Consumable and method of manufacturing a consumable

Abstract

An apparatus for securing a closure to a container of a consumable unit for use with an inhalation device is disclosed, wherein the container includes a plurality of pegs protruding from the container. The apparatus includes a device configured to deform the plurality of pegs to secure the closure to the container. A method for securing a closure to a container of a consumable unit for use with an inhalation device is also disclosed, wherein the method includes deforming a plurality of pegs to secure the closure to the container.

Description

Technical Field

[0001] This invention relates to an apparatus and method for manufacturing a consumable unit for an inhalation device, and particularly, but not limited to, an apparatus and method for manufacturing a tobacco pod comprising particulate tobacco material for use in an inhalation device. The invention also relates to a consumable unit for an inhalation device, such as a consumable unit comprising particulate tobacco material for use with an inhalation device. Background Technology

[0002] JP2011182710A discloses an apparatus for filling a small container with tobacco material, the container being a consumable unit for an inhalation device. The filling apparatus includes a screw that dispenses a measured amount of tobacco material into a funnel, and a conduit that guides the tobacco material from the funnel to the open end of the container. A suction conduit is positioned at the opposite end of the container to draw air out of the container, thereby ensuring that the tobacco material enters the container.

[0003] There is a need for a reliable and rapid filling of chambers with particulate tobacco material to provide efficient manufacturing of consumable units for inhalation devices. Summary of the Invention

[0004] According to an embodiment of the invention, a device is provided for securing a closure to a container of a consumable unit for use with an inhalation device, the container including a plurality of posts protruding from the container;

[0005] The device includes a means configured to deform multiple piles to secure the closure to the container.

[0006] The device may include an extruder configured to deform a plurality of piles. The device may further include an actuator arranged to move the extruder.

[0007] In some examples, the device may include multiple extruders to deform the piles of multiple containers simultaneously.

[0008] The device may include a first extruder having a preliminary extrusion surface configured to partially deform and flip a plurality of piles toward a closure. The device may further include a second extruder configured to complete the deformation of the plurality of piles against the closure. The device may be configured such that the first and second extruders act sequentially on the container.

[0009] The first extrusion member may include a recessed extrusion surface. For example, the recessed extrusion surface may be at an angle of approximately 45 degrees to the closure. The second extrusion member may include a flat extrusion surface. In this way, the first extrusion member deforms the pile at approximately 45 degrees, and the second extrusion member deforms the remaining portion of the pile to secure the closure to the container.

[0010] In some examples, the device may include an extrusion head, and a first extruder and a second extruder may be disposed on the extrusion head. For example, the first extruder and the second extruder may be arranged adjacent to each other on the extrusion head.

[0011] In some examples, the device may include a first extrusion head and a second extrusion head, the first extrusion head being disposed on the first extrusion head and the second extrusion head being disposed on the second extrusion head. The first extrusion head may have a first actuator, and the second extrusion head may have a second actuator. In this way, the first extrusion head can move independently of the second extrusion head.

[0012] In other examples, the first extruder may include a hole, and the second extruder may be movably disposed within the hole. In this way, the first and second extruders are arranged concentrically and can move independently of each other.

[0013] The device may further include a heater arranged to heat the extruded member. In other examples, particularly when the closure comprises metal, the device may include an induction heater arranged to heat the closure. Heating the closure will heat the pile portion adjacent to the closure.

[0014] The equipment may further include support members arranged to support containers. The support members may include rails for supporting a machine pallet. The machine pallet may be adapted to support multiple containers.

[0015] The device may further include a closure positioning station configured to position the closure on the container before the device deforms the multiple piles.

[0016] In the example, the closure is fed into the closure positioning station in the closure support net, and the closure positioning station may include a stamping machine arranged to separate the closure from the closure support net and move the closure into the container.

[0017] According to a further aspect of the invention, a method is provided for securing a closure to a container of a consumable unit for use with an inhalation device, the container including a plurality of studs protruding from the container;

[0018] The method includes deforming multiple piles to secure the closure to the container.

[0019] This method may include simultaneously deforming multiple piles of multiple containers.

[0020] Deformation of multiple piles may include bending multiple piles.

[0021] For example, deforming multiple piles may include: first using a first extruder to partially bend and flip the multiple piles toward the closure; and then using a second extruder to bend the multiple piles against the closure.

[0022] The method may further include positioning the closure on the container.

[0023] The method may further include providing a dose of aerosolizable material to the container before positioning the closure on the consumable unit. The aerosolizable material may include tobacco. The aerosolizable material may include particulate material, such as particulate tobacco material.

[0024] According to a further aspect of the invention, a consumable unit for use with an inhalation device is also provided, the consumable unit comprising a container including a closure secured to the container according to the method described above. The consumable unit may additionally include a dose of aerosolizable material within the container. Attached Figure Description

[0025] Embodiments of the invention will be described by way of example only with reference to the accompanying drawings, in which:

[0026] Figure 1 An inhalation device including a consumable unit is shown;

[0027] Figure 2A and Figure 2B It shows Figure 1 Consumable units of the inhalation device;

[0028] Figure 3A It shows Figure 2A and Figure 2B Consumable units in which the closure is removed;

[0029] Figure 3B It shows Figure 3A A schematic diagram of a consumable unit, which is provided with particulate material and a closure;

[0030] Figure 4 It shows the manufacturing process. Figure 2A and Figure 2B A schematic diagram of a device with consumable units;

[0031] Figure 5A and Figure 5B It shows the method for passing through Figure 4 The equipment is used to support the machine trays containing consumable units;

[0032] Figure 6A and Figure 6B A metered feeding station for supplying particulate material to consumable units is shown;

[0033] Figures 7A to 7C It shows Figure 6A and Figure 6B The fixed-dose feeding mechanism at the fixed-dose feeding station;

[0034] Figure 8A and Figure 8B A closure positioning station is shown for positioning the closure on each consumable unit;

[0035] Figure 9 It shows the use of with Figure 8A and Figure 8B The enclosure support mesh used together with the enclosure positioning station;

[0036] Figure 10 It shows Figure 8A and Figure 8B A stamping machine for positioning closed components;

[0037] Figure 11 A closure securing station is shown for securing the closure to a consumable unit;

[0038] Figure 12 It shows Figure 11 A schematic diagram of the operation of the first example of the sealing component fixing station; and

[0039] Figure 13 It shows Figure 11 A schematic diagram of the operation of the second example of the fixed station for the closure component. Detailed Implementation

[0040] This patent specification discloses apparatus and methods for manufacturing consumable units for inhalation devices. In particular, this patent specification discloses apparatus and methods for manufacturing consumable units for delivering vapor generated in the inhalation device under non-combustion conditions.

