Method for assembling cartridge for smoking article

Abstract

The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by conveying brackets between various substations that add parts to the base. In another method of assembly, the base may be moved between a plurality of robots that guide the base down into contact with a component to couple the component thereto. An inspection system may inspect the cartridge at each completion stage.

Description

[0001] This application is a divisional application of the patent application filed on February 13, 2015, with international application number PCT / US2015 / 015878 and Chinese application number 201580019489.X, entitled "Method for assembling a tobacco cartridge for a tobacco product". This divisional application is filed in response to the unity of invention issue raised in the first office action of the divisional application filed on June 23, 2022, with application number 202210718369.0, entitled "Method for assembling a tobacco cartridge for a tobacco product". Technical Field

[0002] This disclosure relates to cartridges for aerosol delivery devices such as tobacco products, and more specifically to a method for assembling cartridges comprising an atomizer for tobacco products. The atomizer may be configured to heat an aerosol precursor that may be made from or derived from tobacco or otherwise incorporated into tobacco to form an inhalable substance for human consumption. Background Technology

[0003] Cigarettes, cigars, and pipes are popular tobacco products using various forms of tobacco. For example, a conventional type of cigarette has a generally cylindrical rod-shaped structure and comprises a state, roll, or column of smokeable material, such as shredded tobacco (e.g., in the form of cut filler), surrounded by wrapping paper, thus forming what is called a "smoking rod," "tobacco rod," or "cigarette rod." Typically, this cigarette has a cylindrical filter element aligned end-to-end with the tobacco rod. Preferably, the filter element comprises a plasticized cellulose acetate tow surrounded by a paper material called "forming paper." Preferably, the filter element is attached to one end of the tobacco rod using a wrapping material called "tip paper." Perforating the tip paper and forming paper to provide dilution of the smoked mainstream with ambient air has also become desirable. A description of cigarettes and their various components is presented in *Tobacco Production, Chemistry and Technology* (1999) by Davis et al. (eds.), which is incorporated herein by reference in its entirety. Traditional cigarettes are consumed by the smoker by lighting one end of a tobacco stick. The smoker then receives the mainstream smoke into his / her mouth by inhaling at the opposite end of the burning cigarette (e.g., the filter end or mouthpiece end).

[0004] For many years, efforts have been made to improve the components, construction, and properties of tobacco products that require the combustion of tobacco for smoke production. Many of the improvements allegedly proposed attempt to provide the sensations associated with smoking cigarettes, cigars, or pipes, but do not deliver the substantial byproducts of incomplete combustion and pyrolysis produced by burning tobacco. See, for example, the various references described, discussed, or cited in U.S. Patent No. 7,753,056 to Borschke et al., which is incorporated herein by reference in its entirety.

[0005] Certain types of cigarettes using carbon-containing fuel elements have been commercially available under the trademarks "Premier" and "Eclipse" of RJ 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" (RJ Reynolds Tobacco Company Monograph (1988)) and "Inhalation Toxicology" (12:5, pp. 1-58, (2000)). Additionally, similar types of cigarettes have recently been marketed in Japan by Japan Tobacco Inc. under the trademark "Steam Hot One". Furthermore, various types of tobacco products incorporating carbon-containing fuel elements for heat generation and aerosol formation have recently been described in patent literature. See, for example, the types of tobacco products proposed in the following patents: U.S. Patent No. 7,836,897 to Borschke et al.; 8,469,035 to Banerjee et al. and 8,464,726 to Sebastian et al.; U.S. Patent Publication No. 2012 / 0042885 to Stone et al.; 2013 / 0019888 to Tsuruizumi et al.; 2013 / 0133675 to Shinozaki et al. and 2013 / 0146075 to Poget et al.; PCT WO No. 2012 / 0164077 to Gladden et al.; 2013 / 098380 to Raether et al.; 2013 / 098405 to Zuber et al.; 2013 / 098410 to Zuber et al. and 2013 / 104914 to Woodcock; EP 1808087 to Baba et al. and EP 1808087 to Tsuruizumi et al. 2550879; The above patent is incorporated herein by reference in its entirety.

[0006] In recent years, numerous tobacco products, aroma generators, and pharmaceutical 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; all of which are incorporated herein by reference in their entirety.

[0007] In this regard, certain tobacco products that utilize electrical energy to generate heat for smoke or aerosol formation, and specifically, certain products now known as electronic cigarettes, are commercially available worldwide. Representative products with many attributes similar to traditional types of cigarettes, cigars, or pipes are also commercially available, such as those from Philip Morris Incorporated. ALPHA of InnoVapor LLC TM JOYE 510 TM and M4 TM ; CIRRUS by White Cloud Cigarettes TM and FLING TM ;BLU by Lorillard Technologies, Inc. TM ; COHITA International Inc. TM COLIBRI TM ELITE CLASSIC TM MAGNUM TM PHANTOM TM and SENSE TM ; DUOPRO by Electronic Cigarettes, Inc. TM STORM TM and Egar Australia's EGAR TM Joyetech's eGo-C TM and eGo-T TM ELUSION UK Ltd TM Eonsmoke LLC's FINBranding Group, LLC's FIN TM ;Green Smoke Inc.USA Greenarette LLC's Greenarette TM Smoke 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 TMVaporNine LLC's Vapor Nine TM Vapor 4Life, Inc. VEPPO, E-CigaretteDirect, LLC TM RJ Reynolds Vapor Company Mistic Ecigs' Mistic Menthol products; and CN Creative Ltd.'s Vype products. Other powered aerosol delivery devices, and specifically those devices described as so-called electronic cigarettes, are marketed under the trademark: 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 technologies that may be used 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, Rachau-Malkelsbach, Germany; Perrigo L.Co., Allegheny, Michigan; Needs Co., Ltd., Allegheny, Michigan; Smokefree Innotec, Las Vegas, Nevada; McNeil AB, Helsingborg, Sweden; Chong Corp.; Alexza, Mountain View, California. Pharmaceuticals; BLEC, LLC, Charlotte, North Carolina; Gaitrend Sarl, Raoul Barclays, France; FeelLife Bioscience International, Shenzhen, China; Vishay Electronic BMGH, Seilb, Germany; Shenzhen Smaco Technology Ltd., Shenzhen, China; Vapor Systems International, Berkley, Florida; Exonoid Medical Devices, Israel; Shenzhen Nowotech Electronics, Shenzhen, China; Minilogic Device Corporation, Hong Kong, China; Shenzhen Kontle Electronics, Shenzhen, China; Fuma International, LLC, Medina, Ohio, China; and 21st Century Smoke, Berloit, Wisconsin.

[0009] However, embodiments of e-cigarette products may be difficult to manufacture. In this respect, for example, the various components in e-cigarette products may be relatively small and / or fragile. Therefore, advancements in the manufacture of e-cigarette products would be desirable. Summary of the Invention

[0010] This disclosure relates to the assembly of an aerosol delivery device configured to generate an aerosol. In one aspect, a method for assembling a cartridge for an aerosol delivery device is provided. The method may include: providing a reservoir substrate extending at least partially around an atomizer; providing an outer body configured to receive the reservoir substrate and the atomizer therein at least partially; and inserting the reservoir substrate into the outer body using a tool that defines a funnel portion configured to reduce the external dimensions of the reservoir substrate, such that the external dimensions of the reservoir substrate are less than or equal to the internal dimensions of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0011] In some embodiments, the method may further include twisting the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body using the tool. Providing a reservoir substrate that extends at least partially around the atomizer may include wrapping the reservoir substrate at least partially around the atomizer before inserting the reservoir substrate into the outer body using the tool. Wrapping the reservoir substrate at least partially around the atomizer may include directing airflow to the reservoir substrate.

[0012] In some embodiments, the method may further include engaging the reservoir substrate with one or more fingers such that the reservoir substrate remains at least partially wrapped around the atomizer when insertion of the reservoir substrate into the outer body begins via the tool. The method may 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 may 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 may include releasing the fingers sequentially. The method may further include coupling the atomizer to a base before at least partially wrapping the reservoir substrate around the atomizer, and coupling the outer body to the base after insertion of the reservoir substrate into the outer body via the tool. Additionally, the method may include supplying the reservoir substrate from a generally continuous reservoir substrate input and controlling the tension in the generally continuous reservoir substrate input.

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

[0014] In some embodiments, determining the positions of the first heating terminal and the second heating terminal may include determining the midpoint between the first heating terminal tab and the second heating terminal tab. The heating element may include a first contact portion and a second contact portion, and determining the position of the heating element may include determining the midpoint between the first contact portion and the second contact portion. The method may 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.

[0015] In some embodiments, the method may 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 may include adjusting the 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 may 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 may include directing the laser beam at the back side of the first heating terminal tab and the second heating terminal tab opposite to the heating element.

[0016] The method may further include inserting a heating element, a first heating terminal, and a second heating terminal into a generally sealed chamber before guiding a laser beam to a first heating terminal tab and a second heating terminal tab. Providing the heating element may include supplying the heating element from a generally continuous heating element input and controlling the tension in the generally continuous heating element input. The method may further include coupling the heating element to a liquid delivery element. Providing the first heating terminal and the second heating terminal may include supplying the first heating terminal from a generally continuous first heating terminal input and supplying the second heating terminal from a generally continuous second heating terminal input. The heating element may include a wire wound around the liquid delivery element. The wire may include two contact portions, a central portion, and two external portions positioned outside the contact portions, the two contact portions and the central portion defining the heating element, wherein the contact portions define a first coil spacing, the central portion defines a second coil spacing, and the external portions define a third coil spacing greater than the second coil spacing, and the second coil spacing greater than the first coil spacing, and attaching the heating element to the first heating terminal and the second heating terminal may include attaching the contact portions to the first heating terminal and the second heating terminal.

[0017] In an additional aspect, a test fixture is provided. The test fixture may 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 via the electrical contacts to test the cartridge when the base of the cartridge is engaged with the socket. The controller may be configured to determine the resistance of the atomizer of the cartridge and compare the resistance with a desired resistance.

[0018] In some embodiments, the controller may be further configured to determine whether the atomizer is shorted to the external body of the cartridge. The test fixture may further include a third electrical contact coupled to the socket and configured to engage a control component terminal of the cartridge. The controller may be configured to transmit program code instructions to an electronic control component of the cartridge via the third electrical contact and the control component terminal. The controller may 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 a desired program code instruction. The test fixture may further include a slot located on an opposite side of the socket, the slot configured to receive a gripper such that the gripper can grasp under the base to remove the cartridge from the socket. The test fixture may further include an orifice configured to provide airflow through the base of the cartridge.

[0019] In an additional aspect, a method for filling a tobacco cartridge is provided. The method may include: providing a tobacco cartridge for an aerosol delivery device, the tobacco cartridge including a reservoir substrate positioned in an outer body; sequentially positioning an outlet of a filling device near a plurality of angular portions of the reservoir substrate; and directing a flow of an aerosol precursor composition through the outlet of the filling device to each of the angular portions of the reservoir substrate.

[0020] In some embodiments, the outlet of the filling device may remain uncontacted with the reservoir substrate. The method may further include conveying the cartridge between a plurality of filling stations, wherein at each of the filling stations, the flow of the aerosol precursor composition is directed to at least one of the angled portions of the reservoir substrate. The flow of the aerosol precursor composition may be directed at a first filling station to each of the angled portions of the reservoir substrate. The flow of the aerosol precursor composition may be directed at the remaining portions of the filling station to one of the angled portions of the reservoir substrate, respectively. The method may further include controlling the environment surrounding the filling cartridge such that the environment defines a relative humidity of less than about 40%.

[0021] In an additional aspect, a method for assembling a cigarette cartridge for an aerosol delivery device is provided. The method may 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, gripping the base may include gripping the inner surface of an attachment end of the base configured to engage a control body. Guiding the base to contact a component in a resting position may include guiding the base downwards to contact the component. The method may further include inserting the base into a retaining device and checking the position of first and second heating terminals coupled to the base via the retaining device.

[0023] In an additional aspect, a conveying system is provided, configured to convey cartridges for the tobacco product during assembly. The conveying system may include: a track; a bracket configured to engage and move along the track, the bracket including a clamping mechanism configured to engage one or more components of the cartridge during assembly; and a locking device configured to temporarily restrain the movement of the bracket along the track.

[0024] In some embodiments, the clamping mechanism may be configured to engage the base of the cartridge. The locking device may include a positioner mechanism coupled to the bracket and an engagement mechanism configured to engage the positioner mechanism. The positioner mechanism may include a plurality of pins. The engagement mechanism may include rollers.

[0025] The present invention includes (but is not limited to) the following embodiments.

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

[0027] Provide a reservoir substrate that extends at least partially around the atomizer;

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

[0029] The reservoir substrate is inserted into the outer body using a tool that defines a funnel-shaped portion configured to reduce the external dimensions of the reservoir substrate, such that the external dimensions of the reservoir substrate are less than or equal to the internal dimensions of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0030] Example 2: The method according to any of the foregoing or subsequent embodiments further includes twisting the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body using the tool.

[0031] Example 3: The method according to any of the foregoing or subsequent embodiments, wherein providing the reservoir substrate extending at least partially around the atomizer includes wrapping the reservoir substrate at least partially around the atomizer before inserting the reservoir substrate into the outer body by means of the tool.

[0032] Example 4: The method according to any of the foregoing or subsequent embodiments, wherein at least partially wrapping the reservoir substrate around the atomizer includes directing an airflow to the reservoir substrate.

[0033] Example 5: The method according to any of the foregoing or subsequent embodiments further includes engaging the reservoir substrate with one or more fingers when inserting the reservoir substrate into the outer body using the tool, such that the reservoir substrate remains at least partially wrapped around the atomizer.

[0034] Example 6: The method according to any of the foregoing or subsequent embodiments further includes 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: A method according to any of the foregoing or subsequent embodiments, wherein releasing the one or more fingers includes 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 according to any of the foregoing or subsequent embodiments, wherein releasing the one or more fingers includes releasing the fingers sequentially.

[0037] Example 9: The method according to any of the foregoing or subsequent embodiments further includes coupling the atomizer to the base before at least partially wrapping the atomizer around the reservoir substrate; and

[0038] After the reservoir substrate is inserted into the outer body using the tool, the outer body is coupled to the base.

[0039] Example 10: The method according to any of the foregoing or subsequent embodiments further includes supplying the reservoir substrate from a generally continuous reservoir substrate input; and

[0040] Control the tension in the generally continuous reservoir substrate input.

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

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

[0043] Determine the positions of the first heating terminal and the second heating terminal;

[0044] Determine the position of the heating element; and

[0045] The heating element is attached to the first heating terminal and the second heating terminal based on the positions of the first heating terminal and the second heating terminal and the position of the heating element.

[0046] Example 12: According to the method of any of the foregoing or subsequent embodiments, determining the positions of the first heating terminal and the second heating terminal includes determining the midpoint between the first heating terminal tab and the second heating terminal tab.

[0047] Example 13: According to the method of any of the foregoing or subsequent embodiments, the heating element includes a first contact portion and a second contact portion, and

[0048] Determining the position of the heating element includes determining the midpoint between the first contact portion and the second contact portion.

[0049] Example 14: The method according to any of the foregoing or subsequent embodiments further includes 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] The first contact portion engages with the first heating terminal tab; and

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

[0052] Example 15: The method according to any of the foregoing or subsequent embodiments further includes 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 according to any of the foregoing or subsequent embodiments, wherein clamping the first heating terminal and the second heating terminal includes adjusting the spacing between the first heating terminal and the second heating terminal.

[0054] Example 17: The method according to any of the foregoing or subsequent embodiments, wherein attaching the heating element to the first heating terminal and the second heating terminal includes guiding a laser beam at the first heating terminal tab and the second heating terminal tab.

[0055] Example 18: According to any of the foregoing or subsequent embodiments, guiding the laser beam to the first heating terminal tab and the second heating terminal tab includes guiding the laser beam to the back side of the first heating terminal tab and the second heating terminal tab opposite to the heating element.

[0056] Example 19: The method according to any of the foregoing or subsequent embodiments further includes inserting the heating element, the first heating terminal and the second heating terminal into a generally sealed chamber before guiding the laser beam to the first heating terminal tab and the second heating terminal tab.

[0057] Example 20: A method according to any of the foregoing or subsequent embodiments, wherein providing the heating element comprises:

[0058] The heating element is supplied with a generally continuous heating element input; and

[0059] Control the tension in the generally continuous heating element input.

[0060] Example 21: The method according to any of the foregoing or subsequent embodiments further includes coupling the heating element to the liquid delivery element.

[0061] Example 22: A method according to any of the foregoing or subsequent embodiments, wherein providing the first heating terminal and the second heating terminal includes:

[0062] The first heating terminal is supplied with a generally continuous input from the first heating terminal; and

[0063] The second heating terminal is supplied with a generally continuous second heating input.

[0064] Example 23: According to any of the foregoing or subsequent embodiments, the heating element includes a wire wound around the liquid delivery element.

[0065] Example 24: According to the method of any of the foregoing or subsequent embodiments, wherein the wire includes two contact portions, a central portion, and two external portions located outside the contact portions, the two contact portions and the central portion of the wire defining the heating element.

[0066] The contact portion defines a first coil spacing, the central portion defines a second coil spacing, and the outer portion defines a third coil spacing, wherein the third coil spacing is greater than the second coil spacing, and the second coil spacing is greater than the first coil spacing.

[0067] 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] Example 25: A test fixture, comprising:

[0069] The socket is constructed to engage with the base of the cigarette cartridge;

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

[0071] A controller configured to communicate with the cartridge via electrical contacts to test the cartridge when the base of the cartridge engages with the slot.

[0072] Example 26: A test fixture according to any of the foregoing or subsequent embodiments, wherein the controller is configured to determine the resistance of the atomizer of the cartridge and compare the resistance with a desired resistance.

[0073] Example 27: A test fixture according to any of the foregoing or subsequent embodiments, wherein the controller is further configured to determine whether the atomizer is shorted to the external body of the cartridge.

[0074] Example 28: A test fixture according to any of the foregoing or subsequent embodiments, further comprising a third electrical contact coupled to the socket and configured to engage the control component terminal of the cartridge.

[0075] Example 29: A test fixture according to any of the foregoing or subsequent embodiments, wherein the controller is configured to transmit program code instructions to the electronic control component of the cartridge via the third electrical contact and the control component terminal.

[0076] Example 30: A test fixture according to any of the foregoing or subsequent embodiments, 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 desired program code instructions.

[0077] Example 31: A test fixing device according to any of the foregoing or subsequent embodiments further includes a slot located on the opposite side of the socket, the slot being configured to receive a gripper such that the gripper can grasp from below the base to remove the cartridge from the socket.

[0078] Example 32: A test fixture according to any of the foregoing or subsequent embodiments, wherein the test fixture includes an orifice configured to provide an airflow through the base of the cartridge.

[0079] Example 33: A method for filling a cigarette cartridge, comprising:

[0080] A cartridge for an aerosol delivery device is provided, the cartridge including a reservoir substrate positioned in an outer body;

[0081] The outlet of the filling device is sequentially positioned near multiple angular portions close to the reservoir substrate; and

[0082] The flow of the aerosol precursor composition is directed through the outlet of the filling device to each of the angular portions of the reservoir substrate.

