which is positioned below bulk consumable packaging 118 as a container receiving station 144. When dispenser unit 100 is activated, such as by completing a precursor selection and purchase transaction, the stand 132 can be signaled by the controller to report to container receiving station 144 and retrieve empty container 120.

[0121] exist Figures 5A-5E An exemplary process for removing an empty container 120 from a bulk consumable package 118 is illustrated, wherein only a partial view of the bulk consumable package 118 is shown for ease of illustration. A robot 130 may have an extendable suction cup 146 that can rise to contact the bottom of the empty container 120. Figure 5B As shown, suction can be applied to grip the bottom of container 120. Figure 5C and Figure 5D As shown in the progress, when suction is applied, the suction cup 146 can be lowered to pull the container 120 out of the bulk consumable package 118. The bulk consumable package 118 can be gravity-fed, such that when an empty container 120 is removed, the next container 120a above it lowers into a ready position. The bottom of the bulk consumable package 118 may include friction tabs 148 to prevent the removal of additional containers when the pulling force of the suction cup 146 is not applied. Figure 5E As shown, after one container 120 is retrieved, the next container 120a is correctly positioned for the next operation of the dispenser unit 100.

[0122] The gravity-fed bulk consumable package 118, retrieved by a suction-activated pull, is merely one possible configuration for selecting empty containers 120 and engaging them with the platform 132 of the robot 130. For example, instead of being part of the raw material drawer 116, the bulk consumable package 118 could be formed as a separate tray within the dispenser unit 100. Alternatively, the bulk consumable package 118 could be positioned below the robot 130. The container receiving station 144 may not be a single location or multiple closely adjacent locations. Rather, for example, if the empty containers 120 are arranged to pass through a certain depth in the tray positioned below the robot 130, the container receiving station 144 could be any location within the dispenser unit 100 corresponding to an available empty container.

[0123] As discussed further below, bulk consumable packaging 118 can be configured to receive empty containers 120, which include bottles 150 and caps 152 pre-attached to each other (see...). Figure 7 In other embodiments, individual bulk consumable packages may be provided with a bottle 150 and a cap 152, in which case the dispenser unit 100 will be configured to combine the bottle 150 with the corresponding cap 152 only after the bottle has been filled with the aerosol precursor composition.

[0124] If container 120 initially includes a lid 152, robot 130 can be activated to move the container from container receiving station 144 to lid sealing station 154, the movement being... Figure 6 The thick horizontal arrow in the image indicates this. Figure 7An example of a capping station 154 is shown. This capping station 154 may include a cap holder 156. At the capping station 154, a robot 130 aligns a container 120 with the cap holder 156. In the example shown, at least one of the container 120 and the cap holder 156 moves vertically along the Z-axis to engage the cap holder with the cap 152 of the container. In one embodiment, the robot 130 and / or the platform 132 are configured to lift the container 120 to engage with the cap holder 156. Engagement can be facilitated by vacuum pressure, friction, a stop mechanism, or other known means that allow the cap holder 156 to grip the cap 152 and temporarily hold the cap while the rest of the container 120 (e.g., bottle 150) is removed. In the embodiment shown, the cap 152 is removed from the bottle 150 by rotation. Therefore, the capping station 154 may also include a rotary actuator 158 connected to the cap holder 156 to rotate the cap 152 relative to the bottle 150. The cap holder 156 can be rotated directly or indirectly by a motor using a belt system or gear system. In other embodiments, those skilled in the art will understand that the stand 132 may have a mechanism for rotating the bottle 150 while the cap 152 and cap holder 156 remain substantially stationary relative to the dispenser unit 100.

[0125] Go to Figure 8 The stage 132, as indicated by thick arrow A, has moved from the capping station 154 to the first bulk material filling station 126a. Bottle 150 is ready to receive the precursor components. Similarly, the cap 152 can initially be separated from bottle 150, or can be separated from the bottle via the capping station 154. As described above, the first filling station 126a can provide an aerosol forming agent. The aerosol forming agent will be included in substantially all aerosol precursor compositions. However, the aerosol forming agent need not be the first component dispensed into bottle 150.

