Filling station for heat-not-burn (HNB) aerosol generating capsules and automated production line including the same

Abstract

A filling station for heated non-combustible (HNB) aerosol-generating capsules may comprise a filling receptacle, a plurality of carriages, and at least one vacuum source. The filling receptacle defines a first vacuum port array. The filling receptacle is configured to receive an aerosol-forming substrate. The plurality of carriages are located below the filling receptacle. Each of the plurality of carriages defines a second vacuum port array and optionally a third vacuum port array. Each of the plurality of carriages is configured to receive and hold a capsule casing for filling with an aerosol-forming substrate. At least one vacuum source is configured to draw a vacuum through the capsule casing so that the aerosol-forming substrate is drawn through the first vacuum port array in the filling receptacle and introduced into the capsule casing below.

Description

[Technical Field]

[0001] <Cross-references to related applications> This application claims priority under 35 U.S.C. § 119, based on U.S. Provisional Application No. 63 / 454,034 (filed March 22, 2023). The entire contents of that application are incorporated herein by reference.

[0002] This disclosure relates to the filling of capsules for a heat-not-burn (HNB) aerosol generator configured to generate aerosols without significant thermal decomposition of the aerosol-forming substrate. [Background technology]

[0003] Some electronic devices are configured to heat plant material to a temperature sufficient to release its components. However, significant thermal decomposition of the plant material is avoided by keeping it below its ignition point. Such devices are called aerosol generators (e.g., heated non-combustible (HNB) aerosol generators or heated tobacco products; HTPs), and the plant material heated may be tobacco and / or cannabis. In some cases, the plant material may be introduced directly into the heating chamber of the aerosol generator. Alternatively, the plant material may be pre-packaged in individual containers to facilitate insertion and removal from the aerosol generator. The introduction of the plant material into the containers may be done by manual or mechanical processes. [Overview of the Initiative]

[0004] At least one embodiment relates to a filling station for heated non-combustible (HNB) aerosol-generating capsules. In one embodiment, the filling station comprises a filling receptacle, a plurality of carriages, and at least one vacuum source. The filling receptacle defines a first series of vacuum ports. The filling receptacle is configured to receive an aerosol-forming substrate. The plurality of carriages are located below the filling receptacle. Each of the plurality of carriages defines a second series of vacuum ports and optionally a third series of vacuum ports. Each of the plurality of carriages is configured to receive and hold a capsule casing for filling with an aerosol-forming substrate. At least one vacuum source is configured to draw a vacuum through the capsule casing so that the aerosol-forming substrate is drawn through the first series of vacuum ports in the filling receptacle and introduced into the capsule casing below.

[0005] In an exemplary embodiment, the filling receptacle and the multiple carriages are configured to be rotatable and share a common axis of rotation, and the multiple carriages are configured to be axially movable relative to the axis of rotation.

[0006] In an exemplary embodiment, a plurality of carriages are configured to engage with a filling receptacle by raising the capsule casing to facilitate the filling of the aerosol-forming substrate, and to lower the capsule casing after filling.

[0007] In one exemplary embodiment, the first vacuum port array within the filled receptacle has a shape corresponding to the cross-sectional shape of the capsule casing.

[0008] In one exemplary embodiment, the first vacuum port array is arranged in a ring shape within the filled receptacle.

[0009] In an exemplary embodiment, a plurality of carriages are configured to raise the capsule casing so that the capsule casing is inserted into a first vacuum port array within a filled receptacle.

[0010] In one exemplary embodiment, each vacuum port in the first vacuum port array within the filled receptacle has a chamfered lower end such that its bottom opening is larger than the corresponding upper opening.

[0011] In one exemplary embodiment, the second vacuum port array is configured to align with the permeable lower end of the capsule casing.

[0012] In an exemplary embodiment, an optional third vacuum port array is configured to hold the capsule casing against multiple carriages when suction is performed by at least one vacuum source.

[0013] In one exemplary embodiment, at least one vacuum source is configured to perform suction such that the packing density of the aerosol-forming substrate drawn into the capsule casing is greater than that achieved by gravity.

[0014] In one exemplary embodiment, the filling station further comprises at least one motor that generates vibrations to facilitate particle motion of the aerosol-forming substrate within the filling receptacle.

[0015] In one exemplary embodiment, the filling station further includes at least one baffle configured to modify the distribution of aerosol-forming substrate within the filling receptacle.

[0016] In an exemplary embodiment, at least one baffle is configured to vibrate in response to at least one motor.

[0017] In an exemplary embodiment, the filling receptacle and the plurality of cartridges are configured to rotate, while at least one baffle is configured to remain fixed relative to the rotation of the filling receptacle and the plurality of cartridges.

[0018] In an exemplary embodiment, at least one baffle is configured to direct the aerosol-forming substrate toward the first vacuum port array during rotation of the filling receptacle.

[0019] In an exemplary embodiment, at least one baffle includes a first baffle, a second baffle, a third baffle, and a fourth baffle.

[0020] In an exemplary embodiment, the first baffle is configured to facilitate an initial filling of the aerosol-forming substrate within the capsule casing, and the third baffle is configured to facilitate a subsequent filling of the aerosol-forming substrate within the capsule casing.

[0021] In an exemplary embodiment, the second baffle is C-shaped or U-shaped and is disposed at a higher position from the surface of the filling receptacle than the first baffle, the third baffle, and the fourth baffle.

[0022] In an exemplary embodiment, the second baffle is configured to temporarily accumulate the aerosol-forming substrate for the purpose of appropriately determining the supply rate of the aerosol-forming substrate to the filling receptacle.

[0023] In an exemplary embodiment, the fourth baffle is configured to wipe off excess aerosol-forming substrate from the first vacuum port array and direct the excess aerosol-forming substrate toward the inner portion of the filling receptacle.

[0024] At least one embodiment relates to a method for filling a capsule casing with an aerosol-forming substrate. In an exemplary embodiment, the method includes the step of supplying the aerosol-forming substrate to a filling receptacle that defines a vacuum port array.

[0025] In an exemplary embodiment, the method further includes the step of engaging a capsule casing below a filling receptacle and with a vacuum port array. The capsule casing has an open upper end and a permeable lower end.

[0026] In one exemplary embodiment, the method further comprises the step of applying vibrations to increase the particle motion of the aerosol-forming substrate within the filled receptacle.