[0041] In the embodiments disclosed herein, the inhalation device includes: an operating unit having a size and shape suitable for being held by an adult consumer; an atomizer cartridge removably attached to the operating unit having an atomizer for atomizing a consumable liquid held in the cartridge; a tobacco chamber removably attached to the cartridge having a container and mouthpiece containing a charge of an aerosolizable material (e.g., particulate tobacco material); and a closure for retaining the particulate tobacco material within the container.

[0042] When the atomizer cartridge and tobacco chamber need to be replaced, i.e. when the consumable liquid runs out, or when the tobacco in the tobacco chamber runs out, the user can replace the atomizer cartridge and tobacco chamber separately.

[0043] In use, as the consumer inhales air through the inhalation device, the operating unit, under the consumer's control, delivers energy to the atomizer cartridge. The liquid in the atomizer cartridge is atomized to form an aerosol, and the particulate tobacco material in the tobacco chamber is volatilized, releasing volatile flavors. Therefore, the air inhaled from the inhalation device delivers the aerosol of the atomized liquid, along with vapor generated by heating the particulate tobacco material in the tobacco chamber, from the atomizer cartridge to the consumer. A wide range of combinations of vaporizable tobacco material and consumable liquid components can be selected to deliver flavors appealing to the consumer.

[0044] As described above, this specification relates to apparatus and methods for manufacturing a tobacco capsule for an inhalation device. However, it should be understood that in alternative inhalation devices, the particulate tobacco material may be replaced by an alternative particulate vaporizable material. For example, the particulate vaporizable material may be particulate plant material. The apparatus and methods described below are not limited to the particulate material in the tobacco capsule, and therefore the tobacco capsule will be referred to as a consumable unit containing particulate material.

[0045] refer to Figure 1 The inhalation device 1 has three hollow sections made of molded plastic material: a body 2, which contains the operating system and mechanisms for the device; an atomizer cartridge 3, which contains a volatile liquid flavoring substance; and a consumable unit 4, which contains a dose of particulate material that generates an aerosol when heated. These three sections are removably connected to each other, such that the atomizer cartridge 3 and the consumable unit 4 can be disconnected from each other and from the body 2, allowing replacement consumable unit 4 and atomizer cartridge 3 to be fitted into the body 2.

[0046] The body 2 has a generally cylindrical shape, elongated in the axial direction and flattened so that it can be comfortably held in the hand of an adult consumer. The body 2 is formed of two axially aligned hollow molded sections (upper section 2a and lower section 2b). The upper section 2a of the body 2 has an open upper end and a closed lower end wall 5, which define a recess for receiving the atomizer cartridge 3. The lower section 2b of the body is isolated from the upper section 2a by the lower end wall 5 of the upper section 2a to provide a firewall. The lower section 2b of the body 2 contains a battery, an electronic circuit board, an inhalation sensor, and other operating components not shown here, which can be activated by an operating button 6 on one side of the body. A light housed in an opening in the body 2 indicates the operating status of the inhalation device 1.

[0047] The atomizer cartridge 3 is removably connected to the body 2 via a push-fit connection into a recess in the upper body section 2a, and tapers toward the upper outlet 3a of the atomizer cartridge 3 in an axial direction away from the body 2. The atomizer cartridge 3 includes a reservoir filled with volatile liquid flavoring substances and a heating element for evaporating the liquid, the power supply from the battery in the body 2 to the heating element being controlled by operating button 6.

[0048] The consumable unit 4 is removably connected to the atomizer cartridge 3 via a push-in engagement connection into the upper outlet 3a of the atomizer cartridge 3. The outer surface of the consumable unit 4 forms a skirt-like portion that continues the tapered shape of the atomizer cartridge 3 in the axial direction toward the vapor outlet 7, which is configured to be comfortably held in the consumer's mouth.

[0049] As in Figure 2A and Figure 2B As shown, the consumable unit 4 includes an inlet component 8 and an axially extending open-end container 9. In this example, the container 9 has an elliptical radial cross-section. One end of the container 9 is located within the skirt-like portion 10 of the inlet component 8 and terminates in a connector 11, which is received within a socket 12 having a complementary shape, the socket 12 being formed on the inner surface of the inlet component 8 upstream of the vapor outlet 7.

[0050] The mouth part 8 can be attached to the container 9 by ultrasonic welding, induction welding or any other suitable method. Alternatively, the mouth part 8 and the container 9 can be integrally formed, for example, by injection molding.

[0051] In this embodiment, an internally perforated screen 13, integrally molded with the container 9, extends radially throughout the container 9 to define a vapor-permeable baffle throughout the container 9 at a short distance upstream of the vapor outlet 7. (As in...) Figure 2B As shown, the internal perforated mesh 13 extends throughout the interior end of the container 9. The other end 15 of the container 9 protrudes from the skirt-like portion 10 of the opening member 8 and is provided with a closure 14. In this example, the closure 14 is in the form of a perforated mesh. The closure 14 is constructed of, for example, a mesh, sheet, or molded part of a plastic material.

[0052] In an alternative example, the internal perforated screen 13 is integrally molded to the mouth part 8 and positioned to cover the ends of the container 9 when the mouth part 8 is combined with the container 9.

[0053] An internal perforated screen 13 and a closure 14 define the end walls of a chamber 16 within the container 9, in which a controlled dose of particulate material is held. The perforations in the internal perforated screen 13 and the closure 14 allow vapor to pass axially downstream through the chamber 16 toward the inlet component 8 and the vapor outlet 7. The size of the perforations is selected relative to the particle size of the particulate material to prevent particles from falling out of the container 9 or being drawn into the inlet component 8 with the inhaled vapor.