[0126] As described above, the first filling station 126a may include a first bulk material package 124a. Figure 9An exemplary bulk material package 124 is shown removed from compartment 122. The bulk material package 124 is shown as having a bag-in-a-box construction with a housing 160 and a pouch 162 positioned within it. The housing 160 may include cardboard and plastic portions. The rigid plastic portion of the housing 160 may be used to fit a corresponding compartment 122 within a raw material drawer 116. The pouch 162 provides a storage section 164 for the bulk material components of the aerosol precursor composition. For some bulk materials, the storage section 164 may have a volume of at least about 500 ml. For other bulk material packages 124, the storage section 164 may have a volume of at least about 2000 ml. An RFID tag 166 may be applied to the housing 160 for use, as described below.

[0127] The bulk material packaging 124 may also include a pump 168 integrated with the storage section 164. The pump 168 may include a distribution chamber 170 located between the storage section 164 and the outlet 172 (see [link to related document]). Figure 10A The distribution chamber 170 may be configured to hold a measured dose of the corresponding bulk material, such that each activation of the pump 168 delivers a measured dose of bulk material from the outlet 172. In some embodiments, a drip shield 174 may be provided to selectively cover the outlet 172 when the bottle 150 is not ready to receive bulk material from the corresponding bulk material package 124. The drip shield 174 may be displaced via the stand 132 to access the bottle 150. In some embodiments, the pump 168 may be protected during delivery by having a retracted position in which the pump is at least partially recessed into the housing 160.

[0128] Bulk material package 124 is configured for single use and can be easily removed from compartment 122 of raw material drawer 116. Therefore, the entire bulk material package 124 can be replaced when storage section 164 is empty. By integrating pump 168 as part of bulk material package 124, cross-contamination of the components is minimized or eliminated. Furthermore, flushing and cleaning of the pipeline is unnecessary, which would be necessary if an external electric pump were used. However, if desired, pump 168 can alternatively be provided as an element of container 122, and bulk material package 124 can be configured to mate with pump 168 in substantially the configuration described above when inserted into container 122.

[0129] Reference Figure 8 and Figure 10A-10D The description further details the bulk material filling station 126. For example... Figure 10AAs shown, robot 130 can be actuated to deliver rack 132 and bottles 150 to the desired bulk material filling station 126, where the bottles are aligned below the corresponding pump 168. Rack 132 may include RFID antenna 176 configured to read RFID tags 166 on bulk material packages 124 at the corresponding filling station 126 and verify the correct placement of the rack. The use of RFID may be optional. Controller 142 may be pre-programmed with the coordinates of rack 132 corresponding to each compartment 122. When dispensing dispenser unit 100, the user can then program controller 142 using user interface 102 to inform dispenser unit 100 which bulk material is located in each compartment 122 or positioned at each filling station 126.

[0130] like Figure 10B As shown, once the robot 130 positions the bottle 150 at the appropriate filling station 126 for the preferred precursor formulation, the platform 132 can rise vertically such that a portion of the platform engages with a portion of the pump 168. In other embodiments, the bottle 150 itself may engage with a portion of the pump 168. In the illustrated embodiment, the platform 132 is shown having a pair of alignment posts 178 configured to contact a portion of the pump 168, for example, engaging with a pair of alignment holes 180 formed in the pump flange 181. Figure 10C As indicated by the thick arrow, once the alignment post 178 engages with the alignment hole 180, the continued upward movement of the stage 132 presses upward on the pump 168 to release bulk material from the outlet 172 into the bottle 150. Activation of the pump 168 can also be achieved by rotating a cam.

[0131] After a certain amount (e.g., a measured dose) of bulk material has been received from the dispensing chamber 170, the bottle 150 can retract, disengaging the pump 168. In some cases, the desired precursor may include multiple doses of bulk material from a single filling station 126. Therefore, the stand 132 can retract from the pump 168 sufficiently to reload the pump without completely disengaging it. The stand 132 can then be pressed upward again to extract an additional amount of bulk material. When the bottle 150 has received the desired amount of bulk material from the current filling station 126, the stand 132 can be disengaged from the pump 168, for example, by moving the stand downward along the Z-axis.