[0027] In an exemplary embodiment, the method further includes the step of applying suction to the permeable lower end of the capsule casing, thereby drawing the aerosol-forming substrate within the filling receptacle through the vacuum port array and flowing into the open top of the capsule casing. [Brief explanation of the drawing]

[0028] Various features and advantages of the non-limiting embodiments described herein will become more apparent upon closer examination of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and should not be construed as limiting the scope of the claims. Unless expressly stated otherwise, the accompanying drawings are not to be considered to be drawn to scale. For clarity, various dimensions in the drawings may be exaggerated.

[0029] [Figure 1] This is a front perspective view of an automated production line, including a filling station for heated non-combustible (HNB) aerosol generating capsules, according to an exemplary embodiment.

[0030] [Figure 2]This diagram shows a more open state of Figure 1, with various panels / covers hidden to allow visibility of the interior.

[0031] [Figure 3] Figure 1 is a first side perspective view of the automated production line.

[0032] [Figure 4] This diagram shows a more open state of Figure 3, with various panels / covers hidden to allow visibility of the interior.

[0033] [Figure 5] Figure 1 is a rear perspective view of the automated production line.

[0034] [Figure 6] This diagram shows a more open state of Figure 5, with various panels / covers hidden to allow visibility of the interior.

[0035] [Figure 7] Figure 1 is a second side perspective view of the automated production line.

[0036] [Figure 8] This diagram shows a more open state of Figure 7, with various panels / covers hidden to allow visibility of the interior.

[0037] [Figure 9] This is a downstream perspective view of an aerosol generating capsule for an aerosol generating device according to an exemplary embodiment.

[0038] [Figure 10] Figure 9 is a cross-sectional view of the aerosol-generating capsule.

[0039] [Figure 11] Figure 9 is a partially disassembled view of the aerosol-generating capsule.

[0040] [Figure 12]This is a standalone view of a substrate supply station according to an exemplary embodiment.

[0041] [Figure 13] This is an enlarged view including a capsule casing supply station according to an exemplary embodiment.

[0042] [Figure 14] This is a photograph of the capsule casing alignment bowl of a capsule casing supply station according to an exemplary embodiment.

[0043] [Figure 15] This is an enlarged view of a truck for supplying capsule casings according to an exemplary embodiment to a pre-filling inspection station.

[0044] [Figure 16] This is an enlarged view including a pre-fill inspection station according to an exemplary embodiment.

[0045] [Figure 17] This is an enlarged view of the transport point upstream of a pre-filling inspection station according to an exemplary embodiment.

[0046] [Figure 18] This is another enlarged view including a pre-fill inspection station according to an exemplary embodiment.

[0047] [Figure 19] This is a photograph of a pre-filling inspection station according to an exemplary embodiment.

[0048] [Figure 20] This is an enlarged view of the transport point between the pre-filling inspection drum and the pre-filling rejection drum in a pre-filling inspection station according to an exemplary embodiment.

[0049] [Figure 21]This is an enlarged view of the transport point downstream of a pre-filling inspection station according to an exemplary embodiment.

[0050] [Figure 22] This is an enlarged view of the transport point upstream of the filling station according to an exemplary embodiment.

[0051] [Figure 23] This is a perspective view of a filling station according to an exemplary embodiment.

[0052] [Figure 24] This is an enlarged view including the carriage of a filling station according to an exemplary embodiment.

[0053] [Figure 25] This is an enlarged view including the underside of the filling pan of a filling station according to an exemplary embodiment.

[0054] [Figure 26] This is an enlarged view including the filling drum of a filling station according to an exemplary embodiment.

[0055] [Figure 27] This is an enlarged view including a pair of baffles in a filling station according to an exemplary embodiment.

[0056] [Figure 28] This is a photograph showing the supply of an aerosol-forming substrate to a filling station according to an exemplary embodiment.

[0057] [Figure 29] This is a photograph including a pair of baffles in a filling station according to an exemplary embodiment.

[0058] [Figure 30] This is an enlarged view including another pair of baffles in the filling station according to an exemplary embodiment.

[0059] [Figure 31] This is a photograph showing the portion of the filling pan of a filling station according to an exemplary embodiment, between the first pair of baffles and the second pair of baffles.

[0060] [Figure 32] This is a photograph showing the downstream portion of the second baffle pair in the filling pan of a filling station according to an exemplary embodiment.

[0061] [Figure 33] This is a photograph of a filled capsule casing on a lowered carriage of a filling station according to an exemplary embodiment.

[0062] [Figure 34] This is a photograph showing the transport of filled capsule casings from a filling drum to a post-filling inspection drum according to an exemplary embodiment.

[0063] [Figure 35] This is a perspective view including a cap-fitting station according to an exemplary embodiment.

[0064] [Figure 36] This is an enlarged view of a truck supplying caps to a cap-fitting station according to an exemplary embodiment.

[0065] [Figure 37] This is an enlarged view including the cap supply drum of a cap mounting station according to an exemplary embodiment.

[0066] [Figure 38] This is an enlarged view of the cap mounting portion of a cap mounting station according to an exemplary embodiment.

[0067] [Figure 39] This is a photograph of the cap mounting portion of a cap mounting station according to an exemplary embodiment.

[0068] [Figure 40] This is an enlarged view of a cap mounting station according to an exemplary embodiment, including the post-cap mounting inspection drum.

[0069] [Figure 41] This is an enlarged view of a cap mounting station according to an exemplary embodiment, including a post-cap mounting inspection drum and a post-cap mounting rejection drum.

[0070] [Figure 42] This is a photograph showing how a capsule is transported from the rejection drum to the recovery station after the cap has been attached, according to an exemplary embodiment.

[0071] [Figure 43] This is an enlarged view including a collection station according to an exemplary embodiment.

[0072] [Figure 44] This is another enlarged view including a collection station according to an exemplary embodiment.

[0073] [Figure 45] This is a block diagram of a method for filling a capsule casing with an aerosol-forming substrate according to an exemplary embodiment. [Modes for carrying out the invention]

[0074] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for the purpose of illustrating the exemplary embodiments. The exemplary embodiments may be carried out in many alternative forms and should not be construed as being limited only to the exemplary embodiments described herein.

[0075] Therefore, while exemplary embodiments are subject to various improvements and substitutions, they are illustrated in the drawings and described in detail herein. However, it should be understood that exemplary embodiments are not intended to limit themselves to any particular form disclosed, but rather encompass all modifications, equivalents, and substitutions that fall within the scope of the exemplary embodiments. Similar numbers refer to similar elements throughout the description of the figures.