[0054] In use, the consumer turns on the inhalation device 1 using the operation button 6 and inhales the vapor drawn from the inhalation device 1 through the mouthpiece 8. Upon activation, the electronic system within the main body 2 sufficiently heats the air in the inhalation device 1 and the liquid in the atomizer cartridge 3 to induce atomization. The heated air causes the flavor substances from the particulate material in the container 9 to volatilize, and also entrains the atomized liquid flavor substances from the atomizer cartridge 3. Thus, the combination of flavor substances is delivered to the consumer as an aerosol for inhalation.

[0055] The method of manufacturing consumable unit 4 includes accepting in Figure 3A The empty consumable unit shown has chamber 16 empty and closure 14 absent, such that end 15 of chamber 16 is open. Figure 3B The method schematically illustrated includes: supplying a dose of particulate material 17 to a chamber 16 through an opening 15 of the chamber; positioning a closure 14 over the end 15 of the chamber 16; and then securing the closure 14 to the container 9. (As shown in...) Figure 3A As shown, container 9 includes a plurality of pilings 18 that initially project axially from end 15 of container 9. A closure 14 is received between these pilings 18, and as shown in... Figure 2A and Figure 2B As shown, the pile 18 is then bent and flipped onto the closure 14 to secure the closure 14 to the container 9.

[0056] Specifically, such as in Figure 3A As shown, the container 9 defining the chamber 16 includes an end 15, and a post 18 projectes axially from the radial edge 19 of the end 15, such that a lip 20 is defined at the end of the container 9. As in Figure 2B As shown, the closure 14 is positioned against the lip 20, and the post 18 is bent and flipped onto the outside of the closure 14, thereby securing the closure 14 to the container 9.

[0057] As shown, the piles 18 are spaced apart around the radial edge 19 of the container 9, and the gaps between the piles 18 allow them to fold and flip without colliding. The piles 18 may have different dimensions (widths). Narrower piles 18 are preferably positioned at the portion of the radial edge 19 of the container 9 with a smaller radius, making it easier for the piles 18 to bend and flip, as there will be lower stress and strain at the point where the piles 18 bend.

[0058] Figure 4 A reference for manufacturing is shown. Figures 2A to 3B A schematic diagram of the device 21 for the described consumable unit 4 is shown, specifically the consumable unit 4 including the mouth part 8 and the container 9 for holding the particulate material 17. The illustrated device 21 includes equipment for performing the following method steps:

[0059] The particulate material 17 is fed in a fixed dose into the chamber 16 of the consumable unit 4.

[0060] Position the closure 14 onto the container 9 of the consumable unit 4, and

[0061] Secure the closure 14 to the container 9.

[0062] As in Figure 4 As shown, the first step is an empty consumable unit 4 at input 22. The consumable unit 4 is presented at input 22. Figure 3A As shown in the diagram. Specifically, the empty consumable unit 4 includes a port component 8 and a container 9 with an open end 15 at the input 22. The container 9 includes as shown in... Figure 3A The protruding stake 18 shown is used to secure the closure 14 after the granular material 17 has been placed in the chamber 16.

[0063] After the input of the empty consumable unit 4, the dosage feeding station 23 supplies a specific dose of granular material 17 to the chamber 16 of the consumable unit 4. Next, the closure positioning station 24 positions the closure 14 above the end 15 of the container 9. Then, the closure fixing station 25 fixes the closure 14 to the container 9. Specifically, the closure fixing station 25 bends and flips the stake 18 to abut against the closure 14 to fix the closure 14 to the container 9, as in Figure 2A and Figure 2B As shown in the diagram. The consumable unit 4 is constructed using particulate material 17, as in... Figure 2A and Figure 2B As shown in the diagram, and then output from device 21.

[0064] In the described device 21, the dosing station 23, the closure positioning station 24, and the closure fixing station 25 are each separate and arranged adjacent to each other, and the consumable unit 4 can move sequentially between stations 23, 24, and 25. The consumable unit 4 can be moved manually or on a conveyor. The use of a conveyor allows for automated manufacturing. For example, the conveyor can be a so-called "smart conveyor," which allows for independent control of individual carriers along the conveyor track. An example of such a conveyor is the XTS series conveyor from Beckhoff. In the example using a conveyor, the dosing station 23, the closure positioning station 24, and the closure fixing station 25 can be arranged such that the consumable unit 4 moves linearly through the dosing station 23, the closure positioning station 24, and the closure fixing station 25.

[0065] In other examples, the dosing station 23, the closure positioning station 24, and the closure fixing station 25 may be arranged around a single location where the consumable unit is placed, and each station 23, 24, 25 may sequentially perform its function on the consumable unit 4. In a further example, one or more of stations 23, 24, 25 may be combined such that a single station has the function of performing a reference... Figure 4 One or more tools in the described process. For example, tools for one or more of the dosing station 23, the closure positioning station 24, and the closure fixing station 25 may be arranged on a rotary table, and the consumable unit 4 may be placed below the rotary table, which rotates to align each part of the tool.

[0066] Each of the following stations will now be described in further detail: the dosing station 23, the closure positioning station 24, and the closure fixing station 25.

[0067] Figure 5A and Figure 5B A machine tray 27 holding multiple consumable units 4 is shown. At input 22 of device 21, the machine tray 27 is provided with multiple empty consumable units 4, and the machine tray 27 is then moved via a reference. Figure 4 The described device 21 provides a dose of particulate material 17 to the consumable unit 4, and while the consumable unit 4 is held in the machine tray 27, the closure 14 is positioned and secured.

[0068] The machine tray 27 holds the consumable units 4 in an upright orientation, with the open end 15 of the container 9 pointing vertically upwards, allowing the supply of particulate material 17 to them, and the closure 14 can be positioned and secured. As shown in Figure 5A, the machine tray 27 includes an array of support recesses 28, each of which is shaped to receive and support the consumable units 4. In particular, as in Figure 5B As shown, each support recess 28 is shaped to receive and support the mouth part 8 of the consumable unit 4, such that the end 15 of the opening of the container 9 points upward.

[0069] Optionally, the machine pallet 27 may include one or more handles for manually lifting and moving the machine pallet 27. Alternatively, if the equipment 21 includes a conveyor, as previously described, the machine pallet 27 may be mounted to the conveyor for movement through the equipment 21. The machine pallet 27 may be detachably mounted to such a conveyor.