[0083] Example 34: A cartridge filling method according to any of the foregoing or subsequent embodiments, wherein the outlet of the filling device remains not in contact with the reservoir substrate.

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

[0085] Example 36: A cartridge filling method according to any of the foregoing or subsequent embodiments, wherein the flow of the 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: A cartridge filling method according to any of the foregoing or subsequent embodiments, wherein the flow of the aerosol precursor composition is directed at the remaining portion of the filling station to one of the angular portions of the reservoir substrate.

[0087] Example 38: A cartridge filling method according to any of the foregoing or subsequent embodiments further includes controlling the 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 smoke cartridge for an aerosol delivery device, comprising:

[0089] Grasp the base;

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

[0091] The component is coupled to the base by guiding the base into contact with the component in the rest position.

[0092] Example 40: The method according to any of the foregoing or subsequent embodiments, wherein gripping the base includes gripping the inner surface of the attachment end of the base configured to engage the control body.

[0093] Example 41: A method according to any of the foregoing or subsequent embodiments, wherein guiding the base to contact the component in the rest position includes guiding the base downward to contact the component.

[0094] Example 42: The method according to any of the foregoing or subsequent embodiments further includes inserting the base into the fixing device; and

[0095] Check the positions of the first and second heating terminals coupled to the base via the fixing device.

[0096] Example 43: A conveying system configured to convey cartridges for the tobacco product during assembly of the tobacco product, the conveying system comprising:

[0097] track;

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

[0099] A locking device, which is constructed to temporarily restrain the movement of the bracket along the track.

[0100] Example 44: A delivery system according to any of the foregoing or subsequent embodiments, wherein the clamping mechanism is configured to engage the base of the cartridge.

[0101] Example 45: A conveying system according to any of the foregoing or subsequent embodiments, wherein the locking device includes a positioner mechanism coupled to the carriage and an engagement mechanism configured to engage the positioner mechanism.

[0102] Example 46: A delivery system according to any of the foregoing or subsequent embodiments, wherein the positioner mechanism includes a plurality of studs.

[0103] Example 47: A conveying system according to any of the foregoing or subsequent embodiments, wherein the engagement mechanism includes rollers.

[0104] These and other features, aspects, and advantages of this disclosure will become apparent from the following detailed description and the accompanying drawings, which are briefly described below. The invention encompasses any combination of two, three, four, or more of the above embodiments, as well as any combination of two, three, four, or more features or elements stated in this disclosure, regardless of whether such features or elements are explicitly combined in the specific embodiments described herein. It is intended that this disclosure be read in its entirety so that, unless the context clearly indicates otherwise, any separable feature or element of the disclosed invention in any of the various aspects and embodiments thereof be considered inherently composable. Attached Figure Description

[0105] Therefore, having already described this disclosure in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0106] Figure 1 The present disclosure describes an aerosol delivery device comprising a cartridge and a control body according to an example embodiment, wherein the cartridge is described as being in a disassembled configuration and the control body is described as being in an assembled configuration;

[0107] Figure 2 Description of the example embodiments according to this disclosure in the process of decomposition construction Figure 1 The controlling entity;

[0108] Figure 3 The system for manufacturing cartridges for an aerosol delivery device according to an example embodiment of the present disclosure is illustrated, comprising a cartridge assembly subsystem, a cartridge filling subsystem, a cartridge capping system, a cartridge labeling subsystem, and an inspection subsystem.

[0109] Figure 4 Illustrative illustration of exemplary embodiments according to this disclosure Figure 3 A first embodiment of the cigarette cartridge assembly subsystem;

[0110] Figure 5 Description of exemplary embodiments according to this disclosure Figure 4 A perspective view of the bracket of the cigarette cartridge assembly subsystem;

[0111] Figure 6 Description of an example embodiment of the present disclosure, wherein a base is retained Figure 5 bracket;

[0112] Figure 7 This describes an example embodiment of the present disclosure with an engagement mechanism that disengages therefrom. Figure 5Side view of the bracket;

[0113] Figure 8 This describes an example embodiment of the present disclosure having a coupling mechanism that engages with it. Figure 5 Rear view of the bracket;

[0114] Figure 9 A perspective view illustrating a generally continuous terminal input including multiple terminals according to an example embodiment of the present disclosure;

[0115] Figure 10 Description of exemplary embodiments according to this disclosure Figure 4 A perspective view of the terminal sealing substation of the cartridge assembly subsystem;

[0116] Figure 11 Description of exemplary embodiments according to this disclosure Figure 10 Enlarged perspective view of the sealant applicator of the terminal sealing substation;

[0117] Figure 12 Description of exemplary embodiments according to this disclosure Figure 4 A perspective view of the heating element coupling substation of the cigarette cartridge assembly subsystem;

[0118] Figure 13 Description of exemplary embodiments according to this disclosure Figure 4 A perspective view of the generally continuous heating element input of the cartridge assembly subsystem;

[0119] Figure 14 Description of exemplary embodiments according to this disclosure Figure 12 A perspective view of the preparation section of the heating element coupling substation;

[0120] Figure 15 Illustrative illustration of exemplary embodiments according to this disclosure Figure 14 The preparation section of the heating element coupling substation;

[0121] Figure 16 Description of exemplary embodiments according to this disclosure Figure 12 Alternate perspective view of the preparation section of the heating element coupling substation;

[0122] Figure 17 Description of exemplary embodiments according to this disclosure Figure 12 A perspective view of the welding section of the heating element coupling substation;

[0123] Figure 18 Description of exemplary embodiments according to this disclosure Figure 17 An enlarged perspective view of the welding section of the heating element coupling substation;

[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 cigarette cartridge assembly subsystem;

[0147] Figure 41 Description of exemplary embodiments according to this disclosure Figure 40 A top view of the cigarette cartridge assembly subsystem;

[0148] Figure 42 Description of exemplary embodiments according to this disclosure Figure 40 A perspective view of the terminal coupling substation of the cigarette cartridge assembly subsystem;

[0149] Figure 43 Description of exemplary embodiments according to this disclosure Figure 42 A perspective view of the base gripper of the terminal coupling substation;

[0150] Figure 44 Description of exemplary embodiments according to this disclosure Figure 42 A perspective view of the bare die of the terminal coupling substation;

[0151] Figure 44A illustrate Figure 44 A magnified perspective view of the bare film;

[0152] Figure 45 Description of exemplary embodiments according to this disclosure Figure 42 The terminal is coupled to the transmission component of the substation;

[0153] Figure 46 Description of exemplary embodiments according to this disclosure Figure 40 A perspective view of the control component coupling substation of the cartridge assembly subsystem;

[0154] Figure 47 Description of exemplary embodiments according to this disclosure Figure 46 A magnified perspective view of the control components coupled to the substation;

[0155] Figure 48 Description of exemplary embodiments according to this disclosure Figure 40 A perspective view of the flow tube coupling substation of the cigarette cartridge assembly subsystem;

[0156] Figure 49 Description of exemplary embodiments according to this disclosure Figure 40 Side view of the terminal grippers of the cigarette cartridge assembly subsystem;

[0157] Figure 50 Description of the gripping heating terminal according to an example embodiment of the present disclosure Figure 49 A perspective view of the terminal grippers;

[0158] Figure 51 Description of the gripping heating terminal according to an example embodiment of the present disclosure Figure 49An enlarged side view of the terminal gripper;

[0159] Figure 52 Description of exemplary embodiments according to this disclosure Figure 40 A perspective view of the heating element coupling substation of the cigarette cartridge assembly subsystem;

[0160] Figure 53 Description of exemplary embodiments according to this disclosure Figure 52 The heating element is coupled to the substation via a generally continuous heating element input reel;

[0161] Figure 54 Description of exemplary embodiments according to this disclosure Figure 52 A perspective view of the welding section of the heating element coupling substation;

[0162] Figure 55 Description of the welding process according to exemplary embodiments of the present disclosure Figure 52 A side view of the welding section of the heating element coupling substation;

[0163] Figure 56 Description of exemplary embodiments according to this disclosure Figure 40 The liquid delivery element bending substation of the cigarette cartridge assembly subsystem;

[0164] Figure 57 This describes an example embodiment of a cigarette cartridge partially assembled therein, according to the present disclosure. Figure 56 The liquid delivery element is a curved substation;

[0165] Figure 58 Description of exemplary embodiments according to this disclosure Figure 40 A perspective view of the base and core wire clamps of the cartridge assembly subsystem;

[0166] Figure 59 This describes a cigarette cartridge assembled with a gripping portion according to an example embodiment of the present disclosure. Figure 58 Side view of the base and core wire clamps;

[0167] Figure 60 Description of exemplary embodiments according to this disclosure Figure 40 The reel of the generally continuous storage substrate input of the storage coupling substation of the cartridge assembly subsystem;

[0168] Figure 61 Description of exemplary embodiments according to this disclosure Figure 60 A perspective view of a single unit of a storage-coupled substation;

[0169] Figure 62 Description of exemplary embodiments according to this disclosure Figure 61 An alternative perspective view of the single unit of the storage coupling substation;

[0170] Figure 63 Description of exemplary embodiments according to this disclosure Figure 40 A perspective view of the winding mechanism of the storage coupling substation of the cigarette cartridge assembly subsystem;

[0171] Figure 64 Description of exemplary embodiments according to this disclosure Figure 40 A top view of the external main coupling substation of the cigarette cartridge assembly subsystem;

[0172] Figure 65 Description of exemplary embodiments according to this disclosure Figure 64 An enlarged top view of the external main body coupling substation, with tools constructed to pass through the open structure to receive the assembled smoke cartridges.

[0173] Figure 66 Description of exemplary embodiments according to this disclosure Figure 64 An enlarged top view of the external main body coupling substation, with tools constructed to pass through the receiving portion assembled in a closed structure;

[0174] Figure 67 Description of exemplary embodiments according to this disclosure Figure 64 Exploded view of the storage gripper jaws of the external main body coupling substation;

[0175] Figure 68 Description of the assembly construction according to the example embodiments of this disclosure Figure 67 The storage gripper claw;

[0176] Figure 69 Description of finger-like structures according to exemplary embodiments of the present disclosure Figure 64 An alternative embodiment of the storage gripper of the external main body coupling substation;

[0177] Figure 70 An enlarged perspective view illustrating a heating element formed by passing a guide wire through and winding the guide wire around a liquid delivery element according to an example embodiment of the present disclosure;

[0178] Figure 71 Illustrative illustration of exemplary embodiments according to this disclosure Figure 3 The cartridge filling subsystem;

[0179] Figure 72 A top view illustrating a partially assembled cartridge according to an example embodiment of the present disclosure, during filling and before coupling with the dropper.

[0180] Figure 73 This describes the cartridge during filling according to an example embodiment of the present disclosure;

[0181] Figure 74 Description of exemplary embodiments according to this disclosure Figure 3 The inspection subsystem's side-view camera is configured to inspect the distance the terminal extends from the base;

[0182] Figure 75 Description of exemplary embodiments according to this disclosure Figure 3 The end-view camera of the inspection subsystem is configured to inspect the radial position of the terminals;

[0183] Figure 76 Description of alternative embodiments according to this disclosure Figure 3 The inspection subsystem includes side-view and end-view cameras, which are configured to inspect terminal height and radial position;

[0184] Figure 77 Description of embodiments according to this disclosure Figure 3 A side view of the fixture of the inspection subsystem, which is constructed to facilitate inspection of the terminals;

[0185] Figure 78 Description of exemplary embodiments according to this disclosure Figure 3 The inspection subsystem includes side-view and end-view cameras, which are configured to inspect the external body of the cartridge;

[0186] Figure 79 Description of alternative embodiments according to this disclosure Figure 3 The inspection subsystem includes side-view and end-view cameras, which are configured to inspect the external body of the cartridge;

[0187] Figure 80 Description of exemplary embodiments according to this disclosure Figure 3 A perspective view of the blow station of the inspection subsystem;

[0188] Figure 81 Description of alternative embodiments according to this disclosure Figure 3 A perspective view of the blow station of the inspection subsystem;

[0189] Figure 82 Description of exemplary embodiments according to this disclosure Figure 3 A perspective view of the pressure drop station of the inspection subsystem;

[0190] Figure 83 Description of alternative embodiments according to this disclosure Figure 3 A perspective view of the pressure drop station of the inspection subsystem;

[0191] Figure 84 This description illustrates an example embodiment of the present disclosure that includes a test fixture. Figure 3 A perspective view of the electrical test station of the inspection subsystem;

[0192] Figure 85 Description of exemplary embodiments according to this disclosure Figure 84 Enlarged perspective view of the test fixture;

[0193] Figure 86 Explanation of the crossing according to exemplary embodiments of this disclosure Figure 84 A cross-sectional view of the test fixture;

[0194] Figure 87 This description illustrates an alternative embodiment of the present disclosure that includes a test fixture. Figure 3 A perspective view of the electrical test station of the inspection subsystem;

[0195] Figure 88 This illustration illustrates a method for assembling a smoke cartridge for an aerosol delivery device according to an example embodiment of the present disclosure;

[0196] Figure 89 This illustration illustrates a method for assembling an atomizer for an aerosol delivery device according to an example embodiment of the present disclosure;

[0197] Figure 90 This illustration illustrates a cartridge filling method according to an example embodiment of the present disclosure;

[0198] Figure 91 This illustration illustrates a method for assembling a smoke cartridge for an aerosol delivery device according to exemplary embodiments of the present disclosure; and

[0199] Figure 92 The controller is illustrated in an example embodiment of the present disclosure. Detailed Implementation

[0200] This disclosure will now be described more fully hereinafter with reference to exemplary embodiments thereof. These exemplary embodiments are described so that this disclosure will be exhaustive and complete, and will fully convey the scope of this disclosure to those skilled in the art. In fact, this disclosure may be 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 satisfy applicable legal requirements. Unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” as used in this specification and the appended claims include plural variations.

[0201] As described below, embodiments of this disclosure relate to aerosol delivery devices and methods and apparatus for assembling them. Aerosol delivery devices according to this disclosure can use electrical energy to heat materials (preferably without causing combustion to any significant extent) to form an inhalable substance; these articles are most preferably sufficiently compact to be considered "handheld" devices. Aerosol delivery devices can provide some or all of the sensations of smoking a cigarette, cigar, or pipe (e.g., inhalation and exhalation habits, type of taste or odor, sensory effects, bodily sensations, usage habits, visual cues (e.g., those provided by visible aerosols), and the like) without any substantial degree of combustion of any component of the article or device. In the sense that the aerosol is derived from a byproduct of the combustion or pyrolysis of tobacco, the aerosol delivery device may not produce smoke; rather, the article or device may produce vapors derived from the volatile or vaporized components of the article or device (including vapors within an aerosol that can be considered as a visible aerosol, which may be considered as smoke-like). In a highly preferred embodiment, the aerosol delivery device may incorporate components containing tobacco and / or derived from tobacco.

[0202] The aerosol delivery device of this disclosure can also be characterized as a vapor-generating article or a pharmaceutical delivery article. Therefore, the article or device can be adapted to deliver one or more substances (e.g., flavoring agents and / or active pharmaceutical ingredients) in an inhalable form or state. For example, an inhalable substance can be in the form of a vapor (i.e., a substance that is in the gaseous phase at temperatures below its critical point). Alternatively, an inhalable substance can be in the form of an aerosol (i.e., a suspension of fine solid particles or droplets in a gas). For simplicity, the term "aerosol" as used herein intentionally includes vapors, gases, and aerosols in forms or types suitable for human inhalation, whether visible or not, and whether or not they can be considered as smoke.

[0203] In use, the aerosol delivery device of this disclosure can withstand many of the physical actions a person takes when using a conventional type of tobacco product (e.g., a cigarette, cigar, or pipe used by lighting and inhaling tobacco). For example, a user of the aerosol delivery device of this disclosure can hold the product, very similar to a conventional type of tobacco product, inhale from one end of the product to inhale the aerosol produced by the product, exhale smoke at selected time intervals, etc.

[0204] The aerosol delivery device disclosed herein generally comprises several components provided within an outer body or shell. The overall design of the outer body or shell can vary, and the format or construction of the outer body, which 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 modular shell; or the elongated body can be formed from two or more separable components. For example, the aerosol delivery device may include an elongated shell or body, which may be generally tubular in shape and therefore similar in shape to a conventional cigarette or cigar. In one embodiment, all components of the aerosol delivery device are contained within a single outer body or shell. Alternatively, the aerosol delivery device may include two or more joined and separable shells. For example, an aerosol delivery device may have a control body at one end, the control body comprising an outer body or shell containing one or more reusable components (e.g., a rechargeable battery and various electronic devices for controlling the operation of the article), and an outer body or shell removably attached thereto at the other end, the outer body or shell containing a disposable portion (e.g., a disposable scented cartridge). Given the further disclosure provided herein, more specific formats, constructions, and arrangements of components within a single-shell type unit or a multi-piece separable-shell type unit will become apparent. Additionally, various aerosol delivery device designs and component arrangements can be understood after considering commercially available electronic aerosol delivery devices (e.g., those representative products listed above in this disclosure). For example, embodiments of an aerosol delivery device including multiple outer bodies and a coupler are described in U.S. Patent Application Serial No. 14 / 170,838, filed February 3, 2014, by Bless et al., which is incorporated herein by reference in its entirety as described above.

[0205] The aerosol delivery device disclosed herein most preferably includes one combination of the following: a power source (i.e., an electrical power supply); at least one control component (e.g., a component for actuating, controlling, regulating, and stopping the power used for heat generation by controlling the current flow from the power source to other components of the article); a heater or heat generation component (e.g., a resistance heating element or component commonly referred to as an "atomizer"); and an aerosol precursor composition (e.g., a liquid that is typically capable of producing an aerosol after sufficient heat is applied, such as components commonly referred to as "e-liquid," "e-fluid," and "e-oil"); and a mouthpiece region or tip for allowing aspiration of the aerosol delivery device to inhale the aerosol (e.g., through a defined airflow path across the article, such that the generated aerosol can be withdrawn from it after aspiration).

[0206] The alignment of the components within the aerosol delivery device can vary. In a particular embodiment, the aerosol precursor composition may be located near one end of the article (e.g., within a cartridge, which may in some cases be replaceable and disposable), said end being configured to be positioned close to the user's mouth to maximize aerosol delivery to the user. However, other configurations are not excluded. Generally, a heating element may be positioned sufficiently close to the aerosol precursor composition such that heat from the heating element causes the aerosol precursor (and one or more flavorings, pharmaceuticals, or the like that may be used for delivery to the user) to evaporate and form an aerosol for delivery to the 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 the consumer. It should be noted that the foregoing terms are intended to be interchangeable, such that references to release, released, released out, or released include formation or generation, formed or generated, formed out or generated out, and formed or generated. Specifically, the inhalable substance is released in the form of vapor or aerosol or a mixture thereof. In addition, after considering commercially available electronic aerosol delivery devices (such as those representative products listed above in this disclosure), one can understand the selection of various aerosol delivery device components.