[0076] When an element or layer is referred to as “on,” “connected to,” “coupled to,” or “covering” another element or layer, it should be understood that it may be directly on, connected to, coupled to, or covering the other element or layer, or there may be an intervening element or layer. Conversely, when an element is referred to as “directly on,” “directly connected to,” or “directly coupled to,” there is no intervening element or layer. Throughout the specification, similar numbers indicate similar components. As used herein, the term “and / or” includes any and all combinations of one or more of the related enumerated items.

[0077] In this specification, terms such as first, second, third, etc. may be used to describe various elements, regions, layers, and / or parts, but it should be understood that these elements, regions, layers, and / or parts should not be limited by these terms. These terms are used solely to distinguish one element, region, layer, or part from another. Accordingly, the first element, configuration, region, layer, or part described below may be referred to as the second element, region, layer, or part without departing from the teaching of the exemplary embodiments.

[0078] Spatially relative terms (e.g., “beneath,” “below,” “lower,” “above,” “upper,” etc.) are used herein for the sake of clarity and to describe the relationship between one element or feature and another, as shown in the figures. It should be understood that spatially relative terms are intended to encompass different orientations of the device during use or operation, in addition to the orientation depicted in the figures. For example, if the device is shown upside down in the figures, an element described as “below” or “beneath” another element or feature will be located on the “above” side of that other element or feature. Therefore, the term “below” may encompass both up and down orientations. The device may also be in other orientations (90-degree rotation or other orientations), and the spatially relative descriptors used herein will be interpreted accordingly.

[0079] The terms used herein are for illustrative purposes only and are not intended to limit the exemplary embodiments. Where used herein, the singular forms “a,” “an,” and “the” are intended to include the plural form unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and / or “comprising” identify the presence of a described feature, integer, step, operation, and / or element, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0080] Where the terms “about” or “substantially” are used in relation to numerical values ​​in this specification, the numerical values ​​are intended to include manufacturing or operational tolerances (e.g., ±10%) around the stated numerical values. Furthermore, where the terms “generally” or “substantially” are used in relation to geometric shapes, precision of the geometric shape is not required, but rather the tolerance of the shape is intended to be within the scope of the disclosure. Moreover, regardless of whether numerical values ​​or shapes are modified with “about,” “generally,” or “substantially,” it will be understood that these values ​​and shapes should be interpreted as including manufacturing or operational tolerances (e.g., ±10%) around the stated numerical values ​​or shapes.

[0081] Unless otherwise specified, all terms used herein (including technical and scientific terms) have the same meaning as those generally understood by those skilled in the art in the field to which the exemplary embodiments belong. Furthermore, terms including those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and it will be understood that they should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0082] In this specification, “coupled” includes both a detachably coupled state and a permanently coupled state. For example, if the elastic layer and the support layer are detachably coupled to each other, the elastic layer and the support layer can be separated by applying sufficient force.

[0083] Figure 1 is a front perspective view of an automated production line including a filling station for heated non-combustible (HNB) aerosol-generating capsules, according to an exemplary embodiment. Figure 2 is a more open view of Figure 1, with various panels / covers concealed to allow visibility of the interior. Referring to Figures 1 and 2, the automated production line 1000 includes a substrate supply station 100 configured to supply aerosol-forming substrate to the filling station 400. A capsule casing supply station 200 is configured to supply empty capsule casings to a pre-fill inspection station 300. According to one exemplary embodiment, the capsule casing supply station 200 is configured to adjust the orientation of the empty capsule casings so that the open end faces upward, and the adjusted capsule casings are then supplied to the pre-fill inspection station 300. Capsule casings that are improperly oriented (e.g., upside down) and / or physically defective are detected and rejected at the pre-fill inspection station 300. Subsequently, the correctly oriented capsule casings are filled with aerosol-forming substrate at the filling station 400. The filling station 400 can also inspect for proper filling. The cap supply station 600 is configured to supply caps to the capping station 500. Properly filled capsule casings are sealed with these caps at the capping station 500. The capping station 500 also inspects for proper capping before sending the capsules to the recovery station 700. The operator 1200 can interface with the automated production line 1000 via the control station 800. Furthermore, electronic equipment and other precision instruments can be housed in the electrical enclosure assembly 900.

[0084] Figure 3 is a first side perspective view of the automated production line of Figure 1. Figure 4 is a diagram showing a more open state of Figure 3, with various panels / covers concealed to allow visibility of the interior. Referring to Figures 3 and 4, the pre-fill inspection station 300 includes, among other things, a rejection chute and a rejection bin for rejected (e.g., improperly oriented) capsule casings. In an exemplary embodiment, empty capsule casings detected at the pre-fill inspection station 300 as improperly oriented (e.g., upside down) and / or having physical defects are discharged into the rejection chute, which leads those rejected capsule casings into the rejection bin. Optionally, the capsule casings collected in the rejection bin can be further inspected in a separate step / process to identify and collect capsule casings that are simply improperly oriented and have no physical defects. These are returned (e.g., manually or automatically via a conveying system) to the capsule casing supply station 200 for further orientation adjustment. This ensures that the empty capsule casings are supplied to the pre-filling inspection station 300 with their openings facing upwards.

[0085] Figure 5 is a rear perspective view of the automated production line of Figure 1. Figure 6 is a more open view of Figure 5, with various panels / covers concealed to allow visibility of the interior. Referring to Figures 5 and 6, the filling station 400 includes, among other things, a rejection chute and a rejection bin for improperly filled capsule casings. In one embodiment, capsule casings detected as improperly filled at the filling station 400 are discharged into a rejection chute that leads the improperly filled capsule casings to a rejection bin. Similarly, the capping station 500 also includes, among other things, a rejection chute and a rejection bin for improperly capped capsules. In one exemplary embodiment, capsules detected as improperly capped at the capping station 500 are discharged into a rejection chute that leads the improperly capped capsules to a rejection bin.

[0086] Figure 7 is a second side perspective view of the automated production line of Figure 1. Figure 8 is a more open view of Figure 7, with various panels / covers concealed to allow visibility of the interior. Referring to Figures 7 and 8, capsules that have passed inspection at the capping station 500 are sent to the recovery station 700. In an exemplary embodiment, the recovery station 700 may include a recovery chute. The recovery chute is configured to first receive capsules from the capping station 500 and transport them to a recovery container. The capsules may then be discharged (e.g., manually or automatically via a conveying system) for further processing and / or packaging.