[0070] Figure 6A and Figure 6B The diagram shows a dosing station 23 for feeding particulate material 17 into each of the containers 9 of the consumable unit 4.

[0071] The dosing station 23 includes a machine tray support 29, which includes components for supporting the feed. Figure 5A The machine tray 27 and the rails 30 supporting the multiple consumable units 4 are shown. The machine tray 27 can be inserted into the dosing station 23 by sliding it onto the rails 30 on the opposite side supporting the machine tray 27. The machine tray support 29 also includes a stop against which the machine tray 27 abuts when inserted into the machine tray support 29. The machine tray support 29 ensures that the machine tray 27 and the consumable units 4 are accurately and reliably positioned and supported within the dosing station 23.

[0072] The dosing station 23 may include a proximity switch that confirms that the machine tray 27 has been properly positioned on the machine tray support 29. Alignment pins may be provided additionally or alternatively to ensure correct positioning.

[0073] The dosing station 23 also includes a movable shelf 31. The movable shelf 31 is slidably mounted on the support column 33 via a sliding support 34, allowing it to move upward and downward relative to the machine tray support 29 and relative to the machine tray 27 and the consumable unit 4. An actuator (not shown) may be provided to move the movable shelf 31, or it may be moved manually, for example, via a handle 32. The movable shelf 31 is positioned above the machine tray support 29. The movable shelf 31 includes a dosing feeding mechanism 35 for dosing granular material into the container 9 of the consumable unit 4 on the machine tray 27, as further explained below. The movable shelf 31 is movable between a disengaged position and an engaged position. In the engaged position, the movable shelf 31 is close to the machine tray 27 and the consumable unit 4, positioned for dosing granular material 17 into the container 9. In the disengaged position, the movable shelf 31 is spaced apart from the machine tray 27 and the consumable unit 4, such that the machine tray 27 can be inserted into or removed from the machine tray support 29.

[0074] The fixed-dose feeding station 23, particularly the fixed-dose feeding mechanism 35, simultaneously feeds the granular material 17 into multiple containers 9 on the machine tray 27 in a fixed dose. Preferably, the fixed-dose feeding station 23 simultaneously feeds the granular material 17 into all containers 9 on the machine tray 27 in a fixed dose.

[0075] exist Figures 7A to 7C The dosing mechanism 35 shown is embedded in the movable shelf 31 (also in...) Figure 6A and Figure 6B (As shown in the diagram), the dosing mechanism 35 includes a hopper component 36, which includes a hopper 37 in which particulate material 17 is received. The hopper 37 has a planar lower wall 38, which includes an array of openings 39 extending through the lower wall 38. The array of openings 39 in the hopper 37 corresponds to an array of consumable units 4 held in the machine tray 27, as shown in the diagram. Figure 5A As shown in the diagram, the hopper 37 includes an inclined surface 40 between openings 39, such that the particulate material 17 is guided toward the openings 39. Figure 6B The vibrator 41 shown can be attached to the hopper component 36 or the movable shelf 31 to vibrate the hopper component 36 and ensure that the particulate material 17 is not blocked or bridged, and to cause the particulate material 17 to move into the opening 39.

[0076] The lower wall 38 of the hopper 37 is flat, and below the lower wall 38 is a dose feeder, which in this example is a dose feed plate 42. The dose feed plate 42 is slidably mounted and can be accessed via... Figure 7B The position shown is in Figure 7A The position shown and in Figure 7C The feed plate 42 slides linearly between the positions shown. The dosing plate 42 includes an array of dosing chambers 43 corresponding to openings 39 in the hopper 37 and an array of consumable units 4 in the machine tray 27. Figure 6B The figure shows an actuator 44 for moving the fixed-dose feed plate 42. The actuator 44 is arranged to move the fixed-dose feed plate 42 parallel to the machine tray 27 held in the machine tray support 29 below the movable shelf 31 in the plane of the fixed-dose feed mechanism 35 and the movable shelf 31.

[0077] Alignment member 45 is positioned below the dose-controlled feed plate 42. Alignment member 45 also has an array of openings 46 corresponding to openings 39 in hopper 37, dose-controlled feed cavities 43 in dose-controlled feed plate 42, and arrays of consumable units 4 in machine tray 27. (As in...) Figures 7A to 7C As shown, the opening 46 in the alignment member 45 is aligned with the container 9 of the consumable unit 4 in the machine tray 27. The alignment member 45 is in a fixed position on the movable shelf 31 and does not move with the dosing feed plate 42. As shown, the opening 46 in the alignment member 45 is offset from the opening 39 in the hopper 37.

[0078] In a preferred embodiment, the alignment member 45 engages the container 9 of the consumable unit 4, particularly the end 15 of the container 9 where the peg 18 is located, as in Figure 3A As shown in the diagram. After the machine tray 27 is inserted into the machine tray support 29, the movable shelf 31 can be moved downward to an engaged position such that the alignment member 45 engages the container 9. The underside of each opening 46 in the alignment member 45 may include a recess to engage the container 9. Preferably, the opening 46 is smaller than the container 9 (e.g., smaller in diameter) such that the flow of the particulate material 17 is guided into the container 9 without getting stuck at the edge of the container 9. Alternatively, the opening 46 in the alignment member 45 may be larger than the container 9 such that the container 9 is inserted into the opening 46. Alternatively, in the engaged position of the movable shelf 31, the alignment member 45 is positioned close to the container 9.

[0079] Figures 7A to 7C The dosage feeding mechanism 35 is schematically shown. It should be understood that the plates (hopper plate, dosage feeding plate 42, alignment member 45) will abut against each other during use, or plates 42 and 45 will be closely adjacent to each other, and therefore will not have the same... Figures 7A to 7C The gap is as shown.

[0080] The operation of the dosing feeding mechanism 35 will now be described. Figure 7AThe initial position of the dosing feed plate 42 is shown when the machine tray 27 and consumable unit 4 are first inserted into the dosing feed station 23. As explained above, the particulate material 17 is placed in the hopper 37 and moves downward into the opening 39 due to gravity and optionally with the aid of vibration from the vibrator 41. Figure 7A The initial position is not aligned with the opening 39 in the hopper 37 because the fixed-dose feeding chamber 43 in the fixed-dose feeding plate 42 is not aligned with the opening 39 in the hopper 37. Therefore, the fixed-dose feeding plate 42 prevents the particulate material 17 from leaving the opening 39 in the hopper 37.