[0207] The aerosol delivery device incorporates a battery or other power source to provide sufficient current to supply the article with various functionalities (e.g., power to the heater, power to the control system, power to the indicator, and the like). The power source can take various forms. Preferably, the power source is capable of delivering sufficient power to rapidly heat the heating element to form an aerosol and to power the article by use for the desired duration. The power source is preferably sized to fit conveniently within the aerosol delivery device, allowing for easy disposal of the aerosol delivery device; and additionally, the power source is preferably lightweight enough not to impair the desired smoking experience.

[0208] Figure 1 This describes an example embodiment of the aerosol delivery device 100. Specifically, Figure 1 This illustration shows a partially exploded view of an aerosol delivery device 100 comprising a cartridge 200 and a control body 300. The cartridge 200 and the control body 300 can be functionally and permanently or detachably aligned. Various mechanisms can connect the cartridge 200 to the control body 300 to achieve threaded engagement, press-fit engagement, interference engagement, magnetic engagement, or the like. In some embodiments, when the cartridge 200 and the control body 300 are in an assembled configuration, the aerosol delivery device 100 can be generally rod-shaped, generally tubular, or generally cylindrical.

[0209] In certain embodiments, one or both of the cartridge 200 and the control unit 300 may be described as disposable or reusable. For example, the control unit 300 may have a replaceable or rechargeable battery and thus can be combined with any type of recharging technology, including connection to a typical AC power outlet, connection to a car charger (i.e., a cigarette lighter socket), and connection to a computer (e.g., via a Universal Serial Bus (USB) cable). Furthermore, in some embodiments, the cartridge 200 may 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 This illustration shows an exploded view of the control body 300 of an aerosol delivery apparatus 100 according to an exemplary embodiment of the present disclosure. As illustrated, the control body 300 may include a coupler 302, an outer body 304, a sealing member 306, and an adhesive member 308 (e.g., The device includes an adhesive tape, a flow sensor 310 (e.g., a smoke sensor or pressure switch), a control assembly 312, a spacer 314, a power source 316 (e.g., a rechargeable battery), a circuit board with an indicator 318 (e.g., a light-emitting diode (LED)), a connector circuit 320, and an end cap 322. Examples of power sources are described in U.S. Patent Application Publication No. 2010 / 0028766 by Peckerar et al., the disclosure of which is incorporated herein by reference in its entirety.

[0211] Regarding flow sensor 310, representative current regulation components and other current control components for various microcontrollers, sensors, and switches used in aerosol delivery devices are described in the following: U.S. Patent No. 4,735,217 to Gerth et al.; all of them are 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 entirety. Reference is also made to the control scheme 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, indicator 318 may include one or more light-emitting diodes (LEDs). Indicator 318 may communicate with control component 312 via connector circuitry 320 and illuminate, for example, during inhalation by a user on a cartridge coupled to coupler 302, as detected by flow sensor 310. End cap 322 may be adapted to make the illumination provided by indicator 318 visible beneath it. Thus, indicator 318 may illuminate during use of aerosol delivery device 100 to simulate the lit end of a tobacco product. However, in other embodiments, indicator 318 may be provided in different numbers and may present different shapes and may even be an opening in the external body (e.g., for emitting sound when these indicators are present).

[0213] Additional components can be used in the aerosol delivery device disclosed herein. For example, U.S. Patent No. 5,154,192 to Sprinkel et al. discloses an indicator for tobacco products; U.S. Patent No. 5,261,424 to Sprinkel, Jr. discloses a piezoelectric sensor that can be associated with the mouthpiece of the device to detect user lip movements associated with inhalation and subsequently trigger heating; U.S. Patent No. 5,372,148 to McCafferty et al. discloses a smoke sensor for controlling the flow of energy into a heated load array via a drip tip in response to a pressure drop; U.S. Patent No. 5,967,148 to Harris et al. discloses a socket in a tobacco device that includes an identifier for detecting non-uniformity of infrared transmittance of an inserted component and a controller for executing a detection routine when the component is inserted into the socket; U.S. Patent No. 6,040 to Fleischhauer et al. 560 describes a defined executable power cycle with multiple differential phases; U.S. Patent No. 5,934,289 to Watkins et al. discloses a photonic light guide luminescent component; U.S. Patent No. 5,954,979 to Counts et al. discloses a component for altering the draw resistance through a smoke device; U.S. Patent No. 6,803,545 to Blake et al. discloses a specific battery configuration for use in a smoke device; U.S. Patent No. 7,293,565 to Griffen et al. discloses various charging systems for use with smoke devices; U.S. Patent No. 8,402,976 to Fernando et al. discloses a computer interface component for smoke devices 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 smoke devices; and WO 2010 / 003480 to Flick discloses a fluid flow sensing system for indicating smoke in an aerosol generation system; all of the foregoing disclosures are incorporated herein by reference in their entirety.Further examples of components relating to electronic aerosol delivery articles and disclosing materials or components that can be used in the 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. Patent No. 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; and U.S. Patent No. 7,513,253 to Kobayashi. Amano's U.S. Patent No. 7,896,006; Shawan's U.S. Patent No. 6,772,756; Hon's U.S. Patent Nos. 8,156,944 and 8,375,957; Hon's U.S. Patent Application Publication Nos. 2006 / 0196518 and 2009 / 0188490; Thorens et al.'s U.S. Patent Application Publication No. 2009 / 0272379; Monsees et al.'s U.S. Patent Application Publication Nos. 2009 / 0260641 and 2009 / 0260642; Oglesby et al.'s U.S. Patent Application Publication Nos. 2008 / 0149118 and 2010 / 0024834; Wang's U.S. Patent Application Publication No. 2010 / 0307518; Hon's WO WO 2010 / 091593; Foo WO 2013 / 089551; and U.S. Patent Application Serial No. 13 / 841,233, filed March 15, 2013, are all incorporated herein by reference in their entirety. The various materials disclosed in the foregoing documents can be incorporated into the apparatus of the present invention in various embodiments, and all of the foregoing disclosures are incorporated herein by reference in their entirety.

[0214] Return to Figure 1The cartridge 200 is described in detail below. As illustrated, according to an exemplary embodiment of the present disclosure, the cartridge 200 may include a base shipping plug 202, a base 204, a control component terminal 206, an electronic control component 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 may be coupled to a first end of the outer body 216, and the drip tip 220 may be coupled to an opposite second end of the outer body to enclose the remaining components of the cartridge 200 therein. The base 204 may be configured to engage a coupler 302 of a control body 300. In some embodiments, the base 204 may include 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 may be configured to engage and protect the base 204 prior to the use of the cartridge 200. Similarly, the drip tip shipping plug 222 may be configured to engage and protect the drip tip 220 prior to the use of the cartridge 200. The control component terminal 206, electronic control component 208, flow tube 210, atomizer 212, and reservoir substrate 214 may be held within the outer body 216. A label 218 may at least partially surround the outer body 216 and contain information such as a product identifier thereon.

[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 described, the liquid delivery element 238 can be in direct contact with the heating element 240. Figure 1 Further explanation indicates that the heating element 240 may include wires defining a plurality of coils wound around the liquid delivery element 238. In some embodiments, the heating element 240 may be formed by winding wires around the liquid delivery 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. Additionally, in some embodiments, the wires may define a variable coil spacing, 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 constructed to generate heat when an applied current passes through can be used to form the heating element 240. Examples of materials that can be used to form the wire coils include batar alloy (FeCrAl), nickel-chromium alloys, molybdenum disilicide (MoSi2), molybdenum silicide (MoSi), aluminum-doped molybdenum disilicide (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 the method can be used to form the heating element 240, and various other embodiments of the heating element can be used in the 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. Furthermore, additional representative heating elements and materials used therein are described in the following: U.S. Patent No. 5,060,671 to Counts et al.; U.S. Patent No. 5,093,894 to Deevi et al.; U.S. Patent No. 5,224,498 to Deevi et al.; Sprinkel... The disclosures of U.S. Patent Nos. 5,228,460 to Jr. et al.; 5,322,075 to Deevi et al.; 5,353,813 to Deevi et al.; 5,468,936 to Deevi et al.; 5,498,850 to Das et al.; 5,659,656 to Das et al.; 5,498,855 to Deevi et al.; 5,530,225 to Hajaligol; 5,665,262 to Hajaligol; 5,573,692 to Das et al.; and 5,591,368 to Fleischhauer et al. are incorporated herein by reference in their entirety. Furthermore, chemical heating may 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 herein by reference as described above.

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

[0221] A first heating terminal 234a and a second heating terminal 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. Furthermore, when the control body 300 is coupled to the cartridge 200, the electronic control component 208 can form an electrical connection with the control body via control component terminals 206. The control body 300 can therefore use the electronic control component 208 to determine whether the cartridge 200 is genuine and / or to perform other functions. Furthermore, various examples of the electronic control component and the functions thereby performed 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, the user can inhale through the drip tip 220 of the cartridge 200 of the aerosol delivery device 100. This draws air through an opening in the control body 300 or the cartridge. For example, in one embodiment, the opening may 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, in other embodiments, the airflow may be received through other parts of the aerosol delivery device 100. As described above, in some embodiments, the cartridge 200 may include a flow tube 210. The flow tube 210 may be configured to direct the airflow received from the control body 300 to the heating element 240 of the atomizer 212.

[0223] Sensors in the aerosol delivery device 100 (e.g., a smoke or flow sensor in the control body 300) can sense smoke. When smoke is sensed, the control body 300 can direct current to the heating element 240 via a circuit including a first heating terminal 234a and a second heating terminal 234b. The heating element 240 can then vaporize the aerosol precursor composition guided from the reservoir substrate 214 to the atomization zone via the liquid delivery element 238. Therefore, the drip tip 220 can allow air and entrained vapor (i.e., components of the aerosol precursor composition in inhalable form) to be delivered from the cartridge 200 to the consumer inhaling on it.

[0224] Various other details regarding the components that may 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, its Figure 7 An enlarged exploded view illustrating the base and control component terminals; Figure 8 An enlarged perspective view illustrating the base and control component terminals within the assembly structure; 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, the entire cartridge may be formed from one or more carbon materials, which can offer advantages in terms of biodegradability and wire elimination. In this regard, the heating element may include carbon foam, the reservoir may include carbonized fabric, and graphite may be used to form electrical connections with the battery and controller. Example embodiments of carbon-based cartridges are provided in U.S. Patent Application Publication No. 2013 / 0255702 by Griffith et al., which is incorporated herein by reference in its entirety.

[0228] As mentioned above, a cartridge for an aerosol delivery device can comprise many components. Some of these components may be relatively small and / or relatively intricate. Therefore, precision manufacturing techniques may be required to form the aerosol delivery device. Traditionally, aerosol delivery devices have been formed via manual assembly. However, manual assembly of aerosol delivery devices suffers certain drawbacks. The quality of aerosol delivery devices manufactured manually is only comparable to that of the worker performing the task. Furthermore, even skilled workers can sometimes make mistakes. Additionally, labor can be relatively expensive. Therefore, due to these and other problems associated with the manual manufacture of aerosol delivery devices, it may be desirable to manufacture them in an automated manner. Therefore, the automated manufacturing of cartridges for aerosol delivery devices is discussed below, which can provide enhanced repeatability, lower costs, and / or avoid the aforementioned problems.

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

[0230] As illustrated, system 400 may include various subsystems that perform specific functions in the formation of the finished cartridge 200. It should be noted that although the subsystems are described as separate from each other, they may overlap. For example, in some embodiments, common devices may perform two or more functions (e.g., assembly and filling or capping and labeling) rather than performing a specific function by a single device.

[0231] Furthermore, the various subsystems and their portions are available individually. In this regard, while the subsystems and their portions are generally described herein as being usable together, this is done by way of example. Thus, any of the subsystems or portions described herein may be used alone or in any combination with some or all of the other subsystems and their portions described herein. Thus, for example, while exemplary embodiments of the cartridge filling subsystem are described below as being used to fill cartridges filled by embodiments of the cartridge assembly subsystem disclosed herein, the cartridge filling subsystem may be used to fill cartridges formed by other subsystems and / or cartridges assembled by the cartridge assembly subsystem may be filled by other cartridge filling subsystems. Furthermore, while specific embodiments of portions of the subsystems are disclosed below, these embodiments are provided for illustrative purposes only. Thus, in some embodiments, the subsystem may contain fewer or additional portions. Therefore, not every portion of each subsystem, nor every portion of the overall system, is required in all embodiments.

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

[0233] System 400 may additionally include an inspection subsystem 418. Inspection subsystem 418 may inspect component 406, unfilled cartridge 404, filled cartridge 410, capped cartridge 414, and / or finished cartridge 200. Furthermore, in some embodiments, the cartridge may be inspected at an intermediate completion state at one or more of the cartridge assembly subsystem 402, cartridge filling subsystem 408, cartridge capping system 412, and cartridge labeling subsystem 416. Therefore, cartridge 200 and its components can be inspected before, during, and after completion.

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

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

[0236] Figure 4 This section describes an example embodiment of the cigarette cartridge assembly subsystem 402. It should be noted that specific embodiments of the substation and its location may differ from those described below. Figure 4 The embodiments described herein differ from those described elsewhere. Furthermore, the specific operations employed and their order may also vary. In this regard, the equipment used to assemble the cartridges may depend on the specific construction of the final product cartridge. In this regard, the cartridge 200 described above and referenced below is discussed for illustrative purposes only. Additionally, although the description generally refers to portions of the cartridge assembly subsystem 402 as substations, it should be understood that the various assembly operations discussed herein may be performed by a single device, apparatus, or substation, or distributed among multiple devices, apparatuses, and substations. Therefore, the description provided below is for illustrative purposes only, and the equipment and operations employed and their order may vary without departing from the scope of this disclosure. Furthermore, it should be understood that the various substations and the operations performed at each substation should be considered as individual inventive aspects. In this regard, although individual substations and operations are generally described herein as part of a system, each substation may operate independently of and / or in combination with other substations discussed herein.

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

[0238] The cartridge assembly subsystem 402 can assemble cartridges (e.g., cartridge 200) in various ways. For example, in one embodiment, the cartridge can be assembled generally from the base upwards. In other words, components can be inserted into or additionally coupled to the base to build the cartridge from the base.

[0239] In this regard, such as Figure 5 and 6 As explained in the description, in one embodiment, the delivery system may include a tray 600, which may also be referred to as a "pod" or "nest", which can be used to assemble smoke cartridges 200. Figure 5 This indicates that the empty bracket is 600, while Figure 6 This describes the bracket after the base 204 is loaded therein. As illustrated, the bracket 600 may include a clamping mechanism 602. The clamping mechanism 602 may include a displaceable piston 604, which defines a head 606 at one end. A biasing mechanism may bias the displaceable piston 604 toward a recess 608. Thus, as Figure 6The description states that the head 606 of the displaceable piston 604 can cooperate with a groove 608 to hold the base 204 therein. In this respect, the groove 608 can be V-shaped so that the base 204 is centered in the groove.

[0240] Various embodiments of the biasing mechanism can be employed, such as magnets, hydraulic or pneumatic cylinders, etc. However, in the illustrated embodiment, the rod 610 can be received in a support 612. The support 612, which may also be used to align the piston 604 relative to the recess 608, may include a spring that biases the rod 610 toward the head 606 of the piston. Therefore, the head 606 of the piston 604 can be biased toward the recess 608 to hold the base 204 therein. Furthermore, the piston 604 may include a handle 614 at its end opposite the head 606. The handle 614 may be configured to allow gripping via automated or manual methods to release the base 204 against the force provided by the biasing mechanism.

[0241] The conveying system may further include rails 616 or other mechanisms configured to provide movement of the carriage between multiple substations. The carriage 600 may use wheels 618 (see example...). Figure 5 The bracket 600 is mounted to track 616. The bracket 600 can be moved along track 616 via drive wheels 618. Alternatively, magnetic propulsion can be used to move the bracket 600. However, wheels 618 can still be provided to hold the bracket on track 616. In this respect, as... Figure 7 and 8 The description indicates that the magnetic rail 620 can cause the bracket 600 to move. More specifically, the bracket 600 may further include a magnet 622. The magnetic rail 620 can change its polarity in relation to the position of the magnet 622 coupled to the bracket 600, such that the attractive and / or repulsive forces between the magnetic rail 620 and the magnet cause the bracket to move. Therefore, the bracket 600 can be transferred between various substations. In this regard, multiple brackets 600 can be provided. The bracket 600 can be configured to move between various substations described below. In this regard, the bracket 600 can be positioned in various locations along a path defined by the rail during cartridge assembly, such that at any given time, the bracket can be distributed along the length of the rail. Furthermore, multiple cartridges can be assembled simultaneously.

[0242] It may be desirable to stop or slow the movement of the tray 600 at one or more substations while performing one or more operations to simplify the coupling portion from the cartridge to the base. Furthermore, in some embodiments, it may be desirable to lock the tray 600 in a predefined position to substantially prevent movement of the tray at one or more substations. In this regard, magnetic locking of the tray's position may be insufficient to properly lock the tray in place, as magnetic locking may still allow some movement of the tray. Therefore, locking devices may be employed to temporarily constrain the movement of each tray 600 along the track 616.

[0243] The locking device may include a positioner mechanism 624 coupled to each bracket 600. In the illustrated embodiment, the positioner mechanism 624 includes first and second studs 626. Furthermore, the locking device may include an engagement mechanism 628, which can be positioned at each location where the bracket 600 needs to be locked in place. Thus, the engagement mechanism 628 may be positioned at a fixed position relative to the longitudinal length of the track 616. However, the engagement mechanism 628 may be configured to move to contact the positioner mechanism 624 (e.g., via a pneumatic piston, hydraulic piston, or linear motor) to lock the bracket 600 in place.

[0244] In the illustrated embodiment, the engagement mechanism 628 includes a cylinder 630. Therefore, when the engagement mechanism 628 is guided upward, the cylinder 630 can contact one or both of the pins 626 of the locator mechanism 624. Furthermore, the pin 626 can deflect from the cylinder 630, causing the locator mechanism 624 to become centered relative to the engagement mechanism 628. Additionally, in one embodiment, the cylinder 630 may include a roller or wheel configured to rotate, thereby facilitating centering between the pins 626 by allowing the cylinder to rotate rather than scrape against one of the pins when brought into contact. Regardless of whether the cylinder 630 rotates, any inaccuracies in the initial stopping point of the carriage 600 can be resolved by the centering effect generated by the interaction between the pins 626 of the locator mechanism 624 and the cylinder of the engagement mechanism 628. Therefore, the movement of the carriage 600 along the track 616 can be constrained by fixing the interaction between the engagement mechanism 628 and the locator mechanism 624 coupled to the carriage.

[0245] It should be noted that the locking device may include various other mechanisms configured to center the bracket relative to the engaging mechanism. For example, the locator mechanism may include a vertically oriented groove. Alternatively or additionally, the engaging mechanism may include angled components such as a triangular brace.

[0246] Therefore, the bracket 600 can be used to transport the base 204 to various substations where various components are assembled. Furthermore, as... Figure 6 and 8The description indicates that the base 204 can be loaded into the bracket 600 at the base loading substation 502. Subsequently, other components can be assembled with the base 204 (e.g., by guiding the components downwards into contact with the base) to assemble the smoke cartridge.