[0087] Figure 9 is a downstream perspective view of an aerosol generating capsule for an aerosol generating device according to an exemplary embodiment. Figure 10 is a cross-sectional view of the aerosol generating capsule of Figure 9. Figure 11 is an exploded view of the aerosol generating capsule of Figure 9. Referring to Figures 9 to 11, the capsule 1300 has a housing configured to accommodate an aerosol forming substrate (e.g., an aerosol forming substrate 1860' in Figure 28) and a heater, the downstream side of the housing may be in the form of a first end cap 1310 (e.g., a downstream cap) as an aerosol-permeable upper end. The upstream side of the housing may be in the form of a second end cap 1320 (e.g., an upstream cap, a connector cap) as a permeable bottom. The main body of the housing may be in the form of a cover 1330 (e.g., a shell, a box sleeve).

[0088] The first end cap 1310 defines the first opening 1312, and the second end cap 1320 defines the second opening 1322. In one embodiment, the first opening 1312 is in the form of a series of outlet openings (e.g., nine outlet openings), and the second opening 1322 is in the form of a series of inlet openings (e.g., eight inlet openings). In another example, the openings may be arranged in a matrix instead of a single row. Furthermore, each opening may have a width of about 0.26 mm to 0.30 mm (e.g., 0.28 mm) to reduce or prevent the outflow of particles of the aerosol-forming substrate. Rectangular recesses are shown on the sides of the first end cap 1310 and the second end cap 1320, but it should be understood that these features (e.g., gate shapes) are a result of the manufacturing process (e.g., injection molding) and may be omitted in some embodiments. Furthermore, the second end cap 1320 can expose the first end 1342 and the second end 1346 of the heater 1340. As shown in the figure, the second opening 1322 may be provided between the exposed portion of the first end 1342 and the exposed portion of the second end 1346.

[0089] As shown in the figure, the capsule 1300 has an end face or cross-section that resembles a rectangle (e.g., oval, obround, discorectangle, stadium, racetrack) with a pair of opposing semicircular ends. The shape of the capsule 1300 can also be considered as a cylinder that has been elongated or flattened diametrically along its longitudinal axis. However, it should be understood that the capsule 1300 may have other suitable shapes. For example, the capsule 1300 may have an ovoid or ellipsoid shape with an oval or elliptical cross-section. In other cases, the capsule 1300 may have a cuboid or cubic shape with a rectangular cross-section (e.g., a cuboid with rounded corners). The chamber defined within the capsule 1300 may have the same shape as the exterior of the capsule 1300, or a different shape. For example, both the cross-section of the chamber and the cross-section of the capsule 1300's exterior can be oblong (obround). In another example, the chamber's cross-section may be non-obround (e.g., rectangular), while the cross-section of the capsule 1300's exterior may be obround (or vice versa).

[0090] Referring to Figure 10, the middle section 1344 of the heater 1340 is an internal segment configured to heat the aerosol-forming substrate within the capsule 1300. The first end 1342 and second end 1346 of the heater 1340 are external segments configured to establish an electrical connection to a power source. While the heater 1340 can take the form of a resistance heater, it should be understood that other options are also possible. For example, the heater 1340 can take the form of a susceptor for induction heating. Alternatively, there may be no heater within the capsule 1300, and instead, the heater may be configured as part of an aerosol generator designed to receive and heat the capsule 1300.

[0091] In addition to the second opening 1322, the second end cap 1320 also defines a positioning recess 1326 and an inlet recess 1328. The positioning recess 1326 and the inlet recess 1328 can be considered to be in a multi-stage arrangement, with the base / inner end face of the positioning recess 1326 (exposing the first end 1342 and the second end 1346) being considered to be at one height, while the base / inner end face of the inlet recess 1328 (or the grille-like surface of the second opening 1322) being considered to be at another height. The positioning recess 1326 is configured to facilitate the positioning of the capsule 1300 when it is inserted into the device body of the aerosol generator. In one exemplary embodiment, the positioning recess 1326 has an inclined side wall that tapers inward toward the inlet recess 1328. The inclined side wall allows the positioning recess 1326 to more easily and quickly engage with the corresponding engaging member of the device body. For example, when housed in the capsule housing cavity of the aerosol generator, the positioning recess 1326 of the capsule 1300 can engage with the inclined surface, and the inlet recess 1328 of the capsule 1300 can engage with the capsule seal. As a result, the capsule 1300 is properly loaded and positioned within the main body of the aerosol generator in a relatively stable manner.

[0092] The first end cap 1310 is provided with a first seal ridge 1314, and the second end cap 1320 is provided with a second seal ridge 1324. In one exemplary embodiment, the first seal ridge 1314 is in the form of a series of ribs (e.g., four ribs), and the second seal ridge 1324 is in the form of a series of ribs (e.g., four ribs). In some cases, each series of ribs may be of different heights to ensure desired contact with the cover 1330. When the capsule 1300 is assembled, the first seal ridge 1314 of the first end cap 1310 and the second seal ridge 1324 of the second end cap 1320 are configured to face the inner surface of the cover 1330 (e.g., by interference fit) to provide airtightness. As a result, when air is introduced into capsule 1300 during the operation of the aerosol generator, the air enters capsule 1300 via the inlet recess 1328 and second opening 1322 of the second end cap 1320 (rather than entering capsule 1300 through the gap between the second end cap 1320 and the cover 1330, such air can flow essentially along the inner surface of cover 1330, mainly bypassing the aerosol-forming substrate and / or the intermediate portion 1344 of heater 1340). Similarly, with proper sealing, the aerosol generated in the chamber of capsule 1300 is drawn in through the first opening 1312 of the first end cap 1310 (rather than leaking out through the gap between the first end cap 1310 and the cover 1330).

[0093] The first end cap 1310 and the second end cap 1320 may be configured to have an introduction mechanism to facilitate insertion into the cover 1330. For example, the first end cap 1310 may have a tapered end portion at its distal end. Similarly, the second end cap 1320 may have a tapered end portion at its proximal end. Such a configuration facilitates insertion of the first end cap 1310 and the second end cap 1320 into the cover 1330 (for example, by press fit) during the assembly of the capsule 1300. As described herein, the capsule casing 1370 is filled with an aerosol-forming substrate at the filling station 400, and then capped with the first end cap 1310 at the capping station 500 to produce the capsule 1300.