[0081] Next, as in Figure 7B As shown, the fixed-dose feed plate 42 is actuated by the actuator (44, see...) Figure 6B The feed plate 42 moves so that the feed chamber 43 in the feed plate 42 is aligned with the opening 39 in the hopper 37. In this position, the particulate material 17 can move downwards into the feed chamber 43 in the feed plate 42. It should be understood that the particulate material 17 from the hopper 37 will completely fill the feed chamber 43 in the feed plate 42. From the vibrator (41, see...) Figure 6B The vibration can facilitate and promote the movement of particulate material 17 into the fixed-dose feeding chamber 43 of the fixed-dose feeding plate 42.

[0082] Once the particulate material 17 has filled the dose-feeding cavity 43 in the dose-feeding plate 42, the dose-feeding plate 42 is moved to... Figure 7C The position shown is such that the dose-feeding chamber 43 in the dose-feeding plate 42 is aligned with the opening 46 in the alignment member 45, thereby allowing the particulate material 17 to fall into the container 9 through the opening 46 in the alignment member 45. In this way, the particulate material 17 is dosed into the container 9.

[0083] When the fixed-dose feed plate 42 is in Figure 7C The position shown returns to the location in Figure 7A When it is shown in the position, it passes through Figure 7B As shown in the diagram, some particulate material 17 can move into the dose-feeding chamber 43 of the dose-feeding plate 42. As described above, at the start of the next dose-feeding process, the dose-feeding plate 42 moves to... Figure 7B The position. This arrangement is advantageous because it ensures that a full dose of particulate material 17 is provided to the dose-feeding chamber 43 of the dose-feeding plate 42 (because the dose-feeding chamber 43 is exposed to the hopper 37 twice to fill the particulate material 17).

[0084] In the alternative arrangement, the fixed-dose feed plate 42 is in Figure 7B The position shown and in Figure 7C Move between the positions shown, where Figure 7B At the position shown, a certain dose of particulate material 17 is received in the fixed-dose feeding chamber 43, wherein... Figure 7C As shown in the diagram, the particulate material 17 is transferred to the consumable unit 4 through the opening 46 in the alignment member 45. That is, the pre-dose feed plate 42 does not necessarily have to be moved to the position shown in the diagram. Figure 7A The position shown in the figure.

[0085] In some examples, the fixed-dose feed plate 42 is from... Figure 7C The position shown is moved a short distance, and then moved back to the position indicated. Figure 7C The position is shown in the diagram. This action ensures that the granular material 17 is shaken or knocked out of the dose-feeding chamber 43 in the dose-feeding plate 42. The dose-feeding plate 42 can be struck against a hard stop to knock out the granular material 17. Such a knocking action may be beneficial if the granular material 17 comprises tobacco, because the granular tobacco material may have a variable particle size, may be sticky, and may tend to agglomerate.

[0086] The volume of each dose-prep chamber 43 in the dose-prep plate 42 is matched to the volume of particulate material 17 to be dosed into each container 9 of the consumable unit 4. In this way, one cycle of movement of the dose-prep plate 42 provides the desired dose of particulate material 17 to each consumable unit 4. Alternatively, the volume of each dose-prep chamber 43 in the dose-prep plate 42 may be half the volume of particulate material 17 to be dosed into each container 9 of the consumable unit 4, and the dose-prep process is repeated twice for each tray with a consumable unit 4 inserted into the dose-prep station 23. In other examples, the volume may be one-third or one-quarter, thus requiring three or four doses respectively. The thickness of the dose-prep plate 42 may be varied to provide doses of different volumes.

[0087] In some examples, the size (e.g., diameter) of the pre-dose feeding chamber 43 is larger than the size (e.g., diameter) of the opening 39 in the hopper 37. This prevents any edge of the pre-dose feeding plate 42 from obstructing the flow of particulate material 17 into the pre-dose feeding chamber 43. Similarly, the opening 46 in the alignment member 45 may be larger than the pre-dose feeding chamber 43 (e.g., having a larger diameter) so that the flow of particulate material 17 from the pre-dose feeding chamber through the opening 46 in the alignment member 45 is unobstructed.

[0088] In some examples, the number of openings 39, the dosing chamber 43, and the openings 46 are doubled, and they are arranged on the dosing plate 42. Figure 7B The position shown and in Figure 7CThe distance between the positions shown is half the distance of movement. In this way, there are two sets of openings 39, the constant-dose feeding chamber 43, and the opening 46 spaced half a distance apart from each other. Therefore, when one set of openings 39, the constant-dose feeding chamber 43, and the opening 46 is in the position... Figure 7B When the position shown is such that the other set of openings 39, the fixed-dose feeding chamber 43, and the opening 46 are in the position shown, Figure 7C The location is shown in the figure. In this way, more containers 9 can be dosed with particulate material 17 in fewer operations.

[0089] An inspection unit may be positioned at the dosing station 23 for inspecting the consumable units 4 in the machine tray 27. In one example, when the machine tray 27 is removed from the dosing station 23 after the dosing of the granular material 17, an optical scanning system may perform height measurements throughout the machine tray 27, and the inspection system may determine the filling height of the granular material 17 in each container 9 to ensure that sufficient granular material 17 has been dosed into each container 9.

[0090] Figure 8A and Figure 8B The closure positioning station 24 is shown. This closure positioning station 24 positions the closure 14 on each consumable unit 4, on the lip 20, and between the piles 18, as shown in... Figure 3A As shown in the diagram.

[0091] The closure positioning station 24 includes a machine pallet support 29 similar to the one described above for the dosing feed station 23. Specifically, the machine pallet support 29 includes components for supporting the feeder. Figure 5A The machine tray 27 and the rails 30 supporting the multiple consumable units 4 are shown. The machine tray 27 can be inserted into the closure positioning station 24 by sliding it onto the rails 30 on the opposite side supporting the machine tray 27. The machine tray support 29 also includes a stop against which the machine tray 27 abuts when inserted into the machine tray support 29. The machine tray support 29 ensures that the machine tray 27 and the consumable units 4 are accurately and reliably positioned and supported within the closure positioning station 24.