[0247] In this regard, as described above, control component terminal 206 and first heating terminal 234a and second heating terminal 234b can be inserted into base 204 at terminal coupling substation 504. In some embodiments, the first heating terminal 234a, second heating terminal 234b and / or control component terminal 206 can be provided from generally continuous inputs. More specifically, the first heating terminal 234a can be supplied from a generally continuous first heating terminal input, the second heating terminal 234b can be supplied from a generally continuous second heating terminal input, and / or the control component terminal 206 can be supplied from a generally continuous control component terminal input. It should be noted that the term "generally continuous" as used herein with respect to certain specified inputs refers to a construction in which the inputs referenced define stripes, chains or other groups of interconnected underlying components such that individual components can be individually separated from them.

[0248] For example, Figure 9 The description includes a generally continuous first heating terminal input 700 comprising a plurality of first heating terminals 234a. In this respect, each of the first heating terminals 234a is connected to a generally continuous carrier 702. In the illustrated embodiment, each of the first heating terminals 234a is connected to the carrier 702 via first and second couplers 704. However, in other embodiments, a single coupler or additional couplers may be used to hold the first heating terminal 234a to the carrier 702. In some embodiments, as illustrated, the first heating terminals 234a, couplers 704, and carrier 702 may be integrally formed (e.g., formed from a strip of metal sheet).

[0249] The coupler 704 can be cut to release individual first heating terminals 234a from the generally continuous first heating terminal input 700. Furthermore, the carrier 702 may include an aperture 706, a groove, a cut, or other mechanism configured to facilitate movement of the generally continuous first heating terminal input 700, allowing removal of individual first heating terminals 234a therefrom. In this regard, as... Figure 9 The description indicates that wheel 708 may include a protrusion 710 configured to engage orifice 706, such that rotation of wheel 708 causes input 700 to move toward a position from which individual first heating terminals 234a will be removed. It should be noted that while the above description is provided with respect to the first heating terminal 234a, in some embodiments, the second heater terminal 234b and / or control component terminal 206 may be supplied via a generally continuous input in a similar manner.

[0250] After insertion into the base 204, the terminal sealing substation 506 may, in some embodiments, seal one or more of the terminals 206, 234a, and 234b relative to the base to prevent liquid from flowing in or out through the terminals. However, in some embodiments, only the heating terminals 234a and 234b may be sealed. For example, in the illustrated embodiment, the control component terminal 206 may be positioned through or adjacent to an opening in the base 204 through which air inhaled by the user via the cartridge 200 passes during use. Therefore, the control component terminal 206 may not be sealed relative to the base 204 to prevent blockage of the opening extending through the base. Furthermore, the control component terminal 206 may not contact the liquid-filled reservoir substrate 214, so that liquid flowing out through the control component terminal 206 will not be a problem.

[0251] Figure 10 An example embodiment of the terminal sealing substation 506 is described. The terminal sealing substation 506 may include one or more sealant applicators 802a, 802b. In the described embodiment, a first sealant applicator 802a and a second sealant applicator 802b are used to applicate sealant supplied by the pump 804 through one or more conduits 806. A robotic arm 808 may grip a base 204 with a gripper 810. In this regard, the robotic arm 808 may position the base 204 such that it is positioned in front of the nozzles 812a, 812b of the sealant applicators 802a, 802b. For example, the gripper 810 may grip the outer surface of the base 204 and remove the base 204 from the bracket 600. Subsequently, the robotic arm 808 may 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 gripping the outside of the base 204 in this way, the gripper 810 of the robotic arm 808 will not interfere with the application of sealant, because the gripper will not be positioned between the nozzles 812a, 812b and the terminals 206, 234a, 234b extending upward from the base.

[0252] like Figure 11The description indicates that sealant applicators 802a and 802b can be positioned such that nozzles 812a and 812b at least partially point towards each other. Furthermore, the robotic arm 808 can position the base 204 and terminals 206, 234a, and 234b between the sealant applicators 802a and 802b such that nozzles 812a and 812b can guide sealant at opposite sides of the terminals. For example, sealant droplets can be ejected from nozzles 812a and 812b toward opposite sides of the heating terminals 234a and 234b. More specifically, nozzles 812a and 812b can guide sealant droplets at the interface between the heating terminals 234a and 234b and the base 204.

[0253] In some embodiments, the sealant may include a hot-melt adhesive, including polyolefins, comprising random polyalphaolefins, polyurethanes, ethylene-vinyl acetate (EVA), metallocene polyalphaolefins, block copolymers, and / or polyamides. Therefore, the terminal sealing substation 506 may further include a heater 814 capable of melting the sealant (see [link to documentation]). Figure 10 Furthermore, conduit 806 can be heated and / or insulated. The seals in pump 804 and sealant applicators 802a, 802b can conventionally employ… The material is used for lubrication. However, in some embodiments, food-grade grease or lubricant may be used instead, so as to advantageously employ food-grade manufacturing techniques in the production of the cartridges.

[0254] After the liquid sealant droplets contact the heating terminals 234a, 234b and / or the base 204, the droplets can dry relatively quickly in place. Furthermore, the droplets may not contact each other. Therefore, a complete seal around the complete interface between the heating terminals 234a, 234b and the base 204 can be formed without the initial application of sealant droplets. Therefore, the terminal sealing substation 506 may further include a remelting device, such as a hot air gun 816, configured to direct a flow of heated air from the sealant to the heating terminals 234a, 234b and / or the base 204 after the application of the sealant. Thus, the hot air from the hot air gun 816 can remelt 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 respect, the hot air gun 816 is movable relative to the base 204 and the heating terminals 234a, 234b. In some embodiments, the hot air gun 816 may be configured to be movable. However, as illustrated, in another embodiment, the hot air gun 816 may be stationary. Therefore, the robotic arm 804 can move the base 204 relative to the hot air gun 816, causing the hot air to remelt the sealant and guide it around the interface between the heating terminals 234a, 234b and the base. Thus, the sealant can be re-cured 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 may additionally or alternatively seal the control assembly terminals 206 and / or any other components of the smoke cartridge 200 relative to the base 204. Additionally, while the remelting device is described above as a hot air gun 816, in other embodiments, the sealant may be remelted by other methods and other remelting devices, such as by applying ultrasonic vibration with an ultrasonic vibrating device and / or applying radiant heat with a radiant heater. Furthermore, while the sealant is described above as a hot-melt adhesive, various other embodiments of the sealant may be employed. For example, the sealant may include epoxy resin or electro-encapsulating material. After sealing the heated terminals 234a, 234b, the robotic arm 608 may return the base 204 to the bracket 600.

[0256] Subsequently, the control component coupling substation 508 can couple the electronic control component 208 to the control component terminal 206 (e.g., by vertically inserting the control component into a slot defined by the control component terminal). 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 and then snapped into place in a longitudinal groove defined in the flow tube, wherein the horizontal slot in the flow tube engages the top of the electronic control component 208.

[0257] Next, the partially assembled cartridges can be transported to the heating element coupling substation 512, where the heating element 240 can be coupled to the heating terminals 234a and 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 section 902, a welding section 904, and a conveying device 905 configured to convey individual heating elements 240 wound around a liquid conveying element 238 from the preparation section 902 to the welding section 904.

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

[0259] As illustrated, in some embodiments, a generally continuous heating element input 906 can be supplied from a reel 908. The reel 908 can be passively rotated as the generally continuous heating element input 906 is pulled from it. Alternatively, the reel 908 can be actively rotated (e.g., by a motor) such that the reel rotates as the generally continuous heating element input 906 is pulled from it. By actively rotating the reel 908 or passively allowing the reel to rotate generally freely as the generally continuous heating element input 906 is pulled from it, tension in the generally continuous heating element input can be controlled. In this respect, applying excessive tension to the generally continuous heating element input 906 may damage the heating element 240 or the liquid delivery element 238. For example, the spacing of the coils of the heating element 240 can be altered, which may make it difficult to attach the heating element to the heating terminals. Furthermore, excessive tension in the liquid delivery element 238 can cause it to break, or stretching of the liquid delivery element can reduce its diameter and affect its ability to draw the aerosol precursor composition to the heating element 240. Therefore, a generally continuous heating element input 906 can be supplied to the preparation section 902 without damaging the heating element 240 or the liquid delivery 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 shown. In brief, the preparation portion 902 of the heating element coupling substation 512 may be configured to prepare individual heating elements 240, which are coupled to individual liquid delivery elements 238 for welding at the welding portion 904 of the heating element (see, for example, coupling substation 512). In this respect, the preparation portion 902 of the heating element coupling substation 512 may be configured to individually separate a heating element 240 and a liquid delivery element 238, such that the heating element can subsequently be coupled to a heating terminal. In this respect, in one embodiment, the individual heating element and liquid delivery element may be delivered to the preparation portion in a form that prepares them for attachment to the heating terminal without performing additional operations on them.

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

[0262] Figure 15 The illustration shows the preparation section 902 of the heating element coupling substation 512. The applicator 910 can be configured to applicate a generally continuous heating element input 906 of a certain length from the reel 908 (see [reference]). Figure 13 In this respect, the applicator 910 may include a stationary portion 916 and a movable portion 918. The movable portion 918 may include a clamp 920 configured to approximate and grip one end of a generally continuous heating element input 906. The movable portion 918 may be configured to move relative to the stationary portion 916 in a direction 922, such that the generally continuous heating element input 906 is applicated from the reel 908 (see...). Figure 13 For example, in some embodiments, the applicator 910 may include a hydraulic or pneumatic cylinder or a linear electric motor. The applicator 910 may be configured to pull a generally continuous heating element input 906 until it has been applicated to the desired length.

[0263] In this respect, the imaging device 914 can be positioned and configured to capture an image of the substantially continuous heating element input 906 when the substantially continuous heating element input 906 is applied. Controller 417 (see, for example) Figure 3The controller 417 can communicate with the imaging device 914 and is configured to analyze the images captured by the imaging device. Therefore, the controller 417 can be configured to analyze the images captured by the camera 914 to identify the positions of the generally continuous heating element inputs 906 to determine their application length.

[0264] In this regard, the applicator 910 may be configured to begin applicating a generally continuous heating element input 906, and the controller 417 may analyze its image and guide the applicator to stop applicating the generally continuous heating element input when the desired length of the generally continuous heating element input has been applicated. For example, the controller 417 may be configured to analyze the image captured by the imaging device 914 to detect coils or other features of the heating element 240. By way of a further example, in one embodiment, the controller 417 may be configured to detect a first contact portion 926 and a second contact portion 928 of the heating element 240 configured to engage heating terminals. In one embodiment, the controller 417 may determine the position of the inner edges 926a, 928a of the contact portions 926, 928 of the heating element 240. Furthermore, the controller 417 can calculate the midpoint between the contact portions 926 and 928 of the heating element 240, and allow the applicator 910 to continue applicating substantially continuous heating element inputs 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, controller 417 can guide applicator 910 to stop applicating the generally continuous heating element input 906. Additionally, controller 417 can guide conveyor 905 to grasp the generally continuous heating element input 906. For example, conveyor 905 may include clamp 930 comprising a first arm 932a and a second arm 932b, the arms being configured to grasp the generally continuous heating element input 906 outside the contact portions 926, 928 of the heating element 240. This allows the clamp to continuously hold the heating element during welding, as discussed below.

[0266] Furthermore, the controller 417 can guide the cutter 912, which may include a first blade 934a and a second blade 934b, to cut the generally continuous heating element input 906, thereby individually separating the heating element 240 and the liquid delivery element 238 into individual portions of the 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 generally continuous heating element input 906 held by the clamp 920 and the blades 934a, 934b of the cutter 912 is equal to the desired length of the individual heating element 240 and the liquid delivery 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 mentioned above, the bracket 600 can travel along track 616 to various substations. In this regard, such as Figure 17 Further explanation is provided: in some embodiments, the track 616 and the magnetic track 620 may extend to and pass through the welding portion 904 of the heating element coupling substation 512. Therefore, the bracket can deliver the base with the coupled heating terminals to the welding portion 904 of the heating element coupling substation 512. For example, as described above, when the bracket reaches the welding portion 904 of the heating element coupling substation 512, the heating terminals, control component terminals, control components, and flow tubes can be assembled to the base.

[0272] However, to facilitate soldering the heating terminals to the heating element, aligning the heating terminals with the desired configuration is desirable. In this regard, such as Figure 18 As described, the terminal fixing mechanism 944 may include a first cooperating portion 948a and a second cooperating portion 948b. The cooperating portions 948a and 948b of the terminal fixing mechanism 944 may be configured to hold the first heating terminal and the second heating terminal such that their first heating terminal tabs and second heating terminal tabs are substantially coplanar. Alternatively or additionally, the cooperating portions 948a and 948b of the terminal fixing mechanism 944 may be configured to adjust the spacing between the first heating terminal and the second heating terminal. As described, the cooperating portions 948a and 948b of the terminal fixing mechanism 944 may each define a recess 950 configured to receive a heating terminal therein.

[0273] Figures 19 to 21 The operation of the terminal fixing mechanism 944 is illustrated. Figure 19 The cooperating portions 948a and 948b of the terminal fixing mechanism 944 in the initial separation configuration are described. This initial separation configuration allows the heating terminals 234a and 234b to be received between their cooperating portions 948a and 948b. Subsequently, as... Figure 20 As explained, one or both of the cooperating portions 948a and 948b can be moved so that the cooperating portions move toward each other. When the cooperating portions 948a and 948b move toward each other, the groove 950 can cooperate to adjust the spacing between the heating terminals 234a and 234b. For example, the heating terminals 234a and 234b can move toward each other, as explained. Therefore, as... Figure 21 The description explains that when the cooperating portions 948a and 948b are clamped against the opposite sides of the heating terminals, the spacing between the heating terminals 234a and 234b can be adjusted to match the required spacing. Furthermore, by clamping the heating terminals 234a and 234b on the opposite sides between the cooperating portions 948a and 948b, the heating terminals can be held by the terminal fixing mechanism 944, making their heating terminal tabs coplanar, which facilitates the soldering of the heating element to them.

[0274] It should be noted that, Figures 19 to 21 In the embodiment described, the recesses 950 defined in the cooperating portions 948a, 948b are configured to allow the heating terminals 234a, 234b to move toward each other. However, in another embodiment, as... Figure 22 The description indicates that the terminal fixing mechanism 944' may include a first cooperating portion 948a' and a second cooperating portion 948b', each containing a groove 950' configured to adjust the spacing between 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, heating terminal 234a can be centered by providing the groove 950', which is configured to allow each heating terminal 234a, 234b to move in either of two directions. Alternatively, as understood, in another embodiment, the groove may be configured to allow only the terminals to move away from each other. Therefore, the specific shape and functionality of the groove in the cooperating portion of the terminal fixing mechanism can be chosen based on the initial configuration of the heating terminals when the base and heating terminals reach the terminal heating element coupling substation 512.

[0275] While using the terminal fixing mechanism 944 to clamp the heating terminals 234a and 234b in the plane at the required spacing, the conveying device 905 can use the clamp 930 to hold the individual heating element 240 and liquid conveying element 238, so that the heating element is in the imaging device 942 (see Figure 17 Within the field of vision of ( ). For example, such as Figure 23 As explained, the clamp 930 can initially hold the heating element 240 and the liquid delivery element 238 above the heating terminals 234a and 234b, such that the heating element is within the field of view of the imaging device 942, and thus the imaging device can determine the position of the heating element. By further example, as described above, the controller 417 (see, for example...) Figure 3 An imaging device 942 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. Therefore, the midpoint between the contact portions 926, 928 of the heating element 240 can be determined.

[0276] Similarly, the positions of heating terminals 234a and 234b can be determined. In this regard, such as Figure 23The description indicates that heating terminals 234a and 234b may each include heating terminal tabs 952a and 952b at one end of one of the contact portions 926 and 928 configured to be welded to the heating element 240. Therefore, the positions of the heating terminal tabs 952a and 952b can be determined. For example, controller 417 (or another controller) can identify the inner edges 954a and 954b of the heating terminals 234a and 234b from an image captured by imaging device 942. Furthermore, controller 417 can determine the midpoint between the heating terminal tabs 952a and 952b.

[0277] Therefore, the conveying device 905 can move the heating element 240 and the liquid conveying element to a suitable position for welding the heating element to the heating terminals 234a, 234b. In this regard, the controller 417 can guide the conveying device 905 to align the midpoint between the first heating terminal tab 952a and the second heating terminal tab 952b and the midpoint between the first contact portion 926 and the second contact portion 928. Furthermore, the controller 417 can guide the conveying device 905 to bring the heating element 240 into engagement with the heating terminal tabs 952a, 952b. Specifically, the conveying 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 may guide the conveying device 905 to press the heating element 240 against the heating terminal tabs 952a, 952b, causing the heating terminals 234a, 234b to be slightly displaced (e.g., a distance from about 0.002 inches to about 0.006 inches, and preferably about 0.004 inches). In this respect, by pressing the heating element 240 against the heating terminal tabs 952a, 952b (e.g., in a direction perpendicular to its generally flat front surface), contact between the heating element and the heating terminals 234a, 234b can be ensured.

[0278] Therefore, as Figure 24 The description states that laser 940 can weld heating element 240 to heating terminals 234a and 234b. Laser 940 can weld heating element 240 to first heating terminal 234a and second heating terminal 234b by guiding a laser beam to the first heating terminal tab 952a and the second heating terminal tab 952b. (As described above...) Figure 24 The description states that a laser beam can be guided to the back side of the first heating terminal tab 952a and the second heating terminal tab 952b opposite to the heating element 240. Therefore, the energy from the laser beam can heat the heating terminal tabs 952a and 952b, causing them to weld to the contact portions 926 and 928 of the heating element, thereby completing the atomizer 202 (see example...). Figure 1In the illustrated embodiment, the laser is directed at a first position 956a and a second position 956b on each of the heating terminal tabs 952a, 952b to provide a relatively safe soldering. However, in other embodiments, the laser beam can be directed at a larger or smaller number of positions. It should be noted that by directing the laser beam at the heating terminal tabs 952a, 952b, problems concerning damage to the heating element 240 can be avoided by applying heat indirectly rather than directly to the heating element.

[0279] It should be noted that Figure 23 The heating element 240 described herein includes wires defining a variable coil pitch. A variable coil pitch can be used to provide a relatively tight coil pitch for the contact portions 926, 928. This relatively tight coil pitch at the contact portions 926, 928 facilitates soldering of the heating terminals 234a, 234b to these locations where the heating terminals can be attached by providing more wire material.

[0280] The central portion 929 of the heating element 240, defined between contact portions 926, 928, can be used to generate heat when current is supplied therethrough via heating terminals 234a, 234b. The coil spacing at the central portion 929 of the heating element 240 can be greater than the coil spacing at the contact portions 926, 928 because the central portion is not used for attachment to the heating terminals 234a, 234b. However, the coil spacing at the central portion 929 of the heating element 240 can be smaller than the spacing of optional coils at the outer portions 931a, 931b of the conductors positioned outside the contact portions 926, 928 of the heating element. In this respect, the outer portions 931a, 931b may not generate heat or facilitate attachment to the heating terminals 234a, 234b, and therefore the coil spacing can be relatively large to reduce the material used in the conductors during the formation of the heating element 240. In some embodiments, the outer portions 931a, 931b may be provided to facilitate the fabrication of a generally continuous heating element input 906 (see, for example...). Figure 13 Various other details regarding atomizers employing 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 as described above.