[0094] Figure 12 is a standalone view of a substrate supply station according to an exemplary embodiment. Referring to Figure 12, the substrate supply station 100 comprises a first substrate hopper 110 that initially receives aerosol-forming substrates, which are then transported to a second substrate hopper 120 by a first substrate conveyor 130. A second substrate conveyor 140 transports the aerosol-forming substrates to a filling station 400. A first substrate inspection device 150 and a second substrate inspection device 160 can be used in conjunction with the first substrate hopper 110 and the second substrate hopper 120, respectively.

[0095] Figure 13 is an enlarged view including a capsule casing supply station according to an exemplary embodiment. Referring to Figure 13, the capsule casing supply station 200 includes a capsule casing hopper 210 that initially receives a supply of empty capsule casings to be sent to a capsule casing alignment bowl 220. In some embodiments, an alignment bowl inspection device 250 may be used. The oriented capsule casings move to a supply track 230, which becomes a pre-fill inspection track 330.

[0096] The pre-filling inspection drum 310 inspects the capsule casings for improper orientation or physical defects (e.g., upside-down capsule casings, indentations on the upper edge) and identifies capsule casings deemed unsuitable. In the pre-filling rejection drum 320, capsule casings deemed unsuitable are discharged into the rejection chute 326 and led to the rejection bin 328.

[0097] Figure 14 is a photograph of the capsule casing alignment bowl of a capsule casing supply station according to an exemplary embodiment. Referring to Figure 14, the capsule casing alignment bowl 220' is configured as a recirculation loop. In this loop, an electromagnetic pulse acting on a lower spring structure causes the capsule casings 1370' to ascend a spiral path. This spiral path has sections that are easier for capsule casings 1370' with a bottom heavier position (i.e., properly oriented with the closed end down and the open end up) to pass through, in terms of the center of gravity. On the other hand, capsule casings 1370' with a top heavier position (i.e., upside down and improperly oriented) fall to the lower layer and repeat this operation until the correct orientation is obtained. In this way, the capsule casings 1370' are eventually led to a track (e.g., supply track 230) away from the capsule casing supply station.

[0098] Figure 15 is an enlarged view of a truck for supplying capsule casings according to an exemplary embodiment to a pre-fill inspection station. Referring to Figure 15, the capsule casing 1370 can be moved using compressed air through a supply truck 230 and a pre-fill inspection truck 330 (collectively referred to as the inter-station capsule casing truck, casing truck, or simply the truck). The compressed air is released at an upstream position on the truck (e.g., the supply truck 230) and is actuated so that the force on the capsule casing 1370 is sufficient to transport it downstream along the rest of the truck to the pre-fill inspection station 300. As a result, the capsule casing 1370 is continuously supplied from the capsule casing supply station 200 and transported along the truck by compressed air to the pre-fill inspection station 300. This allows a queue to be maintained at the downstream end of the pre-fill inspection truck 330 for intake by the pre-fill inspection drum 310. In other examples, conveyor belts (for example, similar to the cap conveyor 572 in Figure 36) can be used within the supply track 230 and the pre-fill inspection track 330. In such cases, the conveyor belts may be positioned to physically engage with or otherwise contact the capsule casings 1370, thereby allowing the capsule casings 1370 to be transported along the supply track 230 and the pre-fill inspection track 330. The conveyor belts may be positioned to contact the bottom and / or sides of the capsule casings 1370. Furthermore, the conveyor belts may be in the form of a single belt or multiple belts spanning all, substantially all, or part / portion / section / segment of the track between the capsule casing supply station 200 and the pre-fill inspection station 300. With regard to exemplary embodiments of a conveyor belt that spans only a portion / section / section of a track, the conveyor belt can be installed on the upstream side of the track (e.g., a supply track 230).The contact between the capsule casing 1370 and the moving conveyor belt can be operated to be sufficient to transport the capsule casing 1370 downstream along the rest of the track to the pre-fill inspection station 300. Furthermore, the track may have a gentle or slight incline or descent in at least part of the path from the capsule casing supply station 200 to the pre-fill inspection station 300, thereby facilitating the movement of the capsule casing 1370 and the formation / maintaining of queues (e.g., with the assistance of gravity).

[0099] Figure 16 is an enlarged view including a pre-fill inspection station according to an exemplary embodiment. Referring to Figure 16, the queue of capsule casings 1370 in the pre-fill inspection track 330 is designed so that each flute groove of the pre-fill inspection drum 310 is occupied by a capsule casing 1370 when it is transported to the pre-fill inspection drum 310. A pre-fill rejection drum 320 is located downstream of the pre-fill inspection drum 310, and the capsule casings 1370 that have passed through the pre-fill rejection drum 320 are led to a filling track 340 that supplies to the transport drum 410 of the filling station 400.

[0100] Figure 17 is an enlarged view of the transport point upstream of a pre-fill inspection station according to an exemplary embodiment. Referring to Figure 17, the pre-fill inspection drum 310 is configured to receive capsule casings 1370 (from the pre-fill inspection track 330) into flute grooves 312 formed on the drum surface. Furthermore, a port 314 helps to hold the capsule casings 1370 when a vacuum is applied. For example, a queue of capsule casings 1370 in the pre-fill inspection track 330 can be designed so that the capsule casings 1370 are pushed toward the pre-fill inspection drum 310 (e.g., via compressed air and / or a conveyor belt). As a result, as the pre-fill inspection drum 310 rotates (e.g. counterclockwise) and receives a capsule casing 1370 into the flute grooves 312, the queue advances so that the next capsule casing 1370 is ready to be received into the next flute groove 312. Furthermore, although the illustration shows that each flute groove 312 of the pre-filling inspection drum 310 is provided with two ports 314, it should be understood that the embodiments are not limited thereto. For example, each flute groove 312 may have only one port 314, or it may have multiple ports 314 (e.g., three ports).

[0101] Figure 18 is another enlarged view including a pre-fill inspection station according to an exemplary embodiment. Referring to Figure 18, on the pre-fill inspection drum 310, the capsule casing 1370 is inspected by a first pre-fill inspection device 350 and a second pre-fill inspection device 360. The first pre-fill inspection device 350 inspects the capsule casing 1370 from the side, and the second pre-fill inspection device 360 ​​inspects the capsule casing 1370 from above. The pre-fill inspection station 300 is illustrated such that the inspection of the capsule casing 1370 from the side by the first pre-fill inspection device 350 precedes the inspection of the capsule casing 1370 from above by the second pre-fill inspection device 360, but it should be understood that embodiments are not limited thereto. For example, in another embodiment, the pre-fill inspection station 300 may be configured such that a second pre-fill inspection device 360 ​​first inspects the capsule casing 1370 from above, and then a first pre-fill inspection device 350 inspects the capsule casing 1370 from the side. In yet another example, a single pre-fill inspection device may be used to inspect the capsule casing 1370 simultaneously from the side and from above.

