Method for assembling a cartridge for a smoking article

Abstract

The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges can be assembled by transporting a carrier between various sub-stations that add parts to a base. In another assembly method, the base can be moved between multiple robots that guide the base down into contact with an assembly to couple the assembly thereto. Inspection systems can inspect the cartridges at various stages of completion.

Description

[0001] This application is a divisional application of patent application No. 201580019489.X, filed on February 13, 2015, with the international application number PCT / US2015 / 015878, and entitled "Method for Assembling a Cartridge for a Smoking Article", in which, for the single issue pointed out in the first office action of the divisional application No. 201811338992.3, filed on November 12, 2018, and entitled "Method for Assembling a Cartridge for a Smoking Article", of the above-mentioned application, this divisional application is presented. TECHNICAL FIELD

[0002] The present disclosure relates to cartridges for aerosol delivery devices, such as smoking articles, and more specifically to methods for assembling cartridges for smoking articles that include an atomizer. The atomizer can be configured to heat an aerosol precursor that can be made of, or derived from, or otherwise incorporate tobacco, to form an inhalable substance for human consumption. BACKGROUND

[0003] Cigarettes, cigars and pipes are popular smoking articles that employ tobacco in various forms. For example, a conventional type of cigarette has a generally cylindrical rod shape structure and includes a charge, roll or column of smokable material, such as cut tobacco (e.g., in cut filler form), surrounded by a wrapper paper, thereby forming a so-called "rod," "tobacco rod" or "cigarette rod." Typically, this cigarette has a cylindrical filter element aligned in end-to-end relationship with the tobacco rod. Preferably, the filter element includes a plug of plasticized cellulose acetate surround by a paper material known as "tipping paper." Preferably, the filter element is attached to one end of the tobacco rod using a surrounding wrapper material known as "tipping material." It has also become desirable to perforate the tipping material and tipping paper in order to provide dilution of mainstream smoke drawn thereagainst with ambient air. Descriptions of cigarettes and their various components are set forth in Davis et al. (Eds.) Tobacco Production, Chemistry and Technology (1999); which is incorporated herein by reference in its entirety. A conventional type of cigarette is employed by a smoker by lighting one end of the tobacco rod. The smoker then receives mainstream smoke into his / her mouth by drawing on the opposite end of the burning cigarette, e.g., the filter end or mouth end.

[0004] Components, configurations, and performance of smoking articles that require combustion of tobacco for smoke production have been the subject of efforts to improve over the years. Many of those improvements purportedly attempted to provide sensations associated with smoking a cigarette, cigar, or pipe without delivering a substantial amount of products of incomplete combustion and pyrolysis produced by burning tobacco. See, for example, various references described, discussed, or referenced in U.S. Patent No. 7,753,056 to Borschke et al.; incorporated herein by reference in its entirety.

[0005] Certain types of cigarettes employing carbonaceous fuel elements have been marketed under the brand names "Premier" and "Eclipse" by R. J. Reynolds Tobacco Company. See, for example, those types of cigarettes described in Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco (R. J. Reynolds Tobacco Company Monograph (1988)) and Inhalation Toxicology (12:5, pp. 1-58, (2000)). In addition, a similar type of cigarette has recently been marketed in Japan by Japan Tobacco Inc. under the brand name "Steam Hot One." Furthermore, various types of smoking articles incorporating carbonaceous fuel elements for heat generation and aerosol formation have recently been set forth in the patent literature. See, for example, the types of smoking articles set forth in U.S. Patent Nos. 7,836,897 to Borschke et al.; 8,469,035 and 8,464,726 to Banerjee et al.; U.S. Patent Publication No. 2012 / 0042885 to Stone et al.; 2013 / 0019888 to Tsuruizumi et al.; 2013 / 0133675 and 2013 / 0146075 to Shinozaki et al.; 2013 / 098380 to Raether et al.; 2013 / 098405 to Zuber et al.; 2013 / 098410 and 2013 / 104914 to Zuber et al.; EP 1 808 087 to Baba et al.; and EP 2 550 879 to Tsuruizumi et al.; the above patents incorporated herein by reference in their entireties.

[0006] In recent years, a number of smoke products, odor generators, and medicinal inhalers have been proposed that utilize electrical energy to heat and vaporize volatile materials or otherwise attempt to provide many of the sensations of smoking without burning tobacco to any significant degree. See, for example, the various types of aerosol-generating devices described, discussed, or referenced in the following patents: U.S. Patent No. 7,726,320 to Robinson et al.; U.S. Patent Application Serial No. 13 / 826,929 to Ampolini et al., filed March 14, 2013; 14 / 011,992 to Davis et al., filed August 28, 2013; and 14 / 170,838 to Bless et al., filed February 3, 2014; the above patents are incorporated herein by reference in their entireties.

[0007] In this regard, certain tobacco products that employ electrical energy to generate heat for smoke or aerosol formation, and particularly certain products that have been referred to as electronic cigarette products, have become commercially available throughout the world. Representative products that resemble many attributes of a traditional type of cigarette, cigar, or pipe have been marketed, such as: ALPHA by InnoVapor LLC TM , JOYE 510 TM , and M4 TM ; CIRRUS and FLING by White Cloud Cigarettes; TM TM ; BLU by Lorillard Technologies, Inc. TM ; COHITA, COLIBRI, ELITE CLASSIC, MAGNUM, PHANTOM, and SENSE by Philip Morris International Inc. TM TM TM TM TM TM DUOPRO, STORM, and VAMO by Electronic Cigarettes, Inc. TM TM EGAR by Egar Australia TM eGo-C and eGo-T by Joyetech TM TM ELUSION by Elusion UK Ltd TM ​​​​​​​​​​FINBranding Group, LLC, FINTM; Green Smoke Inc., USA Greenarette LLC's Greenarette TM ; HALLIGAN TM HENDU TM JET TM MAXXQ TM PINK TM and Pitbul TM ; HEATBAR by Philip Morris International, Inc. TM ; HYDRO IMPERIAL from Crown7 TM and LXE TM LOGIC Technology's LOGIC TM and THE CUBAN TM Luciano Smokes Inc. Nicotek, LLC Sottera, Inc. and ONEJOY TM SS Choice LLC's No. 7 TM ; PREMIUM ELECTRONIC CIGARETTE by PremiumEstore LLC TM RAPP E-MYSTICK by Ruyan America, Inc. TM ; RED DRAGON of Red Dragon Products, LLC TM ; Ruyan Group (Holdings) Ltd. Smoker Friendly International,LLC GREEN SMART by The Smart Smoking ElectronicCigarette Company Ltd. SMOKE by Coastline Products LLC SMOKING by Smoking Everywhere, Inc. V2CIGS of VMR Products LLC TM VaporNine LLC's Vapor NineTM ; VUSE® by Reynolds American Inc. VEPPO by E-CigaretteDirect, LLC TM ; VUSE® by Reynolds American Inc. Mistic Menthol by Mistic Ecigs; and Vype by CN Creative Ltd. There are other electrically powered aerosol delivery devices and, in particular, those devices that have been characterized as so-called electronic cigarettes that have been marketed under the following trademark names: COOLER VISIONS TM ; DIRECT E-CIG TM ; DRAGONFLY TM ; EMIST TM ; EVERSMOKE TM ; HYBRIDFLAME TM ; KNIGHT STICKS TM ; ROYAL BLUES TM ; SOUTH BEACH SMOKE TM .

[0008] Additional manufacturers, designers, and / or assignees of components and related technology that can be employed in aerosol delivery devices include: Shenzhen Jieshibo Technology, Shenzhen, China; Shenzhen First Union Technology, Shenzhen, China; Safe Cig, Los Angeles, California; Janty Asia Company, Philippines; Joyetech Changzhou Electronics, Shenzhen, China; SIS Resources; B2B International Holdings, Dover, Delaware; Evolv LLC, Ohio; Montrade, Bologna, Italy; Shenzhen Bauway Technology, Shenzhen, China; Global Vapor Trademarks Inc., Pompano Beach, Florida; Vapor Corp., Fort Lauderdale, Florida; Nemtra GMBH, Laatzen-Marbach, Germany; Perrigo L. Co., Allegan, Michigan; Needs Co., Ltd.; Smokefree Innotec, Las Vegas, Nevada; McNeil AB, Helsingborg, Sweden; Chong Corp; Alexza Pharmaceuticals, Mountain View, California; BLEC, LLC, Charlotte, North Carolina; Gaitrend Sarl, Rambouillet, France; FeelLife Bioscience International, Shenzhen, China; Vishay Electronic BMGH, Selb, Germany; Shenzhen Smaco Technology Ltd., Shenzhen, China; Vapor Systems International, Berkeley, Florida; Exonoid Medical Devices, Israel; Shenzhen Nowotech Electronic, Shenzhen, China; Minilogic Device Corporation, Hong Kong, China; Shenzhen Kontle Electronics, Shenzhen, China, and Fuma International, LLC, Medina, Ohio, and 21st Century Smoke, Beloit, Wisconsin.

[0009] However, embodiments of electronic vaping products can be difficult to manufacture. In this regard, for example, various components in electronic vaping products can be relatively small and / or fragile. Accordingly, advances with respect to manufacturing electronic vaping products would be desirable. SUMMARY

[0010] The present disclosure relates to assembly of aerosol delivery devices configured to generate aerosols. In one aspect, a method for assembling a cartridge for an aerosol delivery device is provided. The method can include providing a reservoir substrate extending at least partially around an atomizer, providing an outer body configured to at least partially receive the reservoir substrate and the atomizer therein, and inserting the reservoir substrate into the outer body by a tool defining a funnel portion configured to reduce an outer dimension of the reservoir substrate such that the outer dimension of the reservoir substrate is less than or equal to an inner dimension of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0011] In some embodiments, the method can further include twisting the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body by the tool. Providing the reservoir substrate extending at least partially around the atomizer can include wrapping the reservoir substrate at least partially around the atomizer prior to inserting the reservoir substrate into the outer body by the tool. Wrapping the reservoir substrate at least partially around the atomizer can include directing an airflow at the reservoir substrate.

[0012] In some embodiments, the method can further include engaging the reservoir substrate with one or more fingers to cause the reservoir substrate to remain at least partially wrapped around the atomizer when beginning to insert the reservoir substrate into the outer body by the tool. The method can further include releasing the one or more fingers from the reservoir substrate when the reservoir substrate is inserted into the tool to a predetermined depth. Releasing the one or more fingers can include deflecting the one or more fingers away from the reservoir substrate by contacting the one or more fingers with the tool. Releasing the one or more fingers can include releasing the fingers sequentially. The method can further include coupling the atomizer to a base prior to wrapping the reservoir substrate at least partially around the atomizer, and coupling the outer body to the base after inserting the reservoir substrate into the outer body by the tool. Additionally, the method can include feeding the reservoir substrate from a generally continuous reservoir substrate input, and controlling a tension in the generally continuous reservoir substrate input.

[0013] In additional aspects, a method for assembling an atomizer for an aerosol delivery device is provided. The method can include providing a first heating terminal, a second heating terminal, and a heating element, determining a position of the first heating terminal and the second heating terminal, determining a position of the heating element, and attaching the heating element to the first heating terminal and the second heating terminal based on the position of the first heating terminal and the second heating terminal and the position of the heating element.

[0014] In some embodiments, determining the position of the first heating terminal and the second heating terminal can include determining a midpoint between the first heating terminal tab and the second heating terminal tab. The heating element can include a first contact portion and a second contact portion, and determining the position of the heating element can include determining a midpoint between the first contact portion and the second contact portion. The method can further include aligning the midpoint between the first heating terminal tab and the second heating terminal tab with the midpoint between the first contact portion and the second contact portion, engaging the first contact portion with the first heating terminal tab, and engaging the second contact portion with the second heating terminal tab.

[0015] In some embodiments, the method can further include clamping the first heating terminal and the second heating terminal such that the first heating terminal tab and the second heating terminal tab are substantially coplanar. Clamping the first heating terminal and the second heating terminal can include adjusting a spacing between the first heating terminal and the second heating terminal. Attaching the heating element to the first heating terminal and the second heating terminal can include directing a laser beam at the first heating terminal tab and the second heating terminal tab. Directing the laser beam at the first heating terminal tab and the second heating terminal tab can include directing the laser beam at a back side of the first heating terminal tab and the second heating terminal tab opposite the heating element.

[0016] The method can further include inserting the heating element, the first heating terminal, and the second heating terminal into a substantially sealed chamber prior to directing the laser beam at the first heating terminal tab and the second heating terminal tab. Providing the heating element can include supplying the heating element from a substantially continuous heating element input, and controlling a tension in the substantially continuous heating element input. The method can further include coupling the heating element to a liquid delivery element. Providing the first heating terminal and the second heating terminal can include supplying the first heating terminal from a substantially continuous first heating terminal input, and supplying the second heating terminal from a substantially continuous second heating terminal input. The heating element can include a wire wound around the liquid delivery element. The wire can include two contact portions, a center portion, and two outer portions positioned outside the contact portions, the two contact portions and the center portion of the wire defining the heating element, wherein the contact portions define a first coil spacing, the center portion defines a second coil spacing, and the outer portions define a third coil spacing, the third coil spacing being greater than the second coil spacing, and the second coil spacing being greater than the first coil spacing, and attaching the heating element to the first heating terminal and the second heating terminal can include attaching the contact portions to the first heating terminal and the second heating terminal.

[0017] In additional aspects, a test fixture is provided. The test fixture can include a socket configured to engage a base of a cartridge, first and second electrical contacts coupled to the socket and configured to engage first and second heating terminals of an atomizer of the cartridge, and a controller configured to communicate with the cartridge through the electrical contacts when the base of the cartridge is engaged with the socket to test the cartridge. The controller can be configured to determine a resistance of the atomizer of the cartridge and compare the resistance to a required resistance.

[0018] In some embodiments, the controller can be further configured to determine whether the atomizer is shorted to an exterior body of the cartridge. The test fixture can further include a third electrical contact coupled to the socket and configured to engage a control component terminal of the cartridge. The controller can be configured to transmit program code instructions to an electronic control component of the cartridge through the third electrical contact and control component terminal. The controller can be further configured to read program code instructions stored on the electronic control component and determine whether the program code instructions stored on the electronic control component correspond to required program code instructions. The test fixture can further include a slot positioned on an opposite side of the socket, the slot configured to receive a jaw such that the jaw can grasp under the base to remove the cartridge from the socket. The test fixture can further include an aperture configured to provide an airflow through a base of the cartridge.

[0019] In additional aspects, a cartridge filling method is provided. The method can include providing a cartridge for an aerosol delivery device, the cartridge including a reservoir substrate positioned in an exterior body, sequentially positioning an outlet of a filling device proximate to a plurality of angular portions of the reservoir substrate, and directing a flow of an aerosol precursor composition at each of the angular portions of the reservoir substrate through the outlet of the filling device.

[0020] In some embodiments, an outlet of a filling device can remain out of contact with a reservoir substrate. The method can further include transporting the cartridge between a plurality of filling stations, where the flow of the aerosol precursor composition is directed to at least one of the angular portions of the reservoir substrate at each of the filling stations. The flow of the aerosol precursor composition can be directed at each of the angular portions of the reservoir substrate at a first one of the filling stations. The flow of the aerosol precursor composition can be directed to one of the angular portions of the reservoir substrate at each of the remaining ones of the filling stations, respectively. The method can further include controlling a surrounding environment in which the cartridge is filled such that the surrounding environment defines a relative humidity of less than about 40%.

[0021] In an additional aspect, a method for assembling a cartridge for an aerosol delivery device is provided. The method can include grasping a base, providing a plurality of components configured to engage the base, the components being provided in a rest position, and coupling the components to the base by guiding the base into contact with the components in the rest position.

[0022] In some embodiments, grasping the base can include grasping an inner surface of the base configured to engage an attachment end of a control body. Guiding the base into contact with the components in the rest position can include guiding the base downward into contact with the components. The method can further include inserting the base into a fixture and checking a position of first and second heating terminals coupled to the base by the fixture.

[0023] In an additional aspect, a delivery system configured to deliver a cartridge for a smoking article during assembly of the smoking article is provided. The delivery system can include a track, a carriage configured to engage the track and move along the track, the carriage including a clamping mechanism configured to engage one or more components of the cartridge during assembly of the cartridge, and a locking device configured to temporarily restrain movement of the carriage along the track.

[0024] In some embodiments, the clamping mechanism can be configured to engage a base of the cartridge. The locking device can include a positioner mechanism coupled to the carriage and an engagement mechanism configured to engage the positioner mechanism. The positioner mechanism can include a plurality of pegs. The engagement mechanism can include a roller.

[0025] The disclosure includes, without limitation, the following embodiments.

[0026] Embodiment 1 : A method for assembling a cartridge for an aerosol delivery device, the method comprising:

[0027] providing a reservoir substrate extending at least partially around an atomizer;

[0028] providing an outer body configured to at least partially receive the reservoir substrate and the atomizer therein; and

[0029] inserting the reservoir substrate into the outer body by a tool, the tool defining a funnel portion configured to reduce an outer dimension of the reservoir substrate, such that the outer dimension of the reservoir substrate is less than or equal to an inner dimension of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0030] Example 2: The method of any preceding or subsequent example, further comprising twisting the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body by the tool.

[0031] Example 3: The method of any preceding or subsequent example, wherein providing the reservoir substrate extending at least partially around the atomizer comprises wrapping the reservoir substrate at least partially around the atomizer prior to inserting the reservoir substrate into the outer body by the tool.

[0032] Example 4: The method of any preceding or subsequent example, wherein wrapping the reservoir substrate at least partially around the atomizer comprises directing an air flow at the reservoir substrate.

[0033] Example 5: The method of any preceding or subsequent example, further comprising engaging the reservoir substrate with one or more fingers when beginning to insert the reservoir substrate into the outer body by the tool such that the reservoir substrate remains at least partially wrapped around the atomizer.

[0034] Example 6: The method of any preceding or subsequent example, further comprising releasing the one or more fingers from the reservoir substrate when the reservoir substrate is inserted into the tool to a predetermined depth.

[0035] Example 7: The method of any preceding or subsequent example, wherein releasing the one or more fingers comprises deflecting the one or more fingers away from the reservoir substrate by contacting the one or more fingers with the tool.

[0036] Example 8: The method of any preceding or subsequent example, wherein releasing the one or more fingers comprises releasing the fingers sequentially.

[0037] Example 9: The method of any preceding or subsequent example, further comprising coupling the atomizer to a base prior to wrapping the reservoir substrate at least partially around the atomizer; and

[0038] coupling the outer body to the base after inserting the reservoir substrate into the outer body by the tool.

[0039] Example 10: The method of any preceding or subsequent example, further comprising feeding the reservoir substrate from a substantially continuous reservoir substrate input; and

[0040] controlling a tension in the substantially continuous reservoir substrate input.

[0041] Example 11: A method for assembling an atomizer for an aerosol delivery device, the method comprising:

[0042] providing a first heating terminal, a second heating terminal, and a heating element;

[0043] determining a position of the first heating terminal and the second heating terminal;

[0044] determining a position of the heating element; and

[0045] attaching the heating element to the first heating terminal and the second heating terminal based on the position of the first heating terminal and the second heating terminal and the position of the heating element.

[0046] Example 12: The method of any preceding or subsequent embodiment, wherein determining the position of the first heating terminal and the second heating terminal comprises determining a midpoint between a first heating terminal tab and a second heating terminal tab.

[0047] Example 13: The method of any preceding or subsequent embodiment, wherein the heating element comprises a first contact portion and a second contact portion, and

[0048] wherein determining the position of the heating element comprises determining a midpoint between the first contact portion and the second contact portion.

[0049] Example 14: The method of any preceding or subsequent embodiment, further comprising aligning the midpoint between the first heating terminal tab and the second heating terminal tab and the midpoint between the first contact portion and the second contact portion;

[0050] engaging the first contact portion with the first heating terminal tab; and

[0051] engaging the second contact portion with the second heating terminal tab.

[0052] Example 15: The method of any preceding or subsequent embodiment, further comprising clamping the first heating terminal and the second heating terminal such that the first heating terminal tab and the second heating terminal tab are substantially coplanar.

[0053] Example 16: The method of any preceding or subsequent embodiment, wherein clamping the first heating terminal and the second heating terminal comprises adjusting a spacing between the first heating terminal and the second heating terminal.

[0054] Embodiment 17: The method of any preceding or subsequent embodiment, wherein attaching the heating element to the first heating terminal and the second heating terminal comprises directing a laser beam at the first heating terminal tab and the second heating terminal tab.

[0055] Embodiment 18: The method of any preceding or subsequent embodiment, wherein directing the laser beam at the first heating terminal tab and the second heating terminal tab comprises directing the laser beam at a backside of the first heating terminal tab and the second heating terminal tab opposite the heating element.

[0056] Embodiment 19: The method of any preceding or subsequent embodiment, further comprising inserting the heating element, the first heating terminal, and the second heating terminal into a substantially sealed chamber prior to directing the laser beam at the first heating terminal tab and the second heating terminal tab.

[0057] Embodiment 20: The method of any preceding or subsequent embodiment, wherein providing the heating element comprises:

[0058] supplying the heating element from a substantially continuous heating element input; and

[0059] controlling a tension in the substantially continuous heating element input.

[0060] Embodiment 21: The method of any preceding or subsequent embodiment, further comprising coupling the heating element to a liquid transport element.

[0061] Embodiment 22: The method of any preceding or subsequent embodiment, wherein providing the first heating terminal and the second heating terminal comprises:

[0062] supplying the first heating terminal from a substantially continuous first heating terminal input; and

[0063] supplying the second heating terminal from a substantially continuous second heating terminal input.

[0064] Embodiment 23: The method of any preceding or subsequent embodiment, wherein the heating element comprises a wire wound around a liquid transport element.

[0065] Embodiment 24: The method of any preceding or subsequent embodiment, wherein the wire comprises two contact portions, a center portion, and two outer portions positioned outside the contact portions, the two contact portions and the center portion of the wire defining the heating element,

[0066] wherein the contact portion defines a first coil spacing, the center portion defines a second coil spacing, and the outer portion defines a third coil spacing, the third coil spacing being greater than the second coil spacing, and the second coil spacing being greater than the first coil spacing, and

[0067] wherein attaching the heating element to the first heating terminal and the second heating terminal includes attaching the contact portion to the first heating terminal and the second heating terminal.

[0068] Embodiment 25: A test fixture comprising:

[0069] a socket configured to engage a base of a cartridge;

[0070] first and second electrical contacts coupled to the socket and configured to engage first and second heating terminals of an atomizer of the cartridge;

[0071] a controller configured to communicate with the cartridge through the electrical contacts when the base of the cartridge is engaged with the socket to test the cartridge.

[0072] Embodiment 26: The test fixture of any preceding or subsequent embodiment, wherein the controller is configured to determine a resistance of the atomizer of the cartridge and compare the resistance to a required resistance.

[0073] Embodiment 27: The test fixture of any preceding or subsequent embodiment, wherein the controller is further configured to determine whether the atomizer is shorted to an outer body of the cartridge.

[0074] Embodiment 28: The test fixture of any preceding or subsequent embodiment, further comprising a third electrical contact coupled to the socket and configured to engage a control component terminal of the cartridge.

[0075] Embodiment 29: The test fixture of any preceding or subsequent embodiment, wherein the controller is configured to transmit program code instructions to an electronic control component of the cartridge through the third electrical contact and the control component terminal.

[0076] Embodiment 30: The test fixture of any preceding or subsequent embodiment, wherein the controller is further configured to read program code instructions stored on the electronic control component and determine whether the program code instructions stored on the electronic control component correspond to required program code instructions.

[0077] Example 31: The test fixture of any preceding or subsequent example, further comprising slots positioned on opposite sides of the socket, the slots configured to receive a jaw such that the jaw can grasp underneath the base to remove the cartridge from the socket.

[0078] Example 32: The test fixture of any preceding or subsequent example, wherein the test fixture comprises an orifice configured to provide airflow through the base of the cartridge.

[0079] Example 33: A method of cartridge filling, comprising:

[0080] providing a cartridge for an aerosol delivery device, the cartridge comprising a reservoir substrate positioned in an outer body;

[0081] sequentially positioning an outlet of a filling device proximate to a plurality of angular portions of the reservoir substrate; and

[0082] directing a flow of aerosol precursor composition at each of the angular portions of the reservoir substrate through the outlet of the filling device.

[0083] Example 34: The method of cartridge filling of any preceding or subsequent example, wherein the outlet of the filling device remains out of contact with the reservoir substrate.

[0084] Example 35: The method of cartridge filling of any preceding or subsequent example, further comprising conveying the cartridge between a plurality of filling stations, wherein the flow of aerosol precursor composition is directed to at least one of the angular portions of the reservoir substrate at each of the filling stations.

[0085] Example 36: The method of cartridge filling of any preceding or subsequent example, wherein the flow of aerosol precursor composition is directed at each of the angular portions of the reservoir substrate at a first of the filling stations.

[0086] Example 37: The method of cartridge filling of any preceding or subsequent example, wherein the flow of aerosol precursor composition is directed to one of the angular portions of the reservoir substrate at a remaining portion of the filling stations, respectively.

[0087] Example 38: The method of cartridge filling of any preceding or subsequent example, further comprising controlling a surrounding environment in which the cartridge is filled such that the surrounding environment defines a relative humidity of less than about 40%.

[0088] Example 39: A method for assembling a cartridge for an aerosol delivery device, comprising:

[0089] grasping the base;

[0090] providing a plurality of components configured to engage the base, the components being provided in a rest position; and

[0091] coupling the components to the base by guiding the base into contact with the components in the rest position.