[0132] Figure 11 and 12The table 132 and bottle 150 are shown stopped at the second filling station 126b and the third filling station 126c, respectively. At the second filling station 126b, bottle 150 may receive one or more doses of flavoring material. The flavoring material may be released from the corresponding bulk material package 124b in substantially the same manner as described above. Similarly, at the third filling station 126c, bottle 150 may receive one or more doses of nicotine material. The nicotine material may be released from the corresponding bulk material package 124c in substantially the same manner as described above. The movement of table 132 and bottle 150 from the first filling station 126a to the second filling station 126b and the third filling station 126c is indicated by thick arrows in the corresponding figures. Those skilled in the art will understand that this movement is provided by robot 130 as described above.

[0133] After arriving at the appropriate filling station 126 and receiving the appropriate amount of bulk material from each station, the robot 130 can take the bottle 150 to the test station 182. Figure 13 The table 132 is shown positioning the bottle 150 at the test station 182. Figure 14A and 14B The test station 182 is shown in further detail. Test station 182 may include instruments modularly integrated with capping station 154. Optionally, test station 182 is configured to measure the amount of aerosol precursor within bottle 150. Test station 182 provides quality control functions to ensure the correct volume of aerosol precursor is dispensed to the user. In one example, dispenser unit 100 may be configured to provide at least 15 ml.

[0134] In one embodiment, test station 182 includes an ultrasonic rangefinder 184. For example... Figure 14B As shown, a beam 186, or wave, is sent from instrument 184 into bottle 150. The beam 186 is then reflected from the surface 188 of the aerosol precursor composition and returns to instrument 184. An ultrasonic rangefinder 184, alone or in combination with controller 142, can determine the distance traveled by the beam 186. This distance can then be compared to a preferred distance if bottle 150 is filled to the desired level. If the beam 186 has traveled too far, i.e., the volume of the aerosol precursor is outside an acceptable range, bottle 150 can be returned to one or more filling stations 126 to receive additional bulk material. In another embodiment, as... Figure 2As shown, if bottle 150 is not yet fully filled, container 120 can be discarded in waste bin 112 instead of being provided to the customer. Discarding underfilled container 120 may be preferred because test station 182 may not be able to determine which aerosol precursor component is missing in the final composition, resulting in insufficient overall volume. In one embodiment, robot 130 may bring bottle 150 to test station 182 after reaching each filling station 126. However, testing the volume of bottle 150 after adding each component individually may increase the processing time of dispenser unit 100 to an unacceptable duration.

[0135] Based on the reliability of pump 168, providing a test station 182 to ensure volume control may be important. If the bulk material packages 124 are used until they are completely empty, the volume within bottle 150 may also be insufficient. In this case, when storage compartment 164 is nearly empty, one or more uses of package 124 may only result in a partial dose from outlet 172. Controller 142 can be configured to track the number of times a specific bulk material package 124 has been activated to release a dose of bulk material. For example, controller 142 can use the aforementioned RFID tag 166 and RFID antenna 176 to record the number of accesses to a specific bulk material package 124. Utilizing this tracking capability, bulk material packages 124 can be discontinued and designated for replacement before their performance quality is expected to deteriorate.

[0136] Test station 182 has been described as including an ultrasonic rangefinder 184. Those skilled in the art will understand that test station 182 can provide the same or substantially similar functionality as other laser or optical rangefinders or other measurement techniques known in the art. Instruments using lasers can be used to reliably enter and exit through the narrow neck of bottle 150. In another example, bench 132 may be equipped with a mass balance. The mass balance has a tare weight equal to the empty bottle 150 and is capable of adequately estimating the total volume of the precursor. This balance is also capable of estimating the volume of each component based on the change in mass of bottle 150 at each filling station 126 when components are added. This balance allows for adequate station-by-station monitoring to reduce or eliminate the need for container 120 waste, or to provide a separate testing step at the end of the filling process.

[0137] Figure 15The diagram shows that after the volume of the bottle contents is tested at test station 182, bottle 150 returns to capping station 154. If the contents have an acceptable volume, bottle 150 can move to capping station 154. If bottle 150 is set to be discarded, it can also return to capping station 154 to receive the precursor in container 120 within waste bin 112. Capping station 154 serves to return cap 152 to bottle 150. The manner in which cap 152 is placed on bottle 150 is intended to be very similar to the manner in which a cap is removed from a bottle. Once bottle 150 is aligned with cap 152, cap retainer 156 can simply be rotated in the opposite direction. Additional features of capping station 154 will become clear from the detailed discussion of the container structure provided below.