[0102] Figure 19 is a photograph of a pre-fill inspection station according to an exemplary embodiment. Referring to Figure 19, a queue of capsule casings 1370' from the pre-fill inspection track 330' is received into the pre-fill inspection drum 310' and inspected by the first pre-fill inspection device 350' and the second pre-fill inspection device 360'. Subsequently, the capsule casings 1370' on the pre-fill inspection drum 310' are transported to the pre-fill rejection drum 320'. Here, capsule casings 1370' determined to be unsuitable by the first pre-fill inspection device 350' and / or the second pre-fill inspection device 360' are discharged into the rejection chute 326'.

[0103] Figure 20 is an enlarged view of the transport point between the pre-fill inspection drum and the pre-fill rejection drum in a pre-fill inspection station according to an exemplary embodiment. Referring to Figure 20, when the capsule casing 1370 (similar to, for example, the capsule casing 1370' in Figure 19), which is mounted in the flute groove 312 of the pre-fill inspection drum 310 and held in place by vacuum through port 314, is transported between drums at the transport point with the pre-fill rejection drum 320, the capsule casing 1370 is mounted in the flute groove 322 and held in place by vacuum through port 324. It should be understood that the transport point is a position where the capsule casing 1370, mounted in the flute groove 312 of the pre-fill inspection drum 310 (for example, rotating counterclockwise), is sufficiently close to the flute groove 322 of the pre-fill rejection drum 320 (for example, rotating clockwise), and the capsule casing 1370 can be transported to the flute groove 322 of the pre-fill rejection drum 320. In an exemplary embodiment, at the transport point, the suction connected to the port 314 of the flute groove 312 of the pre-fill inspection drum 310 is temporarily interrupted or stopped, thereby facilitating the transport of the capsule casing 1370 via the suction connected to the port 324 of the corresponding flute groove 322 of the pre-fill rejection drum 320. Furthermore, any capsule casing 1370 deemed unsuitable on the pre-fill inspection drum 310 (by the first pre-fill inspection device 350 and / or the second pre-fill inspection device 360) is discharged to the rejection chute 326. For example, when the flute groove 322 fitted with the inappropriate capsule casing 1370 passes in front of the opening of the rejection chute 326 (not visible in Figure 20), an opening may be provided in the rejection chute 326 for ejecting the inappropriate capsule casing 1370 (for example, by an air jet from one or more of the corresponding ports 324). When an air jet is used to eject the inappropriate capsule casing 1370, the air jet may be designed to be strong enough to counteract the suction that holds the capsule casing 1370 in the flute groove 322 of the pre-filled rejection drum 320.

[0104] Figure 21 is an enlarged view of the transport point downstream of a pre-fill inspection station according to an exemplary embodiment. Referring to Figure 21, as the pre-fill rejection drum 320 rotates clockwise, the capsule casing 1370 in the flute groove 322 is transported to the filling track 340. In an exemplary embodiment, a deflector (e.g., a wedge-like structure with tapered ends) may be provided at the boundary between the pre-fill rejection drum 320 and the filling track 340, configured to eject the capsule casing 1370 from the flute groove 322 of the pre-fill rejection drum 320. For example, the deflector has a first surface and a second surface, the first surface may be in contact with the second surface at its tapered end. The first surface of the deflector may define the side wall to / from the inlet of the filling track 340, and the second surface of the deflector may face the pre-fill rejection drum 320. In some cases, the second surface of the deflection section may have a curvature corresponding to the curvature of the drum surface of the pre-filling rejection drum 320 that defines the flute groove 322. The orientation of the deflection section and its proximity to the pre-filling rejection drum 320 are set such that there is not enough clearance for the capsule casing 1370 to remain in the flute groove 322 after it encounters the deflection section. As a result, when the pre-filling rejection drum 320 rotates clockwise, the capsule casing 1370 reaches the tapered end of the deflection section and disengages from the flute groove 322. Furthermore, the thrust of the capsule casing 1370 due to the rotation of the pre-filling rejection drum 320 helps to transport the disengaged capsule casing 1370 into and along the filling track 340. The filling track 340 defines an internal channel leading to the filling station 400.

[0105] Figure 22 is an enlarged view of the transport point upstream of a filling station according to an exemplary embodiment. Referring to Figure 22, the transport drum 410 receives the capsule casings 1370 from the filling track 340, and ensures that the capsule casings 1370 are fitted into the flute grooves 412 and held in place by suction through the port 414. As previously mentioned (for example in relation to Figures 15-19), compressed air and / or a conveyor belt may also be used to form and maintain a queue of capsule casings 1370 at least at the downstream end of the filling track 340. As a result, as the transport drum 410 rotates (for example counterclockwise) to receive the capsule casings 1370 into the flute grooves 412, the queue advances, and the next capsule casing 1370 is ready to be received into the next flute groove 412. From the transport drum 410, the capsule casing 1370 is transported to the filling drum 420, where it engages with a filling receptacle, such as a filling pan 420-10, via a port 420-14 provided therein.

[0106] Figure 23 is a perspective view of a filling station according to an exemplary embodiment. Referring to Figure 23, the capsule casing 1370 may be received into the conveyor drum 410 of the filling station 400 with the assistance of the conveyor guide 405. The capsule casing 1370 is then received into the carriage 420-20 of the filling drum 420. The aerosol-forming substrate supplied to the filling pan 420-10 is subjected to the action of the first baffle 420-1, the second baffle 420-2, the third baffle 420-3, and the fourth baffle 420-4. The filled capsule casing is moved to the post-fill inspection drum 430 and inspected by the post-fill inspection device 450. The capsule casing 1370 is moved to the post-filling rejection drum 440 with the assistance of an optional transport guide 435, and any capsule casing 1370 deemed to be improperly filled (after inspection by the post-filling inspection device 450) is discharged to the rejection chute 426. Alternatively, improperly filled capsule casings may be subsequently discarded at the capping station 500 (for example, to mitigate potential confusion that may occur when discharging uncapped filled capsule casings 1370).