[0092] The closure positioning station 24 may include a proximity switch that confirms that the machine tray 27 has been properly positioned on the machine tray support 29. Alignment pins may be provided additionally or alternatively to ensure correct positioning.

[0093] The closure positioning station 24 also includes a movable shelf 31 similar to the movable shelf 31 of the dosing feed station 23. Specifically, the movable shelf 31 is slidably mounted on the support column 33 via a sliding support 34, allowing the movable shelf 31 to move upward and downward relative to the machine pallet support 29 and relative to the machine pallet 27 and the consumable unit 4. An actuator 47 may be provided to move the movable shelf 31, or it may be moved manually, for example, by a handle. The movable shelf 31 is positioned above the machine pallet support 29.

[0094] The movable shelf 31 of the closure positioning station 24 includes a closure positioning mechanism 48 that positions the closure 14 onto each container 9 on the machine pallet 27, as further explained below. The movable shelf 31 is movable between a disengaged position and an engaged position. In the engaged position, the movable shelf 31 is close to the machine pallet 27 and the consumable unit 4, positioned for positioning the closure 14 onto each container. In the disengaged position, the movable shelf 31 is spaced apart from the machine pallet 27 and the consumable unit 4, allowing the machine pallet 27 to be inserted into and removed from the machine pallet support 29.

[0095] Closure 14 in closure support mesh 50 (in Figure 9 (As shown) is provided to the closure positioning station 24. The closure support net 50 includes a support structure 51 and a plurality of closures 14 arranged in an array. The closures 14 are removably attached to the support structure 51, for example, via connecting tabs. As shown, individual closures 14 can be removed from the closure support net 50 by pushing them out of the plane of the closure support net 50.

[0096] Preferably, the connecting tongue that attaches the closure 14 to the support structure 51 is configured to break off at the closure 14 rather than at the support structure 51. Therefore, when the closure is removed from the closure support mesh 50, the connecting tongue remains on the support structure. In one example, the connecting tongue is narrower at the closure than at the support structure 51.

[0097] The movable shelf 31 of the closure positioning station 24 includes a support surface 52 and a clamp 49, which together hold the closure support mesh 50, as in Figure 10As shown, the support surface 52 and clamp 49 of the movable shelf 31 hold the closure support net 50 in a position above the consumable units 4 in the machine tray 27, such that the closures 14 in the closure support net 50 are aligned with each consumable unit 4 in the machine tray 27. In a preferred example, the movable shelf 31 includes alignment pins that engage with holes in the closure support net 50 as the movable shelf 31 moves toward the consumable units 4. This ensures alignment between the closures 14 and the containers 9 of the consumable units 4.

[0098] As in Figure 10 As shown, the closure positioning station 24 also includes a press 53 arranged to push the closure 14 from the closure support net 50 into the consumable unit 4. The press 53 includes an actuator for moving a press head 54. The press head 54 includes a plurality of protrusions 55 arranged in an array, which mate with the arrayed closures 14 in the closure support net 50 and also with the arrangement of the consumable units 4 in the machine tray 27. The protrusions 55 push the closure 14 out of the closure support net 50 and into the consumable unit 4. Thus, a single movement of the press head 54 can simultaneously position the closure 14 in each consumable unit 4.

[0099] In a preferred embodiment, the closure support net 50 includes two sets of closures 14, and after one set of closures 14 is moved into the consumable unit 4, the closure support net 50 is moved to align the other set of closures 14 with the next machine tray 27 of the consumable unit 4. This has the advantage of reducing the number of times the closure support net 50 needs to be replaced.

[0100] As in Figure 10 As shown, when the actuator moves the press head 54 downward toward the consumable unit 4, each protrusion 55 on the press head 54 contacts the closure 14 in the closure support mesh 50. The movement of the press head 54 separates the closure 14 from the closure support mesh 50 and pushes the closure 14 into the consumable unit 4. (See previous reference...) Figure 3A As explained, each consumable unit 4's container 9 includes an end face defining a lip 20 and a post 18 projecting from an end 15. A closure 14 is positioned between the posts 18, thereby supporting the lip 20, as in... Figure 3A As shown in the diagram.

[0101] As in Figure 10As shown, the support surface 52 of the movable shelf 31 provides support below the closure support mesh and on the opposite side of the press head 54. This support surface 52 includes an array of openings 56 that allow the individual closures 14 to move through as the press 53 pushes them from the closure support mesh 50 into the consumable unit 4. Preferably, each protrusion 55 on the press head 54 has a size and shape that closely matches the size and shape of the closures 14 and the openings 56 in the support surface 52 to help prevent flexing and movement of the closure support mesh 50 and the closures 14 during operation.

[0102] As in Figure 10 As shown, each opening 56 in the support surface 52 may include a recess 57 that engages the container 9, particularly the stud portion 18, when the movable shelf 31 is in the engaged position. This helps ensure that the closure 14 moves smoothly from the closure support mesh 50 into the consumable unit 4.

[0103] Similar to the dosing station 23, as previously described, the closure positioning station 24 may include an inspection unit for inspecting the consumable units 4 in the machine tray 27 as they are removed from the machine tray support 29. Figure 8A and Figure 8B As shown, the scanner 58 can be positioned above the machine tray support 29, so that the laser / optical system of the scanner 58 can perform height measurements throughout the machine tray 27, and the inspection system can verify the presence and proper mounting of the closure 14 in each container.

[0104] Figure 11 The sealing station 25 is shown. (As in...) Figure 2A and Figure 2B As shown, the closure fixing station 25 secures the closure 14 to the consumable unit 4 by bending and flipping the peg 18.

[0105] The closure fixing station 25 includes a machine pallet support 29 similar to the dosing feed station 23 and the closure positioning station 24. Specifically, the machine pallet support 29 includes components for supporting the closure. Figure 5A The machine tray 27 and the rails 30 supporting the multiple consumable units 4 are shown. The machine tray 27 can be inserted into the closure fixing station 25 by sliding it onto the rails 30 on the opposite side supporting the machine tray 27. The machine tray support 29 also includes a stop against which the machine tray 27 abuts when inserted into the machine tray support 29. The machine tray support 29 ensures that the machine tray 27 and the consumable units 4 are accurately and reliably positioned and supported within the closure fixing station 25.