[0138] The distributor unit 100 may also include a marking station 190. Figure 16 The diagram shows container 120 moving from capping station 154 to marking station 190. Marking station 190 is not limited to use after filling bottle 150 or securing cap 152 to the bottle. Marking station 190 can be used immediately after container 120 is removed from bulk consumable packaging 118. In other embodiments, necessary and optional markings or information may be pre-configured on container 120, making additional marking at marking station 190 unnecessary.

[0139] Information provided on container 120 may include branding or text indicating compliance with any government regulations. This text may specify, specifically or generally, the formulation of the precursor contained within. Text or symbols may provide instructions for use of container 120 or the precursor. Information may include barcodes, QR codes, etc., that can be scanned during the purchase process for inventory control, pricing, etc.

[0140] The content of the markings, commonly referred to as information, may be pre-configured, wholly or partially, on container 120. The content may also be applied, wholly or partially, by marking station 190. This information may be applied directly to bottle 150 or cap 152 of container 120. The information may be set on container 120 via sheet 192 or film, such as adhesive backing film or direct heat transfer marking. The information may be set on sheet 192 before or after the sheet is applied to container 120.

[0141] Figure 17 A marking station 190 in the form of a printhead 194 is shown. The printhead 194 may be biased, for example, spring-loaded, to maintain pressure on the container 120 as the container moves past the printhead. A robot 130 may be used to move the container 120 past the printhead 194. The container 120 may be rotated as needed to facilitate the adhesion of pre-printed markings to the container 120 and / or to facilitate printing on multiple surfaces of the container.

[0142] Go to Figure 18 One or more additional steps may be performed within the dispenser unit 100 before the final product (e.g., a container filled with the precursors) is produced. For example, aerosol-forming agents and flavoring materials typically used to generate the precursors of this disclosure are not necessarily easily mixed simply by adding them to the same bottle 150. However, to provide a consistent product, these precursor components should be thoroughly mixed before use. One option is to provide indicative labels that, for example, prompt the user to “shake well.” Figure 18 In the illustrated embodiment, the mixing step is performed within the dispenser unit 100. Figure 18 A schematic cross-sectional top view of the dispenser unit 100 is shown. The mixing path 196 is shown in a spiral form. The robot 130 may be configured to move the container 120 along the spiral mixing path in the XY plane. Alternatively or additionally, the mixing path 196 may be of a pseudo-random form. Alternatively or additionally, the stand 132 may be configured to move the container 120 out of the XY plane along the Z-axis. The movement along the Z-axis is in the same direction as the movement that can be used for engagement and disengagement at the capping station 154. As the container travels along the spiral mixing path 196, the movement of the container 120 along the Z-axis may be relatively slow. Alternatively, the container 120 may be violently rocked up and down. Additionally or alternatively, the stand 132 may be configured to impart rotational motion to the container 120 about an axis, such as the Z-axis passing through the container. In other embodiments, rotational mixing may be performed within the capping station 154. The cap retainer 156 allows the container 120 to rotate as a whole, wherein the bottle 150 has been temporarily released from the stand 132 or at least is allowed to rotate freely relative to the stand 132.

[0143] Go to Figure 19 An exemplary discharge channel 110 is shown. The discharge channel 110 may include an inlet 200. A robot 130 may be configured to position a container 120 within the inlet 200. A bench 132 or other structure may be used to elevate the container 120. A deflecting surface 202 may push the container 120 along a desired discharge path 204. Upon release from the bench 132, the discharge channel 110 may guide the container 120 to and / or guide it away from the opening 104 in the access door 106.

[0144] Having described the dispenser unit 100, several possible workstations within the dispenser unit 100, and the representative functions of each workstation, those skilled in the art will understand the methods and processes arising from the use of the dispenser unit 100. The use of the dispenser unit 100 can be described as an automated method for manufacturing a custom composition of aerosol precursors. This method may include removing an empty container 120 using a robot 130. The method may then include dispensing a liquid aerosol forming agent into the container 120 at a first location using a first pump 168, moving the container 120 to a second location using the robot 130, and dispensing at least one liquid flavoring material into the container 120 at the second location using a second pump. The container 120 may be sealed or closed using a lid 152. Aerosol precursor components may then be mixed to complete an aerosol precursor composition, which is subsequently discharged from the dispenser unit 100.