[0107] Figure 24 is an enlarged view including the carriage of a filling station according to an exemplary embodiment. Referring to Figure 24, when the capsule casing 1370 is transported from the conveying drum 410 to the filling drum 420, it is mounted in the flute grooves 420-22 of the carriage 420-20 and is configured to be held in place by suction through port 420-24 (which may also be called a vacuum port). In other cases, the capsule casing 1370 can be guided and held in the flute grooves 420-22 via mechanical guides and holding structures, and port 420-24 can be optionally installed. Furthermore, a height guide 415 ensures that the capsule casing 1370 is positioned to cover port 420-21 (which may also be called a vacuum port), thereby facilitating vacuum filling of the aerosol-forming substrate. As will be detailed later, the aerosol-forming substrate is supplied to the filling pan 420-10 and drawn into the capsule casing 1370 through port 420-14 during vacuum filling.

[0108] Figure 25 is an enlarged view including the underside of the filling pan of a filling station according to an exemplary embodiment. Referring to Figure 25, the ports 420-14 (which may also be called vacuum ports) in the filling pan 420-10 each have chamfered ends 420-12 (for example at an angle of 30 degrees) to facilitate the insertion of the capsule casing 1370 into the ports 420-14 when the carriage 420-20 rises to allow filling of the aerosol-forming substrate.

[0109] Figure 26 is an enlarged view including the filling drum of a filling station according to an exemplary embodiment. Referring to Figure 26, the carriage 420-20 of the filling drum 420 is configured to move axially between a lowered position (for loading or unloading the capsule casing 1370) and an elevated position (for filling the capsule casing 1370). As shown in the figure, the carriage 420-20 in the elevated position is within the filling zone, and when it leaves the filling zone it lowers to allow transport from the filling drum 420.

[0110] Figure 27 is an enlarged view including a pair of baffles in a filling station according to an exemplary embodiment. Referring to Figure 27, a first motor 420-1M (e.g., a pneumatic vibration motor) is used to vibrate the first baffle 420-1. This vibration has the function of increasing the particle motion of the aerosol-forming substrate, making it more fluid and facilitating filling. As the filling pan 420-10 rotates, the first baffle 420-1 is angled to direct the aerosol-forming substrate toward the port 420-14. Here, by suction performed through the capsule case 1370, the aerosol-forming substrate flows into the capsule case 1370 through the port 420-14.

[0111] A second motor 420-2M (e.g., a pneumatic vibration motor) is also used to vibrate the second baffle 420-2. The second baffle 420-2 is curved (e.g., U-shaped or C-shaped) and is designed to capture a portion of the aerosol-forming substrate as the filling pan 420-10 rotates. Detector 420-2D measures the height of the temporary deposit of the aerosol-forming substrate captured by the second baffle 420-2 and signals (or controls) that the supply of the aerosol-forming substrate should be delayed if the height exceeds an upper threshold, and signals (or controls) that the supply should be increased if the height falls below a lower threshold.

[0112] Figure 28 is a photograph showing the supply of aerosol-forming substrate to a filling station according to an exemplary embodiment. Referring to Figure 28, the aerosol-forming substrate 1860' supplied from the second substrate hopper 120' to the filling pan 420-10' by the second substrate conveyor 140' is agitated by the first baffle 420-1' (for example to increase fluidity) and guided toward the port 420-14'. A first motor 420-1M' (e.g., a pneumatic vibrating motor) can be used to vibrate the first baffle 420-1' to agitate / fluidize the aerosol-forming substrate 1860' for the first round of filling. A detection unit 420-2D' can measure the height of the temporary deposit of the aerosol-forming substrate 1860' captured by the second baffle (which may be analogous to the second baffle 420-2 in Figure 27) and control the supply rate of the aerosol-forming substrate 1860'.

[0113] Figure 29 is a photograph of a baffle pair in a filling station according to an exemplary embodiment. Referring to Figure 29, a second baffle 420-2' is positioned downstream of the first baffle 420-1', and is positioned slightly higher than the other three baffles (e.g., a few mm above the surface of the filling pan 420-10'). As an example, the second baffle 420-2' is positioned 3 mm above the surface of the filling pan 420-10'. A second motor 420-2M' (e.g., a pneumatic vibration motor) can be used to vibrate the second baffle 420-2 to agitate / move the aerosol-forming substrate 1860'.

[0114] Figure 30 is an enlarged view including another pair of baffles in the filling station according to an exemplary embodiment. Referring to Figure 30, a third motor 420-3M' and a fourth motor 420-4M may be used to vibrate the third baffle 420-3 and the fourth baffle 420-4, respectively, to assist in agitation / fluidization of the aerosol-forming substrate (e.g., aerosol-forming substrate 1860' in Figure 29). The third baffle 420-3 redirects the aerosol-forming substrate toward port 420-14 in the filling pan 420-10 so that a second filling round is generated (i.e., the initial amount from the first baffle 420-1 is drawn in, leaving gaps / space for more aerosol-forming substrate). The fourth baffle 420-4 wipes away the excess, away from port 420-14. This prevents the aerosol-forming substrate from being wasted when the carriage 420-20 descends from the filling pan 420-10 to transport the capsule casing 1370.

[0115] Figure 31 is a photograph showing the portion of the filling pan of a filling station according to an exemplary embodiment, between the first baffle pair and the second baffle pair. Referring to Figure 31, the layer of aerosol-forming substrate 1860' formed on the filling pan 420-10' by the second baffle 420-2' is directed toward the port by the third baffle 420-3', allowing the capsule casing to be topped off to its maximum extent.

[0116] Figure 32 is a photograph showing the downstream portion of the second baffle pair of the filling pan of a filling station according to an exemplary embodiment. Referring to Figure 32, during filling, the edge of the capsule casing 1370' is substantially coplanar with the surface of the filling pan 420-10'. Furthermore, because the size and shape of the capsule casing 1370' fit relatively tightly into the port 420-14', the aerosol-forming substrate 1860' is not substantially lost through its minute gaps.

[0117] Figure 33 is a photograph of a filled capsule casing on a lowered carriage of a filling station according to an exemplary embodiment. Referring to Figure 33, after the fourth baffle (e.g., the fourth baffle 420-4 in Figure 30), the carriage 420-20' and the capsule casing 1370' on it are lowered from the filling pan 420-10' for transport. As shown in the figure, after filling, the aerosol-forming substrate 1860' protrudes slightly above the edge of the capsule casing 1370' by suction (at least partially). Furthermore, due to suction filling, the filling density of the aerosol-forming substrate 1860' drawn into the capsule casing 1370' is greater than that of gravity-fed filling.