[0092] Embodiment 40: The method of any preceding or subsequent embodiment, wherein grasping the base comprises grasping an inner surface of the base configured to engage an attachment end of a control body.

[0093] Embodiment 41: The method of any preceding or subsequent embodiment, wherein guiding the base into contact with the components in the rest position comprises guiding the base downward into contact with the components.

[0094] Embodiment 42: The method of any preceding or subsequent embodiment, further comprising inserting the base into a fixture; and

[0095] checking a position of first and second heating terminals coupled to the base by the fixture.

[0096] Embodiment 43: A delivery system configured to deliver a cartridge for a smoking article during assembly of the smoking article, the delivery system comprising:

[0097] a track;

[0098] a carriage configured to engage the track and move along the track, the carriage comprising a clamping mechanism configured to engage one or more components of the cartridge during assembly of the cartridge; and

[0099] a locking device configured to temporarily restrain movement of the carriage along the track.

[0100] Embodiment 44: The delivery system of any preceding or subsequent embodiment, wherein the clamping mechanism is configured to engage a base of the cartridge.

[0101] Embodiment 45: The delivery system of any preceding or subsequent embodiment, wherein the locking device comprises a positioner mechanism coupled to the carriage and an engagement mechanism configured to engage the positioner mechanism.

[0102] Embodiment 46: The delivery system of any preceding or subsequent embodiment, wherein the positioner mechanism comprises a plurality of pegs.

[0103] Example 47: A delivery system according to any preceding or subsequent example, wherein the engagement mechanism comprises a roller.

[0104] These and other features, aspects, and advantages of the present disclosure will become evident to those skilled in the art from a reading of the following detailed description, together with the accompanying drawings. The present invention includes any combination of two, three, four or more of the above- described embodiments, as well as any combination of any two, three, four or more features or elements set forth in this disclosure, whether or not those features or elements are explicitly described in combination with each other in a particular embodiment description herein. It is intended that the disclosure be read in its entirety and with the benefit of the descriptions of the various aspects and embodiments of the disclosed invention, as well as with the benefit of the descriptions of the features and elements of the various embodiments, as set forth above. It is intended that the disclosure be read with the benefit of the descriptions of the various aspects and embodiments of the disclosed invention, as well as with the benefit of the descriptions of the features and elements of the various embodiments, as set forth above, unless and except where the context clearly indicates otherwise. BRIEF DESCRIPTION OF DRAWINGS

[0105] Accordingly, having generally described the present disclosure, reference will now be made to the drawings, which are not necessarily drawn to scale, and wherein:

[0106] Figure 1 illustrating an aerosol delivery device comprising a cartridge and a control body, the cartridge is illustrated in a disassembled configuration and the control body is illustrated in an assembled configuration, in accordance with example embodiments of the present disclosure;

[0107] Figure 2 illustrating a control body in a disassembled configuration, in accordance with example embodiments of the present disclosure; Figure 1

[0108] Figure 3 schematically illustrating a system for manufacturing cartridges for aerosol delivery devices, comprising a cartridge assembly subsystem, a cartridge filling subsystem, a cartridge capping subsystem, a cartridge labeling subsystem, and an inspection subsystem, in accordance with example embodiments of the present disclosure;

[0109] Figure 4 schematically illustrating a first embodiment of a cartridge assembly subsystem of Figure 3

[0110] Figure 5 schematically illustrating a perspective view of a carrier of a cartridge assembly subsystem of Figure 4

[0111] Figure 6 illustrating a carrier of a cartridge assembly subsystem of Figure 5

[0112] Figure 7 illustrating a cartridge of Figure 5 ​​​​side view of the carrier of the

[0113] Figure 8 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 5 rear view of the carrier of the

[0114] Figure 9 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure;

[0115] Figure 10 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 4 perspective view of a terminal sealing sub-station of the cartridge assembly subsystem of the

[0116] Figure 11 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 10 perspective view of a terminal sealing sub-station of the cartridge assembly subsystem of the

[0117] Figure 12 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 4 perspective view of a heating element coupling sub-station of the cartridge assembly subsystem of the

[0118] Figure 13 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 4 perspective view of a substantially continuous heating element input of the cartridge assembly subsystem of the

[0119] Figure 14 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 12 perspective view of a preparation portion of the heating element coupling sub-station of the

[0120] Figure 15 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 14 preparation portion of the heating element coupling sub-station of the

[0121] Figure 16 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 12 alternative perspective view of a preparation portion of the heating element coupling sub-station of the

[0122] Figure 17 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 12 perspective view of a welding portion of the heating element coupling sub-station of the

[0123] Figure 18 illustrating a perspective view of a substantially continuous terminal input including a plurality of terminals according to example embodiments of the present disclosure; Figure 17 perspective view of a welding portion of the heating element coupling sub-station of the

[0124] Figure 19Schematic illustration of an open configuration according to an example embodiment of the present disclosure Figure 17 Terminal fixing mechanism for the welding part of the heating element coupling substation;

[0125] Figure 20 This illustration depicts an intermediate configuration based on an example embodiment of the present disclosure. Figure 19 Terminal fixing mechanism;

[0126] Figure 21 Schematic illustration of a closed configuration according to an example embodiment of the present disclosure. Figure 19 Terminal fixing mechanism;

[0127] Figure 22 Schematic illustration of an open configuration according to an example embodiment of the present disclosure Figure 19 Alternative embodiments of the terminal fixing mechanism;

[0128] Figure 23 The illustration shows the alignment of the heating element and heating terminal according to an example embodiment of the present disclosure;

[0129] Figure 24 This illustrative diagram illustrates the welding of heating elements to... according to exemplary embodiments of the present disclosure. Figure 23 Heating terminals;

[0130] Figure 25 A perspective view illustrating a liquid delivery element held in a curved structure according to an exemplary embodiment of the present disclosure;

[0131] Figure 26 Description of exemplary embodiments according to this disclosure Figure 4 A perspective view of the storage coupling substation of the cigarette cartridge assembly subsystem;

[0132] Figure 27 Description of exemplary embodiments according to this disclosure Figure 26 A perspective view of the movable fixture of the reservoir coupling substation, positioned at the upper limit of the generally continuous reservoir substrate input during the application period.

[0133] Figure 28 Description of exemplary embodiments according to this disclosure Figure 27 A perspective view of a movable fixture positioned at the lower limit of the dispensing period of a generally continuous reservoir substrate input;

[0134] Figure 29 Description of the reception of the reservoir substrate according to an exemplary embodiment of the present disclosure Figure 26 A perspective view of the transmission mechanism of the storage coupling substation;

[0135] Figure 30 The description of the exemplary embodiments according to this disclosure is close toFigure 26 The finger-shaped connector of the storage coupling substation Figure 29 A perspective view of the conveyor mechanism;

[0136] Figure 31 Description of exemplary embodiments according to this disclosure Figure 26 The fingers of the storage coupling subsystem are oriented towards Figure 29 A perspective view of the movement of the conveyor mechanism;

[0137] Figure 32 Description of exemplary embodiments according to this disclosure Figure 26 The finger-like clamping mechanism of the storage coupling substation;

[0138] Figure 33 Illustrative illustration based on example embodiments of this disclosure Figure 26 The storage coupling substation is wrapped around the storage substrate around the heating element;

[0139] Figure 34 Description of exemplary embodiments according to this disclosure Figure 4 The external main body supply mechanism of the external main body coupling substation of the cigarette cartridge assembly subsystem;

[0140] Figure 35 This describes an example embodiment of the present disclosure constructed to... Figure 34 The section of the tool that guides the external body above the storage substrate of the external body coupling substation;

[0141] Figure 36 Description of the use of examples and embodiments based on this disclosure Figure 26 The fingers of the reservoir coupling subsystem guide the external body above the reservoir substrate;

[0142] Figure 36A According to alternative embodiments of this disclosure, multiple pairs of fingers are used to guide the external body above the reservoir substrate;

[0143] Figure 37 Description of exemplary embodiments according to this disclosure Figure 34 A perspective view of the curler of the external main body coupling substation;

[0144] Figure 38 Description of exemplary embodiments according to this disclosure Figure 37 A side view of a section of the curler;

[0145] Figure 39 Description of exemplary embodiments according to this disclosure Figure 37 A magnified perspective view of a section of the curler;

[0146] Figure 40 Illustrative illustration of exemplary embodiments according to this disclosureFigure 3 a second embodiment of the cartridge assembly subsystem of

[0147] Figure 41 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 40

[0148] Figure 42 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 40

[0149] Figure 43 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 42

[0150] Figure 44 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 42

[0151] Figure 44A illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 44

[0152] Figure 45 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 42

[0153] Figure 46 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 40

[0154] Figure 47 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 46

[0155] Figure 48 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 40

[0156] Figure 49 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 40

[0157] Figure 50 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 49

[0158] Figure 51 illustrating a perspective view of a terminal coupling substation of the cartridge assembly subsystem of Figure 49 ​​​​​​​​​​​enlarged side view of a terminal clip jaw of the cartridge assembly subsystem;

[0159] Figure 52 illustrating a heating element coupling substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 40 perspective view of a heating element coupling substation of the cartridge assembly subsystem;

[0160] Figure 53 illustrating a heating element coupling substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 52 spool of substantially continuous heating element input of the heating element coupling substation;

[0161] Figure 54 illustrating a heating element coupling substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 52 perspective view of a welding portion of the heating element coupling substation;

[0162] Figure 55 illustrating a heating element coupling substation of the cartridge assembly subsystem during welding according to example embodiments of the present disclosure Figure 52 side view of a welding portion of the heating element coupling substation;

[0163] Figure 56 illustrating a heating element coupling substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 40 liquid delivery element bending substation of the cartridge assembly subsystem;

[0164] Figure 57 illustrating a liquid delivery element bending substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 56 liquid delivery element bending substation of the cartridge assembly subsystem;

[0165] Figure 58 illustrating a liquid delivery element bending substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 40 perspective view of a base and wick clip jaw of the cartridge assembly subsystem;

[0166] Figure 59 illustrating a liquid delivery element bending substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 58 side view of a base and wick clip jaw of the cartridge assembly subsystem;

[0167] Figure 60 illustrating a liquid delivery element bending substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 40 spool of substantially continuous reservoir substrate input of the reservoir coupling substation;

[0168] Figure 61 illustrating a reservoir coupling substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 60 perspective view of a singulation unit of the reservoir coupling substation;

[0169] Figure 62 illustrating a reservoir coupling substation of the cartridge assembly subsystem according to example embodiments of the present disclosure Figure 61 alternative perspective view of a singulation unit of the reservoir coupling substation;

[0170] Figure 63 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 40

[0171] Figure 64 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 40

[0172] Figure 65 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 64

[0173] Figure 66 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 64

[0174] Figure 67 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 64

[0175] Figure 68 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 67

[0176] Figure 69 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 64

[0177] Figure 70 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure

[0178] Figure 71 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure Figure 3

[0179] Figure 72 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure

[0180] Figure 73 Illustrating a perspective view of a winding mechanism of a reservoir coupling substation of a cartridge assembly subsystem according to example embodiments of the present disclosure

[0181] ​​​​​​​​Figure 74 A side view camera of an inspection subsystem configured to inspect a distance that a terminal extends from a base; Figure 3 A side view camera of an inspection subsystem configured to inspect a radial position of a terminal;

[0182] Figure 75 An end view camera of an inspection subsystem configured to inspect a radial position of a terminal; Figure 3 An end view camera of an inspection subsystem configured to inspect a radial position of a terminal;

[0183] Figure 76 Side and end view cameras of an inspection subsystem configured to inspect a terminal height and radial position, according to alternative embodiments of the disclosure; Figure 3 Side and end view cameras of an inspection subsystem configured to inspect a terminal height and radial position, according to alternative embodiments of the disclosure;

[0184] Figure 77 A side view of a fixture of an inspection subsystem configured to facilitate inspection of a terminal, according to embodiments of the disclosure; Figure 3 A side view of a fixture of an inspection subsystem configured to facilitate inspection of a terminal, according to embodiments of the disclosure;

[0185] Figure 78 Side and end view cameras of an inspection subsystem configured to inspect an outer body of a cartridge, according to example embodiments of the disclosure; Figure 3 Side and end view cameras of an inspection subsystem configured to inspect an outer body of a cartridge, according to example embodiments of the disclosure;

[0186] Figure 79 Side and end view cameras of an inspection subsystem configured to inspect an outer body of a cartridge, according to alternative example embodiments of the disclosure; Figure 3 Side and end view cameras of an inspection subsystem configured to inspect an outer body of a cartridge, according to alternative example embodiments of the disclosure;

[0187] Figure 80 A perspective view of a blow through station of an inspection subsystem, according to example embodiments of the disclosure; Figure 3 A perspective view of a blow through station of an inspection subsystem, according to example embodiments of the disclosure;

[0188] Figure 81 A perspective view of a blow through station of an inspection subsystem, according to alternative example embodiments of the disclosure; Figure 3 A perspective view of a blow through station of an inspection subsystem, according to alternative example embodiments of the disclosure;

[0189] Figure 82 A perspective view of a pressure drop station of an inspection subsystem, according to example embodiments of the disclosure; Figure 3 A perspective view of a pressure drop station of an inspection subsystem, according to example embodiments of the disclosure;

[0190] Figure 83 A perspective view of a pressure drop station of an inspection subsystem, according to alternative example embodiments of the disclosure; Figure 3 A perspective view of a pressure drop station of an inspection subsystem, according to alternative example embodiments of the disclosure;

[0191] Figure 84 A perspective view of an electrical test station of an inspection subsystem including a test fixture, according to example embodiments of the disclosure; Figure 3 A perspective view of an electrical test station of an inspection subsystem including a test fixture, according to example embodiments of the disclosure;

[0192] Figure 85 An enlarged perspective view of a test fixture according to example embodiments of the disclosure Figure 84 An enlarged perspective view of a test fixture according to example embodiments of the disclosure

[0193] Figure 86 An enlarged perspective view of a test fixture according to example embodiments of the disclosure Figure 84 A cross-sectional view of a test fixture according to example embodiments of the disclosure

[0194] Figure 87 A perspective view of an electrical test station of an inspection subsystem according to alternative example embodiments of the disclosure Figure 3 A perspective view of an electrical test station of an inspection subsystem according to alternative example embodiments of the disclosure

[0195] Figure 88 A method for assembling a cartridge for an aerosol delivery device according to example embodiments of the disclosure is schematically illustrated;

[0196] Figure 89 A method for assembling an atomizer for an aerosol delivery device according to example embodiments of the disclosure is schematically illustrated;

[0197] Figure 90 A method for assembling a cartridge for an aerosol delivery device according to example embodiments of the disclosure is schematically illustrated;

[0198] Figure 91 A method for assembling a cartridge for an aerosol delivery device according to example embodiments of the disclosure is schematically illustrated; and

[0199] Figure 92 A controller according to example embodiments of the disclosure is schematically illustrated. DETAILED DESCRIPTION

[0200] The present disclosure will now be described hereinafter more fully with reference to the example embodiments of the disclosure. These embodiments are described so that the disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and fully convey the scope of the disclosure to those skilled in the art. Unless otherwise defined, all terms used in disclosing embodiments of the disclosure, including technical and scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The terminology used in the description of the embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure.

[0201] Embodiments of the disclosure relate to aerosol delivery devices and methods and apparatuses for assembly thereof, as described below. Aerosol delivery devices according to the present disclosure can use electrical energy to heat a material, preferably without causing the material to burn to any significant degree, to form an inhalable substance; these articles are most preferably sufficiently compact to be considered "hand-held" devices. The aerosol delivery devices can provide some or all of the sensations of smoking a cigarette, cigar or pipe (e.g., the habits of inhaling and exhaling, the types of tastes or odors, the sensory effects, the physical sensations, the habits of use, the visual cues (such as those provided by visible aerosols), and the like) without causing any substantial degree of combustion of any component of the article or device. In the sense that an aerosol results from the byproducts of combustion or pyrolysis of tobacco, the aerosol delivery devices can not produce smoke, but rather, the articles or devices can produce a vapor resulting from volatilization or vaporization of certain components of the article or device, including a vapor within an aerosol that can be considered a visible aerosol, which can be considered to be described as smoke-like. In highly preferred embodiments, the aerosol delivery devices can incorporate tobacco and / or components derived from tobacco.

[0202] Aerosol delivery devices of the present disclosure can also be characterized as vapor-producing articles or medicament delivery articles. Thus, the articles or devices can be adapted to provide one or more substances (e.g., flavorants and / or pharmaceutically active ingredients) in inhalable form or state. For example, the inhalable substance can be in the form of a vapor (i.e., a substance in the gas phase at a temperature lower than its critical point). Alternatively, the inhalable substance can be in the form of an aerosol (i.e., a suspension of fine solid particles or liquid droplets in a gas). For simplicity, the term "aerosol" as used herein is intended to encompass vapors, gases, and aerosols in forms or types suitable for human inhalation, whether or not visible and whether or not in a form that can be considered smoke-like.

[0203] In use, aerosol delivery devices of the present disclosure can be subject to many of the physical actions employed by a person in using a traditional type of smoking article (e.g., a cigarette, cigar or pipe employed by lighting and inhaling tobacco). For example, a user of an aerosol delivery device of the present disclosure can hold the article much like a traditional type of smoking article, puff on one end of the article to inhale aerosol produced by the article, puff at selected time intervals, and the like.

[0204] Aerosol delivery devices of the present disclosure generally include several components provided within an outer body or shell. The overall design of the outer body or shell can vary, and the format or configuration of the outer body that defines the overall size and shape of the aerosol delivery device can vary. Typically, an elongated body similar in shape to a cigarette or cigar can be formed from a single unitary shell; or the elongated body can be formed from two or more separable pieces. For example, an aerosol delivery device can include an elongated shell or body that can be generally tubular in shape, and thus similar in shape to a conventional cigarette or cigar. In one embodiment, all of the components of the aerosol delivery device are contained within one outer body or shell. Alternatively, the aerosol delivery device can include two or more shells that are joined and separable. For example, an aerosol delivery device can have a control body at one end that includes an outer body or shell containing one or more reusable components (e.g., a rechargeable battery and various electronics for controlling the operation of the article), and at the other end an outer body or shell that is removably attached thereto that contains disposable portions (e.g., a disposable flavor-containing cartridge). The more specific format, configuration, and arrangement of the components within a single shell type unit or a multiple piece separable shell type unit will be apparent in view of the further disclosure provided herein. Additionally, various aerosol delivery device designs and component arrangements can be appreciated after considering commercially available electronic aerosol delivery devices, such as those representative products listed above in the present disclosure. For example, embodiments of aerosol delivery devices that include multiple outer bodies and a coupler are described in Bless et al., U.S. Patent Application Serial No. 14 / 170,838, filed February 3, 2014, which is incorporated herein by reference in its entirety, as described above.

[0205] Aerosol delivery devices of the present disclosure most preferably include some combination of a power source (i.e., an electrical power source); at least one control component (e.g., a means for actuating, controlling, regulating, and stopping the electrical power for heat generation, for example, by controlling the flow of electrical current from the power source to other components of the article); a heater or heat generation component (e.g., a resistive heating element or component commonly referred to as an "atomizer"); and an aerosol precursor composition (e.g., typically a liquid that is capable of yielding an aerosol upon the application of sufficient heat, such as compositions commonly referred to as "e-liquid," "electronic liquid," and "e-juice"); and a mouth end region or tip for allowing the aerosol delivery device to be drawn upon to inhale an aerosol (e.g., through a defined airflow path of the article such that the generated aerosol can be withdrawn therefrom upon drawing).

[0206] The alignment of components within the aerosol delivery device can vary. In certain embodiments, the aerosol precursor composition can be located near one end of the article (e.g., within a cartridge, which in certain instances can be replaceable and disposable), which can be configured to be positioned proximate a user's mouth in order to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, the heating element can be positioned in sufficient proximity to the aerosol precursor composition such that heat from the heating element can volatilize the aerosol precursor (and one or more flavorants, medicaments, or the like that can likewise be used for delivery to a user) and form an aerosol for delivery to a user. When the heating element heats the aerosol precursor composition, an aerosol is formed, released, or generated in a physical form suitable for inhalation by a consumer. It should be noted that the foregoing terms are intended to be interchangeable such that reference to releasing, released, released, or the release includes forming or generating, formed or generated, formed or generated, and formed or generated. In particular, the inhalable substance is released in the form of a vapor or aerosol or a mixture thereof. Additionally, the selection of various aerosol delivery device components can be appreciated in view of commercially available electronic aerosol delivery devices such as those representative products listed above in the present disclosure.

[0207] The aerosol delivery device incorporates a battery or other power source to provide current sufficient to provide various functionality to the article (e.g., power to the heater, power to the control system, power to the indicator, and the like). The power source can take on various embodiments. Preferably, the power source is capable of delivering sufficient power to rapidly heat the heating element in order to form an aerosol, and to power the article through use over a desired duration. The power source is preferably sized to fit conveniently within the aerosol delivery device, such that the aerosol delivery device can be easily disposed of; and additionally, the preferred power source is sufficiently lightweight as to not detract from a desirable smoking experience.

[0208] Figure 1 An example embodiment of an aerosol delivery device 100 is illustrated. In particular, Figure 1 A partial exploded view of an aerosol delivery device 100 including a cartridge 200 and a control body 300 is illustrated. The cartridge 200 and the control body 300 can be permanently or detachably aligned in a functional relationship. Various mechanisms can connect the cartridge 200 to the control body 300 to result in a threaded engagement, a press-fit engagement, an interference fit, a magnetic engagement, or the like. In some embodiments, the aerosol delivery device 100 can be a generally rod-like, a generally tubular shape, or a generally cylindrical shape when the cartridge 200 and the control body 300 are in an assembled configuration.

[0209] In particular embodiments, one or both of the cartridge 200 and the control body 300 can be referred to as disposable or reusable. For example, the control body 300 can have replaceable or rechargeable batteries and thus can be combined with any type of recharging technology, including connection to a typical AC outlet, connection to a car charger (i.e., a cigarette lighter outlet), and connection to a computer (e.g., through a Universal Serial Bus (USB) cable). Moreover, in some embodiments, the cartridge 200 can include a disposable cartridge as disclosed in U.S. Patent Application Serial No. 13 / 603,612, filed September 5, 2012, which is incorporated herein by reference in its entirety.

[0210] Figure 2 An exploded view of the control body 300 of the aerosol delivery device 100 according to example embodiments of the disclosure is illustrated. As illustrated, the control body 300 can include a coupler 302, an outer body 304, a sealing member 306, a bonding member 308 (e.g., adhesive tape), a flow sensor 310 (e.g., puff sensor or pressure switch), a control assembly 312, a spacer 314, a power source 316 (e.g., which can be a rechargeable battery), a circuit board with an indicator 318 (e.g., a light emitting diode (LED)), a connector circuit 320, and an end cap 322. Examples of power sources are described in U.S. Patent Application Publication No. 2010 / 0028766 to Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0211] With respect to the flow sensor 310, representative current regulating assemblies and other current control assemblies for various microcontrollers, sensors, and switches for aerosol delivery devices are described in U.S. Patent No. 4,735,217 to Gerth et al.; all of U.S. Patent Nos. 4,922,901, 4,947,874, and 4,947,875 to Brooks et al.; U.S. Patent No. 5,372,148 to McCafferty et al.; U.S. Patent No. 6,040,560 to Fleischhauer et al.; U.S. Patent No. 7,040,314 to Nguyen et al.; and U.S. Patent No. 8,205,622 to Pan, all of which are incorporated herein by reference in their entireties. Reference is also made to the control schemes described in U.S. Application Serial No. 13 / 837,542 to Ampolini et al., filed March 15, 2013, which is incorporated herein by reference in its entirety.

[0212] ​In one embodiment, the indicators 318 can comprise one or more light emitting diodes. The indicators 318 can be in communication with the control assembly 312 via the connector circuit 320 and illuminate, for example, during periods when the flow sensor 310 detects a user drawing on a cartridge coupled to the coupler 302. The end cap 322 can be adapted to make visible the illumination provided by the indicators 318 thereunder. Thus, the indicators 318 can illuminate during use of the aerosol delivery device 100 to simulate a lit end of a smoking article. However, in other embodiments, the indicators 318 can be provided in different numbers and can take on different shapes and can even be openings in the outer body (e.g., for releasing sound when present).