[0145] Go to Figure 20-23 The illustration details an example of a container 120 used with the dispenser unit 100. In one embodiment, the container 120 dispensed by the dispenser unit 100 will have one or more "child-proof" features. Those skilled in the art will understand that "child-proof" features require a combination of two or more different actions to restrict access to the contents of the container 120. One example includes applying a squeezing action while rotating the lid 152. Other conventional child-proof lids require pressure during rotation. Additionally, other conventional child-proof lids require alignment of certain elements before the lid can be removed.

[0146] In one embodiment, container 120 includes one or more tamper-proof features. These tamper-proof features are designed to alter the appearance or function of container 120 after it has been initially touched, making the user aware that the container has previously been opened. For example, several bottle caps have buttons that pop out after the container is initially opened. In a preferred embodiment, container 120 having aerosol precursors received from dispenser unit 100 will have child-protective and tamper-proof features.

[0147] Figure 20A cross-sectional view of container 120 in a first state is shown. The first state typically corresponds to a pre-filled state (i.e., before or after filling, and therefore substantially empty or unfilled). Container 120 in the first state may be in a bulk consumable package 118, ready to be removed by robot 130. Container 120 includes a bottle 150 and a cap 152. Bottle 150 includes a storage volume 210 for holding liquid contents such as aerosol precursors. Storage volume 210 may be at least about 5 ml, and preferably at least about 15 ml. Because dispenser unit 100 is preferably configured as a counter-top device with a large number of containers 120 internally, storage volume 210 is not expected to exceed 100 ml. In many cases, storage volume 210 is large enough to contain sufficient aerosol precursors for more than one use in an aerosol delivery device. In other words, a storage section of an aerosol delivery device, such as one located within a cartridge, may be two times or more smaller than the storage volume 210 of bottle 150.

[0148] Bottle 150 may include a neck 212 having external threads 214, which at least partially assist in attaching cap 152 to bottle 150. Between threads 214 and storage volume 210, neck 212 may include radial flange 216.

[0149] The cap 152 may include a nozzle 220 having an orifice 222 for dispensing aerosol precursors from the storage volume 210. The nozzle 220 may be at least partially fitted within the neck 212. The cap 152 may also include an inner cover 224. The inner cover 224 may include internal threads 226 configured to mate with external threads 214 of the neck 212. The inner cover 224 may provide an anti-tamper feature in the form of an anti-tamper band 228 located within the inner cover 224.

[0150] In the first pre-fill position, the anti-tampering strip 228 is not activated. Therefore, removing the cap 152 to allow filling the bottle 150 with the precursor will not cause damage to the anti-tampering strip 228. Figure 20 As shown, the anti-tampering strap 228 can press against the top of the radial flange 216 in the first state. This press-fit between the strap 228 and the top of the radial flange 216 helps ensure that the cap 152 does not come loose from the bottle 150 during transport or loading of the empty container 120.

[0151] The cap 152 may also include an outer cover 230 configured to rest on the inner cover 224. Selective movement between the inner cover 224 and the outer cover 230 may provide preferred child-protective features for the container 120. For example, the outer cover 230 may need to be radially pressed against the inner cover 224 to rotate the inner cover 224 relative to the neck 212. Alternatively, the outer cover 230 may need to be pressed downward toward the bottle 150 onto the inner cover 224 to rotate the inner cover 224 relative to the neck 212.

[0152] Figure 20 The first state shown includes a cap 152 partially attached to the bottle 150. For example, the nozzle 220 is inserted into the neck 212 with a first insertion distance I1. The inner cover 224 is threaded into the neck 212 with a first thread distance T1. In the first state, the cap 152 can be completely removed from the bottle 150 without triggering the anti-tampering features, allowing the bottle 150 to receive the aerosol precursor composition components. Complete removal of the cap 152 before filling may include simultaneous removal of the nozzle 220, the inner cover 224, and the outer cover 230.