[0281] It should be noted further that the aforementioned coil spacing, applicable to any atomizer described herein, may not be uniform throughout every section of the conductor. In this respect, there may be some variation in the coil spacing within one or more sections of the conductor. For example, the coil spacing may vary at the center of the heating element. Thus, by way of a further example, the aforementioned variation in coil spacing may involve the average coil spacing across every section of the conductor.

[0282] After welding, the bracket 600 with the partially assembled smoke cartridge 200 can be guided to the liquid delivery element bending substation 514. The liquid delivery element bending substation 514 can be configured to bend the liquid delivery element 238 such that its end extends downward along the heating element terminals 234a, 234b. However, the liquid delivery element 238 and / or the wires wound on it may have some degree of elasticity and tend to return to their initial straight configuration after bending.

[0283] In this regard, such as Figure 25 As described, in some embodiments, the bracket 600 may further include pivotable arms 632a, 632b configured to engage the ends of the liquid delivery element 238 such that the ends of the liquid delivery element are held against the heating terminals 234a, 234b. In this regard, the pivotable arms 632a, 632b may be configured to apply force to the liquid delivery element 238 to hold the liquid delivery element against the heating terminals 234a, 234b. For example, a magnet and / or a spring may 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 may include magnetic components 634a, 634b that cooperate with the stationary magnetic base components 636a, 636b of the bracket 600 to bias the pivotable arms 632a, 632b against the liquid delivery element 238. However, various other biasing mechanisms may be employed in other embodiments.

[0284] After the liquid delivery element 238 is bent and held in the bent configuration by pivotable arms 632a, 632b, the bracket 600 can be guided to the reservoir coupling substation 516. For example... Figure 26 The description indicates that the reservoir coupling substation 516 may include a reel 1002. The reel 1002 may be configured to supply a generally continuous reservoir substrate input 1004 from which individual reservoir substrates may be cut. Tension in the generally continuous reservoir substrate input 1004 can be controlled to prevent stretching of the reservoir substrate material, which could affect its liquid storage and transport characteristics. In this regard, in some embodiments, the generally continuous reservoir substrate input 1004 may be actively supplied from the reel 1002 (e.g., via a belt 1006) rather than pulled from the reel 1002. However, in other embodiments, the generally continuous reservoir substrate input 1004 may be passively supplied.

[0285] Figure 27 and 28Individual reservoir substrates are individually separated from the generally continuous reservoir substrate input 1004 supplied from the reel 1002. In this regard, as described, the reservoir coupling substation 516 may further include a movable clamp 1008 and a stationary clamp 1009. The movable clamp 1008 may be configured to pull a predefined amount of the generally continuous reservoir substrate input 1004 downwards into the cutter 1010. In this regard, Figure 27 The movable clamp 1008 is described at the upper limit, where it grips the generally continuous reservoir substrate input 1004. Figure 28 The movable clamp 1008 is described at the lower limit. When the movable clamp 1008 reaches the lower limit, the movable clamp has moved a predefined length of substantially continuous reservoir substrate input 1004 into a cutter 1010, which cuts the substantially continuous reservoir substrate input to define individual reservoir substrates with the desired length.

[0286] Furthermore, when the movable clamp 1008 reaches its lower limit, the stationary clamp 1009 grips the substantially continuous reservoir substrate input 1004. Therefore, movement of the substantially continuous reservoir substrate input 1004 is prevented during the cutting of the substantially continuous reservoir substrate input 1004 into individual reservoirs of the desired length. Additionally, the stationary clamp 1009 prevents undesirable upward movement of the substantially continuous reservoir substrate input 1004 by continuously holding the substantially continuous reservoir substrate input as the movable clamp 1008 returns to its upper limit. Once the movable clamp 1008 reaches its upper limit and grips the substantially continuous reservoir input 1004, the stationary clamp 1009 can release the substantially continuous reservoir substrate input to allow the movable clamp to pull a predefined amount of the substantially continuous reservoir substrate input downward into the cutter 1010, as described above.

[0287] After a single output, the transfer mechanism 1012 can receive the storage substrate. For example... Figure 28 and 29 The description indicates that the transfer mechanism 1012 may include a head portion 1014 configured to hold the reservoir substrate in a releasable manner. In some embodiments, the head portion 1014 of the transfer mechanism 1012 may be configured to apply a vacuum to the reservoir substrate thereon. In this regard, the head portion 1014 may define a plurality of orifices for applying the vacuum. However, in other embodiments, the reservoir may be held on the transfer mechanism 1012 by means of a clamp or other mechanical mechanism.

[0288] like Figure 29The description indicates that the conveying mechanism 1012 may be configured to receive a reservoir substrate from the cutter 1010 and transport the reservoir substrate to the winding mechanism 1016. In this regard, the conveying mechanism 1012 may travel along a longitudinal path 1018 and then along a transverse path 1020 to transport the reservoir substrate to the winding mechanism 1016. The winding mechanism 1016 may include a head portion 1022 configured to receive the reservoir substrate. The head portion 1022 of the winding mechanism 1016 may employ a vacuum to hold the reservoir substrate. In this regard, the head portion 1022 of the winding mechanism 1016 may define a plurality of orifices on its inner surface for applying a vacuum. In some embodiments, during the transport of the reservoir substrate from the head portion 1014 of the conveying mechanism 1012 to the head portion 1022 of the winding mechanism 1016, the vacuum at the head portion of the conveying mechanism may be switched to a positive pressure. Therefore, the air guided from the head portion 1014 of the conveying mechanism 1012 can push the reservoir substrate toward the head portion 1022 of the winding mechanism 1016, which can be used to firmly bond the reservoir substrate using the vacuum applied thereto.

[0289] After receiving the reservoir substrate from the transfer mechanism 1012, the winding mechanism 1016 can spin (e.g., about 180 degrees) so that its head portion 1022 is positioned close to the track 616, as... Figure 30 The description continues. In this regard, the bracket 600 can deliver partially assembled cartridges to the storage coupling substation 516. For example, the partially assembled cartridges can be defined as described above and... Figure 25 The configuration described herein includes a liquid delivery element 238 that is bent and held in place by pivotable arms 632a, 632b.

[0290] Figures 30 to 32 This describes the movement of a portion of the storage coupling substation 516 during the addition of the storage substrate to the cartridge. It should be noted that... Figures 30 to 32 For clarity, the components of the bracket and the cartridge coupled thereto are not described. However, as... Figures 30 to 32 The description further indicates that the reservoir coupling substation 516 may include fingers 1024a, 1024b, which cooperate with the head portion 1022 of the winding mechanism 1016 to wind the reservoir substrate around the cartridge assembly. In short, Figure 30 This describes the movement of the head portion 1022 of the winding mechanism 1016 in the direction 1026 toward the location where the smoke cartridge will be located. For example... Figure 31 The description states that the fingers 1024a and 1024b can then move in a direction 1028 toward the location where the smoke cartridge will be located. Furthermore, as... Figure 32 The description states that the fingers 1024a and 1024b can move in directions 1030a and 1030b toward each other. For example... 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 illustrated, in some embodiments, one or both of the fingers 1024a, 1024b may engage the reservoir substrate 214 such that the reservoir substrate remains at least partially wrapped around the atomizer when the reservoir substrate is initially inserted into the outer body 216 via the outer body coupling tool 1002. In this respect, the fingers 1024a, 1024b may prevent the reservoir substrate 214 from unwinding as the outer body 216 is inserted over the reservoir substrate. However, the fingers 1024a, 1024b may be released 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 unwinding is substantially reduced.

[0300] It should be noted that in some embodiments, multiple sets of fingers 1024a, 1024b, 1024a', 1024b', 1024a”, 1024b” may be used to hold the reservoir substrate 214 in the wound structure, such as Figure 36A As explained below, when the reservoir substrate 214 is inserted into the external body 216 via the external body coupling tool 1002, the fingers 1024a, 1024b, 1024a', 1024b', 1024a”, and 1024b” can be released sequentially. For example, when the reservoir substrate 214 is inserted into the external body 216, the first set of fingers 1024a and 1024b can be released, followed by the second set of fingers 1024a' and 1024b', and then the third set of fingers 1024a” and 1024b”. By employing multiple sets of fingers at different positions along the longitudinal length of the partially assembled cartridge, the reservoir substrate can be more securely held in the winding structure during insertion into the external body, thus avoiding problems regarding the movement of the reservoir substrate from the winding structure.

[0301] Furthermore, in some embodiments, the external body coupling tool 1102 can be twisted during the insertion of the reservoir substrate 214 into the external body 216 via the external body coupling tool, such as... Figure 36 and 36AThe description is as follows. Specifically, the external body coupling tool 1102 can be twisted about its longitudinal axis 1114. Therefore, 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 rotations in first and second opposing directions 1116a, 1116b during insertion, which can reduce the chance of movement of the reservoir substrate 214 during insertion into the external body 216 via the external body coupling tool. It should be noted that in some embodiments, a segment 1102a of the external body coupling tool 1102 can be clamped onto the external body 216, causing the external body to rotate with the external body coupling tool. Therefore, friction between the external body 216 and the reservoir substrate 214 can be reduced. Therefore, the torsional movement of the outer body 216 relative to the reservoir substrate 214 can further facilitate the insertion of the reservoir substrate into the outer body.

[0302] After the reservoir substrate 214 and other components of the cartridge are inserted into the outer body 216, the outer body can be coupled to the base 204. In this regard, the outer body coupling substation 518 may further include a curler 1118, such as Figure 37 As described below. In some embodiments, the curler 1118 may include a plurality of segments 1118a. For example, in Figure 37 In the embodiment described herein, the curler 1118 includes four substantially identical segments 1118a. In this respect, the use of a curler including four or more segments can curl the outer body more uniformly than a curler defining fewer segments, thus preventing leakage between the outer body and the base. However, in other embodiments, the number of segments can vary. For example, two or more segments may be used.

[0303] Figure 38 Explain one of the segments 1118a of the curler 1118. As explained, each segment 1118a may include a lip 1120 configured to curl the outer body 216. Figure 39 Explanation from Figure 38 An enlarged view of section A. As illustrated, in Figure 39In this configuration, the angled portion 1122 extends from the lip 1120 to the inner surface 1124 of the section 1118a of the curler 1118. In some embodiments, the angled portion 1122 of the section 1118a may define an angle 1126 relative to the longitudinal axis 1128 of the curler 1118, along which the curler receives the outer body 216 from about 10 degrees to about 15 degrees, and preferably about 12 degrees. In this respect, the angled portion 1122 can provide a smooth transition from the curl formed in the outer body 216 by the lip 1120 to the remainder of the outer body. Furthermore, leakage between the outer body 216 and the base 204 can be largely avoided.

[0304] therefore, Figures 4 to 39 This describes one embodiment of the cartridge assembly subsystem 402. However, it will be understood that various other embodiments of the cartridge assembly subsystem can be used to assemble cartridges according to embodiments of this disclosure. In this regard, Figure 40 This illustration illustrates a cartridge assembly subsystem 402' according to another embodiment of the present disclosure.

[0305] As described, the cartridge assembly subsystem 402' may include a base loading substation 1202, a terminal coupling substation 1204, a terminal sealing substation 1206, a control component 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 external body coupling substation 1218. Furthermore, the controller 417 may be configured to control one or more of the substations 1202 to 1218 of the cartridge assembly subsystem 402'. Therefore, the cartridge assembly subsystem 402' can be similar to that described above and... Figures 4 to 39 The cartridge assembly subsystem 402 is described below. Therefore, for the sake of brevity, the description of the cartridge assembly subsystem 402' provided below will focus primarily on the differences from the previously described cartridge assembly subsystem 402.

[0306] In this regard, the cartridge assembly subsystem 402 described above generally assembles cartridges upward from the carrier 600, which is transported between the various subsystems. More specifically, the carrier 600 will be generally paused at each substation, so that the base 204 is in a stationary position, wherein the components move to contact it from above.

[0307] However, the cartridge assembly subsystem 402' described below differs in that the base 204 is generally guided to contact the stationary component to form a cartridge. Specifically, in some embodiments, the base 204 may be flipped and generally guided downward to engage with the component to form a cartridge. Figure 41This is a top view illustrating one embodiment of the cartridge assembly subsystem 402'. In this respect, a robot (e.g., a robotic arm) may be configured to hold the base 204 and guide the base to contact the components during assembly to form a cartridge.

[0308] For example, such as Figure 41 The description states that multiple robots can be used to move the base 204 to engage with various components to assemble the cartridge. The robots can interact with the cartridge components and with each other to perform various assembly operations, ensuring that each robot is not specific to any particular component. Figure 40 Only one of the sub-sites 1202 to 1218 described herein is associated. However, as... Figure 41 As explained below, in one embodiment, the cartridge assembly subsystem 402' may include a control component terminal robot 1302, a heating terminal robot 1304, a robot arm 1306, a control component and flow tube robot 1308, a heating element robot 1310, a reservoir substrate robot 1312, and an external body robot 1314.

[0309] like Figure 42 The description indicates that the base loading substation 1202 may include a base feeder 1402 configured to supply base 204. In some embodiments, the base feeder 1402 may include a vibrating hopper. Furthermore, the base feeder 1402 may be oriented towards the base 204 for gripping. In this regard, the attachment end 204a of the base (see...) Figure 1 It can be oriented upwards by the base supply 1202.

[0310] As described above, in some embodiments, portions of the cartridge assembly subsystem 402' may be configured to grip the base 204 so that the base flips during cartridge assembly. Alternatively, portions of the cartridge assembly subsystem 402' may be configured to grip the inner surface 204a' of the attachment end 204a of the base 204, which is configured to engage the control body (see [link to documentation]). Figure 1 To grip the inner surface 204a' of the attachment end 204a of the base 204, appropriate grippers may be used.

[0311] In this regard, Figure 43The base gripper 1500, which can be used by a robot in the cartridge assembly subsystem 402', is described. As illustrated, the base gripper 1500 may define a plurality of segments 1502. The segments 1502 may be configured to contract (e.g., move radially inward toward each other) during insertion into the attachment end 204a of the base 204, and expand (e.g., move radially outward away from each other) 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 may assist in gripping the base 204. For example, the protrusions 1504 may be configured to engage recesses defined in the inner surface 204a' of the attachment end 204a of the base 204. In this respect, the outer surface 1506 of the segment 1502 of the base jaw 1500 may be configured to correspond to the shape of the inner surface 204a' of the attachment end 204a of the base 204. Thus, the base jaw 1500 can securely and releasably engage the base 204.

[0312] Terminal coupling substation 1204 may include control component terminal robot 1302. For example... Figure 42 The description indicates that the control component terminal robot 1302 may include a base gripper 1500. Furthermore, the control component terminal robot 1302 can grasp a base 204 supplied by a base supplier 1402. Therefore, the control component terminal robot 1302 can couple control component terminals to the base.

[0313] In this regard, such as Figure 44 The description further indicates that the terminal coupling substation 1204 may include a die 1600 configured for attachment to the control component terminal 206 of the base 204. For example, the control component terminal 206 can be cut from a generally continuous control component terminal input 1602. In this respect, a cutter 1604 can cut the control component terminal 206 from the generally continuous control component terminal input 1602.

[0314] Figure 44A This shows a magnified view of the 1600mm bare metal wafer. (Example:) Figure 44AThe description indicates that the bare die 1600 may further include a first pressure pad 1606a and a second pressure pad 1606b that can be positioned on opposite sides of the cutter 1604. When the cutter 1604 cuts the control component terminal 206 from the generally continuous control component terminal input 1602, the pressure pads 1606a and 1606b may extend to contact and press against the generally continuous control component terminal input 1602. More specifically, the first pressure pad 1606a may press against the first control component terminal 206a cut by the cutter 1604 from the generally continuous control component terminal input 1602, and the second pressure pad 1606b may press against the second control component terminal 206b that will subsequently separate from the generally continuous control component terminal input within the line. Therefore, the first control component terminal 206a can be held in the proper position while being cut from the generally continuous control component terminal input 1602, and the second control component terminal 206b is also held in the proper position, the second control component terminal then becoming the first control component terminal at the end of the generally continuous control component terminal input.

[0315] After individual branching, the first control component terminal 206a can be held in a stationary position to facilitate coupling with the base 204. More specifically, the first control component terminal 206a can be sandwiched between the backing member 1608 and the opposing pressure pad 1610. In this respect, one or both of the opposing pressure pad 1610 and the backing member 1608 can move toward the first control component terminal 206a, such that the first control component terminal is sandwiched therebetween. As illustrated, the opposing pressure pad 1610 and the backing member 1608 can define a profile that matches each control component terminal 206, such that the control component terminal can be securely held in place without affecting the shape of the control component terminal. Furthermore, the base 204 can be guided to contact the individually branched control component terminal 206. For example, the control component terminal robot 1302 can guide the base 204 downward to contact the stationary control component terminal 206, such that the control component terminal engages the base.

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

[0317] like 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] Regardless of whether the terminal-sealed substation 1206 is used, the robotic arm 1306 can place the base 204 on the third transfer component 1700C. The base 204 can then be guided to the control component coupling substation 1208 and the flow tube coupling substation 1210. In the illustrated embodiment, both the control component coupling substation 1208 and the flow tube coupling substation 1210 include and employ the control component and the flow tube robot 1308.

[0321] In this regard, such as Figure 46 As explained, the control assembly and flow tube robot 1308 can be configured to engage the base 204 at the third transfer member 1700C. For example, as illustrated, the control assembly and flow tube robot 1308 may include grippers such as base grippers 1500. Furthermore, the control assembly and flow tube robot 1308 can transfer the base 204 to the control assembly coupling substation 1208.

[0322] In addition, the control coupling substation 1208 may include a control component supplier 1802 (see Figure 41 This device is configured to supply the electronic control component 208. In some embodiments, the control component supplier 1802 may include a vibrating hopper. Furthermore, the control component supplier 1802 may be oriented in a desired manner for the electronic control component 208. For example, such as... Figure 47 As explained, each electronic control component 208 may be oriented such that the chip 208' (e.g., a memory chip) or other portions of the electronic control component are oriented upwards. In this respect, the first and second main sides of the electronic control component 208 may be asymmetrical, which may facilitate the orientation of the chip 208' by the control component supplier 1802 to extend upwards.

[0323] like Figure 47 Further explanation is provided, the electronic control component 208 can define first and second opposing longitudinal ends 208A, 208B. A connector at the first end 208A of the electronic control component 208 can be configured to engage the control component terminal 206. In this respect, as... Figure 46 As explained, the 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 component 208, depending on the direction in which the control component supplier 1802 supplies the electronic control component.