[0213] Still further components can be utilized in aerosol delivery devices of the present disclosure. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for a smoking article; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with a mouth end of a device to detect user lip activity associated with a puff and then trigger heating; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a puff sensor for controlling energy flow into a heating load array in response to a pressure drop through a drip tip; U.S. Patent No. 5,967,148 to Harris et al. discloses a socket in a smoking device that includes an identifier that detects non-uniformities in infrared transmission of an inserted component and a controller that performs a detection routine when the component is inserted into the socket; U.S. Patent No. 6,040,560 to Fleischhauer et al. describes defined executable power cycles with multiple differential phases; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic light guide light assembly; U.S. Patent No. 5,954,979 to Counts et al. discloses a means for altering draw resistance through a smoking device; U.S. Patent No. 6,803,545 to Blake et al. discloses a particular battery configuration for use in a smoking device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with a smoking device; U.S. Patent No. 8,402,976 to Fernando et al. discloses computer interface means for a smoking device to facilitate charging and allow computer control of the device; U.S. Patent Application Publication No. 2010 / 0163063 to Fernando et al. discloses an identification system for a smoking device; and WO 2010 / 003480 to Flick discloses a fluid flow sensing system for indicating a puff in an aerosol generating system; the foregoing disclosures are all incorporated herein by reference in their entirety.Additional examples of components related to electronic aerosol delivery articles and disclosing materials or components that can be used in the present articles include U.S. Patent No. 4,735,217 to Gerth et al.; U.S. Patent No. 5,249,586 to Morgan et al.; U.S. Patent No. 5,666,977 to Higgins et al.; U.S. Patent No. 6,053,176 to Adams et al.; U.S. 6,164,287 to White; U.S. Patent No. 6,196,218 to Voges; U.S. Patent No. 6,810,883 to Felter et al.; U.S. Patent No. 6,854,461 to Nichols; U.S. Patent No. 7,832,410 to Hon; U.S. Patent No. 7,513,253 to Kobayashi; U.S. Patent No. 7,896,006 to Hamano; U.S. Patent No. 6,772,756 to Shayan; U.S. Patent Nos. 8,156,944 and 8,375,957 to Hon; U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490 to Hon; U.S. Patent Application Publication No. 2009 / 0272379 to Thorens et al.; U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642 to Monsees et al.; U.S. Patent Application Publication Nos. 2008 / 0149118 and 2010 / 0024834 to Oglesby et al.; U.S. Patent Application Publication No. 2010 / 0307518 to Wang; WO 2010 / 091593 to Hon; WO 2013 / 089551 to Foo; and U.S. Patent Application Serial No. 13 / 841,233, filed March 15, 2013, each of which is incorporated herein by reference in its entirety. Various materials disclosed in the foregoing documents can be incorporated into the devices of the present application in various embodiments, and the foregoing disclosures are all incorporated herein by reference in their entirety.

[0214] Returning to Figure 1The cartridge 200 is illustrated in exploded configuration. As illustrated, according to example embodiments of the present disclosure, the cartridge 200 can include a base shipping plug 202, a base 204, control assembly terminals 206, an electronic control assembly 208, a flow tube 210, an atomizer 212, a reservoir substrate 214, an outer body 216, a label 218, a drip tip 220, and a drip tip shipping plug 222. The base 204 can be coupled to a first end of the outer body 216, and the drip tip 220 can be coupled to an opposite second end of the outer body to enclose the remaining components of the cartridge 200 therein. The base 204 can be configured to engage the coupler 302 of the control body 300. In some embodiments, the base 204 can include anti-rotation features that substantially prevent relative rotation between the cartridge and the control body, as disclosed in U.S. Patent Application Serial No. 13 / 840,264, filed March 15, 2013, which is incorporated herein by reference in its entirety.

[0215] The base shipping plug 202 can be configured to engage and protect the base 204 prior to use of the cartridge 200. Similarly, the drip tip shipping plug 222 can be configured to engage and protect the drip tip 220 prior to use of the cartridge 200. The control assembly terminals 206, the electronic control assembly 208, the flow tube 210, the atomizer 212, and the reservoir substrate 214 can be held within the outer body 216. The label 218 can at least partially surround the outer body 216, and contain information thereon, such as a product identifier.

[0216] The atomizer 212 may include a first heating terminal 234a and a second heating terminal 234b, a liquid delivery element 238, and a heating element 240. In this regard, the reservoir substrate 214 may be configured to hold the aerosol precursor composition. The aerosol precursor composition, also known as a vapor precursor composition, may include a variety of components, including, for example, polyols (e.g., glycerol, propylene glycol, or mixtures thereof), nicotine, tobacco, tobacco extracts, and / or flavorings. Various components that may be included in the aerosol precursor composition are described in U.S. Patent No. 7,726,320 to Robinson et al., which is incorporated herein by reference in its entirety. Additional representative types of aerosol precursor compositions are described in the following: U.S. Patent No. 4,793,365 to Sensabaugh, Jr. et al.; U.S. Patent No. 5,101,839 to Jakob et al.; PCT WO 98 / 57556 to Biggs et al.; and Chemical and Biological Studies on New Cigarette Prototypes that Heat Instead of Burn Tobacco (RJ Reynolds Tobacco Company Monograph (1988)); the disclosures of the foregoing are incorporated herein by reference in their entirety. Other aerosol precursors that may be used in the aerosol delivery devices of this disclosure include aerosol precursors contained in the following products: RJ Reynolds Vapor Company Products; BLU from Lorillard Technologies TM Products; Mistic Menthol products from Mistic Ecigs; and Vype products from CN Creative Ltd. So-called “e-liquids” for electronic cigarettes, already available from Johnson Creek Enterprises LLC, are also desirable. Additional exemplary formulations of aerosol precursor materials that can be used according to this disclosure are described in U.S. Patent Publication No. 2013 / 0008457 to Zheng et al., the disclosure of which is incorporated herein by reference in its entirety.

[0217] The reservoir substrate 214 may comprise multiple layers of nonwoven fibers formed in a tubular shape, surrounding the interior of the outer body 216 of the cartridge 200. Thus, liquid components can be retained by the reservoir substrate 214, for example, by adsorption. The reservoir substrate 214 is fluidly connected to a liquid delivery element 238. Therefore, the liquid delivery element 238 may be configured to deliver liquid from the reservoir substrate 214 to the heating element 240 via capillary action.

[0218] As illustrated, the liquid transport element 238 can be in direct contact with the heating element 240. As Figure 1 As further illustrated in the middle, the heating element 240 can include a wire that defines a plurality of coils that are wrapped around the liquid transport element 238. In some embodiments, the heating element 240 can be formed by wrapping the wire around the liquid transport element 238, as described in U.S. Patent Application Serial No. 13 / 708,381, filed December 7, 2012, which is incorporated herein by reference in its entirety. Further, in some embodiments, the wire can define a variable coil pitch, as described in U.S. Patent Application Serial No. 13 / 827,994, filed March 14, 2013, which is incorporated herein by reference in its entirety. Various embodiments of materials configured to generate heat when an electrical current is applied therethrough can be employed to form the heating element 240. Example materials that can be used to form the wire coils include Ferroalloy (FeCrAl), Nichrome, Molybdenum disilicide (MoSi2), Molybdenum silicide (MoSi), Molybdenum disilicide doped with aluminum (Mo(Si,Al)2), graphite and graphite-based materials; and ceramics (e.g., positive or negative temperature coefficient ceramics).

[0219] However, various other embodiments of methods can be employed to form heating element 240, and various other embodiments of heating elements can be employed in atomizer 212. For example, an embossed heating element can be used in an atomizer as described in U.S. Patent Application No. 13 / 842,125, filed March 15, 2013, which is incorporated herein by reference in its entirety. Still further, additional representative heating elements and materials used therein are described in Counts et al., U.S. Patent No. 5,060,671; Deevi et al., U.S. Patent No. 5,093,894; Deevi et al., U.S. Patent No. 5,224,498; Sprinkel Jr. et al., U.S. Patent No. 5,228,460; Deevi et al., U.S. Patent No. 5,322,075; Deevi et al., U.S. Patent No. 5,353,813; Deevi et al., U.S. Patent No. 5,468,936; Das, U.S. Patent No. 5,498,850; Das, U.S. Patent No. 5,659,656; Deevi et al., U.S. Patent No. 5,498,855; Hajaligol, U.S. Patent No. 5,530,225; Hajaligol, U.S. Patent No. 5,665,262; Das et al., U.S. Patent No. 5,573,692; and Fleischhauer et al., U.S. Patent No. 5,591,368, the disclosures of which are incorporated herein by reference in their entireties. Additionally, chemical heating can be employed in other embodiments. Various additional examples of heaters and materials used to form heaters are described in U.S. Patent Application Serial No. 13 / 602,871, filed September 4, 2012, which is incorporated by reference herein, as described above.

[0220] A variety of heater assemblies can be used in the present aerosol delivery devices. In various embodiments, one or more micro-heaters or similar solid state heaters can be used. Embodiments of micro-heaters that can be utilized are further described herein. Additional micro-heaters and atomizers incorporating micro-heaters suitable for use in the presently disclosed devices are described in U.S. Patent Application Serial No. 13 / 602,871, filed September 4, 2012, which is incorporated by reference herein in its entirety.

[0221] The first and second heating terminals 234a, 234b (e.g., positive and negative terminals) at opposite ends of the heating element 240 are configured to form an electrical connection with the control body 300 when the cartridge 200 is connected thereto. Further, the electronic control assembly 208 can form an electrical connection with the control body through the control assembly terminals 206 when the control body 300 is coupled to the cartridge 200. The control body 300 can thus employ the electronic control assembly 208 to determine whether the cartridge 200 is authentic and / or perform other functions. Further, various examples of electronic control assemblies and functions performed thereby are described in U.S. Patent Application Serial No. 13 / 647,000, filed October 8, 2012, which is incorporated herein by reference in its entirety.

[0222] During use, a user can draw on the drip tip 220 of the cartridge 200 of the aerosol delivery device 100. This can pull air through an opening in the control body 300 or in the cartridge. For example, in one embodiment, the opening can be defined between the coupler 302 and the outer body 304 of the control body 300, as described in U.S. Patent Application Serial No. 13 / 841,233, filed March 15, 2013, which is incorporated herein by reference in its entirety. However, air flow can be received through other portions of the aerosol delivery device 100 in other embodiments. As described above, in some embodiments, the cartridge 200 can include a flow tube 210. The flow tube 210 can be configured to direct air flow received from the control body 300 to the heating element 240 of the atomizer 212.

[0223] A sensor in the aerosol delivery device 100 (e.g., a puff or flow sensor in the control body 300) can sense a puff. When a puff is sensed, the control body 300 can direct current to the heating element 240 through a circuit including the first and second heating terminals 234a, 234b. Thus, the heating element 240 can vaporize aerosol precursor composition directed through the liquid transport element 238 from the reservoir substrate 214 to the atomization region. Thus, the drip tip 220 can allow air and entrained vapor (i.e., components of the aerosol precursor composition in inhalable form) to pass from the cartridge 200 to a consumer drawing on it.

[0224] Various other details regarding components that can be included in the cartridge 200 are provided, for example, in U.S. Patent Application Serial No. 13 / 840,264, filed March 15, 2013, which is incorporated herein by reference in its entirety. In this regard, for example, Figure 7 An enlarged, exploded view of the base and control assembly terminals is illustrated; it Figure 8 An enlarged, perspective view of the base and control assembly terminals in an assembled configuration is illustrated; it Figure 9This illustration shows an enlarged perspective view of the base, control component terminals, electronic control components, and atomizer heating terminals within the assembled structure; Figure 10 This illustration shows an enlarged perspective view of the base, atomizer, and control components in the assembly structure; Figure 11 Explain its Figure 10 The opposite perspective view of the assembly; its Figure 12 This illustration shows an enlarged perspective view of the base, atomizer, flow tube, and reservoir substrate within the assembled structure; Figure 13 This illustrates a perspective view of the base and outer body within the assembled structure; Figure 14 A perspective view illustrating the cartridge in the assembly process; Figure 15 Explain its Figure 14 A perspective view of the first part of the cigarette cartridge and the coupler used to control the main body; Figure 16 Explain its Figure 14 The smoke cartridges and their Figure 11 The opposite second perspective view of the coupler; its Figure 17 The illustration shows a perspective view of a cigarette cartridge including a base with an anti-rotation mechanism; Figure 18 This illustration shows a perspective view of the control body, including a coupler with an anti-rotation mechanism; Figure 19 illustrate Figure 17 smoke cartridges and Figure 18 The alignment of the control subject; its Figure 3 The description includes its Figure 17 The smoke cartridges and their Figure 18 The aerosol delivery device of the control body, and a modified view through the aerosol delivery device, illustrate the engagement of the anti-rotation mechanism of the cartridge with the anti-rotation mechanism of the connector body; Figure 4 A perspective view illustrating the base with an anti-rotation mechanism; Figure 5 A perspective view illustrating a coupler with an anti-rotation mechanism; and its Figure 6 Explanation of passing through its in the joint structure Figure 4 The base and its Figure 5 A cross-sectional view of the coupler.

[0225] The various components of the aerosol delivery device according to this disclosure can be selected from components described in the prior art and commercially available components. For example, reference is made to the reservoir and heater system for the controlled delivery of various atomizable materials in electronic cigarette products disclosed in U.S. Patent Application Publication No. 2014 / 0000638 by Sebastian et al., which is incorporated herein by reference in its entirety.

[0226] Further attention should be paid to, Figure 1 Some parts of the cartridge 200 described herein are optional. In this regard, for example, in some embodiments, the cartridge 200 may not include the flow tube 210, the control component terminal 206, and / or the electronic control component 208.

[0227] In another embodiment, substantially the entire cartridge can be formed from one or more carbon materials, which can provide advantages in terms of biodegradability and elimination of wiring. In this regard, the heating element can comprise a carbon foam, the reservoir can comprise a carbonized fabric, and graphite can be employed to form the electrical connections to the battery and controller. Example embodiments of carbon-based cartridges are provided in U.S. Patent Application Publication No. 2013 / 0255702 to Griffith et al., which is incorporated herein by reference in its entirety.

[0228] As described above, a cartridge of an aerosol delivery device can include a number of components. Some of the components can be relatively small and / or relatively intricate. As a result, precision manufacturing techniques can be required to form an aerosol delivery device. In this regard, aerosol delivery devices have traditionally been formed via manual assembly. However, the use of human labor to assemble aerosol delivery devices suffers from certain drawbacks. In this regard, the quality of aerosol delivery devices manufactured via human labor is only as good as the worker performing the labor. Moreover, even skilled workers can make mistakes from time to time. Additionally, human labor can be relatively expensive. Thus, due to these and other problems associated with manufacturing aerosol delivery devices via human labor, it can be desirable to manufacture aerosol delivery devices in an automated manner. Accordingly, automated manufacturing of cartridges for aerosol delivery devices is discussed below, which can provide enhanced repeatability, lower cost, and / or avoid other problems described above.

[0229] In this regard, Figure 3 An embodiment of a system 400 for manufacturing a cartridge for an aerosol delivery device (e.g., the aerosol delivery device 100 described above) (e.g., the cartridge 200 described above) is schematically illustrated. It should be noted that the aerosol delivery device 100 described above is provided by way of example. In this regard, the methods, systems, and apparatuses described herein can be employed to form various embodiments of cartridges that differ from the cartridge described above in one or more respects.

[0230] As illustrated, the system 400 can include various subsystems that perform particular functions in the formation of the finished cartridge 200. It should be noted that while the subsystems are illustrated as being separate from one another, the subsystems can overlap. For example, in some embodiments, a common apparatus can perform two or more functions (e.g., assembly and filling or capping and labeling, etc.), rather than a particular function being performed by a separate apparatus.

[0231] Further, various subsystems and portions thereof are individually available. In this regard, while the subsystems and portions thereof are generally described herein as being usable together, this is by way of example. Thus, any of the subsystems or portions thereof described herein can be available on their own or can be used in any combination with some or all of the other subsystems and portions thereof described herein. Thus, for example, while example embodiments of a cartridge filling subsystem are described below as being used to fill cartridges filled by embodiments of a cartridge assembly subsystem disclosed herein, the cartridge filling subsystem can be used to fill cartridges formed by other subsystems and / or cartridges assembled by a cartridge assembly subsystem can be filled by other cartridge filling subsystems. Further, while specific embodiments of portions of the subsystems are disclosed below, these embodiments are provided for example purposes only. Thus, in some embodiments, the subsystems can include fewer or additional portions. Thus, each portion of each subsystem and each portion of the overall system is not required in all embodiments.

[0232] As illustrated, the subsystems can include a cartridge assembly subsystem 402 configured to form unfilled cartridges 404 from components 406 (e.g., a base 204, heating terminals 234a, 234b, etc.). A cartridge filling subsystem 408 can fill the unfilled cartridges 404 to produce filled cartridges 410. A cartridge capping subsystem 412 can cap the filled cartridges 410 to produce capped cartridges 414. A cartridge labeling subsystem 416 can apply labels to the capped cartridges 414 to complete finished cartridges 200.

[0233] The system 400 can additionally include an inspection subsystem 418. The inspection subsystem 418 can inspect the components 406, unfilled cartridges 404, filled cartridges 410, capped cartridges 414, and / or finished cartridges 200. Further, in some embodiments, cartridges can be inspected at intermediate completion states at one or more of the cartridge assembly subsystem 402, cartridge filling subsystem 408, cartridge capping subsystem 412, and cartridge labeling subsystem 416. Thus, cartridges 200 and components thereof can be inspected before, during, and after completion of the cartridges.

[0234] The system can further include at least one controller 417. The controller 417 can be configured to control the cartridge assembly subsystem 402, cartridge filling subsystem 408, cartridge capping subsystem 412, and / or cartridge labeling subsystem 416. In this regard, in addition to otherwise directing operations described herein, the controller can be configured to receive data from one or more of the sensors described herein and output instructions based thereon.

[0235] It should be noted that some or all of system 400 can be automated. In this regard, as described below, robotic devices can be employed in some embodiments of system 400. Robotic devices can be provided from a variety of robotic manufacturers, including by way of example, DENSO Robotics of Long Beach, California, FANUC of Rochester Hills, Michigan, Mitsubishi Electric Automation of Vernon Hills, Illinois, and Siemens Automation Technology of Munich, Germany.

[0236] Figure 4 An example embodiment of cartridge assembly subsystem 402 is described in detail in the Background. It should be noted that the particular embodiments of the sub-stations and their locations can differ from those described and illustrated in the Background Figure 4

[0237] ​For example, the cartridge assembly subsystem 402 can include a base loading substation 502, a terminal coupling substation 504, a terminal sealing substation 506, a control component coupling substation 508, a flow tube coupling substation 510, a heating element coupling substation 512, a liquid delivery element bending substation 514, a reservoir coupling substation 516, and an outer body coupling substation 518. As explained, the controller 417 can be configured to control one or more of the substations 502-518 of the cartridge assembly subsystem 402. Briefly, the base loading substation 502 can be configured to receive a base (e.g., the base 204) and orient the base for assembly with various other components of a cartridge. The terminal coupling substation 504 can be configured to couple one or more terminals (e.g., the first and second heating terminals 234a and 234b and the control component terminals 206) to the base. The terminal sealing substation 506 can be configured to seal one or more of the terminals relative to the base to prevent fluid flow in or out between the base and the terminals. The control component coupling substation 508 can be configured to couple a control component (e.g., the electronic control component 208) to the control component terminals. The flow tube coupling substation 510 can be configured to couple a flow tube (e.g., the flow tube 210) to the control component, the first and second heating terminals, and / or other components. The heating element coupling substation 512 can be configured to couple a heating element (e.g., the heating element 240) to the heating terminals. The liquid delivery element bending substation 514 can be configured to bend a liquid delivery element (e.g., the liquid delivery element 238) around the heating terminals. The reservoir coupling substation 516 can be configured to couple a reservoir substrate (e.g., the reservoir substrate 214) to the liquid delivery element. Further, the outer body coupling substation 518 can be configured to couple an outer body (e.g., the outer body 216) to the base.

[0238] The cartridge assembly subsystem 402 can assemble a cartridge (e.g., the cartridge 200) in a variety of ways. For example, in one embodiment, the cartridge can be assembled generally upward from the base. In other words, components can be inserted or otherwise coupled to the base to build the cartridge from the base.

[0239] In this regard, as Figure 5 and 6 explained in the'1 1 1 Application, in one embodiment, the delivery system can include a cradle 600, which can also be referred to as a "pod" or "nest," which can be used to assemble the cartridge 200. Figure 5 An empty cradle 600 is illustrated, while Figure 6 illustrates the cradle after the base 204 has been loaded therein. As illustrated, the cradle 600 can include a clamping mechanism 602. The clamping mechanism 602 can include a displaceable piston 604 that defines a head 606 at one end thereof. A biasing mechanism can bias the displaceable piston 604 toward a recess 608. Thus, as Figure 6As illustrated, the head 606 of the displaceable piston 604 can cooperate with the recess 608 to retain the susceptor 204 therein. In this regard, the recess 608 can be V-shaped so as to center the susceptor 204 in the recess.

[0240] Various embodiments of biasing mechanisms can be employed, such as magnets, hydraulic or pneumatic cylinders, etc. However, in the illustrated embodiment, the rod 610 can be received in the standoff 612. The standoff 612, which can also serve to align the piston 604 with respect to the recess 608, can contain a spring therein that biases the rod 610 toward the head 606 of the piston. Thus, the head 606 of the piston 604 can be biased toward the recess 608 to retain the susceptor 204 therein. In addition, the piston 604 can contain a handle 614 at an end thereof opposite the head 606. The handle 614 can be configured to allow grasping thereof, either via automated or manual methods, to release the susceptor 204 against the force provided by the biasing mechanism.

[0241] The transport system can further include a track 616 or other mechanism configured to provide movement of the carrier between a plurality of sub-stations. The carrier 600 can be mounted to the track 616 using wheels 618 (see, e.g., Figure 5 ). By driving the wheels 618, the carrier 600 can be moved along the track 616. Alternatively, magnetic propulsion can be employed to move the carrier 600. However, the wheels 618 can still be provided in order to retain the carrier on the track 616. In this regard, as illustrated in Figure 7 and 8 , a magnetic track 620 can cause the carrier 600 to move. More particularly, the carrier 600 can further include a magnet 622. The magnetic track 620 can change polarity in relation to the position of the magnet 622 coupled to the carrier 600 such that an attractive and / or repulsive force between the magnetic track 620 and the magnet causes the carrier to move. Thus, the carrier 600 can be transferred between various sub-stations. In this regard, a plurality of carriers 600 can be provided. The carriers 600 can be configured to move between the various sub-stations described below. In this regard, the carriers 600 can be disposed in various positions along a path defined by the track during assembly of the cartridges such that, at any given time, the carriers can be distributed along the length of the track. In turn, multiple cartridges can be constructed simultaneously.

[0242] It can be desirable to stop or slow the movement of the carriages 600 at one or more sub-stations while one or more operations are performed in order to simplify the coupling of the cartridges to the base. Further, in some embodiments, it can be desirable to lock the carriages 600 in a predefined position to substantially prevent movement of the carriages at one or more sub-stations. In this regard, magnetic locking of the position of the carriages can not be sufficient to properly lock the carriages in place as the magnetic locking can still allow for some movement of the carriages. Accordingly, a locking device can be employed to temporarily restrain the movement of each carriage 600 along the track 616.

[0243] The locking device can include a positioner mechanism 624 coupled to each carriage 600. In the illustrated embodiment, the positioner mechanism 624 includes first and second pegs 626. Further, the locking device can include an engagement mechanism 628 that can be positioned at each location where it is desirable to lock the carriage 600 in place. Accordingly, the engagement mechanism 628 can be positioned at a fixed location relative to the longitudinal length of the track 616. However, the engagement mechanism 628 can be configured to move into contact with the positioner mechanism 624 (e.g., via a pneumatic piston, a hydraulic piston, or a linear motor) to lock the carriage 600 in place.

[0244] In the illustrated embodiment, the engagement mechanism 628 includes a cylinder 630. Accordingly, as the engagement mechanism 628 is directed upward, the cylinder 630 can contact one or both of the pegs 626 of the positioner mechanism 624. In turn, the pegs 626 can be deflected from the cylinder 630 such that the positioner mechanism 624 becomes centered relative to the engagement mechanism 628. Further, in one embodiment, the cylinder 630 can include a roller or wheel that is configured to rotate to facilitate centering between the pegs 626 by allowing the cylinder to rotate when brought into contact with one of the pegs rather than scraping against it. Whether or not the cylinder 630 rotates, any inaccuracy in the initial stopping point of the carriage 600 can be addressed by the centering action that results from the interaction between the pegs 626 of the positioner mechanism 624 and the cylinder of the engagement mechanism 628. Accordingly, movement of the carriage 600 along the track 616 can be restrained by fixing the interaction between the engagement mechanism 628 and the positioner mechanism 624 coupled to the carriage.

[0245] It should be noted that the locking device can include various other mechanisms configured to center the carriage relative to the engagement mechanism. For example, the positioner mechanism can include a vertically oriented groove. Alternatively or additionally, the engagement mechanism can include an angled component such as a gusset.

[0246] Accordingly, the carriages 600 can be employed to transport the base 204 to various sub-stations where various components are assembled therewith. In turn, as Figure 6 and 8The base 204 can be loaded into the carrier 600 at the base loading substation 502 as illustrated. Subsequently, the other components can be assembled with the base 204 (e.g., by guiding the components downward into contact with the base) to assemble the cartridge.

[0247] In this regard, the control component terminals 206, as well as the first and second heater terminals 234a, 234b can be inserted into the base 204 at the terminal coupling substation 504 as described above. In some embodiments, the first heater terminals 234a, the second heater terminals 234b, and / or the control component terminals 206 can be provided from a substantially continuous input. More particularly, the first heater terminals 234a can be supplied from a substantially continuous first heater terminal input, the second heater terminals 234b can be supplied from a substantially continuous second heater terminal input, and / or the control component terminals 206 can be supplied from a substantially continuous control component terminal input. It should be noted that the term "substantially continuous" as used herein with respect to certain specified inputs refers to a configuration in which the input in question defines a strip, chain, or other grouping of interconnected underlying components such that individual components can be singulated therefrom.