[0153] Figure 21 The cap 152 is shown fully attached to the bottle 150 in the second state. The second state is typically carried out after the bottle 150 has been filled with the aerosol precursor. Figure 21 The complete anti-tampering band 228 is shown, and it is activated before the user has first used the aerosol precursor. In the second state, the cap 152 engages with the bottle 150 such that the nozzle 220 is inserted into the neck 212 with a second insertion distance I2 greater than I1. In the second state, the inner cover 224 is threaded into the neck 212 with a second thread distance T2 greater than T1. When the inner cover 224 is fully screwed onto the neck 212, the anti-tampering band 228 is activated by being positioned below the radial flange 216. With the band 228 activated, the anti-tampering band is damaged (e.g., permanently deformed or broken) as the inner cover 224 is removed from the nozzle 220, passing over the radial flange 216.

[0154] In the first state, such as Figure 20As shown, the first insertion distance I1 is configured to provide a loose fit to the nozzle 220 within the neck 212. When the inner cover 224 is threadedly removed from the neck 212 for filling into the bottle 150, the nozzle 220 is carried by and held together with the cap 152 by the inner cover 224. In one example, the nozzle 220 has a stop 232 to engage with the inner cover 224 by interacting with a protrusion 234. When the nozzle is only loosely inserted into the neck 212, the stop 232 and the protrusion 234 allow the nozzle 220 to follow the inner cover 224. In other words, the stop 232 allows the cap 152 to be completely removed from the bottle 150 in a single step at the capping station 154 when in the first state. This eliminates the need for the nozzle 220 to be individually removed from or added to the bottle 150 as needed.

[0155] However, in the second state, as Figure 21 As shown, the second insertion distance I2 is configured to provide a tight, substantially permanent press-fit to the nozzle 220 into the neck 212. The nozzle 220 may include a shoulder 236 located below a step 238 of the inner cover 224. When the inner cover 224 is fully screwed onto the neck 212, the step 238 of the inner cover 224 presses against the shoulder 236 of the nozzle 220, thereby forcing the nozzle to reach the second insertion distance I2. In the second position, the retaining force between the neck 212 and the nozzle 220 is significantly greater than the retaining force between the stop 232 and the protrusion 234. Therefore, once the second state is achieved, the inner cover 224 is configured to be threadedly removed from the bottle 150 while the nozzle 220 remains engaged with the neck 212.

[0156] When the nozzle 220 is inserted into the neck 212 at a second insertion distance I2 and the inner cover 224 is not threaded into the neck, the container 120 can be considered to be in the third state. In the third state, the contents of the bottle 150 can be dispensed through the orifice 222 of the nozzle 220.

[0157] In some embodiments, the sidewalls 240 of the bottle 150 and the sidewalls 242 of the cap 152 may not be cylindrical. Therefore, screwing the cap 152 relative to the bottle 150 may create misalignment between the sidewalls 242 of the cap 152 and the sidewalls 240 of the bottle 150. To address this potential problem and to help ensure alignment of the respective sidewalls when the cap 152 is fully screwed onto the bottle 150, the neck 212 may be provided with a bottle alignment stop 244. The bottle alignment stop 244 may be... Figure 22 The inner cover 224 may also have a cover alignment stop 246, which can be viewed optimally in the center. Figure 23The best view is as follows. When the cap 152 is screwed onto the bottle 150, the bottle alignment stop 244 will abut against the cap alignment stop 246 in the second state, at which point the side walls 240, 242 of the container 120 will be aligned.

[0158] Having shown and described the structure of container 120 according to one embodiment, methods and processes for using or filling the container will be apparent to those skilled in the art. In one example, container 120 may be used as part of a method of filling the container with an aerosol precursor liquid. The method includes separating a cap 152 from bottle 150 using a machine, wherein cap 152 includes a nozzle 220, an inner cover 224, and an outer cover 230. The method may then include filling at least partially the storage volume 210 of bottle 150 with aerosol precursor liquid from a plurality of filling stations 12, each station including a liquid component of the aerosol precursor. The method may continue by attaching cap 152 to bottle 150 such that nozzle 220 is substantially permanently fixed to bottle, and anti-tampering band 228 formed on cover 224 is activated below radial flange 216 extending from neck 212 of bottle.