[0106] The enclosure fixing station 25 may include a proximity switch that confirms that the machine tray 27 has been properly positioned on the machine tray support 29. Alignment pins may be provided additionally or alternatively to ensure correct positioning.

[0107] As in Figure 11 As shown, the closure fixing station 25 includes a pressing member 59. The pressing member 59 bends and flips the stump 18 of the container 9 against the closure 14 to secure the closure 14 to the container 9, as shown in... Figure 2A and Figure 2B As shown in the diagram.

[0108] As in Figure 11 As shown, the closure fixing station 25 includes a movable shelf 31 similar to the dosing feed station 23 and the closure positioning station 24. In this example, the movable shelf 31 includes the extrusion head 60 of the extruder 59, which is further described below. The supports 33 and sliding support 34 of the movable shelf 31 guide the movable shelf 31 and the extrusion head 60, thereby ensuring reliable and accurate operation of the extrusion head 60. In other examples, the closure fixing station 25 does not include the movable shelf 31, and the extrusion head 60 is a separate component.

[0109] Extrusion member 59 includes an actuator 61 for vertically moving extrusion head 60, as in Figure 11 As shown in the diagram, the extrusion head 60 has multiple individual extruders arranged in an array to match the array of consumable units 4 in the machine tray 27. In this way, multiple or all consumable units 4 can be processed simultaneously to bend the piling 18 and secure the closure 14 to the consumable unit 4.

[0110] In one example, the extrusion head 60 includes a first set of extruders 62 for performing a first bending process and a second set of extruders 63 for performing a second bending process. The first set of extruders 62 and the second set of extruders 63 may each be arranged to occupy half of the extrusion head 60. In an alternative arrangement, the first set of extruders 62 is positioned at a station separate from the second set of extruders 63.

[0111] Figure 12 The sequence shown is as follows: the first set of extruders 62 and the second set of extruders 63 bend and flip the pile 18 to abut against the closure 14 (moving from left to right). Figure 12 The consumable unit 4 is shown when it is received in the closure station 25, wherein the pile 18 extends upward and the closure 14 is received between the piles 18.

[0112] As shown, the first extruder 64 of the first set of extruders 62 includes an angled extrusion surface 66 that causes the pile portion 18 to bend and flip. In particular, in this example, the angled extrusion surface 66 is at a 45-degree angle, causing the pile portion 18 to bend and flip at a 45-degree angle during the first bending process.

[0113] Subsequently, the second extruder 65 of the second set of extruders 63 includes a flat extrusion surface 67, which causes the pile 18 to bend and flip over the remaining portion to position against the closure 14 and fix the closure 14 to the container 9.

[0114] The arrangement of the first set of extrusion members 64 and the second set of extrusion members 65 in two stages helps to ensure that the pile 18 can be reliably bent and flipped without breaking.

[0115] In some examples, the first extruder 64 and / or the second extruder 65 are heated, or the entire extrusion head 60 is heated, to facilitate bending of the pile 18. In some examples where the closure 14 is metal or includes metal, an induction heating system may be arranged to cause the closure 14 to heat, which in turn heats the surrounding portion of the container 9, including the pile 18. It will be understood that this depends on the materials of the container 9 and the pile 18. For example, if the pile 18 is made of thermoplastic, then the heated extruders facilitate the bending process.

[0116] Figure 13 An alternative extruder is shown, wherein a first extruder 68 and a second extruder 69 are arranged concentrically. As shown, in this example, the first extruder 68 has an angled extrusion surface 70 and a central hole 71. Within the central hole 72 is the second extruder 69, which is movable within the hole 71. In this way, as shown, the first extruder 68 can initially be moved to initiate bending of the pile 18 through the angled extrusion surface 70. Subsequently, the second extruder 69 can be moved to bend the pile 18 against the closure 14 to secure the closure to the container 9.

[0117] exist Figure 13 In this arrangement, the extrusion head 60 may include a first plate having a protrusion forming a first extruder 68 and an opening for producing a hole 71 in the first extruder 68, and a second plate may include a protrusion forming a second extruder 69 extending through the opening in the first plate. The first and second plates may be arranged adjacent to each other, and separate actuators may move the first and second plates to perform [operation / action]. Figure 13 The process is shown in the example. In this example, all consumable units 4 can be processed simultaneously by a single enclosed station 25.

[0118] In some examples, the first extruder 68 and the second extruder 69 are heated, or the entire extrusion head 60 is heated, to facilitate bending of the pile 18. It should be understood that this depends on the material of the container 9 (particularly the pile 18). For example, if the pile 18 is made of thermoplastic, then the heated extruder facilitates the bending process.

[0119] In alternative arrangements, the closure fixing station 25 may include alternative devices for securing the closure 14 to the consumable unit 4. For example, the closure fixing station 25 may include a welding station, such as an ultrasonic welding station, which welds the closure 14 to the container 9 of the consumable unit 4. In other examples, the closure fixing station 25 may include a pressing member that press-fits the closure 14 into the chamber 16 of the consumable unit 4 to secure the closure 14 to the container 9 of the consumable unit 4.

[0120] Similar to the dosing station 23 and the closure positioning station 24, as previously described, the closure fixing station 25 may include an inspection unit for inspecting the consumable units 4 as they are removed from the machine tray 27 from the machine tray support 29. Specifically, a scanner may be positioned above the machine tray support 29 such that the scanner's laser / optical system can perform height measurements throughout the machine tray 27, and the inspection system can verify the presence and correct bearing of the closures 14 in each container 9, as well as the presence and correct positioning of the pegs 18, to ensure that the closures 14 are properly secured.

[0121] Once removed from the closure station 25, the manufacturing of consumable unit 4 is complete. Consumable unit 4 can then be removed from machine pallet 27, and the packaging and dispensing process continues. Machine pallet 27 can be returned to the beginning of the process and reused.

[0122] It will be understood that the dosing station 23, the closure positioning station 24, and the closure fixing station 25 share many common features. For example, each station 24, 25, 26 includes a machine pallet support 29 and a movable shelf 31 mounted on a support column 33 for vertical movement. This allows stations 23, 24, 25 to be modularly arranged within larger equipment, such as equipment for packaging consumable units 4, and / or assembled or formed within... Figure 3A The device shown is an empty consumable unit 4.