[0248] For example, Figure 9 A substantially continuous first heater terminal input 700 including a plurality of first heater terminals 234a is illustrated. In this regard, each of the first heater terminals 234a is connected to a substantially continuous carrier 702. In the illustrated embodiment, each of the first heater terminals 234a is connected to the carrier 702 by first and second couplers 704. However, in other embodiments, a single coupler or additional couplers can be employed to retain the first heater terminals 234a to the carrier 702. In some embodiments, the first heater terminals 234a, the couplers 704, and the carrier 702 can be integrally formed (e.g., from a strip of sheet metal) as illustrated.

[0249] The couplers 704 can be cut to release individual first heater terminals 234a from the substantially continuous first heater terminal input 700. Further, the carrier 702 can include apertures 706, grooves, cutouts, or other mechanisms configured to facilitate movement of the substantially continuous first heater terminal input 700 such that individual first heater terminals 234a can be removed therefrom. In this regard, as illustrated, Figure 9 The wheel 708 can include a protrusion 710 configured to engage the apertures 706 such that rotation of the wheel 708 causes movement of the input 700 toward a location from which individual first heater terminals 234a are to be removed as illustrated. It should be noted that while the description provided above is provided in terms of first heater terminals 234a, in some embodiments, the second heater terminals 234b and / or the control component terminals 206 can be supplied via a substantially continuous input in a similar manner.

[0250] After insertion into the base 204, the terminal sealing substation 506 can seal one or more of the terminals 206, 234a, 234b relative to the base in some embodiments, in order to prevent liquid from flowing in or out through the terminals. However, in some embodiments, only the heating terminals 234a, 234b can be sealed. For example, in the illustrated embodiment, the control assembly terminals 206 can extend through an opening through the base 204 or be positioned adjacent to the opening through which air is drawn by a user through the cartridge 200 during use of the cartridge. Thus, the control assembly terminals 206 can not be sealed relative to the base 204 in order to prevent clogging of the opening through the base. Furthermore, the control assembly terminals 206 can not contact the liquid-filled reservoir substrate 214, such that liquid flowing out through the control assembly terminals 206 is not problematic.

[0251] Figure 10 An example embodiment of the terminal sealing substation 506 is illustrated. The terminal sealing substation 506 can include one or more sealant applicators 802a, 802b. In the illustrated embodiment, a first sealant applicator 802a and a second sealant applicator 802b are employed to apply sealant provided by a pump 804 through one or more conduits 806. A robotic arm 808 can grasp the base 204 with grippers 810. In this regard, the robotic arm 808 can position the base 204 such that the base is positioned in front of nozzles 812a, 812b of the sealant applicators 802a, 802b. For example, the grippers 810 can grasp an outer surface of the base 204 and remove the base 204 from the carrier 600. Subsequently, the robotic arm 808 can position the base 204 such that the terminals 206, 234a, 234b extend generally upward in a position proximate to the sealant applicators 802a, 802b. By grasping the exterior of the base 204 in this manner, the grippers 810 of the robotic arm 808 do not interfere with the application of sealant, as the grippers are not positioned between the nozzles 812a, 812b and the terminals 206, 234a, 234b extending upward from the base.

[0252] As Figure 11As illustrated, the sealant applicators 802a, 802b can be positioned such that the nozzles 812a, 812b at least partially point toward one another. In turn, the robot arm 808 can position the base 204 and the terminals 206, 234a, 234b between the sealant applicators 802a, 802b such that the nozzles 812a, 812b can direct sealant at opposite sides of the terminals. For example, droplets of sealant can be ejected from the nozzles 812a, 812b toward opposite sides of the heated terminals 234a, 234b. More particularly, the nozzles 812a, 812b can direct droplets of sealant at the interface between the heated terminals 234a, 234b and the base 204.

[0253] In some embodiments, the sealant can include a hot melt adhesive, including a polyolefin, including a random polyalphaolefin, a polyurethane, an ethylene vinyl acetate (EVA), a metallocene polyalphaolefin, a block copolymer, and / or a polyamide. Accordingly, the terminal sealing substation 506 can further include a heater 814 (see Figure 10 ) that can melt the sealant. Furthermore, the conduit 806 can be heated and / or insulated. The seals in the pump 804 and the sealant applicators 802a, 802b can conventionally employ grease for lubrication. However, in some embodiments, food grade grease or lubricant can instead be employed so as to advantageously employ food grade manufacturing techniques in the production of the cartridge.

[0254] After a drop of liquid sealant contacts the heating terminals 234a, 234b and / or the base 204, the drop can dry relatively quickly in place. Moreover, the drops can not contact one another. Thus, a complete seal around the interface of the heating terminals 234a, 234b and the base 204 can not be formed by the initial application of the drops of sealant. Accordingly, the terminal sealing substation 506 can further include a re-melting device, such as a hot air gun 816, configured to direct a stream of heated air at the sealant after application of the sealant to the heating terminals 234a, 234b and / or the base 204. Thus, the heated air from the hot air gun 816 can re-melt the sealant and blow the molten sealant around the heating terminals 234a, 234b such that the interface between the heating terminals and the base 204 is completely sealed around the periphery of each heating terminal. In this regard, the hot air gun 816 can be movable relative to the base 204 and the heating terminals 234a, 234b. In some embodiments, the hot air gun 816 can be configured to move. However, as illustrated, in another embodiment, the hot air gun 816 can be stationary. Accordingly, the robotic arm 804 can move the base 204 relative to the hot air gun 816 such that the heated air re-melts the sealant and directs the sealant around the interface between the heating terminals 234a, 234b and the base. Thus, the sealant can re-solidify and seal any gaps between the heating terminals 234a, 234b and the base 204.

[0255] It should be noted that the terminal sealing substation 506 can additionally or alternatively seal any other components of the control assembly terminals 206 and / or the cartridge 200 relative to the base 204. Additionally, while the re-melting device is described above as a hot air gun 816, in other embodiments, the sealant can be re-melted by other methods and other re-melting devices, such as by applying ultrasonic vibrations with an ultrasonic vibration device and / or applying radiant heat with a radiant heater. Moreover, while the sealant is described above as a hot melt adhesive, various other embodiments of the sealant can be employed. For example, the sealant can include an epoxy or an electrically potting material. After sealing the heating terminals 234a, 234b, the robotic arm 608 can return the base 204 to the cradle 600.

[0256] Subsequently, the control assembly coupling substation 508 can couple the electronic control assembly 208 to the control assembly terminals 206 (e.g., by vertically inserting the control assembly into a slot defined by the control assembly terminals). Next, the flow tube coupling substation 510 can couple the flow tube 210 to the partially assembled cartridge. For example, the flow tube 210 can be inserted horizontally such that the heating terminals 234a, 234b are slightly spread out and then snapped into place in longitudinal grooves defined in the flow tube, with horizontal slots in the flow tube engaging the top of the electronic control assembly 208.

[0257] Next, the partially assembled cartridge can be transported to the heating element coupling substation 512, where the heating element 240 can be coupled to the heating terminals 234a, 234b. In this regard, Figure 12 An example embodiment of the heating element coupling substation 512 is described. In the described embodiment, the heating element coupling substation 512 includes a preparation portion 902, a soldering portion 904, and a transport device 905 configured to transport individual heating elements 240 wrapped around a liquid transport element 238 from the preparation portion 902 to the soldering portion 904.

[0258] As Figure 13 As described in the Background, in some embodiments, the heating elements and liquid transport elements can be supplied from a generally continuous heating element input 906. In this regard, the generally continuous heating element input 906 can include a plurality of heating elements 240 wrapped around a liquid transport element 238. Examples of heating elements wrapped around a liquid transport element are provided in U.S. Patent Application Serial No. 13 / 827,994, filed March 14, 2013, and 13 / 708,381, filed December 7, 2012, which are incorporated by reference herein in their entirety.

[0259] As described, in some embodiments, the generally continuous heating element input 906 can be supplied from a spool 908. The spool 908 can be passively rotated as the generally continuous heating element input 906 is pulled therefrom. Alternatively, the spool 908 can be actively rotated (e.g., by a motor) such that the spool rotates as the generally continuous heating element input 906 is pulled therefrom. By actively rotating the spool 908 or passively allowing the spool to generally freely rotate as the generally continuous heating element input 906 is pulled therefrom, the tension in the generally continuous heating element input can be controlled. In this regard, too much tension applied to the generally continuous heating element input 906 can damage the heating elements 240 or the liquid transport element 238. For example, the pitch of the coils of the heating elements 240 can be altered, which can make it difficult to attach the heating elements to the heating terminals. Further, too much tension in the liquid transport element 238 can cause it to break, or the stretching of the liquid transport element can decrease its diameter and affect its ability to draw the aerosol precursor composition to the heating elements 240. Thus, the generally continuous heating element input 906 can be supplied to the preparation portion 902 without damaging the heating elements 240 or the liquid transport element 238 by controlling the tension therein.

[0260] Figure 14An enlarged view of the preparation portion 902 of the heating element coupling substation 512 is illustrated. Briefly, the preparation portion 902 of the heating element coupling substation 512 can be configured to prepare individual heating elements 240 that are coupled to individual liquid delivery elements 238 for welding at a weld portion 904 of the heating element (see, e.g., the coupling substation 512). In this regard, the preparation portion 902 of the heating element coupling substation 512 can be configured to singulate a heating element 240 and a liquid delivery element 238, such that the heating element can be subsequently coupled to a heating terminal. In this regard, in one embodiment, the individual heating element and liquid delivery element can be delivered to the preparation portion in a form that is ready to be attached to a heating terminal without performing additional operations thereon.

[0261] However, as noted above, in the illustrated embodiment, the generally continuous heating element input 906 can include a coil of wire that is wrapped around a generally continuous liquid delivery element. In turn, the generally continuous heating element input 906 can be cut to remove individual heating elements 240 and liquid delivery elements 238 therefrom. In this regard, as illustrated, the preparation portion 902 of the heating element coupling substation 512 can include a dispenser 910, a cutter 912, and an imaging device 914 (e.g., a camera).

[0262] Figure 15 The preparation portion 902 of the heating element coupling substation 512 is schematically illustrated. The dispenser 910 can be configured to dispense a length of the generally continuous heating element input 906 from the spool 908 (see Figure 13 ). In this regard, the dispenser 910 can include a stationary portion 916 and a movable portion 918. The movable portion 918 can include a clamp 920 that is configured to grasp the generally continuous heating element input 906 proximate to one end thereof. The movable portion 918 can be configured to move in a direction 922 relative to the stationary portion 916 such that the generally continuous heating element input 906 is dispensed from the spool 908 (see Figure 13 ). For example, in some embodiments, the dispenser 910 can include a hydraulic or pneumatic cylinder or a linear motor. The dispenser 910 can be configured to pull the generally continuous heating element input 906 until the desired length thereof has been dispensed.

[0263] In this regard, the imaging device 914 can be positioned and configured to capture images of the generally continuous heating element input 906 as it is being dispensed. The controller 417 (see, e.g., Figure 3) can be in communication with the imaging device 914 and configured to analyze images captured by the imaging device. Thus, the controller 417 can be configured to analyze images captured by the camera 914 to identify the location of a substantially continuous heating element input 906 to determine its dispensed length.

[0264] In this regard, the dispenser 910 can be configured to begin dispensing a substantially continuous heating element input 906, and the controller 417 can analyze images thereof and direct the dispenser to stop dispensing the substantially continuous heating element input when the desired length of the substantially continuous heating element input has been dispensed. For example, the controller 417 can be configured to analyze images captured by the imaging device 914 to detect the coils or other features of the heating element 240. By way of further example, in one embodiment, the controller 417 can be configured to detect the first contact portion 926 and the second contact portion 928 of the heating element 240 that are configured to engage the heating terminals. In one embodiment, the controller 417 can determine the location of the inner edges 926a, 928a of the contact portions 926, 928 of the heating element 240. In turn, the controller 417 can calculate the midpoint between the contact portions 926, 928 of the heating element 240 and allow the dispenser 910 to continue dispensing the substantially continuous heating element input 906 until the midpoint between the first contact portion 926 and the second contact portion 928 is aligned with the midpoint of the imaging device 914.

[0265] At this point, the controller 417 can direct the dispenser 910 to stop dispensing the substantially continuous heating element input 906. Additionally, the controller 417 can direct the transport device 905 to grasp the substantially continuous heating element input 906. For example, the transport device 905 can include a gripper 930 that includes a first arm 932a and a second arm 932b that are configured to grasp the substantially continuous heating element input 906 outside of the contact portions 926, 928 of the heating element 240, which can allow the gripper to continuously hold the heating element during welding, as discussed below.

[0266] Furthermore, the controller 417 can direct the cutter 912, which can include a first blade 934a and a second blade 934b, to cut the substantially continuous heating element input 906, thereby singulating a heating element 240 and a liquid transport element 238 having a desired length. In this regard, the imaging device 914 can be positioned such that when the midpoint between the first contact portion 926 and the second contact portion 928 of the heating element 240 is aligned with the midpoint of the imaging device, the distance between one end of the substantially continuous heating element input 906 held by the gripper 920 and the blades 934a, 934b of the cutter 912 is equal to the desired length of the singulated heating element 240 and liquid transport element 238.

[0267] It should be noted that the preparation section 902 of the heating element coupling substation 512 may further include a pipe 936. A generally continuous heating element input 906 can be supplied to the cutter 912 through the pipe 936. Therefore, after cutting the generally continuous heating element input 906, the pipe 936 can approach a new end of the generally continuous heating element input and support it. Furthermore, the clamping mechanism 910 of the conveying device 905 can release from the individually separated heating element 240 and liquid conveying element 238 and grasp the new end of the generally continuous heating element input 906, allowing the preparation section 902 of the heating element coupling substation 512 to repeat the above operations, such as... Figure 16 The explanation is as follows.

[0268] like Figure 16 Further explanation is provided that after the individual separation of heating element 240 and liquid delivery element 238, the delivery device 905 can guide the heating element and liquid delivery element to the welding section 904 (see example). Figure 17 In this respect, the conveying device 905 may include a robotic arm 938 configured to move a gripper 930 between the preparation section 902 and the welding section 904 of the heating element coupling substation 512. Thus, the gripper 930 of the conveying device 905 can grasp the heating element 240 and the liquid delivery element 238 at the preparation section 902 and maintain the heating element and the liquid delivery element during transport to the welding section 904.

[0269] Figure 17 The welding portion 904 of the heating element coupling substation 512 is described. As illustrated, the welding portion 904 may include a laser 940, an imaging device 942 (e.g., a camera), a terminal holding mechanism 944, and a gas applicator 946. Briefly, the laser 940 may be configured to generate a laser beam to weld the heating element 240 to the heating terminals. The imaging device 942 may be configured to capture images of the heating element 240 and the heating terminals. The terminal holding mechanism 944 may be configured to hold the first and second heating terminals during welding. The gas applicator 946 may be configured to apply an inert gas (e.g., argon) to improve the resulting weld (e.g., by preventing its oxidation).

[0270] It should be noted that although the heating element is described herein as being attached to the heating terminal via laser welding, various other types of welding can be used, such as arc welding, metal inert gas welding (MIG), tungsten inert gas welding (TIG), plasma welding, etc. More broadly, the heating element can be attached to the heating terminal by other methods, such as soldering and mechanical connection. Therefore, it should be understood that various other embodiments of the coupling methods and related equipment can be employed without departing from the scope of this disclosure.

[0271] As described above, the carriage 600 can travel along the track 616 to various sub-stations. In this regard, as Figure 17 Further described in FIG. 6, in some embodiments, the track 616 and the magnetic track 620 can extend to and past the solder portion 904 of the heating element coupling sub-station 512. Thus, the carriage can deliver the base with the coupled heating terminals to the solder portion 904 of the heating element coupling sub-station 512. For example, as described above, when the carriage reaches the solder portion 904 of the heating element coupling sub-station 512, the heating terminals, the control assembly terminals, the control assembly, and the flow tube can be assembled to the base.

[0272] However, to facilitate welding of the heating terminals to the heating element, it can be desirable to align the heating terminals in a desired configuration. In this regard, as Figure 18 Further described in FIG. 6, the terminal securing mechanism 944 can include a first cooperating portion 948a and a second cooperating portion 948b. The cooperating portions 948a, 948b of the terminal securing mechanism 944 can be configured to grasp the first and second heating terminals such that their first and second heating terminal tabs are substantially coplanar. Alternatively or additionally, the cooperating portions 948a, 948b of the terminal securing mechanism 944 can be configured to adjust the spacing between the first and second heating terminals. As illustrated, the cooperating portions 948a, 948b of the terminal securing mechanism 944 can each define a recess 950 configured to receive a heating terminal therein.

[0273] Figures 19 to 21 The operation of the terminal securing mechanism 944 is illustratively described. Figure 19 The cooperating portions 948a, 948b of the terminal securing mechanism 944 in an initial, separated configuration are described. The initial, separated configuration can allow the heating terminals 234a, 234b to be received between their cooperating portions 948a, 948b. Subsequently, as Figure 20 Further described in FIG. 6, one or both of the cooperating portions 948a, 948b can be moved such that the cooperating portions are moved toward one another. As the cooperating portions 948a, 948b are moved relatively toward one another, the recesses 950 can cooperate to adjust the spacing between the heating terminals 234a, 234b. For example, the heating terminals 234a, 234b can be moved toward one another as illustrated. Thus, as Figure 21 Further described in FIG. 6, when the cooperating portions 948a, 948b are clamped against opposite sides of the heating terminals, the spacing of the heating terminals 234a, 234b can be adjusted to match a desired spacing. Moreover, by clamping the heating terminals 234a, 234b on opposite sides between the cooperating portions 948a, 948b, the heating terminals can be held by the terminal securing mechanism 944 such that their heating terminal tabs are coplanar, which can facilitate welding of a heating element thereto.

[0274] It is noted that in the embodiment described in Figures 19 to 21 , the recess 950 defined in the cooperating portions 948a, 948b is configured to move the heating terminals 234a, 234b toward each other. However, in another embodiment, as described in Figure 22 , the terminal fixation mechanism 944' can include a first cooperating portion 948a' and a second cooperating portion 948b' that include a recess 950' that is configured to adjust the spacing between the heating terminals 234a, 234b by moving each of the heating terminals toward or away from the other heating terminal, depending on the initial position of the heating terminals. Thus, the heating terminals 234a can be centered by providing a recess 950' that is configured to move each heating terminal 234a, 234b in either of two directions. Alternatively, as can be appreciated, in another embodiment, the recess can be configured to only move the terminals away from each other. Thus, the selection of the particular shape and functionality of the recess of the cooperating portions of the terminal fixation mechanism can depend on the initial configuration of the heating terminals when the base and heating terminals reach the terminal heating element coupling substation 512.

[0275] While the heating terminals 234a, 234b are clamped in the plane at the desired spacing using the terminal fixation mechanism 944, the delivery apparatus 905 can hold the single singulated heating element 240 and the liquid delivery element 238 with the gripper 930 so that the heating element is in the field of view of the imaging device 942 (see Figure 17 ). For example, as described in Figure 23 , the gripper 930 can initially hold the heating element 240 and the liquid delivery element 238 above the heating terminals 234a, 234b so that the heating element is in the field of view of the imaging device 942, and the imaging device can determine the position of the heating element. By way of further example, as described above, the controller 417 (see, e.g., Figure 3 ) or a separate controller can determine the position of the inner edges 926a, 928a of the contact portions 926, 928 of the heating element 240 from the image captured by the imaging device 942. Thus, the midpoint between the contact portions 926, 928 of the heating element 240 can be determined.

[0276] Similarly, the position of the heating terminals 234a, 234b can be determined. In this regard, as described in Figure 23As explained above, the heating terminals 234a, 234b can include heating terminal tabs 952a, 952b at an end thereof configured to weld to one of the contact portions 926, 928 of the heating element 240, respectively. Thus, the position of the heating terminal tabs 952a, 952b can be determined. For example, the controller 417 (or another controller) can identify the inner edges 954a, 954b of the heating terminals 234a, 234b from an image captured by the imaging device 942. In turn, the controller 417 can determine the midpoint between the heating terminal tabs 952a, 952b.

[0277] Thus, the transport device 905 can move the heating element 240 and the liquid transport element into position for welding the heating element to the heating terminals 234a, 234b. In this regard, the controller 417 can direct the transport device 905 to align the midpoint between the first and second heating terminal tabs 952a, 952b with the midpoint between the first and second contact portions 926, 928. Further, the controller 417 can direct the transport device 905 to bring the heating element 240 into engagement with the heating terminal tabs 952a, 952b. In particular, the transport device 905 can engage the first contact portion 926 of the heating element 240 with the first heating terminal tab 952a and the second contact portion 928 with the second heating terminal tab 952b. In some embodiments, the controller 417 can direct the transport device 905 to press the heating element 240 against the heating terminal tabs 952a, 952b such that the heating terminals 234a, 234b are slightly displaced (e.g., a distance from about 0.002 inches to about 0.006 inches, and preferably about 0.004 inches). In this regard, by pressing the heating element 240 against the heating terminal tabs 952a, 952b (e.g., in a direction normal to the generally planar front surface thereof), contact between the heating element and the heating terminals 234a, 234b can be ensured.

[0278] Thus, as Figure 24 As explained above, the laser 940 can weld the heating element 240 to the heating terminals 234a, 234b. The laser 940 can weld the heating element 240 to the first and second heating terminals 234a, 234b by directing a laser beam at the first and second heating terminal tabs 952a, 952b. As explained above, the laser beam can be directed at the backside of the first and second heating terminal tabs 952a, 952b opposite the heating element 240. Thus, the energy from the laser beam can heat the heating terminal tabs 952a, 952b to cause the heating terminal tabs to weld to the contact portions 926, 928 of the heating element, thereby completing the atomizer 202 (see, e.g., FIG. 1). Figure 24 As explained above, the laser 940 can weld the heating element 240 to the heating terminals 234a, 234b. The laser 940 can weld the heating element 240 to the first and second heating terminals 234a, 234b by directing a laser beam at the first and second heating terminal tabs 952a, 952b. As explained above, the laser beam can be directed at the backside of the first and second heating terminal tabs 952a, 952b opposite the heating element 240. Thus, the energy from the laser beam can heat the heating terminal tabs 952a, 952b to cause the heating terminal tabs to weld to the contact portions 926, 928 of the heating element, thereby completing the atomizer 202 (see, e.g., FIG. 1). Figure 1). In the illustrated embodiment, the laser is directed at first and second locations 956a, 956b on each heating terminal tab 952a, 952b to provide a relatively safer weld. However, in other embodiments, the laser beam can be directed at a greater or lesser number of locations. It should be noted that by directing the laser beam at the heating terminal tabs 952a, 952b, the problem of damaging the heating element 240 can be avoided by indirectly, rather than directly, applying heat to the heating element.

[0279] It should be noted that, Figure 23 The heating element 240 illustrated in FIG. 6 includes wire defining a variable coil spacing. The variable coil spacing can be employed to provide a relatively tight coil spacing for the contact portions 926, 928. This relatively tight coil spacing at the contact portions 926, 928 can facilitate welding the heating terminals 234a, 234b thereto by providing more wire material at these locations to which the heating terminals can be attached.

[0280] The central portion 929 of the heating element 240 defined between the contact portions 926, 928 can be used to generate heat when current is supplied therethrough via the heating terminals 234a, 234b. The spacing of the coils at the central portion 929 of the heating element 240 can be greater than the spacing of the coils at the contact portions 926, 928 because the central portion is not used to attach to the heating terminals 234a, 234b. However, the spacing of the coils at the central portion 929 of the heating element 240 can be less than the spacing of optional coils at the outer portions 931a, 931b of the wire positioned outside of the contact portions 926, 928 of the heating element. In this regard, the outer portions 931a, 931b can not generate heat or facilitate attachment of the heating terminals 234a, 234b, and thus the spacing of the coils can be relatively large in order to reduce material usage of the wire in forming the heating element 240. While in some embodiments, the outer portions 931a, 931b can be provided to facilitate manufacturing of a substantially continuous heating element input 906 (see, e.g., FIG. 6), in other embodiments, the outer portions 931a, 931b can be omitted. Figure 13 Various other details regarding an atomizer employing a variable coil spacing are provided in U.S. Patent Application Serial No. 13 / 827,994, filed March 14, 2013, which is incorporated herein by reference in its entirety.

[0281] It is further noted that the above-described coil spacing applicable to any of the atomizers described herein can not be uniform throughout each portion of the wire. In this regard, there can be some variation in the coil spacing in one or more portions of the wire. For example, the spacing of the coils can vary over the central portion of the heating element. Thus, by way of further example, the difference in the above-described coil spacing can relate to the average coil spacing of each portion of the wire.

[0282] After welding, the cradle 600 with the partially assembled cartridge 200 can be directed to a liquid delivery element bending sub-station 514. The liquid delivery element bending sub-station 514 can be configured to bend the liquid delivery element 238 so that its terminal end extends downward along the heating element terminals 234a, 234b. However, the liquid delivery element 238 and / or the wire wound thereon can have some degree of elasticity and tend to return to the original straight configuration after being bent.

[0283] In this regard, as explained in Figure 25 In some embodiments, the cradle 600 can further include pivotable arms 632a, 632b configured to engage the terminal end of the liquid delivery element 238 so that the terminal end of the liquid delivery element is held against the heating terminals 234a, 234b. In this regard, the pivotable arms 632a, 632b can be configured to exert a force on the liquid delivery element 238 to hold the liquid delivery element against the heating terminals 234a, 234b. For example, magnets and / or springs can be configured to bias each of the pivotable arms 632a, 632b toward the liquid delivery element 238. In this regard, in the illustrated embodiment, the pivotable arms 632a, 632b can include magnetic components 634a, 634b that cooperate with stationary magnetic base components 636a, 636b of the cradle 600 to bias the pivotable arms 632a, 632b against the liquid delivery element 238. However, various other biasing mechanisms can be employed in other embodiments.