[0324] Therefore, as Figure 47As explained, based on the determined orientation of the electronic control component 208, the control component gripper 1806 can grasp the second end 208B of the electronic control component. In this regard, the control component gripper 1806 may include a first finger 1808A and a second finger 1808B configured to grip the second end 208B of the control component 208 therebetween. As explained, the first finger 1808A and the second finger 1808B may be relatively narrow. In this regard, the control component dispenser 1802 can guide the control component 208 to the support member 1810. The support member 1810 may define a first slot 1812A and a second slot 1812B configured to align with the first end 208A and the second end 208B of the electronic control component 208, respectively, when the electronic control component is received on the support member. Therefore, the grippers 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 component 208.

[0325] Furthermore, such as Figure 47 Further explanation: the control component gripper 1806 can rotate the electronic control component 208 so that its first end 208A points upward. Therefore, the control component and the flow tube robot 1308 can guide the base 204 downward such that the first end 208A of the electronic control component 208 engages the control component terminal 206. In some embodiments, the connector (e.g., a contact tab) at the first end 208A of the electronic control component 208 can be located on only one of the main sides of the electronic control component, and the control component terminal 206 can be asymmetrical and configured to engage only said particular side. Therefore, the control component and the flow tube robot 1308 can rotate the base 204 such that the desired rotational alignment of the electronic control component 208 and the control component terminal 206 is achieved when the base 204 is guided downward toward the electronic control component.

[0326] After the electronic control component 208 is coupled to the control component terminal 206, the base 204 can be guided by the control component and the flow tube robot 1308 to the flow tube coupling substation 1210. For example... Figure 41 As described, the flow tube coupling substation 1210 may include a flow tube supplier 1902 configured to supply flow tube 210. In some embodiments, the flow tube supplier 1902 may include a vibrating hopper. Furthermore, the flow tube supplier 1902 may orient the flow tube 210 in a desired manner.

[0327] The flow tube coupling substation 1210 may further include a base 1904, such 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 51The description indicates that the terminal gripper 2002 can grasp a partially assembled cartridge. Specifically, the first pair of forks 2006A and the second pair of forks 2006B can clamp the heating terminals 234a and 234b therebetween. More specifically, one of the first pair of forks 2006A and one of the second pair of forks 2006B can press against the opposite side of the first heating terminal 234a, thereby holding the first heating terminal therebetween. Similarly, one of the first pair of forks 2006A and one of the second pair of forks 2006B can press against the opposite side of the second heating terminal 234b, thereby holding the second heating terminal therebetween. As described, forks 2006A and 2006B can engage the heating terminals 234a and 234b to expose the heating terminal tabs 952a and 952b. For example, when the base 204 is oriented such that the heating terminals 234a, 234b extend downward therefrom, the forks 2006A, 2006B may engage the heating terminals slightly above the heating terminal tabs 952a, 952b.

[0331] Furthermore, by gripping the heating terminals 234a and 234b in the manner described above, the heating terminal tabs 952a and 952b can be configured in the desired positions for attachment of the heating element thereto. In this regard, as described above, the flow tube gripper 1906 can press the heating terminals 234a and 234b against the flow tube 210. Furthermore, when the terminal gripper 2002 grips the heating terminals 234a and 234b, the heating terminal tabs 952a and 952b can define the desired separation between them, as defined by the width of the flow tube 210. Additionally, when the terminal gripper 2002 presses against the opposite sides of each heating terminal tab 952a and 952b with the forks 2006A and 2006B, the heating terminal tabs can be aligned.

[0332] The heating element coupling substation 1212 may include the aforementioned heating element robot 1310. Additionally, as... Figure 52 The description indicates that the heating element coupling substation 1212 may include a preparation section 2008 and a welding section 2010. The preparation section 2008 and welding section 2010 may be connected to the aforementioned preparation section 902 and welding section 904 (see example...). Figure 12 They operate in largely the same way. In this respect, such as Figure 53 As explained herein, in some embodiments, heating elements may be supplied from a generally continuous heating element input 2012. The generally continuous heating element input 2012 may include a plurality of heating elements 240 wound around the liquid delivery element 238, as described, for example, in U.S. Patent Application Serial No. 13 / 827,994, filed March 14, 2013, and U.S. Patent Application Serial No. 13 / 708,381, filed December 7, 2012, both of which are incorporated herein by reference in their entirety.

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

[0334] In one embodiment, the position of the substantially continuous heating element input 2012 can be monitored, allowing the reel 2014 to actively supply a substantially continuous heating element input to maintain the required slack. For example, such as Figure 53 The description indicates that, in one embodiment, an upper sensor 2016a and a lower sensor 2016b may be provided, wherein a generally continuous heating element input 2012 is pulled away from the reel 2014 so that it extends between the sensors 2016a and 2016b. In one embodiment, sensors 2016a and 2016b may each include a light emitter and a light detector, the light detector being able to detect when an object blocks light from reaching the light detector. Therefore, the reel 2014 can be actively driven based on the detection of the generally continuous heating element input 2012. For example, if the upper sensor 2016a detects light obstruction caused by the generally continuous heating element input 2012, then the reel 2014 can be guided to rotate or rotate faster. Conversely, if the lower sensor 2016b detects light obstruction caused by the generally continuous heating element input 2012, then the reel 2014 can be guided to rotate slower or stop. Therefore, the tension in the generally continuous heating element input 2012 can be controlled. For example, controller 417 can communicate with sensors 2016a and 2016b and is configured to guide the rotation of reel 2014 as described above.

[0335] As described above, the preparation section 2008 of the heating element coupling substation 1212 can be substantially similar to the preparation section 902 described above. In this respect, the preparation section 2008 can be configured to prepare individual heating elements 240 coupled to the liquid delivery element 238 for welding. Therefore, the preparation section 2008 will not be described in detail.

[0336] However, in short, such 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 23A top-view imaging device can be used to determine the horizontal position of the heating terminals 234a, 234b relative to the heating element 240, enabling contact to be established therebetween. The laser 2036 can be directed towards 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., an accessory coupled to the bottom of the housing 2030) can be configured to applicate an inert gas (e.g., argon) into the chamber 2032 to improve the resulting weld (e.g., by preventing oxidation).

[0340] Furthermore, the cavity 2032 defined by the housing 2030 can be substantially sealed before the heating element 240 is soldered to the first heating terminal 234a and the second heating terminal 234b. In this regard, as... Figure 55 The description indicates that the heating element robot 1310 may include a sealing member 2038 configured to engage the housing 2030. In this regard, the sealing member 2038 of the heating element robot 1310 can abut against the housing 2030 to provide a seal when the heating terminals 234a, 234b are inserted into it. Similarly, a second sealing member 2040 can seal the conveying device 2024 to the housing 2030 when the conveying device guides the heating element 240 into the chamber 2032, and a third sealing member 2042 can create a seal between the camera 2034 and / or the laser 2036 and the housing 2030. Therefore, by substantially sealing the chamber 2032 defined by the housing, problems regarding the laser beam exiting the chamber can be avoided. Furthermore, the use of a substantially sealed chamber 2032 can facilitate the use of an inert gas by at least partially maintaining an inert gas within the chamber 2032. Moreover, as described above, various alternative attachment methods, including various other types of welding, can be used to couple the heating element to the heating terminals.

[0341] After welding, the partially assembled smoke cartridges can be conveyed to the liquid delivery element bending substation 1214. In this regard, in some embodiments, the heating element robot 1310 can convey the partially assembled smoke cartridges thereto. Figure 56 An example embodiment of the liquid delivery element bending substation 1214 is described. As illustrated, the liquid delivery element bending substation 1214 may include a first upright member 2102a and a second upright member 2102b. Upper channels 2104a and 2104b and side channels 2106a and 2106b may be defined in the upright members 2102a and 2102b.

[0342] The heating element robot 1310 can be configured to guide a partially assembled cartridge between the upright members 2102a, 2102b of the liquid delivery element bending substation 1214. More specifically, the heating element robot 1310 can orient the partially assembled cartridge so that the liquid delivery element 238 enters the upper channels 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 channels 2106a, 2106b defined at the inner surfaces of the upright members. Furthermore, as... Figure 57 The description states that the upright components 2102a and 2102b can be clamped together to cause the liquid delivery element 238 to bend more and come into contact with the heating terminals 234a and 234b.

[0343] Once the liquid delivery element 238 bends, the reservoir substrate robot 1312 can grasp the partially assembled smoke cartridge. For example... Figure 58 The description indicates that the reservoir substrate robot 1312 may include a base and a wire gripper 2202. The base and wire gripper 2202 may include a first portion 2204a and a second portion 2204b. Each of portions 2204a and 2204b may include a base gripper segment 2206. For example, in the illustrated embodiment, the base gripper segment 2206 includes a plurality of V-shaped notches that cooperate to center the base 204 therein. Furthermore, each of portions 2204a and 2204b may include a wire gripper segment 2208 configured to engage the liquid delivery element 238.

[0344] In this regard, Figure 59 The base and wire clamps 2202 that engage with the partially assembled cartridge are described. As illustrated, the base 204 can be received between the base clamp segments 2206. Furthermore, the wire clamp segments 2208 can be clamped against the end of the liquid delivery element 238. Thus, the base and wire clamps 2202 can hold the liquid delivery element 238 in a curved configuration.

[0345] The reservoir substrate robot 1312 can therefore transport the partially assembled cartridge and the liquid delivery element 238 in a curved 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 respect, as... Figure 60As described, in some embodiments, a generally continuous reservoir substrate input 2302 can be supplied from a reel 2304. The reel 2304 can be passively rotated as the generally continuous reservoir substrate input 2302 is pulled from it. Alternatively, the reel 2304 can be actively driven (e.g., by an electric motor) such that the reel rotates as the generally continuous reservoir substrate input 2302 is pulled from it. By actively rotating the reel 2304 or passively allowing the reel to rotate substantially freely as the generally continuous reservoir substrate input 2302 is pulled from it, tension in the generally continuous reservoir substrate input can be controlled to avoid damage to it.

[0346] In one embodiment, the position of the substantially continuous reservoir substrate input 2302 can be monitored, allowing the reel 2304 to actively supply the substantially continuous reservoir substrate input to maintain a desired amount of slack therein. For example, such as Figure 60 The description indicates that, in one embodiment, an upper sensor 2306a and a lower sensor 2306b may be provided, wherein a generally continuous reservoir substrate input 2302 is pulled away from the reel 2304 such that it extends between sensors 2306a and 2306b. In one embodiment, sensors 2306a and 2306b may each include a light emitter and a photodetector that can be positioned at opposite ends of slot 2308, and the photodetector can detect when an object blocks light from reaching the photodetector. Therefore, the reel 2304 can be actively driven based on the detection of the generally continuous reservoir substrate input 2302. For example, if the upper sensor 2306a detects light obstruction caused by the generally continuous reservoir substrate input 2302, then the reel 2304 can be guided to rotate or rotate more rapidly. Conversely, if the lower sensor 2306b detects light obstruction caused by the generally continuous reservoir substrate input 2302, the reel 2304 can be guided to stop or rotate more slowly. Therefore, tension in the generally continuous reservoir substrate input 2302 can be controlled. For example, the controller 417 can communicate with sensors 2306a and 2306bb and is configured to guide the rotation of the reel 2304 as described above.

[0347] A generally continuous memory substrate input 2302 can be supplied from a reel 2304 to the unitized cell 2310. For example... Figure 61 The description indicates that the unification unit 2310 may include a rotating wheel 2312 that defines a plurality of apertures 2314 on its outer surface. The apertures 2314 may be configured to apply a vacuum to a substantially continuous reservoir substrate input 2302 such that a substantially continuous reservoir substrate input is maintained thereon. Furthermore, the unification unit 2310 may include a cutter 2316, such as... Figure 62The 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 63Up to the position described above. At this point, the first arm 2328a and the second arm 2328b of the winding member 2330 can be clamped together toward each other, which can cause the reservoir substrate 214 to be wound around the partially assembled cartridge. Arms 2328a and 2328b can move simultaneously (e.g., to create a mating joint at the end of the reservoir substrate 214) or sequentially one after another (e.g., to cause one end of the reservoir substrate to be wound around the other end). In this respect, arms 2328a and 2328b can be as described above and in Figure 33 Arms 1024a and 1024b, as described in the text, operate in largely the same manner.

[0350] After the storage substrate 214 is wound, the partially assembled smoke cartridges can be guided to the external main body coupling substation 1218 by the external main body robot 1314. For example... Figure 64 The description indicates that, in addition to the external host robot 1314, the external host coupling substation 1218 may also include an external host supplier 2402 configured to supply external hosts 216 204. In some embodiments, the external host supplier 2402 may include a vibrating hopper, such as... Figure 41 The explanation is as follows.

[0351] The external body supplier 2402 can supply the external body 216 to the conveying member 2404. The conveying member 2404 can be configured to grasp individual external bodies 216 and position the external bodies for coupling to a partially assembled cartridge. In this respect, as Figure 65 The description indicates that the external body coupling substation 1218 may include an external body coupling tool 2406 configured to facilitate insertion of the reservoir substrate 214 into the external body 216, and a curler 2408 configured to curl the external body to the base 204 after the external body extends over the reservoir substrate and engages the base. A chamber 2410 defined in the curler 2408 may be configured to receive the external body 216 such that a partially assembled cartridge can be inserted therein and then the external body can be curled to the base 204.

[0352] In order to place the outer body 216 into the chamber 2410, such as Figure 66The 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 69The gripper in an assembly configuration according to an example embodiment of the present disclosure is described. As illustrated, the reservoir gripper 2420 may include a first body portion 2422a and a second body portion 2422b. The first body portion 2422a and the second body portion 2422b may be configured to releasably grip the base 204 therebetween in order to hold a partially assembled cartridge.

[0355] Furthermore, the reservoir substrate grippers 2420 may include fingers 2424 configured to hold the reservoir substrate 214 in the wound configuration. It should be noted that... Figure 67 and 68 For clarity, the reservoir substrate is not described. The finger 2424 may be movably coupled relative to the first body portion 2422a of the reservoir substrate gripper 2420. The reservoir substrate gripper 2420 may have various features configured to facilitate movement of the finger 2424 as described below. However, in the illustrated embodiment, the first body portion 2422a of the reservoir substrate gripper 2420 includes a channel 2426. The channel 2426 may be configured to receive a protrusion or pin 2428 at the upper portion of the finger 2424. In some embodiments, the channel 2426 may be generally straight. Furthermore, the finger 2424 may include an elongated aperture 2430 configured to receive a protrusion or pin 2432 coupled to the first body portion 2422a. As illustrated, in some embodiments, the elongated orifice 2430 may generally define a path extending upward and away from the tip 2434 of the finger 2424.

[0356] The fingers 2424 can be configured to hold the reservoir substrate 214 in the wound configuration. In this respect, the tips 2434 of the fingers 2424 can be configured to press against the wound reservoir substrate 214 while the external main robot 1314 delivers the partially assembled smoke cartridge to the external main coupling substation 1218. In this respect, as... Figure 63 The description states that the arms 2328a and 2328b of the winding mechanism 2318 may each include an upper protrusion 2334a and a lower protrusion 2334b that assist in the winding operation. Furthermore, the protrusions 2334a and 2334b from one arm 2328a can contact the protrusions 2334a and 2334b on the opposite arm 2334b when the arms move toward each other, resulting in a gap between the arms when the reservoir substrate is in the winding configuration.

[0357] Furthermore, while arms 2328a and 2328b hold the reservoir substrate in the winding structure, the external main robot 1314 can engage the partially assembled cartridge with the reservoir substrate gripper 2420. More specifically, the first main body portion 2422a and the second main body portion 2422b can engage the base 204 of the partially assembled cartridge. Additionally, the tips 2434 of the fingers 2424 can extend between or below the protrusions 2334a and 2334b to engage the reservoir substrate at a position where they overlap near the end of the reservoir substrate or meet at a joint. Therefore, when the arms 2328a and 2328b of the winding mechanism 2318 retract, the reservoir substrate gripper 2420 can hold the reservoir substrate 214 in the winding structure by pressing against the reservoir substrate.

[0358] Therefore, the partially assembled cartridge may include a reservoir substrate 214 that wraps around it when it is initially inserted into the external body 216 via the external body coupling tool 2406. However, the fingers 2424 may be configured to be released from the reservoir substrate 214 during the insertion of the partially assembled cartridge into the external body 216. In this respect, when the external body robot 1314 inserts the partially assembled cartridge via the external body coupling tool 2406, the fingers 2424 of the reservoir substrate gripper 2420 may contact the external body coupling tool. Therefore, while the fingers 2424 remain in contact with the external body coupling tool, the first body portion 2422a may continue to move toward the external body coupling tool 2406. Thus, the fingers 2424 may move along a path relative to the first body portion 2422a defined by the interaction between the channel 2426 and the pin 2428 and between the elongated orifice 2430 and the pin 2432. Therefore, since the channel 2426 is generally straight, the upper portion of the finger 2424 can remain generally stationary. However, since the elongated aperture 2430 defines an upward path extending away from the tip 2434 of the finger, the lower portion of the finger 2424 can be guided outward away from the reservoir substrate 214 and the rest of the partially assembled cartridge. Thus, the tip 2434 of the finger 2424 can be deflected away from and released from the reservoir substrate 214 when the external body robot 1314 inserts the partially assembled cartridge via the external body coupling tool 2406.

[0359] It should be noted that specific 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 described. The reservoir substrate gripper 2420' may be configured to grip the base 204 of the partially assembled cartridge in a manner similar to the reservoir substrate gripper 2420 described above. Furthermore, the reservoir substrate gripper 2420' may include fingers 2424' configured to releasably hold the reservoir substrate 214 in a winding configuration. In this respect, the innermost portion 2434a' of the fingers 2424' may be configured to press against the reservoir substrate 214. However, the outermost portion 2434b' may be configured to deflect outside and away from the external body coupling tool 2406 when the external body robot 1314 guides the partially assembled cartridge via the external body coupling tool. In this respect, the fingers 2424' can be released from the reservoir substrate 214 due to the deflection. Therefore, the partial assembly of the cartridges can be completed in a largely similar manner by inserting the external body coupling tool 2406.

[0360] Once the partially assembled cartridge is inserted into the outer body 216, the curler 2408 can curl the outer body into the base 204. In this respect, as Figure 65 and 66 As described, the curler 2408 may include multiple segments 2408a. For example, the curler 2408 may include at least four segments 2408a, which can facilitate a tight seal between the base and the outer body 216. Each of the segments 2408a may include a lip, an angled portion, and some or all of the features of the curler 1118 described above (see [link to documentation]). Figures 37 to 39 Therefore, section 2408a can be constructed from an open structure (see example...). Figure 65 Move to a closed structure (see example) Figure 66 The outer body 216 is rolled up to the base 204. However, it should be noted that the curler 2408 can be flipped relative to the curler 1118 described above. Furthermore, the curler 2408 can be configured to hold the outer body 216 during insertion of the partially assembled cartridge via the outer body coupling tool 2406. Therefore, in one or more aspects, the curler 2408 can differ from the curler 1118 described above.