[0123] As used herein, the term "aerosolizable material" means that when heated, the aerosolizable material will produce an aerosol. For example, an aerosolizable material may be or include a flavor matrix. The flavor matrix may include flavoring agents (such as tobacco flavoring agents or other flavoring agents), and / or may include glycerol or other additives or enhancers to replace or replace glycerol. A flavor matrix with or without glycerol or other additives may be heated to produce an aerosol.

[0124] It is worth noting that, generally speaking, an aerosol is a colloidal substance of fine solid particles or liquid droplets in air or another gas, wherein a colloid is a substance in which microscopically dispersed insoluble particles are suspended throughout another substance. On the other hand, a vapor is a gaseous substance at a temperature below its critical temperature, meaning that, for example, vapor can be condensed into a liquid by increasing its pressure without lowering the temperature. It should be understood that, as used herein, the term aerosol includes both aerosols and / or vapors.

[0125] As previously explained, aerosolizable materials may include tobacco. For example, aerosolizable materials may be particulate tobacco materials.

[0126] As used herein, the term "tobacco" or "particulate tobacco material" means material including tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Particulate material may also include non-tobacco materials. In some examples, "particulate material" is in powder form, and in alternative examples, "particulate material" is formed by cutting or shredding the material into smaller particles. In some examples, "particulate tobacco material" may include so-called "cut rag," which is formed by cutting or shredding tobacco into small particles. Particulate tobacco material can be produced by extruding tobacco pulp and cutting the extruded material into particles.

[0127] It should be understood that the examples of consumable units described above can be used in the reference. Figure 1 In devices other than the described inhalation device. For example, the inhalation device may be a device that releases a compound from particulate material without combustion, such as a heated tobacco product. In one embodiment, the inhalation device is a heating device that releases the compound by heating rather than burning a matrix material (e.g., particulate material). The particulate material may be, for example, tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment, the inhalation device is a heated tobacco device.

[0128] In another embodiment, the tobacco industry product is a blending system used to generate an aerosol by heating rather than burning a combination of matrix materials (e.g., the contents of an atomizer cartridge and particulate material in a consumable unit). The matrix material in the atomizer cartridge and the particulate material in the consumable unit may be, for example, solid, liquid, or gel, and may or may not contain nicotine. In one embodiment, the blending system includes a liquid or gel matrix and a solid matrix. The solid matrix may be, for example, tobacco or other non-tobacco products, and may or may not contain nicotine. In one embodiment, the blending system includes a liquid or gel matrix and tobacco.

[0129] To address a variety of problems and advance the field, this disclosure illustrates various embodiments by way of example, in which the claimed invention(s) can be practiced and provides superior methods and apparatus for manufacturing consumable units for use with inhalation devices. The advantages and features of this disclosure are merely representative examples of embodiments and are not exhaustive and / or exclusive. They are shown only to aid understanding and to teach the claimed features. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of this disclosure should not be considered as limitations on the disclosure as defined by the claims, or on equivalents of the claims, and that other embodiments may be utilized and modifications may be made without departing from the scope and / or spirit of this disclosure. Various embodiments may suitably include, comprise, or substantially comprise various combinations of the disclosed elements, components, features, portions, steps, devices, etc. Furthermore, this disclosure includes other inventions not currently claimed but which may be claimed in the future.

Claims

1. A consumable comprising a container, the consumable including a closure disposed at a first end of the container, wherein the closure is secured to the container by a plurality of deformable studs projecting from the first end of the container, and wherein, When the closure is secured to the container, the consumable allows particulate material to be contained within the cavity of the container.

2. The consumable item according to claim 1, wherein the closure is fixed between the plurality of deformable posts and the lip of the container at a first end of the container.

3. The consumable according to claim 1 or 2, wherein the plurality of deformable posts are spaced apart about the radial edge of the container.

4. The consumable according to claim 1 or 2, wherein the plurality of deformable studs protrude axially from the radial edge of the container.

5. The consumable according to claim 1 or 2, wherein the plurality of deformable posts include a first deformable post located at a first portion of a radial edge of the container, and a second deformable post located at a second portion of the radial edge, wherein the second deformable post is narrower than the first deformable post, and wherein the second portion of the radial edge has a smaller radius than the first portion.

6. The consumable according to claim 1 or 2, wherein the plurality of deformable piles are arranged to define a gap therebetween, wherein the gap is configured such that the deformable piles do not collide with each other.

7. The consumable according to claim 1 or 2, wherein the first end wall of the chamber is defined by the closure, and / or wherein the second end wall of the chamber is defined by an internal perforated screen.

8. The consumable according to claim 7, wherein the internal perforated screen is integrally molded into the inlet component.

9. The consumable of claim 7, wherein the internal perforated screen extends radially throughout the second end of the container.

10. The consumable according to claim 7, wherein the internal perforated screen is arranged upstream of the steam outlet of the consumable.

11. The consumable according to claim 1 or 2, wherein the closure comprises a perforated screen.

12. The consumable item of claim 11, wherein the closure comprises a mesh or sheet or a molded part of a plastic material.

13. The consumable according to claim 1 or 2, wherein the consumable includes a mouth part.

14. The consumable of claim 13, wherein the container is arranged to protrude from the skirt-shaped portion of the mouth component.

15. The consumable of claim 13, wherein the container includes a connector received within a socket having a complementary shape, the socket being formed on the inner surface of the mouth member.

16. The consumable according to claim 13, wherein the mouth component and the container are integrally formed, or wherein the mouth component and the container are connected to each other by ultrasonic welding or induction welding.

17. The consumable according to claim 1 or 2, wherein the container has an elliptical radial cross section.

18. A method for manufacturing a consumable item, the method comprising: A dose of particulate material is provided within the cavity of the consumable container; and The closure is secured to the container by deforming a plurality of axially extending piles of the container onto the closure.

19. The method of claim 18, further comprising the step of: After the step of providing a certain dose of particulate material, the closure is positioned against the lip of the consumable, and the step of deforming the plurality of posts includes deforming the plurality of posts in order to keep the closure against the lip of the consumable.

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