[0284] After bending of the liquid delivery element 238 and holding the liquid delivery element in the bent configuration with the pivotable arms 632a, 632b, the cradle 600 can be directed to a reservoir coupling sub-station 516. As explained in Figure 26 In this regard, in some embodiments, the substantially continuous reservoir substrate input 1004 can be actively dispensed from the spool 1002 (e.g., by a belt 1006) rather than being pulled from the spool 1002. However, in other embodiments, the substantially continuous reservoir substrate input 1004 can be passively dispensed.

[0285] Figure 27 and 28It is illustrated that a single individual reservoir substrate is singulated from a generally continuous reservoir substrate input 1004 supplied from a spool 1002. In this regard, as illustrated, the reservoir coupling substation 516 can further include a movable clamp 1008 and a stationary clamp 1009. The movable clamp 1008 can be configured to pull a predefined amount of the generally continuous reservoir substrate input 1004 down into a cutter 1010. In this regard, Figure 27 It is illustrated that the movable clamp 1008 at an upper limit where it grips the generally continuous reservoir substrate input 1004. Figure 28 It is illustrated that the movable clamp 1008 at a lower limit. When the movable clamp 1008 reaches the lower limit, the movable clamp has moved a predefined length of the generally continuous reservoir substrate input 1004 into the cutter 1010, which cuts the generally continuous reservoir substrate input to define individual reservoir substrates having a desired length.

[0286] Furthermore, when the movable clamp 1008 reaches the lower limit, the stationary clamp 1009 grips the generally continuous reservoir substrate input 1004. Thus, the generally continuous reservoir substrate input 1004 is prevented from moving during cutting of the generally continuous reservoir substrate input 1004 into individual reservoir substrates having a desired length. Furthermore, the stationary clamp 1009 can prevent unwanted upward movement of the generally continuous reservoir substrate input 1004 by continuously holding the generally continuous reservoir substrate input as the movable clamp 1008 returns to the upper limit. Once the movable clamp 1008 reaches the upper limit and grips the generally continuous reservoir input 1004, the stationary clamp 1009 can release the generally continuous reservoir substrate input to allow the movable clamp to pull a predefined amount of the generally continuous reservoir substrate input down into the cutter 1010, as described above.

[0287] After singulation, a transfer mechanism 1012 can receive the reservoir substrate. As Figure 28 and 29 illustrated in FIGS. 1 1 and 12, the transfer mechanism 1012 can include a head portion 1014 configured to releasably hold the reservoir substrate. In some embodiments, the head portion 1014 of the transfer mechanism 1012 can be configured to exert a vacuum on the reservoir substrate thereon. In this regard, the head portion 1014 can define a plurality of apertures to apply the vacuum. However, in other embodiments, the reservoir can be held on the transfer mechanism 1012 by a clamp or other mechanical mechanism.

[0288] As Figure 29As explained above, the transport mechanism 1012 can be configured to receive the reservoir substrate from the cutter 1010 and transport the reservoir substrate to the winding mechanism 1016. In this regard, the transport mechanism 1012 can travel along the longitudinal path 1018 and then along the transverse path 1020 to transport the reservoir substrate to the winding mechanism 1016. The winding mechanism 1016 can include a head portion 1022 configured to receive the reservoir substrate. The head portion 1022 of the winding mechanism 1016 can employ a vacuum to hold the reservoir substrate. In this regard, the head portion 1022 of the winding mechanism 1016 can define a plurality of apertures at its inner surface to apply the vacuum. In some embodiments, the vacuum at the head portion of the transport mechanism can switch to positive pressure during the transport of the reservoir substrate from the head portion 1014 of the transport mechanism 1012 to the head portion 1022 of the winding mechanism 1016. Thus, the air directed out of the head portion 1014 of the transport mechanism 1012 can push the reservoir substrate towards the head portion 1022 of the winding mechanism 1016, which can securely engage the reservoir substrate using the vacuum applied thereto.

[0289] After receiving the reservoir substrate from the transport mechanism 1012, the winding mechanism 1016 can spin (e.g., about 180 degrees) such that its head portion 1022 is positioned proximate to the track 616, as Figure 30 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in Figure 25 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in

[0290] Figures 30 to 32 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in Figures 30 to 32 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in Figures 30 to 32 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in Figure 30 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in Figure 31 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in Figure 32 As explained above, the carriage 600 can deliver the partially assembled cartridge to the reservoir coupling substation 516. For example, the partially assembled cartridge can define the configuration described above and explained in Figure 32It is further explained that the winding mechanism 1016 can be moved away from the fingers 1024a and 1024b at this time.

[0291] Figure 33 The diagram schematically illustrates the interaction between the winding mechanism 1016 and the fingers 1024a, 1024b of the reservoir coupling substation 516 and the reservoir substrate 214. As illustrated, the reservoir substrate 214 can be held to the head portion 1022 of the winding mechanism 1016 by a vacuum applied through an aperture 1032 extending therethrough. Therefore, the first end 1034a and the second end 1034b of the reservoir substrate 214 can extend around the opposite sides of the flow tube 210 and / or other components of the cartridge. In this respect, the inner surface of the head portion 1022 of the winding mechanism 1016 can define a curved configuration that causes the ends 1034a, 1034b of the reservoir substrate 214 to extend around the flow tube 210 in a manner that allows them to be grasped by the fingers 1024a, 1024b. More specifically, the inner surface of the head portion 1022 of the winding mechanism 1026 can define a partially elliptical structure, such that the ends 1034a, 1034b of the reservoir substrate 214 remain close to the flow tube 210 when wound around the flow tube and can be grasped by the fingers 1024a, 1024b.

[0292] The flow tube 210 may be asymmetrical. In this respect, the flow tube 210 may define a shortened side 210a and an elongated side 210b (see, for example...). Figure 1 ).like Figure 33 The description states that the winding mechanism 1016 can be configured such that its head portion 1022 is guided toward the extended side 210b of the flow tube 210. In this respect, the extended side 210b of the flow tube 210 can contact the reservoir substrate 214 in a uniform manner and promote winding around the reservoir substrate, while winding the reservoir substrate around the shortened side 210a of the flow tube can lead to uneven winding of the reservoir substrate or damage to lower-level components such as control components.

[0293] It should be further noted that the heating terminals 234a, 234b may be oriented relative to the winding mechanism 1016 such that when the reservoir substrate 214 is wound around the partially assembled cartridge, the liquid delivery element 238 is forced to engage further with the heating terminals. In this regard, as illustrated by arrows 1036a, 1036b, the liquid delivery element 238 can be pressed into the interior angle defined by the heating elements 234a, 234b by the reservoir substrate 214. More specifically, as illustrated, the heating elements 234a, 234b may include generally vertically extending walls defining an "L" shape, and may force the liquid delivery element 238 into the interior angle between the two walls. Thus, winding the reservoir substrate 214 around the partially assembled cartridge can assist in positioning the liquid delivery element 238 in a desired location (e.g., where the liquid delivery element extends generally parallel to the longitudinal length of the heating terminals 234a, 234b).

[0294] The fingers 1024a and 1024b may be configured to engage the reservoir substrate 214 and further wrap around the flow tube 210 and / or the remainder of the partially assembled cartridge around the reservoir substrate. For example, as Figure 32 and 33 The description indicates that the fingers 1024a and 1024b can be configured to move in directions 1030a and 1030b toward each other, such that other components surrounding the flow tube 210 and / or the partially assembled cartridge clamp the reservoir substrate 214. In some embodiments, the fingers 1024a and 1024b can be guided substantially simultaneously toward each other. This can be used, for example, in embodiments where the ends 1034a and 1034b of the reservoir substrate 214 form a butt joint or are not additionally overlapping cartridges. However, in embodiments where the ends 1034a and 1034b of the reservoir substrate 214 overlap, one of the fingers 1024a and 1024b can move ahead of and / or faster than the other finger, such that one of the ends can wrap around the flow tube 210, and then the other end of the reservoir substrate can wrap around that end.

[0295] After the reservoir substrate 214 is wound around the flow tube 210 and atomizer 212 and / or cartridge, the external body coupling substation 518 can couple the external body to the base. In this regard, as Figures 30 to 32 As explained in the description, in some embodiments, the external body coupling substation 518 may include an external body coupling tool 1102 that can be located by accessing the fingers 1024a, 1024b.

[0296] In addition, the external entity coupling substation 518 may include the external entity supply mechanism 1104, such as Figure 34The external body supply mechanism 1104 may include a pivot fork 1106. The pivot fork 1106 may be configured to receive the external body 216 guided thereto in an initial generally horizontal configuration (see example). Figure 1 Then, as indicated by arrow 1108, it pivots so that the outer body received thereon extends substantially vertically. Furthermore, the outer body coupling tool 1102 can be guided above the outer body 216 so that the outer body can be received therein.

[0297] The external body coupling tool 1102 may include multiple segments (e.g., two or more segments) that cooperate to receive the external body 216 by radially separating from each other. In this respect, Figure 35 A perspective view illustrating a segment 1102a of the external body coupling tool 1102 is shown. As illustrated, each segment 1102a may define a lip 1110, which is configured to hold the external body 216 within the external body coupling tool 1102 when the segments of the external body coupling tool contract radially toward each other. In this respect, the external body coupling tool 1102 may include a body receiving portion 1113 defining an inner radius at least as large as the outer radius of the external body 216, and the inner radius of the lip 1110 may be smaller than the outer radius of the external body.

[0298] Therefore, as Figure 36 As explained, the outer body 216 can be held in the outer body coupling tool 1102 by means of the lip 1110. For example... Figure 36 Further explanation clarifies that the external body coupling tool 1102 facilitates the placement of the external body 216 on the reservoir substrate 214. In this regard, each segment 1102a of the external body coupling tool 1002 may define a funnel portion 1112. The funnel portion 1112 may be configured to reduce the external dimensions of the reservoir substrate 214 such that the external dimensions of the reservoir substrate are less than or equal to the internal dimensions of the external body 216 to facilitate insertion of the reservoir substrate into the external body. In this regard, the reservoir substrate 214 may comprise a flexible fabric-like material that extends in certain directions, making it difficult to directly insert the reservoir substrate 214 into the external body 216 when the reservoir substrate is wrapped around the flow tube 210 and / or other components of the cartridge. Therefore, the funnel portion 1112 may define a minimum internal radius less than or equal to the internal radius of the external body. Therefore, when the external body coupling tool 1102 presses down on the reservoir substrate 214, the reservoir substrate can be compacted by the funnel portion 1112, making it relatively easy to slide into the external body 216.

[0299] As explained, in some embodiments, one or both of the fingers 1024a, 1024b can engage the reservoir substrate 214 such that the reservoir substrate remains at least partially wrapped around the atomizer when the reservoir substrate is inserted into the outer body 216 by the outer body coupling tool 1002. In this regard, the fingers 1024a, 1024b can prevent the reservoir substrate 214 from unwrapping as the outer body 216 is inserted over the reservoir substrate. However, the fingers 1024a, 1024b can release from the reservoir substrate 214 after the outer body 216 has received the reservoir substrate therein for a predefined distance (e.g., when the reservoir substrate is halfway into the outer body), at which point the risk of the reservoir substrate unwrapping is substantially reduced.

[0300] It should be noted that in some embodiments, multiple sets of fingers 1024a, 1024b, 1024a', 1024b', 1024a", 1024b" can be employed to hold the reservoir substrate 214 in the wrapped configuration, as explained in Figure 36A Thus, the fingers 1024a, 1024b, 1024a', 1024b', 1024a", 1024b" can be released sequentially as the reservoir substrate 214 is inserted into the outer body 216 by the outer body coupling tool 1002. For example, the first set of fingers 1024a, 1024b can be released as the reservoir substrate 214 is inserted into the outer body 216, followed by the second set of fingers 1024a', 1024b', followed by the third set of fingers 1024a", 1024b". By employing multiple sets of fingers at different locations along the longitudinal length of the partially assembled cartridge, the reservoir substrate can be more securely held in the wrapped configuration during insertion into the outer body, such that issues with the reservoir substrate moving from the wrapped configuration can be avoided.

[0301] Furthermore, in some embodiments, the outer body coupling tool 1102 can twist the reservoir substrate 214 during insertion of the reservoir substrate into the outer body 216 by the outer body coupling tool, as explained in Figure 36 and 36AThe external body coupling tool 1102 can be twisted about its longitudinal axis 1114. Thus, friction between the funnel portion 1112 of the external body coupling tool 1102 and the reservoir substrate 214 can be reduced. In some embodiments, the external body coupling tool 1102 can be twisted about the longitudinal axis 1114 in a single direction. In another embodiment, the external body coupling tool 1102 can oscillate between rotating in a first and second opposite directions 1116a, 1116b during insertion, which can reduce the chance of the reservoir substrate 214 moving during insertion into the external body 216 by the external body coupling tool. It should be noted that in some embodiments, a segment 1102a of the external body coupling tool 1102 can grip on the external body 216 such that the external body rotates with the external body coupling tool. Thus, friction between the external body 216 and the reservoir substrate 214 can be reduced. Accordingly, twisting movement of the external body 216 relative to the reservoir substrate 214 can further facilitate insertion of the reservoir substrate into the external body.

[0302] After the reservoir substrate 214 and other components of the cartridge are inserted into the external body 216, the external body can be coupled to the base 204. In this regard, the external body coupling substation 518 can further include a crimper 1118, as Figure 37 As explained above, the crimper 1118 can include a plurality of segments 1118a. For example, in Figure 37 As explained above, the crimper 1118 can include a plurality of segments 1118a. For example, in

[0303] Figure 38 One of the segments 1118a of the crimper 1118 is illustrated. As illustrated, each segment 1118a can include a lip 1120 configured to crimp the external body 216. Figure 39 An enlarged view of segment A from Figure 38 is illustrated. As illustrated, in Figure 39In particular embodiments, the angled portion 1122 can extend from the lip 1120 to an inner surface 1124 of the segment 1118a of the crimper 1118. In some embodiments, the angled portion 1122 of the segment 1118a can define an angle 1126 relative to a longitudinal axis 1128 of the crimper 1118 along which the outer body 216 is received from about 10 degrees to about 15 degrees and preferably about 12 degrees. In this regard, the angled portion 1122 can provide a smooth transition from the crimp formed in the outer body 216 by the lip 1120 to the remainder of the outer body. In turn, leakage between the outer body 216 and the base 204 can be substantially avoided.

[0304] Accordingly, Figures 4 to 39 An embodiment of the cartridge assembly subsystem 402 is illustrated. However, as can be appreciated, various other embodiments of the cartridge assembly subsystem can be employed to assemble a cartridge in accordance with embodiments of the present disclosure. In this regard, Figure 40 A cartridge assembly subsystem 402' in accordance with another embodiment of the present disclosure is schematically illustrated.

[0305] As illustrated, the cartridge assembly subsystem 402' can include a base loading substation 1202, a terminal coupling substation 1204, a terminal sealing substation 1206, a control assembly coupling substation 1208, a flow tube coupling substation 1210, a heating element coupling substation 1212, a liquid delivery element bending substation 1214, a reservoir coupling substation 1216, and an outer body coupling substation 1218. Further, the controller 417 can be configured to control one or more of the substations 1202-1218 of the cartridge assembly subsystem 402'. Thus, the cartridge assembly subsystem 402' can be similar to the cartridge assembly subsystem 402 described above and illustrated in Figures 4 to 39 detail above. Accordingly, for brevity purposes, the description provided below with respect to the cartridge assembly subsystem 402' will primarily focus on the differences relative to the previously described cartridge assembly subsystem 402.

[0306] In this regard, the cartridge assembly subsystem 402 described above generally assembles cartridges from the tray 600 transported between various subsystems. More particularly, the tray 600 is generally paused at each substation such that the base 204 is in a stationary position with components moved into contact therewith from above.

[0307] However, the cartridge assembly subsystem 402' described below differs in that the base 204 is generally directed into contact with stationary components to form cartridges. In particular, in some embodiments, the base 204 can be flipped and generally directed downwardly to engage with components to form cartridges. Figure 41A top view of one embodiment of the cartridge assembly subsystem 402' is illustrated. In this regard, a robot (e.g., a robotic arm) can be configured to hold the base 204 and guide the base into contact with the components during assembly to form the cartridge.

[0308] As described above, for example, Figure 41 As described above, for example, Figure 40 As described above, for example, Figure 41 As described above, for example, Figure 41 As described above, for example,

[0309] As described above, for example, Figure 42 As described above, for example, Figure 1 As described above, for example,

[0310] As described above, for example, Figure 1 As described above, for example,

[0311] As described above, for example, Figure 43Base gripper 1500 as can be employed by the robot of the cartridge assembly subsystem 402' is illustrated. As illustrated, base gripper 1500 can define a plurality of segments 1502. Segments 1502 can be configured to contract (e.g., move radially inward toward one another) during insertion into the attachment end 204a of the base 204, and expand (e.g., move radially outward away from one another) after insertion into the attachment end of the base. A plurality of protrusions 1504 or other features (e.g., recesses) on the outer surface 1506 of each of the segments 1502 can assist in gripping the base 204. For example, protrusions 1504 can be configured to engage recesses defined in the inner surface 204a' of the attachment end 204a of the base 204. In this regard, the outer surface 1506 of the segments 1502 of the base gripper 1500 can be configured to correspond to the shape of the inner surface 204a' of the attachment end 204a of the base 204. Thus, the base gripper 1500 can securely and releasably engage the base 204.

[0312] The terminal coupling substation 1204 can include a control component terminal robot 1302. As Figure 42 illustrated in the middle, the control component terminal robot 1302 can include a base gripper 1500. In turn, the control component terminal robot 1302 can grasp a base 204 supplied by the base supplier 1402. Thus, the control component terminal robot 1302 can couple a control component terminal to the base.

[0313] In this regard, as Figure 44 illustrated in the bottom, the terminal coupling substation 1204 can further include a die 1600 configured to prepare a control component terminal 206 for attachment to the base 204. For example, the control component terminal 206 can be cut from a generally continuous control component terminal input 1602. In this regard, a cutter 1604 can cut the control component terminal 206 from the generally continuous control component terminal input 1602.

[0314] Figure 44A An enlarged view of the die 1600 is illustrated. As Figure 44AAs illustrated, the die 1600 can further include a first pressure pad 1606a and a second pressure pad 1606b that can be positioned on opposite sides of the cutter 1604. As the cutter 1604 cuts the control assembly terminals 206 from the generally continuous control assembly terminal input 1602, the pressure pads 1606a, 1606b can extend to contact and press against the generally continuous control assembly terminal input 1602. More particularly, the first pressure pad 1606a can press against a first control assembly terminal 206a that is cut from the generally continuous control assembly terminal input 1602 by the cutter 1604, and the second pressure pad 1606b can press against a second control assembly terminal 206b that is next to be separated from the generally continuous control assembly terminal input. Thus, the first control assembly terminal 206a can be held in place while being cut from the generally continuous control assembly terminal input 1602, and the second control assembly terminal 206b is also held in place, which then becomes the first control assembly terminal at the end of the generally continuous control assembly terminal input.

[0315] After singulation, the first control assembly terminal 206a can be held in a stationary position to facilitate coupling with the base 204. More particularly, the first control assembly terminal 206a can be sandwiched between a backing member 1608 and an opposing pressure pad 1610. In this regard, one or both of the opposing pressure pad 1610 and the backing member 1608 can be moved toward the first control assembly terminal 206a such that the first control assembly terminal is sandwiched therebetween. As illustrated, the opposing pressure pad 1610 and the backing member 1608 can define a profile that matches each of the control assembly terminals 206 such that the control assembly terminals can be securely held in place without affecting the shape of the control assembly terminals. In turn, the base 204 can be guided into contact with the singulated control assembly terminal 206. For example, the control assembly terminal robot 1302 can guide the base 204 downward into contact with the stationary control assembly terminal 206 such that the control assembly terminal engages the base.

[0316] The terminal coupling substation 1204 can further include a heating terminal robot 1304. In this regard, after the control assembly terminal robot 1302 couples the control assembly terminal 206 to the base 204, the control assembly terminal robot can transfer the base to the heating terminal robot 1304. In some embodiments, a transfer member can facilitate the transfer of the base 204 from the control assembly robot 1302 to the heating terminal robot 1304.

[0317] As Figure 45As described, in one embodiment, the transfer member 1700A includes a wheel 1702 that rotates to deliver the base 204 from the control component terminal robot 1302 to the heating terminal robot 1304. The transfer member 1700A may further include one or more fixing devices 1704 coupled to the wheel 1702. Thus, the control component terminal robot 1302 can place the base 204 in a fixing device 1704, the transfer member 1700A can rotate, and the heating terminal robot 1304 can grasp the base in the fixing device and remove the base therefrom.

[0318] In this regard, by placing the base 204 in the fixing device 1704, the base can be positioned such that the heating terminal robot 1304 can grasp the base in a manner substantially the same as that used by the control component terminal robot 1302 to grasp the base. For example, the heating terminal robot 1304 may include base grippers, such as the base gripper 1500 described above. Furthermore, the base 204 can be guided by the heating terminal robot 1304 to engage with the first heating terminal 234a and the second heating terminal 234b (see, for example...). Figure 1 Contact. More specifically, such as Figure 45 The description states that the first die 1612a and the second die 1612b can be cut from the first and second substantially continuous control component terminal inputs, which is substantially similar to the substantially continuous first heating terminal input 700 described above. Furthermore, after engaging the first heating terminal 234a and the second heating terminal 234b with the base 204, the heating terminal robot 1304 can place the base in the second transfer member 1700B (see, for example...). Figure 41 This is roughly similar to the aforementioned transmission component 1700A.

[0319] The base 204 can then be engaged by the robotic arm 1306. The robotic arm 1306 can place the base 204 onto a third transfer member 1700C, which may be substantially similar to the previously described transfer members 1700A, 1700B. Furthermore, in some embodiments employing a seal between heated terminals 234a, 234b and the base 204, the robotic arm 1306 may include a portion of the terminal sealing substation 1206. In this respect, the terminal sealing substation 1206 can operate in substantially the same manner as the terminal sealing substation 506 described above, wherein the robotic arm 1306 engages with the robotic arm 808 (see, for example...). Figure 10 They operate in a generally similar manner. In some embodiments, one or both of the robotic arms 808, 1306 may engage the base 204 with the aforementioned base gripper 1500 during the sealing process.

[0320] Whether or not the terminal seal substation 1206 is employed, the robotic arm 1306 can place the base 204 on the third conveyor component 1700C. Subsequently, the base 204 can be directed to the control assembly coupling substation 1208 and the flow tube coupling substation 1210. In the illustrated embodiment, both the control assembly coupling substation 1208 and the flow tube coupling substation 1210 include and employ the control assembly and flow tube robot 1308.

[0321] In this regard, as explained in Figure 46 the control assembly and flow tube robot 1308 can be configured to engage the base 204 at the third conveyor component 1700C. For example, as illustrated, the control assembly and flow tube robot 1308 can include a gripper such as the base gripper 1500. In turn, the control assembly and flow tube robot 1308 can convey the base 204 to the control assembly coupling substation 1208.

[0322] Further, the control coupling substation 1208 can include a control assembly supply 1802 (see Figure 41 ) that is configured to supply the electronic control assembly 208. In some embodiments, the control assembly supply 1802 can comprise a vibratory hopper. Further, the control assembly supply 1802 can orient the electronic control assembly 208 in a desired manner. For example, as explained in Figure 47 each electronic control assembly 208 can be oriented such that a chip 208' (e.g., a memory chip) or other portion of the electronic control assembly is oriented upward. In this regard, the first and second major sides of the electronic control assembly 208 can be asymmetrical, which can facilitate orientation by the control assembly supply 1802 such that the chip 208' extends upward.

[0323] As further explained in Figure 47 the electronic control assembly 208 can define first and second opposing longitudinal ends 208A, 208B. A connector at the first end 208A of the electronic control assembly 208 can be configured to engage the control assembly terminal 206. In this regard, as explained in Figure 46 an imaging device 1804 (e.g., a camera) can be configured to determine whether the first end 208A is in front of or behind the electronic control assembly 208 in view of the orientation of the electronic control assembly supply 1802.

[0324] Thus, as Figure 47As explained above, the control assembly gripper 1806 can grasp the second end 208B of the electronic control assembly based on the determined orientation of the electronic control assembly 208. In this regard, the control assembly gripper 1806 can include a first finger 1808A and a second finger 1808B configured to pinch the second end 208B of the control assembly 208 therebetween. As explained, the first finger 1808A and the second finger 1808B can be relatively narrow. In this regard, the control assembly feeder 1802 can direct the control assembly 208 to a support member 1810. The support member 1810 can define a first slot 1812A and a second slot 1812B configured to align with the first end 208A and the second end 208B, respectively, of the electronic control assembly 208 when the electronic control assembly is received on the support member. Accordingly, the gripper 1808A, 1808B can extend into one of the slots 1812A, 1812B in the support member 1810 and grasp the second end 208B of the control assembly 208.

[0325] Further, as Figure 47 As further explained above, the control assembly gripper 1806 can rotate the electronic control assembly 208 so that its first end 208A is pointed upward. Accordingly, the control assembly and flow tube robot 1308 can direct the base 204 downward so that the first end 208A of the electronic control assembly 208 engages the control assembly terminal 206. In some embodiments, the connector (e.g., contact tab) at the first end 208A of the electronic control assembly 208 can be located on only one of the major sides of the electronic control assembly, and the control assembly terminal 206 can be asymmetric and configured to engage only that particular side. Accordingly, the control assembly and flow tube robot 1308 can rotate the base 204 so that the required rotational alignment of the electronic control assembly 208 and the control assembly terminal 206 is achieved when the base 204 is directed downward toward the electronic control assembly.