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

[0362] For example, such 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 cartridges can be guided to the cartridge filling substation 408. The cartridge filling substation 408 may contain one or more filling stations. For example... Figure 71 As explained below, in one embodiment, the cartridge filling substation 408 may include five filling stations 2502a to 2502e. Furthermore, in some embodiments, the cartridge filling substation 408 may include an environmental control housing 2504, in which filling stations 2502a to 2502e are located. Therefore, the environment within the environmental control housing 2504 can be controlled. Additionally, the environmental modification device 2506 may be configured to influence the environment within the environmental control housing 2504. In some embodiments, the controller 417 may be configured to control one or more of stations 2502a to 2502e and / or the environmental modification device 2506 of the cartridge filling substation 408.

[0365] In one embodiment, the environment modification device 2506 may include a dehumidifier configured to influence the ambient environment within the environmental control housing 2504. By way of an additional example, the environment modification device 2506 may be configured to control the ambient environment within the environmental control housing 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 humidity in this way, problems related to the aerosol precursor composition absorbing ambient moisture can be avoided, which may undesirably dilute the aerosol precursor composition and / or overfill the cartridge.

[0366] Figure 72 This illustration shows a top view of the partially assembled cartridge during filling and before the drip tip is coupled to it. As illustrated, the outlet 2508 of the filling device 2510 (e.g., a filling needle) can be positioned close to and adjacent to a plurality of angular portions 2512a to 2512d (e.g., quarter circles) of the reservoir substrate 214, wherein said angular portions are defined relative to a longitudinal axis extending through the cartridge. For example, as Figure 72 The description indicates that the outlet 2508 of the filling device 2510 can be sequentially positioned at a first angle portion 2512a, followed by a second angle portion 2512b, a third angle portion 2512c, and a fourth angle portion 2512d. Guiding the aerosol precursor composition at multiple angle positions can increase the filling rate of the reservoir substrate 214 with the aerosol precursor composition. In this respect, the absorption rate of the reservoir composition 214 can be less than the outflow rate of the outlet 2508 of the filling device 2510. Therefore, by moving the outlet 2508 to the various angle portions 2512a to 2512d, each angle portion can receive the flow of the aerosol precursor composition, thus avoiding the problem that a single angle portion of the reservoir substrate 214 cannot absorb the aerosol precursor composition at the rate at which the filling device 2510 applies the aerosol precursor composition.

[0367] In one embodiment, the outlet 2508 of the filling device 2510 can be sequentially moved at filling station 2502a from each of the first angle portion 2512a to the fourth angle portion 2512d. Subsequently, filling stations 2502b to 2502e can position the outlet 2508 of the filling device 2510 at one of the angle portions. For example, filling station 2502b can position the outlet 2508 of the filling device 2510 at the first angle portion 2512a, filling station 2502c can position the outlet 2508 of the filling device 2510 at the second angle portion 2512b, filling station 2502d can position the outlet 2508 of the filling device 2510 at the third angle portion 2512c, and filling station 2502e can position the outlet 2508 of the filling device 2510 at the fourth angle portion 2512d. Therefore, the smoke cartridge can be delivered between filling stations 2502a to 2502e, and the flow of the aerosol precursor composition can be directed at each of the filling stations to at least one of the angled portions 2512a to 2512d of the reservoir substrate 214.

[0368] In addition, such as Figure 73 The description states that while guiding the flow of the aerosol precursor composition 2514 through the outlet of the filling device at each angular portion of the reservoir substrate, the outlet 2508 of the filling device 2510 can be kept away from contact with the reservoir substrate 214. In this respect, damage to the reservoir substrate 214 can be avoided by preventing contact with it. Furthermore, as... Figure 72 and 73 The description states that the filling device 2510 can be configured to press against the inner surface of the outer body 216 during filling at each angle portion 2512a to 2512d. Therefore, the cartridge can be slightly tilted and the aerosol precursor composition 2514 can be guided downward along the inner surface of the outer body 216, allowing the reservoir substrate 214 to be filled at a relatively fast rate.

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

[0370] Various quality control measures can be employed to ensure the proper construction of the finished e-cigarette cartridge 200. In this regard, as described above and Figure 3The description indicates that system 400 may additionally include an inspection subsystem 418, which can inspect component 406, unfilled cartridge 404, filled cartridge 410, capped cartridge 414, and / or finished cartridge 200. Furthermore, in some embodiments, the cartridge can be inspected at an intermediate completion state at one or more of the cartridge assembly subsystem 402, cartridge filling subsystem 408, cartridge capping system 412, and cartridge labeling subsystem 416. Therefore, the cartridge and its components can be inspected before, during, and after completion.

[0371] In this regard, imaging devices (e.g., cameras) can be employed at multiple locations to ensure that the aforementioned processes are performed as required within specifications. Therefore, cameras and / or other inspection equipment can be employed at multiple locations within system 400. However, inspection at certain locations may have specific importance.

[0372] In this regard, it is important to check the position of terminals 206, 234a, 234b after insertion into base 204. For example, one or more cameras may be configured to check the radial position (e.g., relative to the center of base 204) of each of terminals 206, 234a, 234b. The radial position of terminals 206, 234a, 234b can be determined at the attachment end 204a of base 204. In this regard, proper radial position of terminals 206, 234a, 234b can facilitate attachment of cartridge 200 to control assembly 300. Furthermore, one or more cameras may be used to check the distance of extension of terminals 206, 234a, 234b from base 204. In some embodiments, the distance of extension of terminals 206, 234a, 234b from base 204 can be determined at the inner end 204b (see [link to documentation]). Figure 1 The appropriate distance from the inner end 204b of the base 204 to which the terminals 206, 234a, 234b extend is important to ensure proper coupling of the heating element 240 to it.

[0373] In the cartridge assembly subsystem 402, terminals 206, 234a, and 234b are inserted downwards into the base 204. Therefore, while the base is held in the bracket 600 traveling on the track 616, the distance by which terminals 206, 234a, and 234b extend from their inner ends 204b in the base 204 can be checked. In this respect, as... Figure 74 The description states that the side-view camera 2602 can be configured to capture an image of the side profile of a partially assembled cartridge after one or more of the terminals 206, 234a, and 234b are coupled to the base 204. Furthermore, the controller can be configured to determine the distance from which one or more of the terminals 206, 234a, and 234b extend from the base 204.

[0374] However, since the attachment end 204a of the base 204 is oriented downward toward the bracket 600, the base can be removed from the bracket to inspect the radial position of the terminals 206, 234a, 234b. In this respect, as Figure 75 The description indicates that the removal robot 2604 can be configured to remove a partially assembled cartridge from the carrier 600 and move the partially assembled cartridge above the end-view camera 2606. Therefore, the image captured by the end-view camera 2604 can be analyzed by a controller to determine the radial position of one or more of the terminals 206, 234a, and 234b. Alternatively, an aperture extending through the carrier 600 can allow inspection of the radial position of the terminals 206, 234a, and 234b at the attachment end 204a of the base 204. Furthermore, it should be noted that in some embodiments, a separate camera can be provided for each terminal to focus on each specific terminal. In other embodiments, a single camera can be used, for example, by adjusting the focal length of said camera to inspect multiple terminals.

[0375] In a second embodiment of the cartridge assembly subsystem 402', the cartridge, substantially assembled with the base 204, is oriented in a relative manner such that the components coupled thereto extend downward therefrom. In this respect, as Figure 76 The description states that one or more of the conveying components 1700A to 1700C, along with a fixing device 1704, can be used to facilitate the inspection of terminals 206, 234a, and 234b. For example, the fixing device 1704 can hold the base 204 such that its attached end 204a extends upward. Therefore, the end-view camera 2702, positioned above the base 204, can inspect the radial position of terminals 206, 234a, and 234b.

[0376] In addition, such as Figure 77 The description indicates that the fixing device 1704 may include one or more openings 2704a, 2704b extending through it. Therefore, as... Figure 76 The description indicates that the side-view camera 2706 can be positioned to see through one or more of the openings 2704a and 2704b to determine the distance that the terminals 206, 234a, and 234b extend from the inner end 204b of the base 204. In some embodiments, a separate camera can be provided for each terminal to focus on each specific terminal. In other embodiments, a single camera can be used, for example, by adjusting the focal length of the camera to inspect multiple terminals.

[0377] The inspection subsystem 418 may additionally include one or more cameras configured to inspect the partially assembled cartridge after the outer body 216 is rolled into the base 204. For example, such as Figure 78The description indicates that, when inspecting a first embodiment of the cartridge assembly subsystem 402, the inspection subsystem 418 may include an end-view camera 2802 configured to capture images of the interior of the outer body 216. In this regard, the end-view camera 2802 may be positioned above the track 616 downstream of the curler 1118 such that, when the carrier 600 is guided below the end-view camera, the end-view camera can capture one or more images of the interior of the outer body 216. Furthermore, the controller can determine whether the reservoir substrate 214 is present (a desired condition) or absent (an undesirable condition).

[0378] Furthermore, the cartridge assembly subsystem 402 may include a side-view camera 2804 configured to capture images of the side of a partially assembled cartridge. In this regard, the side-view camera 2804 may be positioned adjacent to the track 616 such that it can capture images of the partially assembled cartridge held by the bracket 600. In this regard, a controller may be configured to analyze the images captured by the side-view camera 2804 to determine whether the curling in the outer body 216 produced by the curler 1118 is appropriate (e.g., when properly curled, the outer body can be substantially flush with the base 204), and further, the controller may determine whether the reservoir substrate 214 extends beyond the outer body (e.g., at the interface between the outer body and the base) (an undesirable condition) or is contained within the outer body (a desired condition).

[0379] like Figure 79 The description explains that, in the second embodiment of inspecting the cartridge assembly subsystem 402', the inspection subsystem 418 may include an end-view camera 2902 configured to capture images of the interior of the external body 216, and a side-view camera 2904 configured to capture images of the sides of the partially assembled cartridge, allowing the controller to analyze the images of the partially assembled cartridge in the manner described above. Furthermore, an external body inspection robot 1316 may be used to receive the partially assembled cartridge from the curler 2408 and guide it to a position where the end-view camera 2902 and the side-view camera 2904 can capture images of the partially assembled cartridge. Additionally, in some embodiments, the external body inspection robot 1316 may include a base gripper 1500 that facilitates gripping the base 204 in the manner described above.

[0380] The inspection subsystem 418 may additionally include a blow-through station. The blow-through station may be configured to direct airflow through the smoke cartridge to purify the flow path defined therethrough. In this respect, although not contemplated, the blow-through station may remove any dust or debris from the flow path through the smoke cartridge. For example, Figure 80The description describes a blow station 3000 that can be used in conjunction with a first embodiment of the cartridge assembly subsystem 402. As described, the blow station 3000 may include a first connector 3002 and a second connector 3004. In one embodiment, the first connector 3002 may be configured to engage an aperture 3006 in the bracket 600 communicating with an attachment end 204a of the base 204. In this regard, in some embodiments, the first connector may include a resilient seal 3008 configured to engage the aperture 3006 in the bracket 600. Furthermore, the second connector 3004 may be configured to engage, for example, via the resilient seal, the end of the outer body 216 opposite the base 204.

[0381] Connectors 3002 and 3004 can be under different pressures. Therefore, the pressure difference applied across the cartridge via connectors 3002 and 3004 can create a flow of guided air. In some embodiments, the first connector 3002 can be at a higher pressure than the second connector 3004, causing air to flow through the cartridge in the same direction as it would during normal use. For example, a vacuum can be applied to the second connector 3004, while the first connector 3002 can be at ambient pressure. This allows any debris in the cartridge to be removed.

[0382] Figure 81 An embodiment of a blow station 3100 that may be included together with the second embodiment of the cartridge assembly subsystem 402' is described. As illustrated, the blow station 3100 may include a first connector 3102 and a second connector 3104. Furthermore, the blow station 3100 may include a rotatable arm 3106 and an external body gripper 3108. An external body inspection robot 1316 can move a partially assembled cartridge into the blow station 3100. Thus, the external body gripper 3108 can grasp the external body 216 of the partially assembled cartridge, and the rotatable arm 3106 can rotate the partially assembled cartridge into the appropriate position between the connectors 3102 and 3104. The connectors 3102 and 3104 can retract against the end of the cartridge to form a seal therewith. For example, the connectors 3102 and 3104 may each include resilient seals 3110 and 3112, which facilitate connection with the attachment end 204a of the base 204 and the opposite end of the external body 216. After the blowing process is completed as described above, connectors 3102 and 3104 can retract and rotatable arm 3106 can rotate the partially assembled cartridge, allowing it to be grasped and moved to an additional station. It should be noted that, as illustrated, an additional blowing station 3100', substantially similar to blowing station 3100, can be provided to increase throughput.

[0383] In addition, the inspection subsystem 418 may further include a pressure drop station. The pressure drop station 418 may be configured to detect the pressure drop associated with directing airflow through the partially assembled cartridge. Thus, the pressure drop associated with the cartridge can be determined and compared with a desired pressure drop to ensure that there are no blockages or leaks in the cartridge.

[0384] In some embodiments, a pressure reduction station can be broadly similar to a blowdown station. In this respect, Figure 82 This describes a pressure drop station 3200 that can be used in conjunction with a first embodiment of the cartridge assembly subsystem 402. As illustrated, the pressure drop station 3200 may include a first connector 3202 and a second connector 3204. In one embodiment, the first connector 3202 may be configured to engage an aperture in the bracket that communicates with the attachment end 204a of the base 204 (see, for example...). Figure 80 (The orifice 3006 in the bracket 600). In this regard, in some embodiments, the first connector 3202 may include a resilient seal 3208 configured to engage the orifice in the bracket. Furthermore, the second connector 3204 may be configured to engage, for example, via a resilient seal, the end of the outer body 216 opposite the base 204.

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

[0386] Figure 83 This describes an embodiment of a pressure drop station 3300 that can be included together with the second embodiment of the cartridge assembly subsystem 402'. As described, the pressure drop station 3300 may include a first connector 3302 and a second connector 3304. Furthermore, the pressure drop station 3300 may include a rotatable arm 3306 and an external body gripper 3308. Therefore, the inspection robot 1318 (see...) Figure 41The partially assembled cartridge can be moved from the blow station 3100 to the pressure drop station 3300. Therefore, the outer body gripper 3308 can grasp the outer body 216 of the partially assembled cartridge, and the rotatable arm 3306 can rotate the partially assembled cartridge into a suitable position between connectors 3302 and 3304, which can move together to seal against the end of the cartridge. For example, connectors 3302 and 3304 may respectively include resilient seals 3310 and 3312, 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 is completed in the manner described above, connectors 3302 and 3304 can retract, and the rotatable arm 3106 can rotate the partially assembled cartridge so that it can be grasped and moved to an additional station. It should be noted that, as illustrated, an additional pressure drop station 3300', which may be substantially similar to pressure drop station 3300, can be provided to increase throughput.

[0387] Furthermore, the inspection subsystem 418 may additionally include an electrical test station. In this regard, Figure 84 An embodiment of an electrical testing station 3400, which may be included together with the first embodiment of the cartridge assembly subsystem 402, is described. As described, the electrical testing station 3400 may include a test fixture 3402. Furthermore, the electrical testing station 3400 may include a robotic arm 3404 configured to move partially assembled cartridges from a tray to the test fixture 3402 and back. The robotic arm 3404 may include an external body gripper 3406 configured to grasp the outer surface of an external body 216.

[0388] Figure 85 An enlarged view of the test fixture 3402 is shown. As illustrated, the test fixture 3402 may include a socket 3408 configured to engage a base 204 of a cartridge. Figure 86 The diagram illustrates a cross-sectional view through the test fixture 3402. In this respect, the socket 3408 may define a shape and size similar to the coupler 302 of the control body 300. However, the socket 3408 may be relatively shorter than the coupler 302 to avoid damaging optional pressure-resistant components in the base 204. Furthermore, the socket 3408 may not include anti-rotation features, allowing the cartridge to engage the base 204 in any rotational position.

[0389] As described, the test fixture 3402 may 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 may be configured to engage a first heating terminal 234a, a second electrical contact 3412 may be configured to engage a second heating terminal 234b, and a third electrical contact 3414 may be configured to engage a control component terminal 206. The first electrical contact 3410 may be defined by a first body portion 3416, the second electrical contact 3412 may be defined by a second body portion 3418, and the third electrical contact 3414 may be defined by a third body portion 3420. The body portions 3416, 3418, and 3420 may be formed of a conductive and relatively rigid material, such as hardened steel, to withstand repeated use and allow electrical communication therethrough in the manner described below.

[0390] Each of the main body portions 3416, 3418, and 3420 can be coupled to a non-conductive component 3422, which can be formed of any of a variety of non-conductive materials, such as plastic. Furthermore, the main body portions 3416, 3418, and 3420 are electrically insulated from each other by avoiding direct contact between them. In this regard, the main body portions 3416, 3418, and 3420 can be positioned to define an air gap between them. For example, the main body portions 3416, 3418, and 3420 can be coupled to the non-conductive component 3422 such that the main body portions are spaced apart from each other when coupled to the non-conductive component. Alternatively or additionally, non-conductive spacers can be placed between the main body portions 3416, 3418, and 3420.

[0391] The test fixture 3402 can be used with, for example, the controller 417 described above (see example...). Figure 3The controller 417 is configured to communicate with the cartridge via electrical contacts 3410, 3412, and 3414 when the cartridge base is engaged with the socket 3402. Furthermore, the cartridge can be tested, and various other functions can be performed. For example, the controller 417 can be configured to determine the resistance of the cartridge's atomizer and compare that resistance with a desired resistance. In some embodiments, the atomizer resistance may preferably be from 1.5 ohms to about 3.5 ohms, and more preferably from about 2.1 ohms to about 3.0 ohms, which corresponds to an atomizer configured to generate a desired amount of heat. Additionally, the controller 417 can be configured to determine whether the atomizer is shorted to the cartridge's external body. In this regard, the controller 417 can check to ensure that the resistance between the external body and one or more of terminals 206, 234a, and 234b is greater than about one megaohm. For example, current can be applied to the outer body 216 of the cartridge via the outer body gripper 3406, and the controller 417 can detect any current reaching one or more of the terminals 206, 234a, and 234b to determine the resistance between the terminals and the outer body. In this regard, in an improperly assembled cartridge, the atomizer may touch the outer body, which could cause current to be transmitted therebetween.

[0392] The test fixture 3402 may further include an orifice 3426 configured to provide airflow through the base 204 of the cartridge. Therefore, in some embodiments, the test fixture 3402 may be used to perform the aforementioned flow-through and / or pressure-drop operations. Thus, for example, the orifice 3426 in the test fixture may communicate with a first connector, and the outer body gripper 3406 may include a second connector, allowing airflow to be provided through the cartridge held by the test fixture 3402 and the outer body gripper.

[0393] Furthermore, the controller 417 may be configured to transmit program code instructions to the electronic control component 208 of the cartridge via the third electrical contact 3414 and the control component terminal 206. Thus, for example, a heating setting defining when and how much current to apply to the atomizer after vapor emission is detected may be written into the electronic control component 208. Additionally, the program code instructions may include a verification code, which can be used to verify that the cartridge is genuine. The controller 417 may be further configured to read 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 required program code instructions. For example, reading the stored program code instructions may be used to ensure that the appropriate heating setting and verification code are stored. A unique identifier associated with the electronic control component 208 may also be read from it, which can be used to record information about the cartridge (e.g., manufacturing date, heater setting, verification code, etc.) in a database. The controller 417 can also initialize the electronic control component 208 so that the electronic control component directs current to the atomizer after detecting the first smoke rather than the second smoke. This may happen when the electronic control component is not initialized, in which case current may be directed to the atomizer after detecting the second smoke.