[0159] Based on the further disclosure provided herein, it will be apparent to those skilled in the art that the foregoing description of the use of dispenser unit 100 and container 120 can be applied, with minor modifications, to the various embodiments described herein. However, the above description of use is not intended to limit the use of the article, but rather to provide all necessary requirements for conforming to this disclosure.

[0160] Many modifications and other embodiments of this disclosure will be apparent to those skilled in the art to which this disclosure pertains, and they have the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it should be understood that this disclosure is not limited to the specific embodiments disclosed, and various modifications and other embodiments are included within the scope of the appended claims. Although specific terminology is used herein, it is used in a general and descriptive sense and not for limiting purposes.

Claims

1. A tamper-evident container for child-resistant, the container comprising: a bottle having a storage volume for containing a liquid content; and a cap assembly comprising: a spout; an inner cover comprising a tamper-evident band; and an outer cover disposed over the inner cover, wherein the outer cover forms a child-resistant feature limiting the ability to remove the inner cover from the bottle, wherein in a first state, the spout, the inner cover and the outer cover can be removed from the bottle simultaneously, and in a second state, the spout is permanently fixed to the bottle, the bottle comprising a neck and a radial flange, and the tamper-evident band is activated in the second state by being positioned below the radial flange.

2. The container of claim 1, wherein: the bottle has a neck comprising an outer thread; the spout is configured to fit at least partially within the neck, and the spout has an aperture for dispensing the liquid content from the bottle; the inner cover further comprises an inner thread for cooperating with the outer thread of the neck, and the tamper-evident band is positioned within the interior of the inner cover.

3. The container of claim 1 or claim 2, wherein, in the first state, the cap cooperates with the bottle such that the spout is inserted into the neck with a first insertion distance Ii, and the inner cover is threadedly cooperated with the neck with a first thread distance Ti; in the second state, the cap cooperates with the bottle such that the spout is inserted into the neck with a second insertion distance I2 that is greater than Ii, and the inner cover is threadedly cooperated with the neck with a second thread distance T2 that is greater than Ti; and in a third state, the spout is inserted into the neck with the second insertion distance I2, and the inner cover is not threadedly cooperated with the neck such that the liquid content of the bottle can be dispensed through the aperture of the spout.

4. The container of claim 1, wherein the bottle comprises a neck and a radial flange, and in the first state, the cap assembly is fixed to the bottle by a press fit between the tamper-evident band and the radial flange.

5. The container of claim 3, wherein further comprising a fourth state, wherein in the fourth state, the cap assembly is removed from the bottle to allow the storage volume to be at least partially filled with an aerosol precursor.

6. The container of claim 1, wherein the spout comprises a stop to snap fit into the inner cover to remove the spout together with the inner cover from the bottle.

7. The container of claim 2, wherein in the second state, the inner cover abuts a bottle alignment stop formed on the neck, wherein the bottle alignment stop facilitates alignment in the respective second state if the sidewall of the bottle and the sidewall of the cap are not cylindrical.

8. A method of filling a container of any one of claims 1-7 with an aerosol precursor, the method comprising: taking out a container comprising a bottle and a pre-attached cap assembly; separating the pre-attached cap assembly from the bottle using a machine, the cap assembly including a nozzle, an inner cover, and an outer cover; at least partially filling the storage volume of the bottle with the aerosol precursor from a plurality of filling stations, each of the stations including a liquid component of the aerosol precursor; re-attaching the cap assembly to the bottle such that the nozzle is permanently secured to the bottle and a tamper-evident band formed on the inner cover is activated below a radial flange extending from a neck of the bottle.

9. The method of claim 8, wherein, separating the cap assembly from the bottle includes simultaneously removing the nozzle, the inner cover, and the outer cover from the bottle.

10. The method of claim 8, wherein, separating the pre-attached cap assembly from the bottle includes rotating the cap assembly relative to the bottle.

11. The method of claim 8, wherein, separating the pre-attached cap assembly from the bottle includes removing the cap assembly from the bottle without triggering the tamper-evident band.

12. The method of claim 8, wherein, removing the container includes using a robot to remove the container from the bulk consumable packaging.

Images