[0326] After the electronic control assembly 208 is coupled to the control assembly terminal 206, the base 204 can be directed by the control assembly and flow tube robot 1308 to a flow tube coupling substation 1210. As Figure 41 As explained above, the flow tube coupling substation 1210 can include a flow tube feeder 1902 configured to feed the flow tube 210. In some embodiments, the flow tube feeder 1902 can comprise a vibratory hopper. Further, the flow tube feeder 1902 can orient the flow tube 210 in a desired manner.

[0327] The flow tube coupling substation 1210 can further include a base 1904, as Figure 46 and 48The base 1904 can define a portion configured to mate with the interior of the flow tube 210 to support an upwardly extending protrusion of the flow tube thereon. Furthermore, the control assembly and the flow tube robot 1308 can guide the base 204 downward toward the flow tube 210. Therefore, the flow tube 210 can be received between the heating terminals 234a, 234b and engage with the control assembly 208. Figure 48 The description indicates that the flow tube gripper 1906 can grasp a partially assembled cartridge. More specifically, the flow tube gripper 1906 may include a pair of arms 1908A, 1908B, each including an extension 1910 configured to press against the heating terminals 234a, 234b of the flow tube 210. Therefore, the flow tube gripper 1906 can indirectly hold the flow tube 210 in place by pressing against the heating terminals 234a, 234b of the flow tube. By grasping the partially assembled cartridge in this way, the base gripper 1500 of the control assembly and the flow tube robot 1308 can be released and retracted from the base 204 while the partially assembled cartridge is securely held in place.

[0328] Subsequently, the heating element robot 1310 can engage the partially assembled e-cigarette cartridge. In this regard, such as Figure 49 As described, the heating element robot 1310 may include a terminal gripper 2002. As described, the terminal gripper 2002 may include a first arm 2004A and a second arm 2004B. The first arm 2004A of the terminal gripper 2002 may include a first pair of forks 2006A, and the second arm 2004B of the terminal gripper may include a second pair of forks 2006B.

[0329] In this regard, such as Figure 50 As described, the terminal gripper 2002 can be configured to engage heating terminals 234a, 234b. However, as mentioned above, the partially assembled cartridge can be held in place by the flow tube gripper 1906. Therefore, the terminal gripper 2002 can be configured to avoid contact with the flow tube gripper 1906. For example, as described, the terminal gripper 2002 can be configured to extend at least partially between the arms 1908a, 1908b of the flow tube gripper 1906. In this respect, the heating element robot 1310 can be rotated such that the first arm 2004A and the second arm 2004B of the terminal gripper 2002 extend perpendicular to the first arm 1908A and the second arm 1908B of the flow tube gripper 1906.

[0330] Therefore, as Figure 51As explained, the terminal clamping jaws 2002 can grip the partially assembled cartridge. In particular, the first pair of prongs 2006A and the second pair of prongs 2006B can clamp the heating terminals 234a, 234b therebetween. More particularly, one of the first pair of prongs 2006A and one of the second pair of prongs 2006B can press against opposite sides of the first heating terminal 234a such that the first heating terminal is held therebetween. Similarly, one of the first pair of prongs 2006A and one of the second pair of prongs 2006B can press against opposite sides of the second heating terminal 234b such that the second heating terminal is held therebetween. As explained, the prongs 2006A, 2006B can engage the heating terminals 234a, 234b such that the heating terminal tabs 952a, 952b are exposed. For example, when the base 204 is oriented such that the heating terminals 234a, 234b extend downwardly therefrom, the prongs 2006A, 2006B can engage the heating terminals slightly above the heating terminal tabs 952a, 952b.

[0331] Furthermore, by gripping the heating terminals 234a, 234b in the manner described above, the heating terminal tabs 952a, 952b can be configured in a desired position for attachment of a heating element thereto. In this regard, as described above, the flow tube clamping jaws 1906 can press the heating terminals 234a, 234b against the flow tube 210. In turn, when the terminal clamping jaws 2002 grip the heating terminals 234a, 234b, the heating terminal tabs 952a, 952b can define a desired separation therebetween, as defined by the width of the flow tube 210. Furthermore, when the terminal clamping jaws 2002 press against opposite sides of each of the heating terminal tabs 952a, 952b with the prongs 2006A, 2006B, the heating terminal tabs can be aligned.

[0332] The heating element coupling substation 1212 can include the heating element robot 1310 described above. Additionally, as Figure 52 As explained, the heating element coupling substation 1212 can include a preparation portion 2008 and a welding portion 2010. The preparation portion 2008 and the welding portion 2010 can operate in substantially the same manner as the preparation portion 902 and the welding portion 904 described above (see, e.g., FIG. 9). In this regard, as explained Figure 12 above, the heating element robot 1310 can grip a heating element 240 from the substantially continuous heating element input 2012 and move the heating element to the preparation portion 2008. The heating element robot 1310 can then move the heating element to the welding portion 2010. The heating element robot 1310 can then move the heating element to the heating element coupling substation 1212. Figure 53 In some embodiments, the heating element can be supplied from a substantially continuous heating element input 2012. The substantially continuous heating element input 2012 can include a plurality of heating elements 240 wound around a liquid transport element 238, as described in, e.g., U.S. Patent Application Serial Nos. 13 / 827,994, filed March 14, 2013, and 13 / 708,381, filed December 7, 2012, which are incorporated herein by reference in their entirety.

[0333] As explained, in some embodiments, the generally continuous heating element input 2012 can be supplied from a spool 2014. The spool 2014 can be passively rotated as the generally continuous heating element input 2014 is pulled therefrom. Alternatively, the spool 2014 can be actively driven (e.g., by a motor) such that the spool rotates as the generally continuous heating element input 2012 is pulled therefrom. By actively rotating the spool 2014 or passively allowing the spool to generally freely rotate as the generally continuous heating element input 2012 is pulled therefrom, the tension in the generally continuous heating element input can be controlled to avoid damage thereto.

[0334] In one embodiment, the position of the generally continuous heating element input 2012 can be monitored such that the spool 2014 can actively supply the generally continuous heating element input to maintain a desired amount of slack therein. For example, as explained in Figure 53 In one embodiment, an upper sensor 2016a and a lower sensor 2016b can be provided, with the generally continuous heating element input 2012 pulled away from the spool 2014 such that it extends between the sensors 2016a, 2016b. In one embodiment, the sensors 2016a, 2016b can each include a light emitter and a light detector that can detect when an object blocks light from reaching the light detector. Thus, the spool 2014 can be actively driven based on detection of the generally continuous heating element input 2012. For example, if the upper sensor 2016a detects a blockage of light by the generally continuous heating element input 2012, the spool 2014 can be directed to rotate or rotate faster. Conversely, if the lower sensor 2016b detects a blockage of light by the generally continuous heating element input 2012, the spool 2014 can be directed to rotate slower or stop. Thus, the tension in the generally continuous heating element input 2012 can be controlled. For example, a controller 417 can be in communication with the sensors 2016a, 2016b and configured to direct the spool 2014 to rotate as described above.

[0335] As noted above, the preparation portion 2008 of the heating element coupling substation 1212 can be generally similar to the preparation portion 902 described above. In this regard, the preparation portion 2008 can be configured to prepare individual heating elements 240 for coupling to the liquid delivery element 238 for welding. Thus, the preparation portion 2008 will not be described in detail.

[0336] However, briefly, as Figure 52The description indicates that the preparation section 2008 may include an applicator 2018, a cutter 2020, and an imaging device 2022 (e.g., a camera). Furthermore, the applicator 2018 can be pulled along a substantially continuous heating element input 2012 until the controller determines, based on the image captured by the camera 2022, that a substantially continuous heating element input 2012 of the required length has been applicated. In this regard, the controller can determine the center of the heating element in the same manner as described above. Furthermore, the conveying device 2024 (see...) Figure 54 The heating element input 2012 can be grasped in a generally continuous manner, such that the heating element 240 is centered between its first arm 2026a and second arm 2026b.

[0337] The cutter 2020 can cut the generally continuous heating element input 2012 to individually separate the heating element 240 and the liquid delivery element 238. The new ends of the generally continuous heating element input 2012 can be supported by tubes 2028, such as... Figure 52 The description states that the end is prepared to be grasped by the applicator 2018 in order to repeat the above process.

[0338] like Figure 54 The description indicates that the welding portion 2010 may include a housing 2030. The conveying device 2024 can convey the individually separated heating element 240 and liquid conveying element 238 into the chamber 2032 defined by the housing 2030. Furthermore, as... Figure 55 The description states that the heating element robot 1310 can be configured to contact the housing 2030. More specifically, the heating element robot 1310 can guide at least the heating terminal tabs 952a, 954b of the heating terminals 234a, 234b into the chamber 2032 defined by the housing.

[0339] Therefore, as Figure 52 The description states that the imaging device 2034 (e.g., a camera) can capture images of the heating element 240 and the heating terminal tabs 952a and 954b of the heating terminals 234a and 234b. Furthermore, the controller can guide the transfer device 2024 and the heating element robot 1030 to align the center of the heating element 240 and the centers of the heating terminals 234a and 234b with the center of the imaging device 2034, respectively. Therefore, the heating element robot 1030 can press the heating terminal tabs 952a and 952b against the contact portions 926 and 928 of the heating element 240 (see example...). Figure 23). The top-view imaging device can be employed to determine the horizontal position of the heating terminals 234a, 234b relative to the heating element 240 so that contact therebetween can be established. The laser 2036 can direct a laser beam against the back of the heating terminal tabs 952a, 952b so that the heating element 240 is welded to the heating terminals 234a, 234b in substantially the same manner as described above. In this regard, a gas applicator (e.g., a fitting coupled to the bottom of the housing 2030) can be configured to apply an inert gas (e.g., argon) into the chamber 2032 to improve the resulting weld (e.g., by preventing oxidation thereof).

[0340] Furthermore, the chamber 2032 defined by the housing 2030 can be substantially sealed prior to welding the heating element 240 to the first and second heating terminals 234a, 234b. In this regard, as described in Figure 55 the heating element robot 1310 can include a sealing component 2038 configured to engage the housing 2030. In this regard, the sealing component 2038 of the heating element robot 1310 can seal against the housing 2030 as the heating terminals 234a, 234b are inserted into the housing 2030. Similarly, a second sealing component 2040 can seal the transport device 2024 to the housing 2030 as the transport device directs the heating element 240 into the chamber 2032, and a third sealing component 2042 can create a seal between the camera 2034 and / or the laser 2036 and the housing 2030. Thus, by substantially sealing the chamber 2032 defined by the housing, the problem with the laser beam exiting the chamber can be avoided. Additionally, the use of substantially sealing the chamber 2032 can facilitate the use of an inert gas by at least partially maintaining the inert gas in the chamber 2032. Furthermore, as described above, various alternative attachment methods including various other types of welding can be employed to couple the heating element to the heating terminals.

[0341] After welding, the partially assembled cartridge can be transported to the liquid transport element bending sub-station 1214. In this regard, in some embodiments, the heating element robot 1310 can transport the partially assembled cartridge thereto. Figure 56 An example embodiment of the liquid transport element bending sub-station 1214 is described. As described, the liquid transport element bending sub-station 1214 can include a first upright component 2102a and a second upright component 2102b. Upper channels 2104a, 2104b and side channels 2106a, 2106b can be defined in the upright components 2102a, 2102b.

[0342] The heating element robot 1310 can be configured to guide the partially assembled cartridge between the upright members 2102a, 2102b of the liquid delivery element bending substation 1214. More particularly, the heating element robot 1310 can orient the partially assembled cartridge such that the liquid delivery element 238 enters the upper channel 2104a, 2104b. As the partially assembled cartridge is inserted downward between the upright members 2102a, 2102b, the liquid delivery element 238 can begin to bend and enter the side channel 2106a, 2106b defined at the inner surface of the upright members. Further, as explained in Figure 57 the upright members 2102a, 2102b can pinch toward one another such that the liquid delivery element 238 bends more and becomes in contact with the heating terminals 234a, 234b.

[0343] Once the liquid delivery element 238 is bent, the reservoir substrate robot 1312 can grasp the partially assembled cartridge. As explained in Figure 58 the reservoir substrate robot 1312 can include a base and a wick clamp 2202. The base and wick clamp 2202 can include a first portion 2204a and a second portion 2204b. Each of the portions 2204a, 2204b can include a base clamp segment 2206. For example, in the illustrated embodiment, the base clamp segment 2206 comprises several v-shaped notches that cooperate to center the base 204 therein. Further, each of the portions 2204a, 2204b can include a wick clamp segment 2208 that is configured to engage the liquid delivery element 238.

[0344] In this regard, Figure 59 the base and wick clamp 2202 are illustrated engaging the partially assembled cartridge. As illustrated, the base 204 can be received between the base clamp segments 2206. Further, the wick clamp segments 2208 can pinch against the end of the liquid delivery element 238. Thus, the base and wick clamp 2202 can hold the liquid delivery element 238 in the bent configuration.

[0345] The reservoir substrate robot 1312 can thus deliver the partially assembled cartridge with the liquid delivery element 238 in the bent configuration to the reservoir coupling substation 1216, where the reservoir substrate 214 is coupled to the partially assembled cartridge. Thus, the reservoir substrate 214 can be prepared for attachment to the partially assembled cartridge. In this regard, as Figure 60As explained above, in some embodiments, a substantially continuous reservoir substrate input 2302 can be supplied from a spool 2304. The spool 2304 can be passively rotated as the substantially continuous reservoir substrate input 2302 is pulled therefrom. Alternatively, the spool 2304 can be actively driven (e.g., by a motor) such that the spool rotates as the substantially continuous reservoir substrate input 2302 is pulled therefrom. By actively rotating the spool 2304 or passively allowing the spool to substantially freely rotate as the substantially continuous reservoir substrate input 2302 is pulled therefrom, the tension in the substantially continuous reservoir substrate input can be controlled to avoid damage thereto.

[0346] In one embodiment, the position of the substantially continuous reservoir substrate input 2302 can be monitored such that the spool 2304 can actively supply the substantially continuous reservoir substrate input to maintain a desired amount of slack therein. For example, as explained above, in one embodiment, an upper sensor 2306a and a lower sensor 2306b can be provided with the substantially continuous reservoir substrate input 2302 pulled away from the spool 2304 such that it extends between the sensors 2306a, 2306b. In one embodiment, the sensors 2306a, 2306b can each include a light emitter and a light detector that can be positioned at opposite ends of a slot 2308, and the light detector can detect when an object blocks light from reaching the light detector. Thus, the spool 2304 can be actively driven based on detection of the substantially continuous reservoir substrate input 2302. For example, if the upper sensor 2306a detects a blockage of light by the substantially continuous reservoir substrate input 2302, the spool 2304 can be directed to rotate or rotate faster. Conversely, if the lower sensor 2306b detects a blockage of light by the substantially continuous reservoir substrate input 2302, the spool 2304 can be directed to stop or rotate slower. Thus, the tension in the substantially continuous reservoir substrate input 2302 can be controlled. For example, a controller 417 can be in communication with the sensors 2306a, 2306b and configured to direct the spool 2304 to rotate as described above. Figure 60

[0347] The substantially continuous reservoir substrate input 2302 can be supplied from the spool 2304 to a singulation unit 2310. As explained above, in one embodiment, the singulation unit 2310 can include a rotating wheel 2312 that defines a plurality of apertures 2314 at an outer surface thereof. The apertures 2314 can be configured to apply a vacuum to the substantially continuous reservoir substrate input 2302 such that the substantially continuous reservoir substrate input is held thereon. In addition, the singulation unit 2310 can include a cutter 2316, as explained above. Figure 61 Figure 62 ​​The cutter 2316 can be configured to cut a generally continuous reservoir substrate input 2302 at predetermined intervals to provide individual reservoir substrates 214. For example, a portion of the cutter 2316 may extend through a cut 2317 defined in a rotating wheel 2312 to cut the reservoir substrate without damaging the rotating wheel. Thus, for example, the rotating wheel 2312 may rotate in step increments corresponding to the desired length of the individual reservoir substrate and corresponding to the distance between the centers of the cuts 2317. Figure 61 As explained, after being cut from the generally continuous reservoir substrate input 2302, the individual separated reservoir substrates 214 can be held on the rotating wheel 2312 by means of a vacuum applied through the orifice 2314. However, the rotating wheel 2312 can be configured to convey the reservoir substrates 214 to the winding mechanism 2318.

[0348] In this regard, such as Figure 63 The winding mechanism 2318 may include a movable slide 2320 configured to move on a track 2322. The movable slide 2320 may include a head portion 2324 defining one or more orifices 2326. Furthermore, the movable slide 2320 may move along the track 2322 such that the head portion 2324 becomes close to the rotating wheel 2312. Therefore, the reservoir substrate 214 can be transferred from the rotating wheel 2312 to the head portion 2324 of the movable slide 2320. For example, a vacuum may be applied to the orifices 2326 in the head portion 2324. Furthermore, when the vacuum is released from the orifices 2314 in the rotating wheel 2312 holding the reservoir substrate 214 and / or a positive pressure is applied through the orifices in the rotating wheel, the reservoir substrate can be transferred to the head portion 2324 of the movable slide 2320. In this respect, the rotating wheel 2312 may be configured such that when the orifice 2314 reaches a specified angular position corresponding to the position of the head portion 2324 of the movable slide 2320, the vacuum stops or a positive pressure is applied to the orifice 2314.

[0349] After the reservoir substrate 214 is transferred to the head portion 2324 of the movable slider 2320, the movable slider can begin to move back to its initial starting position. The reservoir substrate robot 1312 can bring the partially assembled cartridge into contact with the reservoir substrate 214 held by the head portion 2324 of the movable slider 2320. Then, the reservoir substrate robot 1312 and the movable slider 2320 can move synchronously in the same direction until the movable portion reaches... Figure 63The first arm 2328a and the second arm 2328b of the wrapping component 2330 can pinch together toward each other up to this point. This can cause the reservoir substrate 214 to wrap around the partially assembled cartridge. The arms 2328a, 2328b can move simultaneously (e.g., to create a butt joint at the ends of the reservoir substrate 214) or sequentially one after the other (e.g., to cause one end of the reservoir substrate to wrap around the other end). In this regard, the arms 2328a, 2328b can operate in substantially the same manner as the arms 1024a, 1024b described above and illustrated in FIGS. 10A-10C. Figure 33

[0350] After wrapping of the reservoir substrate 214, the partially assembled cartridge can be guided by the outer body robot 1314 to the outer body coupling substation 1218. As Figure 64 illustrated in FIG. 12A, the outer body coupling substation 1218 can include an outer body supply 2402 configured to supply the outer bodies 216 204, in addition to the outer body robot 1314. In some embodiments, the outer body supply 2402 can comprise a vibratory hopper, as Figure 41 illustrated in FIG. 12B.

[0351] The outer body supply 2402 can supply the outer bodies 216 to a transfer component 2404. The transfer component 2404 can be configured to grasp individual outer bodies 216 and position the outer bodies for coupling to the partially assembled cartridge. In this regard, as Figure 65 illustrated in FIG. 12C, the outer body coupling substation 1218 can include an outer body coupling tool 2406 configured to facilitate insertion of the reservoir substrate 214 into the outer body 216, and a crimper 2408 configured to crimp the outer body to the base after the outer body extends over the reservoir substrate and engages the base. A cavity 2410 defined in the crimper 2408 can be configured to receive the outer body 216 such that the partially assembled cartridge can be inserted therein and then the outer body can be crimped to the base 204.

[0352] To place the outer body 216 in the cavity 2410, as Figure 66 ​The description indicates that the conveying component 2404 may include an external body gripper 2412 and a rotating arm 2414. Therefore, the external body gripper 2412 can grasp the external body 216 supplied by the external body feeder 2402. In some embodiments, the external body 216 may be supplied in a generally horizontal configuration. Furthermore, the rotating arm 2414 can rotate such that the external body 216 is generally vertical and positioned above the external body coupling tool 2406 and the curler 2408. The external body gripper 2412 can release the external body 216 so that it falls through the external body coupling tool 2406 into the chamber 2410 defined by the curler 2408.

[0353] In this respect, the external body coupling tool 2406 may include multiple segments. For example, in the illustrated embodiment, the external body coupling tool 2406 includes a first segment 2416a and a second segment 2416b. The segments 2416a and 2416b of the external body coupling tool 2406 may be in an extended configuration in which said segments are radially separated from each other (see, for example...). Figure 64 and 65 ) and the contraction structure in contact with each other of the aforementioned sections (see Figure 66 The external body coupling tool 2406 can move between segments 2416a, 2416b. Each segment 2416a, 2416b can define a funnel portion 2418. The funnel portion 2418 can cooperate to define the funnel when segments 2416a, 2416b are in a closed configuration, such as... Figure 66 As explained below. Therefore, when the partially assembled cartridge is guided to contact it, the external body coupling tool 2406 can reduce the external dimensions of the reservoir substrate 214 such that the external dimensions of the reservoir substrate are less than or equal to the internal dimensions of the external body 216 to facilitate insertion of the reservoir substrate into the external body. In this regard, the reservoir substrate 214 may include a flexible fabric-like material that can extend in certain directions, making it difficult to directly insert the reservoir substrate 214 into the external body 216 when the reservoir substrate is wrapped around the flow tube 210 and / or other components of the cartridge. Therefore, the funnel portion 2418 can define a funnel having a minimum internal radius less than or equal to the internal radius of the external body 216. Therefore, when the external body robot 1314 presses down on the partially assembled cartridge via the external body coupling tool 2406, the reservoir substrate 214 can be compacted by the funnel portion 2418, making it relatively easy to slide into the external body 216.

[0354] The external host robot 1314 may include grippers configured to facilitate the insertion of the partially assembled cartridge into the external host 216 via the external host coupling tool 2406. In this respect, Figure 67 An exploded view of the storage gripper 2420 is shown, and Figure 68 and 69A gripper in an assembled configuration according to example embodiments of this disclosure is illustrated. As illustrated, the reservoir gripper 2420 can include a first body portion 2422a and a second body portion 2422b. The first body portion 2422a and the second body portion 2422b can be configured to releasably clamp the base 204 therebetween so as to hold a partially assembled cartridge.

[0355] Further, the reservoir substrate gripper 2420 can include a finger 2424 that is configured to hold the reservoir substrate 214 in a wrapped configuration. It should be noted, Figure 67 and 68 the reservoir substrate is not illustrated for purposes of clarity. The finger 2424 can be movably coupled relative to the first body portion 2422a of the reservoir substrate gripper 2420. The reservoir substrate gripper 2420 can be provided with various features configured to facilitate movement of the finger 2424 in the manner described below. In the illustrated embodiment, however, the first body portion 2422a of the reservoir substrate gripper 2420 includes a channel 2426. The channel 2426 can be configured to receive a protrusion or pin 2428 at an upper portion of the finger 2424. In some embodiments, the channel 2426 can be substantially straight. Further, the finger 2424 can include an elongated aperture 2430 that is configured to receive a protrusion or pin 2432 that is coupled to the first body portion 2422a. As illustrated, in some embodiments, the elongated aperture 2430 can substantially define a path that extends upward and away from a tip 2434 of the finger 2424.

[0356] The finger 2424 can be configured to hold the reservoir substrate 214 in a wrapped configuration. In this regard, the tip 2434 of the finger 2424 can be configured to press against the wrapped reservoir substrate 214 while the outer body robot 1314 is transporting the partially assembled cartridge to the outer body coupling substation 1218. In this regard, as Figure 63 illustrated in FIGS. 23A-23B, the arms 2328a, 2328b of the wrapping mechanism 2318 can each include an upper protrusion 2334a and a lower protrusion 2334b that can assist in the wrapping operation described above. Further, the protrusions 2334a, 2334b from one arm 2328a can contact the protrusions 2334a, 2334b on the opposing arm 2334b as the arms are moved toward one another such that there is a gap between the arms when the reservoir substrate is in the wrapped configuration.

[0357] Further, while the arms 2328a, 2328b hold the reservoir substrate in the wrapped configuration, the outer body robot 1314 can engage the partially assembled cartridge with the reservoir substrate gripper 2420. More particularly, the first body portion 2422a and the second body portion 2422b can engage the base 204 of the partially assembled cartridge. Further, the tips 2434 of the fingers 2424 can extend between or below the protrusions 2334a, 2334b to engage the reservoir substrate at a location where the ends of the reservoir substrate overlap or meet at a joint. Thus, as the arms 2328a, 2328b of the wrapping mechanism 2318 retract, the reservoir substrate gripper 2420 can hold the reservoir substrate 214 in the wrapped configuration by pressing against the reservoir substrate.

[0358] Thus, the partially assembled cartridge can include the reservoir substrate 214 wrapped around it when insertion into the outer body 216 begins by the outer body coupling tool 2406. However, the fingers 2424 can be configured to release from the reservoir substrate 214 during insertion of the partially assembled cartridge into the outer body 216. In this regard, as the outer body robot 1314 inserts the partially assembled cartridge by the outer body coupling tool 2406, the fingers 2424 of the reservoir substrate gripper 2420 can contact the outer body coupling tool. Thus, while the fingers 2424 remain in contact with the outer body coupling tool, the first body portion 2422a can continue to move toward the outer body coupling tool 2406. Thus, the fingers 2424 can move along a path relative to the first body portion 2422a that is defined by the intersection between the channel 2426 and the pin 2428 and the elongated aperture 2430 and the pin 2432. Thus, because the channel 2426 is generally straight, an upper portion of the fingers 2424 can remain generally stationary. However, because the elongated aperture 2430 defines a path that extends upward and away from the tips 2434 of the fingers, a lower portion of the fingers 2424 can be directed outward away from the reservoir substrate 214 and the rest of the partially assembled cartridge. Thus, the tips 2434 of the fingers 2424 can deflect away and release the reservoir substrate 214 as the outer body robot 1314 inserts the partially assembled cartridge by the outer body coupling tool 2406.