[0394] Figure 87 An embodiment of the electrical test station 3500, which can be included in the inspection subsystem 418 along with the second embodiment of the cartridge assembly subsystem 402', is described. 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 slot 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. Therefore, its description will not be repeated. However, the test fixture 3502 can further include a slot 3508 positioned on the opposite side of the slot 3506. The slot 3508 can be configured to receive the gripper 3510 of the test fixture robot 1320, such that the gripper can grasp from below the base to remove the cartridge from the slot. Thus, the gripper 3510 can pull the cartridge away from the slot 3506. It should be noted that, as described, an additional test fixture 3500', which is substantially similar to the test fixture 3500, can be provided to increase throughput.

[0395] In some embodiments, the inspection subsystem 418 may additionally include a quality assurance station. The quality assurance station can be located at any point during the assembly process. For example, the quality assurance station can be located downstream of the curlers 1118, 2408 that curl the outer body 216 to the base 204. However, the quality assurance station can be configured to receive partially assembled cartridges in various completion states. In this regard, the various substations of the cartridge assembly subsystems 402, 402' can be configured to guide cartridges to the quality assurance station in any of the various completion states that occur during their assembly. Thus, for example, the base 204 coupled with terminals 206, 234a, 234b can be guided to the quality assurance station without electronic control components, flow tubes, reservoir substrates, and the outer body being coupled thereto. By means of a further example, the carrier 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 transport partially assembled cartridges to the quality assurance station without performing any operations on them. Partially assembled cartridges guided to the quality assurance station can be inspected manually or via an automated process to ensure proper assembly. In some embodiments, partially assembled cartridges defining various completion states can be guided to the quality assurance station at predefined intervals, allowing for the regular inspection of each type of partially assembled cartridge in its respective completion state.

[0396] The inspection subsystem 418 can be configured to discard defective cartridges that fail to meet certain predefined criteria as described above. For example, in a first embodiment of the cartridge assembly subsystem 402, after a partially assembled cartridge is identified as defective, the holder 600 holding the defective cartridge can skip the remaining assembly station and guide the cartridge to a disposal station, from which the defective cartridge is removed (e.g., via a vacuum hose) for disposal. By a further example, in a second embodiment of the cartridge assembly subsystem 402', after a partially assembled cartridge is identified as defective, a robot near the location where the cartridge was identified as defective can drop the defective cartridge into a waste chute. For example, Figure 79 The diagram describes a socket 3600 in the stage 3602 supporting the cartridge assembly subsystem 402', into which defective cartridges can be inserted (e.g., after inspection of terminals 206, 234a, 234b). In this respect, the socket can be associated with each position of the inspected cartridge, allowing defective cartridges to be discarded immediately.

[0397] The inspection subsystem 418 can further inspect the cartridge after filling at the cartridge filling subsystem 408, capping at the cartridge capping system 410, and / or labeling at the cartridge labeling subsystem 412. For example, the inspection subsystem 418 can be configured to detect leakage in the cartridge after filling. By way of a further example, the inspection subsystem 418 can include a camera, above which the filled cartridge is raised, and the captured image can be compared with a stored image of a known acceptable cartridge without leakage. The additional camera can ensure that the drip tip 220 is properly curled to the outer body 216. For example, the curling associated with the attachment of the drip tip 220 to the outer body 216 can be checked in substantially the same manner as the curling used to attach the base 204 to the outer body. Furthermore, after the label 218 is applied to the outer body 216, the camera can check the placement of the label to ensure its proper positioning.

[0398] Methods for assembling smoke cartridges for aerosol delivery devices are also provided. For example... Figure 88 The method may include providing a reservoir substrate extending at least partially around the atomizer at operation 3702. Furthermore, the method may include providing an outer body at operation 3704 configured to at least partially receive the reservoir substrate and the atomizer therein. Additionally, the method may include inserting the reservoir substrate into the outer body at operation 3706 using a tool that defines a funnel portion configured to reduce the external dimensions of the reservoir substrate, such that the external dimensions of the reservoir substrate are less than or equal to the internal dimensions of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0399] In some embodiments, the method may additionally include, at operation 3706, twisting the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body using the tool. Providing a reservoir substrate extending at least partially around the atomizer at operation 3702 may include at least partially wrapping the reservoir substrate around the atomizer before inserting the reservoir substrate into the outer body using the tool at operation 3706. At least partially wrapping the reservoir substrate around the atomizer may include directing airflow to the reservoir substrate.

[0400] The method may further include engaging the reservoir substrate with one or more fingers as the reservoir substrate is inserted into the outer body via a tool at operation 3706, such that the reservoir substrate remains at least partially wrapped around the atomizer. Furthermore, the method may 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 may include deflecting the one or more fingers away from the reservoir substrate by contacting them with the tool. Additionally, releasing the one or more fingers may include releasing the fingers sequentially. The method may 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 the reservoir substrate is inserted into the outer body via a tool at operation 3706. Additionally, the method may include supplying the reservoir substrate from a generally continuous reservoir substrate input and controlling the tension in the generally continuous reservoir substrate input.

[0401] Methods for assembling atomizers for aerosol delivery devices are also provided. For example... Figure 89 The method may include providing a first heating terminal, a second heating terminal, and a heating element at operation 3802. Furthermore, the method may include determining the positions of the first heating terminal and the second heating terminal at operation 3804. The method may also include determining the position of the heating element at operation 3806. Additionally, the method may include attaching the heating element to the first heating terminal and the second heating terminal (e.g., establishing an electrical connection therebetween) at operation 3808 based on the positions of the first heating terminal and the second heating terminal and the position of the heating element.

[0402] Determining the positions of the first heating terminal and the second heating terminal at operation 3804 may include determining the midpoint between the first heating terminal tab and the second heating terminal tab. The heating element may include a first contact portion and a second contact portion, and determining the position of the heating element at operation 3806 may include determining the midpoint between the first contact portion and the second contact portion. The method may 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 may 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 may include adjusting the 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 may include guiding a plurality of laser beams to the first heating terminal tab and the second heating terminal tab. Guiding the laser beams to the first heating terminal tab and the second heating terminal tab may include guiding the laser beams to the back side of the first heating terminal tab and the second heating terminal tab opposite to the heating element. The method may further include inserting the heating element, the first heating terminal, and the second heating terminal into a substantially sealed cavity before guiding the laser beams to the first heating terminal tab and the second heating terminal tab.

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

[0405] In some embodiments, the heating element may include a wire wound around a liquid delivery element. The wire may include two contact portions, a central portion, and two external portions positioned outside the contact portions, the two contact portions and the central portion defining the heating element. The contact portions may define a first coil spacing, the central portion may define a second coil spacing, and the external portions may define a third coil spacing. The third coil spacing may be greater than the second coil spacing, and the second coil spacing may be greater than the first coil spacing. Furthermore, attaching the heating element to the first and second heating terminals at operation 3808 may include attaching the contact portions to the first and second heating terminals.

[0406] It also provides methods for filling e-cigarette cartridges. For example... Figure 90The method may include, at operation 4002, providing a cartridge for an aerosol delivery device, comprising a reservoir substrate positioned within an outer body. Furthermore, the method may include, at operation 4004, sequentially positioning an outlet of a filling device near a plurality of angular portions of the reservoir substrate. The method may further include, at operation 4006, directing a flow of the aerosol precursor composition through the outlet of the filling device to each of the angular portions of the reservoir substrate.

[0407] In some embodiments, the outlet of the filling device may remain uncontacted with the reservoir substrate. Furthermore, the method may include delivering cartridges between multiple filling stations, wherein at each of the filling stations, a flow of the aerosol precursor composition is directed to at least one of the angled portions of the reservoir substrate. Additionally, the flow of the aerosol precursor composition may be directed at a first filling station to each of the angled portions of the reservoir substrate. The remaining portions of the filling station are then directed to one of the angled portions of the reservoir substrate, respectively. The method may further include controlling the environment surrounding the filling cartridges such that the environment defines a relative humidity of less than about 40%.

[0408] Methods for assembling smoke cartridges for aerosol delivery devices are also provided. For example... Figure 91 The method may include grasping the base at operation 4102. Furthermore, the method may include providing a plurality of components configured to engage the base at operation 4104, the components being provided in a rest position. Additionally, the method may include coupling the components to the base at operation 4106 by guiding the base into contact with the components in the rest position.

[0409] Holding the base at operation 4102 may include holding the inner surface of the base's attachment end, configured to engage the control body. Guiding the base to contact the component in its rest position at operation 4106 may include guiding the base downwards to contact the component. The method may further include inserting the base into a retaining device and checking the position of first and second heating terminals coupled to the base via the retaining device.

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

[0411] The controller 417 may also include a user interface 4206 that allows users to interact with it. For example, the user interface 4206 may take various forms, such as buttons, a keypad, a dial, a touchscreen, an audio input interface, a visual / image capture input interface, or input in the form of sensor data. Furthermore, the user interface 4206 may be configured to output information to the user via a display, speaker, or other output device. The communication interface 4208 can provide, for example, the transmission and reception of data via wired or wireless networks 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 individually 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 operations described above. Specifically, the computer-readable code can be constructed to perform each operation of the methods described herein and is embodied as computer-readable code on a computer-readable medium for controlling the operations described above. In this regard, as used herein, computer-readable storage medium refers to a non-transitory physical storage medium (e.g., a volatile or non-volatile memory device) that can be read by a computer system. Examples of computer-readable media include read-only memory, random access memory, CD-ROM, DVD, magnetic tape, and optical data storage devices. Computer-readable media can also be distributed across a network-coupled computer system, enabling the computer-readable code to be stored and executed in a distributed manner.

[0413] As described above, controller 417 may be configured to execute computer code for performing the operations described above. In this regard, embodiments are provided of non-transitory computer-readable media 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. The non-transitory computer-readable media may 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 receive at least partially the reservoir substrate and the atomizer therein; and program code instructions for inserting the reservoir substrate into the outer body using a tool that defines a funnel portion configured to reduce the external dimensions of the reservoir substrate, such that the external dimensions of the reservoir substrate are less than or equal to the internal dimensions of the outer body to facilitate insertion of the reservoir substrate into the outer body.

[0414] The computer-readable medium may further include program code instructions for twisting the tool relative to the reservoir substrate while inserting the reservoir substrate into the outer body using the tool. Program code instructions for providing a reservoir substrate that extends at least partially around the atomizer may include program code instructions for wrapping the reservoir substrate at least partially around the atomizer before inserting the reservoir substrate into the outer body using the tool. Program code instructions for wrapping the reservoir substrate at least partially around the atomizer may include program code instructions for directing airflow to the reservoir substrate. The computer-readable medium may further include program code instructions for engaging the reservoir substrate with one or more fingers so that the reservoir substrate remains at least partially wrapped around the atomizer when insertion into the outer body using the tool begins. The computer-readable medium may 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. Programming instructions for releasing the one or more fingers may include programming instructions for deflecting the one or more fingers away from the reservoir substrate by contacting the one or more fingers with a tool. Programming instructions for releasing the one or more fingers may include programming instructions for sequentially releasing the fingers. The computer-readable medium may further include programming instructions for coupling the atomizer to a base before at least partially wrapping it around the reservoir substrate; and programming instructions for coupling the outer body to the base after the reservoir substrate has been inserted into the outer body by the tool. The computer-readable medium may further include programming instructions for supplying the reservoir substrate from a generally continuous reservoir substrate input; and programming instructions for controlling 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 (e.g., controller 417) configured to assemble an atomizer for an aerosol delivery device may include: program code instructions for providing a first heating terminal, a second heating terminal, and a heating element; program code instructions for determining the positions of the first and second heating terminals; program code instructions for determining the position of the heating element; and program code instructions for attaching a heating element to the first and second heating terminals based on the positions of the first and second heating terminals and the position of the heating element. The program code instructions for determining the positions of the first and second heating terminals may include program code instructions for determining the midpoint between the first heating terminal tab and the second heating terminal tab.

[0416] In some embodiments, the heating element may include a first contact portion and a second contact portion, and the program code instructions for determining the position of the heating element may include program code instructions for determining the midpoint between the first contact portion and the second contact portion. The computer-readable medium may further include program code instructions for 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; 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 may 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 may include program code instructions for adjusting the 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 may include program code instructions for guiding a laser beam at the first heating terminal tab and the second heating terminal tab. Programming instructions for guiding a laser beam to a first heating terminal tab and a second heating terminal tab may include programming instructions for guiding the laser beam to the back side of the first and second heating terminal tabs opposite to the heating element. The computer-readable medium may further include programming instructions for inserting the heating element, the first heating terminal, and the second heating terminal into a generally sealed chamber before guiding the laser beam to the first and second heating terminal tabs. Programming instructions for providing the heating element may include programming instructions for supplying the heating element from a generally continuous heating element input; and programming instructions for controlling tension in the generally continuous heating element input. The computer-readable medium may further include programming instructions for coupling the heating element to a liquid delivery element. Programming instructions for coupling the heating element to the liquid delivery element may include programming instructions for inserting one end of the heating element through the liquid delivery element; and programming instructions for rotating at least one of the heating element and the liquid delivery element such that the heating element is wound around the liquid delivery element. The program code instructions for providing the first heating terminal and the second heating terminal may include program code instructions for supplying the first heating terminal from a generally continuous first heating terminal; and program code instructions for supplying the second heating terminal from a generally continuous second heating terminal. The heating element may include a wire wound around a liquid delivery element.The conductor may include two contact portions, a central portion, and two external portions located outside the contact portions. The two contact portions and the central portion of the conductor may define a heating element. The contact portions define a first coil spacing, the central portion defines a second coil spacing, and the external portions define a third coil spacing. The third coil spacing is greater than the second coil spacing, and the second coil spacing is greater than the first coil spacing. Attaching the heating element to a first heating terminal and a second heating terminal includes attaching the contact portions to the first heating terminal and the second heating terminal.

[0417] 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 fill cartridges may include: program code instructions for providing cartridges for an aerosol delivery device, the cartridges including a reservoir substrate positioned in an outer body; program code instructions for sequentially positioning an outlet of the filling device near a plurality of angular portions of the reservoir substrate; and program code instructions for directing a flow of an aerosol precursor composition through the outlet of the filling device to each of the angular portions of the reservoir substrate. The outlet of the filling device may remain non-contact with the reservoir substrate. The computer-readable medium may further include program code instructions for delivering cartridges between a plurality of filling stations, wherein a flow of an aerosol precursor composition is directed at at least one of the angular portions of the reservoir substrate at each of the filling stations. The flow of the aerosol precursor composition may be directed at each of the angular portions of the reservoir substrate at a first 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 the remaining portion of the filling station. The computer-readable medium may further include program code instructions for controlling the environment surrounding the filled cartridge such that the 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 may include: program code instructions for gripping a base; program code instructions for providing a plurality of components configured to engage the base, the components being provided in a rest position; and program code instructions for coupling the components to the base by guiding the base into contact with the components in the rest position. The program code instructions for gripping the base may include program code instructions for gripping the inner surface of an attachment end of the base configured to engage a control body. The program code instructions for guiding the base into contact with the components in the rest position may include program code instructions for guiding the base downwards into contact with the components. The computer-readable medium may further include program code instructions for inserting the base into a fixing device; and program code instructions for checking the position of first and second heating terminals coupled to the base via the fixing device.

[0419] Many modifications and other embodiments of this disclosure will arise to those skilled in the art upon which this disclosure pertains, thanks to the teachings presented in the foregoing description and associated drawings. Therefore, it should be understood that this disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terminology is used herein, it is used only in a general and descriptive sense and is not intended for limiting purposes.

Claims

1. A method for assembling an atomizer for an aerosol delivery device, the method comprising: It provides a first heating terminal, a second heating terminal, and a heating element; Determine the positions of the first heating terminal and the second heating terminal; Determine the position of the heating element; as well as The heating element is attached to the first heating terminal and the second heating terminal based on the positions of the first heating terminal and the second heating terminal and the position of the heating element.

2. The method of claim 1, wherein determining the positions of the first heating terminal and the second heating terminal includes determining the midpoint between the first heating terminal tab and the second heating terminal tab.

3. The method according to claim 2, wherein the heating element comprises a first contact portion and a second contact portion, and Determining the position of the heating element includes determining the midpoint between the first contact portion and the second contact portion.

4. The method of claim 3, further comprising: Align 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; engage the first contact portion with the first heating terminal tab; as well as The second contact portion engages with the second heating terminal tab.

5. The method of claim 4, 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.

6. The method of claim 5, wherein clamping the first heating terminal and the second heating terminal includes adjusting the spacing between the first heating terminal and the second heating terminal.

7. The method of claim 4, wherein attaching the heating element to the first heating terminal and the second heating terminal comprises guiding a laser beam at the first heating terminal tab and the second heating terminal tab.

8. The method of claim 7, wherein guiding the laser beam to the first heating terminal tab and the second heating terminal tab comprises guiding the laser beam to the back side of the first heating terminal tab and the second heating terminal tab opposite to the heating element.

9. The method of claim 7, further comprising inserting the heating element, the first heating terminal, and the second heating terminal into a substantially sealed chamber before guiding the laser beam to the first heating terminal tab and the second heating terminal tab.

10. The method according to any one of claims 1 to 9, wherein providing the heating element comprises: The heating element is supplied with a generally continuous heating element input; as well as Control the tension in the generally continuous heating element input.

11. The method according to any one of claims 1 to 9, further comprising coupling the heating element to a liquid delivery element.

12. The method according to any one of claims 1 to 9, wherein providing the first heating terminal and the second heating terminal comprises: The first heating terminal is supplied with a generally continuous input from the first heating terminal; as well as The second heating terminal is supplied with a generally continuous second heating input.

13. The method according to any one of claims 1 to 9, wherein the heating element comprises a wire wound around the liquid delivery element.

14. The method of claim 13, wherein the conductor comprises two contact portions, a central portion, and two external portions positioned outside the contact portions, the two contact portions and the central portion of the conductor defining the heating element. The contact portion defines a first coil spacing, the central portion defines a second coil spacing, and the outer portion defines a third coil spacing. The third coil spacing is greater than the second coil spacing, and the second coil spacing is greater than the first coil spacing. 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.

15. A method for assembling a cigarette cartridge for an aerosol delivery device, comprising: Grasp the base; A plurality of components configured to engage the base are provided, the components being provided in a rest position; as well as The component is coupled to the base by guiding the base into contact with the component in the rest position.

16. The method of claim 15, wherein gripping the base includes gripping the inner surface of the attachment end of the base configured to engage the control body.

17. The method of claim 15 or 16, wherein guiding the base to contact the component in the rest position comprises guiding the base downward to contact the component.

18. The method according to any one of claims 15 or 16, further comprising inserting the base into the fixing device; and Check the positions of the first and second heating terminals coupled to the base via the fixing device.

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