[0359] It should be noted that particular embodiments of the reservoir substrate gripper 2420 can vary while still operating in a manner similar to that described above. For example, Figure 69An alternative embodiment of the reservoir substrate gripper 2420' is illustrated. The reservoir substrate gripper 2420' can be configured to grasp the base 204 of the partially assembled cartridge in a manner similar to the reservoir substrate gripper 2420 described above. In addition, the reservoir substrate gripper 2420' can include fingers 2424' configured to releasably hold the reservoir substrate 214 in a wrapped configuration. In this regard, an innermost portion 2434a' of the fingers 2424' can be configured to press against the reservoir substrate 214. However, an outermost portion 2434b' can be configured to deflect outside and away from the outer body coupling tool 2406 as the outer body robot 1314 guides the partially assembled cartridge through the outer body coupling tool. In this regard, due to the deflection, the fingers 2424' can release from the reservoir substrate 214. Thus, the insertion of the partially assembled cartridge through the outer body coupling tool 2406 can be accomplished in substantially the same manner.

[0360] Once the partially assembled cartridge is inserted into the outer body 216, the crimper 2408 can crimp the outer body to the base 204. In this regard, as Figure 65 and 66 illustrated, the crimper 2408 can include a plurality of segments 2408a. For example, the crimper 2408 can include at least four segments 2408a, which can facilitate creating a tight seal between the base and the outer body 216. Each of the segments 2408a can include a lip, an angled portion, and some or all of the features of the crimper 1118 described above (see Figures 37 to 39 ). Thus, the segments 2408a can move from an open configuration (see, e.g., Figure 65 ) to a closed configuration (see, e.g., Figure 66 ) to crimp the outer body 216 to the base 204. However, it should be noted that the crimper 2408 can be flipped relative to the crimper 1118 described above. In addition, the crimper 2408 can be configured to hold the outer body 216 during the insertion of the partially assembled cartridge through the outer body coupling tool 2406. Thus, in one or more aspects, the crimper 2408 can be different than the crimper 1118 described above.

[0361] It should be noted that the cartridge assembly subsystem 402, 402' described above can be combined and modified in many ways without departing from the scope of the present disclosure. In this regard, the heating elements have been generally described above as being provided as a generally continuous coil of wire wrapped around a generally continuous liquid transport element. Thus, the preparation of the individual heating elements 240 and the liquid transport element 238 involves cutting the generally continuous input into several segments. However, in other embodiments, the heating elements can be formed by the cartridge assembly subsystem.

[0362] For example, as Figure 70As illustrated, in one embodiment, the heating element 240' can be formed by providing a liquid delivery element 238 and coupling a wire 242 thereto to form the heating element. By means of a further example, in one embodiment, the end 240A of the wire 242 can be inserted through the liquid delivery element 238. Subsequently, one or both of the liquid delivery element 238 and the wire 242 can be rotated to define a coil of the heating element 240'. Furthermore, a second end 240B of the wire 242 can be inserted back through the liquid delivery element 238, such that the first end 240A and the second end 240B of the wire are held in place, and the heating element is held in a coiled configuration. Alternatively, one or both ends of the wire can be soldered to an adjacent coil to hold the heating element in place and in a coiled configuration.

[0363] Therefore, the above process can produce a heating element 240' coupled to the liquid delivery element 238, which, when coupled to heating terminals (e.g., heating terminals 234a, 234b) (e.g., via the process disclosed herein), can form a finished atomizer. In this regard, as described above, the wire 242 can extend at least partially through the liquid delivery element 238 at one or both of the first end 240A and the second end 240B of the wire. Thus, the end of the wire 242 can extend through the liquid delivery element 238 generally transverse to the longitudinal length of the liquid delivery element. The liquid delivery element 238 can extend between the first and second opposing ends 238A, 238B. However, the wire 242 does not extend to the opposing ends of the liquid delivery element (it should be noted that the section of the delivery element is in...). Figure 70 (As shown in the diagram, not its full length) to prevent the inclusion of unnecessary wires, as described below. The heating element 240' may include two contact portions 244A, 244B positioned near the ends of the wire 242, and a central portion 246 positioned between the contact portions. As illustrated, the contact portions 244A, 244B may define a first coil spacing, and the central portion 246 may define a second coil spacing, wherein the second coil spacing is greater than the first coil spacing. This facilitates attachment of the heating element to the heating terminal at the contact portions, as described elsewhere herein with respect to another embodiment of the heating element. Furthermore, by forming the heating element 240' with the wire 242 terminating at the contact portions 244A, 244B of the heating element, fewer wires 242 are required to form the heating element compared to embodiments in which the wire extends along substantially the entire length of the liquid delivery element. In this respect, wires positioned outside the heating terminal can be a waste of material in the finished atomizer, as wires at these locations will not be used to facilitate coupling to the heating terminal or generate heat.

[0364] After the outer body 216 is attached to the base, the partially assembled cartridge can be directed to the cartridge filling substation 408. The cartridge filling substation 408 can include one or more filling stations. As Figure 71 As explained in FIG. 25, in one embodiment, the cartridge filling substation 408 can include five filling stations 2502a-2502e. Further, in some embodiments, the cartridge filling substation 408 can include an environmental control enclosure 2504 in which the filling stations 2502a-2502e are positioned. Thus, the environment within the environmental control enclosure 2504 can be controlled. Additionally, an environmental modification device 2506 can be configured to affect the environment within the environmental control enclosure 2504. In some embodiments, the controller 417 can be configured to control one or more of the stations 2502a-2502e and / or the environmental modification device 2506 of the cartridge filling substation 408.

[0365] In one embodiment, the environmental modification device 2506 can comprise a dehumidifier configured to affect the ambient environment within the environmental control enclosure 2504. By way of additional example, the environmental modification device 2506 can be configured to control the ambient environment within the environmental control enclosure 2504 such that the ambient environment defines a relative humidity of less than about 60%, preferably less than about 50%, and most preferably less than about 40%. By controlling the humidity in this manner, problems with the aerosol precursor composition absorbing ambient moisture, which can undesirably dilute the aerosol precursor composition and / or overfill the cartridge, can be avoided.

[0366] Figure 72 A top view of a partially assembled cartridge during filling and prior to the coupling of the drip tip thereto is illustrated. As illustrated, the outlet 2508 of the filling device 2510 (e.g., a filling needle) can be positioned proximate to a plurality of angular portions 2512a-2512d (e.g., quarter circles) of the reservoir substrate 214, wherein the angular portions are defined relative to a longitudinal axis extending through the cartridge. For example, as illustrated in FIG. 25, the outlet 2508 of the filling device 2510 can be positioned at a first angular portion 2512a, followed by a second angular portion 2512b, a third angular portion 2512c, and a fourth angular portion 2512d, sequentially. Directing the aerosol precursor composition at a plurality of angular positions can increase the rate of filling of the reservoir substrate 214 with the aerosol precursor composition. In this regard, the rate of absorption of the reservoir composition 214 can be less than the outflow rate of the outlet 2508 of the filling device 2510. Thus, by moving the outlet 2508 to various angular portions 2512a-2512d, each angular portion can receive a flow of the aerosol precursor composition to avoid problems with a single angular portion of the reservoir substrate 214 not being able to absorb the aerosol precursor composition at the rate at which the aerosol precursor composition is dispensed by the filling device 2510. Figure 72 As illustrated in FIG. 25, in one embodiment, the cartridge filling substation 408 can include five filling stations 2502a-2502e. Further, in some embodiments, the cartridge filling substation 408 can include an environmental control enclosure 2504 in which the filling stations 2502a-2502e are positioned. Thus, the environment within the environmental control enclosure 2504 can be controlled. Additionally, an environmental modification device 2506 can be configured to affect the environment within the environmental control enclosure 2504. In some embodiments, the controller 417 can be configured to control one or more of the stations 2502a-2502e and / or the environmental modification device 2506 of the cartridge filling substation 408.

[0365] In one embodiment, the environmental modification device 2506 can comprise a dehumidifier configured to affect the ambient environment within the environmental control enclosure 2504. By way of additional example, the environmental modification device 2506 can be configured to control the ambient environment within the environmental control enclosure 2504 such that the ambient environment defines a relative humidity of less than about 60%, preferably less than about 50%, and most preferably less than about 40%. By controlling the humidity in this manner, problems with the aerosol precursor composition absorbing ambient moisture, which can undesirably dilute the aerosol precursor composition and / or overfill the cartridge, can be avoided.

[0366] Figure 72 A top view of a partially assembled cartridge during filling and prior to the coupling of the drip tip thereto is illustrated. As illustrated, the outlet 2508 of the filling device 2510 (e.g., a filling needle) can be positioned proximate to a plurality of angular portions 2512a-2512d (e.g., quarter circles) of the reservoir substrate 214, wherein the angular portions are defined relative to a longitudinal axis extending through the cartridge. For example, as illustrated in FIG. 25, the outlet 2508 of the filling device 2510 can be positioned at a first angular portion 2512a, followed by a second angular portion 2512b, a third angular portion 2512c, and a fourth angular portion 2512d, sequentially. Directing the aerosol precursor composition at a plurality of angular positions can increase the rate of filling of the reservoir substrate 214 with the aerosol precursor composition. In this regard, the rate of absorption of the reservoir composition 214 can be less than the outflow rate of the outlet 2508 of the filling device 2510. Thus, by moving the outlet 2508 to various angular portions 2512a-2512d, each angular portion can receive a flow of the aerosol precursor composition to avoid problems with a single angular portion of the reservoir substrate 214 not being able to absorb the aerosol precursor composition at the rate at which the aerosol precursor composition is dispensed by the filling device 2510.

[0367] In one embodiment, the outlet 2508 of the filling device 2510 can be sequentially moved from each of the first 2512a to fourth 2512d angular portions at the filling station one 2502a. Subsequently, the filling station two 2502b to filling station five 2502e can position the outlet 2508 of the filling device 2510 at one of the angular portions. For example, the filling station two 2502b can position the outlet 2508 of the filling device 2510 at the first angular portion 2512a, the filling station three 2502c can position the outlet 2508 of the filling device 2510 at the second angular portion 2512b, the filling station four 2502d can position the outlet 2508 of the filling device 2510 at the third angular portion 2512c, and the filling station five 2502e can position the outlet 2508 of the filling device 2510 at the fourth angular portion 2512d. Thus, the cartridges can be transported between the filling stations 2502a to 2502e, and the flow of aerosol precursor composition can be directed to at least one of the angular portions 2512a to 2512d of the reservoir substrate 214 at each of the filling stations.

[0368] Furthermore, as explained in Figure 73 the outlet 2508 of the filling device 2510 can remain out of contact with the reservoir substrate 214 while the flow of aerosol precursor composition 2514 is directed through the outlet of the filling device at each angular portion of the reservoir substrate. In this regard, by avoiding contact with the reservoir substrate 214, damage thereto can be avoided. Furthermore, as explained in Figure 72 and 73 the filling device 2510 can be configured to press against the inner surface of the outer body 216 when filling at each angular portion 2512a to 2512d. Thus, the cartridge can be tilted slightly and the aerosol precursor composition 2514 can be directed down along the inner surface of the outer body 216 so that the reservoir substrate 214 can be filled at a relatively rapid rate.

[0369] After filling, the cartridge can be directed to a cartridge capping subsystem 412 where the drip tip 220 is coupled to the outer body 216. A crimper, generally similar to the crimper described above, can be used to crimp the outer body 216 to the drip tip 220 in order to prevent leakage between the outer body and the drip tip. Furthermore, in some embodiments, a cartridge labeling subsystem 416 can apply the label 218 to the cartridge.

[0370] Various quality control measures can be employed to ensure that properly constructed cartridges 200. In this regard, as described above and Figure 3As explained, the system 400 can additionally include an inspection subsystem 418, which can inspect the assembly 406, the unfilled cartridge 404, the filled cartridge 410, the capped cartridge 414, and / or the finished cartridge 200. Moreover, in some embodiments, the cartridge can be inspected at intermediate completion states at one or more of the cartridge assembly subsystem 402, the cartridge fill subsystem 408, the cartridge capping subsystem 412, and the cartridge labeling subsystem 416. Thus, the cartridge and its components can be inspected before, during, and after completion of the cartridge.

[0371] In this regard, imaging devices (e.g., cameras) can be employed at a variety of locations to ensure that the above-described processes are performed as desired within specifications. Thus, cameras and / or other inspection equipment can be employed at a variety of locations within the system 400. However, inspection at certain locations can be of particular importance.

[0372] In this regard, it can be important to inspect the position of the terminals 206, 234a, 234b after insertion into the base 204. For example, one or more cameras can be configured to inspect the radial position (e.g., relative to the center of the base 204) of each of the terminals 206, 234a, 234b. The radial position of the terminals 206, 234a, 234b can be determined at the attached end 204a of the base 204. In this regard, proper radial position of the terminals 206, 234a, 234b can facilitate attachment of the cartridge 200 to the control assembly 300. Moreover, one or more cameras can be employed to inspect the distance that the terminals 206, 234a, 234b extend from the base 204. In some embodiments, the distance that the terminals 206, 234a, 234b extend from the base 204 can be determined at the interior end 204b (see FIG. 22) of the base 204. In this regard, proper extension of the terminals 206, 234a, 234b to the interior end 204b of the base 204 can be important to ensure proper coupling of the heating element 240 thereto. Figure 1 ) of the base 204. In this regard, proper extension of the terminals 206, 234a, 234b to the interior end 204b of the base 204 can be important to ensure proper coupling of the heating element 240 thereto.

[0373] In the cartridge assembly subsystem 402, the terminals 206, 234a, 234b are inserted downwardly into the base 204. Thus, while the base is held in the carriage 600 traveling on the track 616, inspection of the distance that the terminals 206, 234a, 234b extend from the interior end 204b of the base 204 can be performed. In this regard, as explained in Figure 74 the side-view camera 2602 can be configured to capture an image of the side profile of the partially assembled cartridge after one or more of the terminals 206, 234a, 234b are coupled to the base 204. In turn, the controller can be configured to determine the distance that one or more of the terminals 206, 234a, 234b extend from the base 204.

[0374] However, because the attachment end 204a of the base 204 is oriented downward toward the cradle 600, the base can be removed from the cradle to inspect the radial position of the terminals 206, 234a, 234b. In this regard, as explained in Figure 75 the removal robot 2604 can be configured to remove the partially assembled cartridge from the cradle 600 and move the partially assembled cartridge over the end view camera 2606. Thus, the images captured by the end view camera 2604 can be analyzed by the controller to determine the radial position of one or more of the terminals 206, 234a, 234b. Alternatively, an aperture extending through the cradle 600 can allow for inspection of the radial position of the terminals 206, 234a, 234b at the attachment end 204a of the base 204. Further, it should be noted that in some embodiments, a separate camera can be provided for each terminal in order to focus on each particular terminal. In other embodiments, one camera can be employed to inspect multiple terminals, for example by adjusting the focal length of the camera.

[0375] In a second embodiment of the cartridge assembly subsystem 402', the cartridge substantially assembled with the base 204 is oriented in an opposite manner such that the components coupled therewith extend downward therefrom. In this regard, as explained in Figure 76 the fixtures 1704 of one or more of the transport members 1700A-1700C can be employed to facilitate inspection of the terminals 206, 234a, 234b. For example, the fixtures 1704 can hold the base 204 such that its attachment end 204a extends upward. Thus, an end view camera 2702 positioned above the base 204 can inspect the radial position of the terminals 206, 234a, 234b.

[0376] Further, as explained in Figure 77 the fixtures 1704 can include one or more apertures 2704a, 2704b extending therethrough. Thus, as explained in Figure 76 a side view camera 2706 can be positioned to look through one or more of the apertures 2704a, 2704b to determine the distance that the terminals 206, 234a, 234b extend from the interior end 204b of the base 204. In some embodiments, a separate camera can be provided for each terminal in order to focus on each particular terminal. In other embodiments, one camera can be employed to inspect multiple terminals, for example by adjusting the focal length of the camera.

[0377] The inspection subsystem 418 can additionally include one or more cameras configured to inspect the partially assembled cartridge after the outer body 216 is crimped to the base 204. For example, as explained in Figure 78As explained above, when inspecting the first embodiment of the cartridge assembly subsystem 402, the inspection subsystem 418 can include the end view camera 2802 configured to capture images of the interior of the outer body 216. In this regard, the end view camera 2802 can be positioned above the track 616 downstream of the crimper 1118 such that the end view camera can capture one or more images of the interior of the outer body 216 as the carriage 600 is guided beneath the end view camera. In turn, the controller can determine whether the reservoir substrate 214 is present (a desired condition) or not present (an undesirable condition).

[0378] Further, the cartridge assembly subsystem 402 can include the side view camera 2804 configured to capture images of the side of the partially assembled cartridge. In this regard, the side view camera 2804 can be positioned alongside the track 616 such that the side view camera can capture images of the partially assembled cartridge held by the carriage 600. In this regard, the controller can be configured to analyze the images captured by the side view camera 2804 to determine whether the crimp in the outer body 216 produced by the crimper 1118 is proper (e.g., the outer body can be substantially flush with the base 204 when the crimp is proper), and further the controller can determine whether the reservoir substrate 214 is protruding out of the outer body (e.g., at the interface between the outer body and the base) (an undesirable condition) or contained within the outer body (a desired condition).

[0379] As Figure 79 As explained above, when inspecting the second embodiment of the cartridge assembly subsystem 402', the inspection subsystem 418 can include the end view camera 2902 configured to capture images of the interior of the outer body 216, and the side view camera 2904 configured to capture images of the side of the partially assembled cartridge, such that the controller can analyze the images of the partially assembled cartridge in the manner described above. Further, the outer body inspection robot 1316 can be employed to receive the partially assembled cartridge from the crimper 2408, and guide the partially assembled cartridge to a location where the end view camera 2902 and the side view camera 2904 can capture images of the partially assembled cartridge. Further, in some embodiments, the outer body inspection robot 1316 can include the base gripper 1500, which can facilitate grasping the base 204 in the manner described above.

[0380] The inspection subsystem 418 can additionally include a blow through station. The blow through station can be configured to direct a flow of air through the cartridge to purge the flow path defined therethrough. In this regard, although not contemplated, the blow through station can remove any dust or debris from the flow path through the cartridge. For example, Figure 80A blow through station 3000 that can be employed with the first embodiment of the cartridge assembly subsystem 402 is illustrated. As illustrated, the blow through station 3000 can include a first connector 3002 and a second connector 3004. In one embodiment, the first connector 3002 can be configured to engage an orifice 3006 in the cradle 600 that is in communication with the attachment end 204a of the base 204. In this regard, in some embodiments, the first connector can include a resilient seal 3008 that is configured to engage the orifice 3006 in the cradle 600. Further, the second connector 3004 can be configured to engage the end of the outer body 216 that is opposite the base 204, for example, via a resilient seal.

[0381] The connectors 3002, 3004 can be at different pressures. Thus, the pressure differential applied across the cartridge by the connectors 3002, 3004 can cause a directed air flow therethrough. In some embodiments, the first connector 3002 can be at a higher pressure than the second connector 3004, such that air flows through the cartridge in the same direction as would occur during normal use of the cartridge. For example, a vacuum can be applied to the second connector 3004, while the first connector 3002 can be ambient pressure. Thus, any debris in the cartridge can be removed.

[0382] Figure 81 An embodiment of a blow through station 3100 that can be included with the second embodiment of the cartridge assembly subsystem 402' is illustrated. As illustrated, the blow through station 3100 can include a first connector 3102 and a second connector 3104. Further, the blow through station 3100 can include a rotatable arm 3106 and outer body jaws 3108. The outer body inspection robot 1316 can move a partially assembled cartridge to the blow through station 3100. Thus, the outer body jaws 3108 can grasp the outer body 216 of the partially assembled cartridge, and the rotatable arm 3106 can rotate the partially assembled cartridge into position between the connectors 3102, 3104. The connectors 3102, 3104 can be retracted against the ends of the cartridge to form a seal therewith. For example, the connectors 3102, 3104 can include resilient seals 3110, 3112, respectively, that facilitate the formation of a connection with the attachment end 204a of the base 204 and the opposite end of the outer body 216. Upon completion of the blow through in the manner described above, the connectors 3102, 3104 can be retracted and the rotatable arm 3106 can rotate the partially assembled cartridge so that it can be grasped and moved to additional stations. It should be noted that, as illustrated, additional blow through stations 3100' that can be substantially similar to the blow through station 3100 can be provided in order to increase throughput.

[0383] Additionally, the inspection subsystem 418 can additionally include a pressure drop station. The pressure drop station 418 can be configured to detect a pressure drop associated with directing a flow of air through a partially assembled cartridge. Thus, a pressure drop associated with the cartridge can be determined and compared to a required pressure drop to ensure that there are no obstructions or leaks in the cartridge.

[0384] In some embodiments, the pressure drop station can be substantially similar to the blow through station. In this regard, Figure 82 A pressure drop station 3200 that can be employed with the first embodiment of the cartridge assembly subsystem 402 is illustrated. As illustrated, the pressure drop station 3200 can include a first connector 3202 and a second connector 3204. In one embodiment, the first connector 3202 can be configured to engage an orifice in the cradle that is in communication with the attachment end 204a of the base 204 (see, e.g., the orifice 3006 in the cradle 600 of FIG. 3). In this regard, in some embodiments, the first connector 3202 can include a resilient seal 3208 that is configured to engage the orifice in the cradle. Additionally, the second connector 3204 can be configured to engage the end of the outer body 216 that is opposite the base 204, e.g., via a resilient seal. Figure 80

[0385] One of the connectors 3202, 3204 can supply air to the cartridge at a known flow rate and / or pressure. Additionally, the flow rate and / or pressure of the air traveling through the other of the connectors 3202, 3204 can be tested to determine a pressure drop associated with the cartridge. In turn, the pressure drop can be compared to a required pressure drop.

[0386] Figure 83 An embodiment of a pressure drop station 3300 that can be included with the second embodiment of the cartridge assembly subsystem 402' is illustrated. As illustrated, the pressure drop station 3300 can include a first connector 3302 and a second connector 3304. Additionally, the pressure drop station 3300 can include a rotatable arm 3306 and an outer body jaw 3308. Thus, the inspection robot 1318 (see Figure 41 ​) The partially assembled cartridge can be moved from the blow through station 3100 to a pressure drop station 3300. Thus, the outer body jaws 3308 can grasp the outer body 216 of the partially assembled cartridge, and the rotatable arm 3306 can rotate the partially assembled cartridge into position between connectors 3302, 3304, which can be moved together to seal against the end of the cartridge. For example, the connectors 3302, 3304 can include resilient seals 3310, 3312, respectively, which facilitate connection with the attachment end 204a of the base 204 and the opposite end of the outer body 216. After the pressure drop test in the manner described above is complete, the connectors 3302, 3304 can be retracted and the rotatable arm 3106 can rotate the partially assembled cartridge so that it can be grasped and moved to additional stations. It should be noted that, as illustrated, additional pressure drop stations 3300' can be provided that can be substantially similar to the pressure drop station 3300 in order to increase throughput.

[0387] Further, the inspection subsystem 418 can additionally include an electrical test station. In this regard, Figure 84 An embodiment of an electrical test station 3400 that can be included with the first embodiment of the cartridge assembly subsystem 402 is illustrated. As illustrated, the electrical test station 3400 can include a test fixture 3402. Further, the electrical test station 3400 can include a robotic arm 3404 configured to move the partially assembled cartridge from the carrier to the test fixture 3402 and back. The robotic arm 3404 can include outer body jaws 3406, which can be configured to grasp the outer surface of the outer body 216.

[0388] Figure 85 An enlarged view of the test fixture 3402 is illustrated. As illustrated, the test fixture 3402 can include a socket 3408 configured to engage the base 204 of the cartridge. Figure 86 A cross-sectional view through the test fixture 3402 is illustrated. In this regard, the socket 3408 can define a similar shape and size as the coupler 302 of the control body 300. However, the socket 3408 can be relatively shorter than the coupler 302 in order to avoid damaging optional pressure relief components in the base 204. Further, the socket 3408 can not include anti-rotation features so that the cartridge can be engaged with the base 204 in any rotational position.

[0389] As illustrated, the test fixture 3402 can include a plurality of electrical contacts coupled to the socket 3408 and configured to engage terminals of the cartridge. For example, a first electrical contact 3410 can be configured to engage the first heating terminal 234a, a second electrical contact 3412 can be configured to engage the second heating terminal 234b, and a third electrical contact 3414 can be configured to engage the control assembly terminal 206. The first electrical contact 3410 can be defined by a first body portion 3416, the second electrical contact 3412 can be defined by a second body portion 3418, and the third electrical contact 3414 can be defined by a third body portion 3420. The body portions 3416, 3418, 3420 can be formed of an electrically conductive and relatively hard material, such as hardened steel, so as to withstand repeated use and allow for electrical communication therethrough in the manner described below.

[0390] Each of the body portions 3416, 3418, 3420 can be coupled to a non-conductive member 3422, which can be formed of any of a variety of non-conductive materials, such as plastic. Further, the body portions 3416, 3418, 3420 can be electrically insulated from one another by avoiding direct contact therebetween. In this regard, the body portions 3416, 3418, 3420 can be positioned such that an air gap is defined therebetween. For example, the body portions 3416, 3418, 3420 can be coupled to the non-conductive member 3422 such that the body portions are spaced apart from one another when coupled to the non-conductive member. Alternatively, or additionally, a non-conductive spacer can be placed between the body portions 3416, 3418, 3420.

[0391] The test fixture 3402 can be in communication with, for example, the controller 417 described above (see, e.g., FIG. 4) to facilitate testing of the cartridge 200. For example, the test fixture 3402 can be in electrical communication with the controller 417 via the electrical contacts 3410, 3412, 3414 and the socket 3408. In this regard, the controller 417 can be configured to apply a voltage to the electrical contacts 3410, 3412, 3414 to test the cartridge 200. Figure 3) controller. The controller 417 can be configured to communicate with the cartridge through the electrical contacts 3410, 3412, 3414 when the base of the cartridge is engaged with the receptacle 3402. In turn, the cartridge can be tested, and various other functions can be performed. For example, the controller 417 can be configured to determine a resistance of the atomizer of the cartridge and compare the resistance to a required resistance. In some embodiments, the resistance of the atomizer can preferably be 1.5 ohms to about 3.5 ohms, and more preferably about 2.1 ohms to about 3.0 ohms, which can correspond to an atomizer configured to generate a required amount of heat. Further, the controller 417 can be configured to determine whether the atomizer is shorted to the outer body of the cartridge. In this regard, the controller 417 can check to ensure that the resistance between the outer body and one or more of the terminals 206, 234a, 234b is greater than about one mega ohm. For example, a current can be applied to the outer body 216 of the cartridge through the outer body clamp 3406, and the controller 417 can detect any current reaching one or more of the terminals 206, 234a, 234b to determine the resistance between the terminals and the outer body. In this regard, in a misassembled cartridge, the atomizer can touch the outer body, which can cause current to be transmitted therebetween.

[0392] The test fixture 3402 can further include an orifice 3426 configured to provide airflow through the base 204 of the cartridge. Thus, in some embodiments, the test fixture 3402 can be employed to perform the flow through and / or pressure drop operations described above. Thus, for example, the orifice 3426 in the test fixture can be in communication with a first connector, and the outer body clamp 3406 can include a second connector, such that airflow can be provided through a cartridge held by the test fixture 3402 and the outer body clamp.

[0393] Additionally, the controller 417 can be configured to transmit program code instructions to the electronic control component 208 of the cartridge through the third electrical contact 3414 and the control component terminal 206. Thus, for example, heating settings defining when and how much current to apply to the atomizer after a puff is detected can be written to the electronic control component 208. Additionally, program code instructions can include a verification code that can be employed to verify that the cartridge is authentic. The controller 417 can be further configured to read the program code instructions stored on the electronic control component 208 and determine whether the program code instructions stored on the electronic control component correspond to the desired program code instructions. For example, the stored program code instructions can be read to ensure that the appropriate heating settings and verification code are stored. A unique identifier associated with the electronic control component 208 can also be read therefrom, which can be used to record information about the cartridge in a database (e.g., date of manufacture, heater settings, verification code, etc.). The controller 417 can also initialize the electronic control component 208 such that the electronic control component directs current to the atomizer after detecting a first puff, but not a second puff, when the electronic control component is not initialized.

[0394] Figure 87 An embodiment of the electrical test station 3500 that can be included in the inspection subsystem 418 with the second embodiment of the cartridge assembly subsystem 402' is illustrated. The cartridge can be delivered to the electrical test station 3500 by the inspection robot 1318 described above. In this regard, the inspection robot 1318 can place the cartridge on the test fixture 3502. The gripper 3504 can be configured to press and hold the cartridge on the socket 3506 of the test fixture 3502. The functionality and structure of the test fixture 3502 can be generally similar to the test fixture 3402 described above. Thus, its description will not be repeated. However, the test fixture 3502 can further include slots 3508 positioned on opposite sides of the socket 3506. The slots 3508 can be configured to receive grippers 3510 of a test fixture robot 1320 such that the grippers can grab underneath the base to remove the cartridge from the socket. Thus, the grippers 3510 can pull the cartridge away from the socket 3506. It should be noted that, as illustrated, additional test fixtures 3500' that can be generally similar to the test fixture 3500 can be provided in order to increase throughput.

[0395] In some embodiments, the inspection subsystem 418 can additionally include a quality assurance station. The quality assurance station can be positioned at any point in the assembly process. For example, the quality assurance station can be positioned downstream of the crimper 1118, 2408 that crimps the outer body 216 to the base 204. However, the quality assurance station can be configured to receive partially assembled cartridges in various states of completion. In this regard, various sub-stations of the cartridge assembly subsystem 402, 402' can be configured to direct a cartridge in any of various states of completion that occur during its assembly to the quality assurance station. Thus, for example, a base 204 coupled with terminals 206, 234a, 234b can be directed to the quality assurance station without the electronic control assembly, flow tube, reservoir substrate, and outer body coupled therewith. By way of further example, the carriages 600 of the first embodiment of the cartridge assembly subsystem 402 can skip various stations, and / or some robots of the second embodiment of the cartridge assembly subsystem 402' can pass partially assembled cartridges to the quality assurance station without performing operations thereon. The partially assembled cartridges directed to the quality assurance station can be inspected manually or via an automated process to ensure that the cartridges are properly assembled. In some embodiments, partially assembled cartridges defining various states of completion can be directed to the quality assurance station at predefined intervals, such that partially assembled cartridges in each of the various states of completion can be regularly inspected.

[0396] The inspection subsystem 418 can be configured to discard defective cartridges that fail to meet certain predefined criteria as described above. For example, upon identifying a partially assembled cartridge as defective in the first embodiment of the cartridge assembly subsystem 402, the carriage 600 holding the defective cartridge can skip the remaining assembly stations and direct the cartridge to a scrap station, where the defective cartridge is removed therefrom (e.g., via a vacuum hose) for disposal. By way of further example, upon identifying a partially assembled cartridge as defective in the second embodiment of the cartridge assembly subsystem 402', the robot proximate to the location at which the cartridge was determined to be defective can drop the defective cartridge into a scrap receptacle. For example, Figure 79 An illustration of a receptacle 3600 in the table 3602 supporting the cartridge assembly subsystem 402' is illustrated, in which a defective cartridge can be placed (e.g., after inspection of the terminals 206, 234a, 234b). In this regard, the receptacle can be associated with each location at which a cartridge is inspected, such that defective cartridges can be immediately discarded.

[0397] The inspection subsystem 418 can additionally inspect the cartridges after filling at the cartridge filling subsystem 408, capping at the cartridge capping subsystem 410, and / or labeling at the cartridge labeling subsystem 412. By way of example, the inspection subsystem 418 can be configured to detect leaks in the cartridges after filling. By way of further example, the inspection subsystem 418 can include a camera over which the filled cartridges are lifted, and can compare the captured images to stored images of known acceptable cartridges without leaks. Additional cameras can ensure that the drip tips 220 are properly crimped to the outer bodies 216. By way of example, the crimp associated with attachment of the drip tips 220 to the outer bodies 216 can be inspected in substantially the same manner as the crimp used to attach the base 204 to the outer body. Moreover, after the label 218 is applied to the outer body 216, a camera can inspect placement of the label to ensure that it is properly positioned.

[0398] Methods for assembling a cartridge for an aerosol delivery device are also provided. As explained in Figure 88 the method can include providing, at operation 3702, a reservoir substrate extending at least partially around an atomizer. Moreover, the method can include providing, at operation 3704, an outer body configured to at least partially receive the reservoir substrate and the atomizer therein. Additionally, the method can include inserting, at operation 3706, the reservoir substrate into the outer body by a tool defining a funnel portion configured to reduce an outer dimension of the reservoir substrate such that the outer dimension of the reservoir substrate is less than or equal to an inner dimension of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0399] In some embodiments, the method can additionally include twisting, at operation 3706, the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body by the tool. Providing, at operation 3702, the reservoir substrate extending at least partially around the atomizer can include wrapping the reservoir substrate at least partially around the atomizer prior to inserting, at operation 3706, the reservoir substrate into the outer body by the tool. Wrapping the reservoir substrate at least partially around the atomizer can include directing an air flow at the reservoir substrate.

[0400] The method can further include engaging the reservoir substrate with one or more fingers to cause the reservoir substrate to remain at least partially wrapped around the atomizer when the reservoir substrate is inserted into the outer body by the tool at operation 3706. In addition, the method can include releasing the one or more fingers from the reservoir substrate when the reservoir substrate is inserted into the tool to a predetermined depth. Releasing the one or more fingers can include deflecting the one or more fingers away from the reservoir substrate by contacting the one or more fingers with the tool. In addition, releasing the one or more fingers can include releasing the fingers sequentially. The method can further include coupling the atomizer to the base before at least partially wrapping the reservoir substrate around the atomizer, and coupling the outer body to the base after inserting the reservoir substrate into the outer body by the tool at operation 3706. Additionally, the method can include feeding the reservoir substrate from a generally continuous reservoir substrate input, and controlling a tension in the generally continuous reservoir substrate input.

[0401] Methods for assembling an atomizer for an aerosol delivery device are also provided. As described in Figure 89 operation 3802. In addition, the method can include determining a position of the first heating terminal and the second heating terminal at operation 3804. The method can also include determining a position of the heating element at operation 3806. Additionally, the method can include attaching the heating element to the first heating terminal and the second heating terminal based on the position of the first heating terminal and the second heating terminal and the position of the heating element at operation 3808 (e.g., such that an electrical connection is established therebetween).

[0402] Determining the position of the first heating terminal and the second heating terminal at operation 3804 can include determining a midpoint between the first heating terminal tab and the second heating terminal tab. The heating element can include a first contact portion and a second contact portion, and determining the position of the heating element at operation 3806 can include determining a midpoint between the first contact portion and the second contact portion. The method can further include aligning the midpoint between the first heating terminal tab and the second heating terminal tab and the midpoint between the first contact portion and the second contact portion, engaging the first contact portion with the first heating terminal tab, and engaging the second contact portion with the second heating terminal tab.

[0403] The method can further include clamping the first heating terminal and the second heating terminal such that the first heating terminal tab and the second heating terminal tab are substantially coplanar. Clamping the first heating terminal and the second heating terminal can include adjusting a spacing between the first heating terminal and the second heating terminal. Attaching the heating element to the first heating terminal and the second heating terminal at operation 3808 can include directing a plurality of laser beams at the first heating terminal tab and the second heating terminal tab. Directing the laser beams at the first heating terminal tab and the second heating terminal tab can include directing the laser beams at back sides of the first heating terminal tab and the second heating terminal tab opposite the heating element. The method can further include inserting the heating element, the first heating terminal, and the second heating terminal into a substantially sealed chamber prior to directing the laser beams at the first heating terminal tab and the second heating terminal tab.

[0404] Providing the heating element at operation 3802 can include supplying the heating element from a substantially continuous heating element input and controlling a tension in the substantially continuous heating element input. The method can further include coupling the heating element to the liquid transport element. Coupling the heating element to the liquid transport element can include inserting an end of the heating element through the liquid transport element and rotating at least one of the heating element and the liquid transport element such that the heating element is wound around the liquid transport element. Providing the first heating terminal and the second heating terminal at operation 3802 can include supplying the first heating terminal from a substantially continuous first heating terminal input and supplying the second heating terminal from a substantially continuous second heating terminal input.

[0405] In some embodiments, the heating element can include a wire wound around the liquid transport element. The wire can include two contact portions, a center portion, and two outer portions positioned outside the contact portions, the two contact portions and the center portion of the wire defining the heating element. The contact portions can define a first coil spacing, the center portion can define a second coil spacing, and the outer portions can define a third coil spacing. The third coil spacing can be greater than the second coil spacing, and the second coil spacing can be greater than the first coil spacing. Further, attaching the heating element to the first heating terminal and the second heating terminal at operation 3808 can include attaching the contact portions to the first heating terminal and the second heating terminal.

[0406] A method of filling a cartridge is also provided. As Figure 90As explained above, the method can include providing, at operation 4002, a cartridge for an aerosol delivery device that includes a reservoir substrate positioned in an outer body. Further, the method can include sequentially positioning, at operation 4004, an outlet of a filling device proximate to a plurality of angular portions of the reservoir substrate. The method can additionally include directing, at operation 4006, a flow of aerosol precursor composition at each of the angular portions of the reservoir substrate through the outlet of the filling device.

[0407] In some embodiments, the outlet of the filling device can remain out of contact with the reservoir substrate. Further, the method can include transporting the cartridge between a plurality of filling stations, where a flow of aerosol precursor composition is directed to at least one of the angular portions of the reservoir substrate at each of the filling stations. Additionally, a flow of aerosol precursor composition can be directed at each of the angular portions of the reservoir substrate at a first one of the filling stations. A flow of aerosol precursor composition is directed to one of the angular portions of the reservoir substrate at the remaining ones of the filling stations, respectively. The method can further include controlling a surrounding environment in which the cartridge is filled such that the surrounding environment defines a relative humidity of less than about 40%.

[0408] Also provided are methods for assembling a cartridge for an aerosol delivery device. As Figure 91 As explained above, the method can include grasping, at operation 4102, a base. Further, the method can include providing, at operation 4104, a plurality of components configured to engage the base, the components being provided in a resting position. Additionally, the method can include coupling, at operation 4106, the components to the base by directing the base into contact with the components in the resting position.

[0409] Grasping, at operation 4102, the base can include grasping an inner surface of the base that is configured to engage an attachment end of a control body. Directing, at operation 4106, the base into contact with the components in the resting position can include directing the base downward into contact with the components. The method can further include inserting the base into a fixture and checking a position of first and second heating terminals coupled to the base by the fixture.

[0410] As described above, the system 400 can include a controller 417. The controller 417 can be configured to execute computer code for performing the operations described herein. In this regard, as Figure 92As described above, the controller 417 can include a processor 4202, which can be a microprocessor or a controller for controlling its overall operation. In one embodiment, the processor 4202 can be specifically configured to perform the functions described herein. The controller 417 can also include a memory device 204. The memory device 4204 can include non-transitory and tangible memory, which can be, for example, volatile and / or non-volatile memory. The memory device 4204 can be configured to store information, data, files, applications, instructions, or the like. For example, the memory device 4204 can be configured to buffer input data to be processed by the processor 4202. Additionally or alternatively, the memory device 4204 can be configured to store instructions for execution by the processor 4202.

[0411] The controller 417 can also include a user interface 4206 that allows a user to interact with it. For example, the user interface 4206 can take a variety of forms, such as a button, a keypad, a dial, a touch screen, an audio input interface, a visual / image capture input interface, input in the form of sensor data, etc. Further, the user interface 4206 can be configured to output information to the user through a display, a speaker, or other output device. A communication interface 4208 can provide for transmission and reception of data, such as through a wired or wireless network 4210, such as a local area network (LAN), a metropolitan area network (MAN), and / or a wide area network (WAN) (e.g., the Internet).

[0412] Various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling the above described operations. In particular, computer readable code can be configured to perform each of the operations described herein and embodied as computer readable code on a computer readable medium for controlling the above described operations. In this regard, the computer readable storage medium, as used herein, refers to a non-transitory physical storage medium such as volatile or non-volatile memory device. Examples of computer readable media include read-only memory, random access memory, CD-ROMs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over a network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion.

[0413] As described above, the controller 417 can be configured to execute computer code for performing the operations described above. In this regard, embodiments of a non-transitory computer-readable medium for storing computer instructions executed by a processor in a controller (e.g., the controller 417) configured to assemble a cartridge for an aerosol delivery device are provided. The non-transitory computer-readable medium can include program code instructions for providing a reservoir substrate extending at least partially around an atomizer; program code instructions for providing an outer body configured to at least partially receive the reservoir substrate and the atomizer therein; and program code instructions for inserting the reservoir substrate into the outer body by a tool defining a funnel portion configured to reduce an outer dimension of the reservoir substrate such that the outer dimension of the reservoir substrate is less than or equal to an inner dimension of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0414] The computer-readable medium can further include program code instructions for twisting the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body by the tool. The program code instructions for providing a reservoir substrate extending at least partially around an atomizer can include program code instructions for wrapping the reservoir substrate at least partially around the atomizer prior to inserting the reservoir substrate into the outer body by the tool. The program code instructions for wrapping the reservoir substrate at least partially around the atomizer can include program code instructions for directing an air flow at the reservoir substrate. The computer-readable medium can further include program code instructions for engaging the reservoir substrate with one or more fingers to cause the reservoir substrate to remain at least partially wrapped around the atomizer when beginning insertion of the reservoir substrate into the outer body by the tool. The computer-readable medium can further include program code instructions for releasing the one or more fingers from the reservoir substrate when the reservoir substrate is inserted into the tool to a predetermined depth. The program code instructions for releasing the one or more fingers can include program code instructions for deflecting the one or more fingers away from the reservoir substrate by contacting the one or more fingers with the tool. The program code instructions for releasing the one or more fingers can include program code instructions for releasing the fingers sequentially. The computer-readable medium can further include program code instructions for coupling the atomizer to a base prior to wrapping the reservoir substrate at least partially around the atomizer; and program code instructions for coupling the outer body to the base after inserting the reservoir substrate into the outer body by the tool. The computer-readable medium can further include program code instructions for feeding the reservoir substrate from a generally continuous reservoir substrate input; and program code instructions for controlling a tension in the generally continuous reservoir substrate input.

[0415] In an additional embodiment, a non-transitory computer-readable medium for storing computer instructions executed by a processor in a controller configured to assemble an atomizer for an aerosol delivery device (e.g., controller 417) can include program code instructions for providing a first heating terminal, a second heating terminal, and a heating element; program code instructions for determining a location of the first heating terminal and the second heating terminal; program code instructions for determining a location of the heating element; and program code instructions for attaching the heating element to the first heating terminal and the second heating terminal based on the location of the first heating terminal and the second heating terminal and the location of the heating element. The program code instructions for determining the location of the first heating terminal and the second heating terminal can include program code instructions for determining a midpoint between a first heating terminal tab and a second heating terminal tab.

[0416] In some embodiments, the heating element can include a first contact portion and a second contact portion, and the program code instructions for determining a position of the heating element can include program code instructions for determining a midpoint between the first contact portion and the second contact portion. The computer readable medium can further include program code instructions for aligning a midpoint between the first heating terminal tab and the second heating terminal tab with the midpoint between the first contact portion and the second contact portion; program code instructions for engaging the first contact portion with the first heating terminal tab; and program code instructions for engaging the second contact portion with the second heating terminal tab. The computer readable medium can additionally include program code instructions for clamping the first heating terminal and the second heating terminal such that the first heating terminal tab and the second heating terminal tab are substantially coplanar. The program code instructions for clamping the first heating terminal and the second heating terminal can include program code instructions for adjusting a spacing between the first heating terminal and the second heating terminal. The program code instructions for attaching the heating element to the first heating terminal and the second heating terminal can include program code instructions for directing a laser beam at the first heating terminal tab and the second heating terminal tab. The program code instructions for directing the laser beam at the first heating terminal tab and the second heating terminal tab can include program code instructions for directing the laser beam at a backside of the first heating terminal tab and the second heating terminal tab opposite the heating element. The computer readable medium can further include program code instructions for inserting the heating element, the first heating terminal, and the second heating terminal into a substantially sealed chamber prior to directing the laser beam at the first heating terminal tab and the second heating terminal tab. The program code instructions for providing the heating element can include program code instructions for supplying the heating element from a substantially continuous heating element input; and program code instructions for controlling a tension in the substantially continuous heating element input. The computer readable medium can further include program code instructions for coupling the heating element to a liquid transport element. The program code instructions for coupling the heating element to the liquid transport element can include program code instructions for inserting an end of the heating element through the liquid transport element; and program code instructions for rotating at least one of the heating element and the liquid transport element such that the heating element is wound around the liquid transport element. The program code instructions for providing the first heating terminal and the second heating terminal can include program code instructions for supplying the first heating terminal from a substantially continuous first heating terminal input; and program code instructions for supplying the second heating terminal from a substantially continuous second heating terminal input. The heating element can include a wire wound around the liquid transport element.The lead can include two contact portions, a center portion, and two outer portions positioned outside the contact portions, the two contact portions and the center portion of the lead can define a heating element, wherein the contact portions define a first coil spacing, the center portion defines a second coil spacing, and the outer portions define a third coil spacing, the third coil spacing being greater than the second coil spacing, and the second coil spacing being greater than the first coil spacing, and wherein attaching the heating element to the first and second heating terminals includes attaching the contact portions to the first and second heating terminals.

[0417] In an additional embodiment, a non-transitory computer-readable medium for storing computer instructions executed by a processor in a controller configured to fill a cartridge (e.g., controller 417) can include program code instructions for providing a cartridge for an aerosol delivery device, the cartridge including a reservoir substrate positioned in an outer body; program code instructions for sequentially positioning an outlet of a filling device proximate to a plurality of angular portions of the reservoir substrate; and program code instructions for directing a flow of aerosol precursor composition at the outlet of the filling device at each of the angular portions of the reservoir substrate. The outlet of the filling device can remain out of contact with the reservoir substrate. The computer-readable medium can further include program code instructions for transporting the cartridge between a plurality of filling stations, wherein the flow of aerosol precursor composition is directed to at least one of the angular portions of the reservoir substrate at each of the filling stations. The flow of aerosol precursor composition can be directed at each of the angular portions of the reservoir substrate at a first one of the filling stations. The flow of aerosol precursor composition can be directed to one of the angular portions of the reservoir substrate at each of the remaining ones of the filling stations, respectively. The computer-readable medium can further include program code instructions for controlling a surrounding environment in which the cartridge is filled such that the surrounding environment defines a relative humidity of less than about 40%.

[0418] In an additional embodiment, a non-transitory computer-readable medium for storing computer instructions executed by a processor in a controller (e.g., controller 417) configured to assemble a cartridge for an aerosol delivery device can include program code instructions to grasp a base; program code instructions to provide a plurality of components configured to engage the base, the components provided in a resting position; and program code instructions to couple the components to the base by directing the base into contact with the components in the resting position. The program code instructions to grasp the base can include program code instructions to grasp an inner surface of an attachment end of the control body configured to engage the base. The program code instructions to direct the base into contact with the components in the resting position can include program code instructions to direct the base downward into contact with the components. The computer-readable medium can further include program code instructions to insert the base into a fixture; and program code instructions to check a position of first and second heating terminals coupled to the base by the fixture.

[0419] Many modifications and other embodiments of the present disclosure set forth herein will come to mind to one skilled in the art to which the present disclosure pertains having the benefit of the teachings presented in the foregoing description and the associated drawings. Therefore, it is to be understood that the present disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A cartridge filling method, comprising: providing a cartridge for an aerosol delivery device, the cartridge comprising a reservoir substrate positioned in an outer body; sequentially positioning an outlet of a filling device proximate to a plurality of angular portions of the reservoir substrate; and directing a flow of aerosol precursor composition at each of the angular portions of the reservoir substrate through the outlet of the filling device.

2. The cartridge filling method of claim 1, further comprising transporting the cartridge between a plurality of filling stations, wherein the flow of aerosol precursor composition is directed to at least one of the angular portions of the reservoir substrate at each of the filling stations.

3. The cartridge filling method of claim 2, wherein the flow of aerosol precursor composition is directed at each of the angular portions of the reservoir substrate at a first one of the filling stations.

4. The cartridge filling method of claim 3, wherein the flow of aerosol precursor composition is directed to one of the angular portions of the reservoir substrate at each of the remaining ones of the filling stations, respectively.

5. The cartridge filling method of any one of claims 1-4, wherein the outlet of the filling device remains out of contact with the reservoir substrate.

6. The cartridge filling method of any one of claims 1-4, further comprising controlling a surrounding environment in which the cartridge is filled such that the surrounding environment defines a relative humidity of less than 40%.

7. The cartridge filling method of claim 3, wherein sequentially positioning the outlet of the filling device proximate to the plurality of angular portions of the reservoir substrate comprises sequentially positioning a filling needle proximate to the plurality of angular portions defined with respect to a longitudinal axis extending through the cartridge.

8. The cartridge filling method of claim 5, further comprising the filling device pressing against an inner surface of the outer body as each angular portion is filled.

9. A system for filling a cartridge of an aerosol delivery device with an aerosol precursor composition, the system comprising: an environmental control enclosure; one or more filling stations disposed within the environmental control enclosure; and a controller configured to control operation of the one or more filling stations to sequentially dispense the aerosol precursor composition to a reservoir substrate positioned in an outer body of the cartridge at different angular portions.

10. The system of claim 9, wherein each filling station comprises a filling device.

11. The system of claim 9 or 10, wherein the environmental control enclosure comprises a dehumidifier.

12. The system of any one of claims 9-11, further comprising a controller configured to maintain a surrounding environment in the environmental control enclosure at a relative humidity of less than 60%.

13. The system of claim 12, wherein the controller is further configured to control operation of the one or more filling stations to sequentially dispense the aerosol precursor composition at different angular portions. ​ 14. The system of any of claims 9-12, wherein the one or more filling stations comprises five filling stations.

15. The system of any of claims 9-14, wherein each of the filling stations comprises a source of aerosol precursor composition.

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