[0118] Figure 34 is a photograph showing the transport of a filled capsule casing from a filling drum to a post-fill inspection drum according to an exemplary embodiment. Referring to Figure 34, the carriage 420-20' of the filling drum 420' begins to descend after passing through a fourth baffle 420-4' that wipes away excess aerosol-forming substrate 1860' and moves it away from the port of the filling pan 420-10'. Once the carriage 420-20' reaches the lowered position, the capsule casing 1370' above it is transported from the filling drum 420' (which is rotating, for example, clockwise) to the flute groove 432' of the post-fill inspection drum 430' (which is rotating, for example, counterclockwise) by suction through port 434'.

[0119] Figure 35 is a perspective view including a cap mounting station according to an exemplary embodiment. Referring to Figure 35, the process and associated mechanisms for adjusting the orientation of caps via the cap supply station 600 (e.g., Figure 1) may be similar to the process and associated mechanisms for adjusting the orientation of capsule casings via the capsule casing supply station 200 (e.g., Figures 13-14). The cap supply station 600 may include a cap hopper 610, a cap alignment bowl 620, and an alignment bowl inspection device 650. The caps are first introduced into the cap supply station 600 via the cap hopper 610 and then move to the cap alignment bowl 620. Within the cap alignment bowl 620, the orientation of the caps (e.g., first end caps 1310) is adjusted as shown in Figure 11 to facilitate insertion into the capsule casing 1370. For example, the cap alignment bowl 620 may be configured as a circulating loop and, when actuated (e.g., by an electromagnetic pulse acting on a spring structure located below), the caps may rise up a helical path. This path includes a section that facilitates properly oriented caps (e.g., the orientation of the first end cap 1310 in Figure 11), ultimately leading to the supply track 630. As a result, properly oriented caps (e.g., upright) are more likely to pass through this section and reach the supply track 630. In contrast, improperly oriented caps (e.g., upside down) are more likely to fall to the lower layer of the cap alignment bowl 620 and repeat the path until they are properly oriented. As shown in Figure 35, the filled capsule casings from the post-filling rejection drum 440 of the filling station 400 are transported to the transport drum 510 of the cap mounting station 500 with the assistance of an optional transport guide 445. Meanwhile, properly oriented caps are transported to the cap supply drum 520 via the supply track 630 and the cap supply track 570 (collectively referred to as the inter-station cap track, cap track, or simply the track). The caps are mounted onto the filled capsule casings by the cap mounting drum 530.The post-cap inspection device 560 inspects the capsules on the post-cap inspection drum 540, after which the capsules are transported to the post-cap rejection drum 550, and defective capsules are discharged via the rejection chute 526. A transport guide 545 may be used to facilitate the transport of capsules from the post-cap inspection drum 540 to the post-cap rejection drum 550.

[0120] Figure 36 is an enlarged view of the truck supplying caps to the capping station according to an exemplary embodiment. Referring to Figure 36, the cap conveyor 572 is used to transport the first end caps 1310 received from the supply truck 630 along the cap supply truck 570. The supply truck 630 and the cap supply truck 570 are configured to maintain an upright, longitudinal orientation (as shown in Figure 36) while the first end caps 1310 from the cap supply station 600 are moving to the capping station 500.

[0121] Figure 37 is an enlarged view including a cap supply drum of a cap-fitting station according to an exemplary embodiment. Referring to Figure 37, a cap conveyor 572 is configured to form and maintain a waiting line of first end caps 1310 at the downstream end of a cap supply track 570, and to provide a stable supply of first end caps 1310 for fitting into recesses 522 of a cap supply drum 520. From the cap supply drum 520, the first end caps 1310 are transported to a cap-fitting drum 530. Simultaneously, a filled capsule casing (e.g., a capsule casing 1370' filled with an aerosol-forming substrate 1860' in Figure 34) held in the flute grooves 512 of a transport drum 510 by suction via a port 514 is transported to the cap-fitting drum 530 for capping with the first end caps 1310. The cap-fitting drum 530 includes, among other things, a drum ring 530-10 and a plurality of carriages 530-20. The carriage 530-20 is configured to move axially between a raised position (for receiving the first end cap 1310) and a lowered position (for inserting the first end cap 1310 into the capsule casing). The drum ring 530-10 defines a flute groove 530-12 for holding the capsule casing by suction through the port 530-14.

[0122] Figure 38 is an enlarged view of the capping portion of a capping station according to an exemplary embodiment. Referring to Figure 38, a filled capsule casing (not shown in this figure) is conveyed to a capping drum 530 (rotating clockwise) while being held in the flute groove 512 by suction through port 514 of a conveying drum 510 (rotating counterclockwise). As previously mentioned, the capping drum 530 includes, in particular, a drum ring 530-10 and a plurality of carriages 530-20 configured to move axially between an elevated position and a lowered position. In particular, the capsule casing from the conveying drum 510 is received into the flute groove 530-12 of the drum ring 530-10 and held in place by suction through port 530-14. The first end cap 1310 from the cap supply drum 520 is received by the carriage 530-20 and held on the underside of the carriage 530-20 via a vacuum port aligned above the flute groove 530-12 of the drum ring 530-10 in which the capsule casing is held. After receiving the first end cap 1310, as the cap mounting drum 530 rotates clockwise, the carriage 530-20 is configured to move from an elevated position to a lowered position (after passing the capsule casing transport point), thereby inserting the first end cap 1310 into the capsule casing held by the drum ring 530-10.

[0123] Figure 39 is a photograph of the capping portion of a capping station according to an exemplary embodiment. Referring to Figure 39, the filled capsule casing 1370' from the conveying drum 510' is transferred to the capping drum 530' at a conveying point, while the first end cap 1310' from the cap supply drum 520' is transferred to the capping drum 530' at another conveying point upstream of the capsule casing 1370' conveying point. After the capsule casing 1370' conveying point, the carriage 530-20' of the capping drum 530' is configured to move from an elevated position (at the first end cap 1310' conveying point) to a lowered position (after the capsule casing 1370' conveying point). This allows the first end cap 1310' to be inserted into the capsule casing 1370' held by the capping drum 530', thereby obtaining the capsule 1300'. In one exemplary embodiment, capsule 1300' may be the same as that disclosed with respect to capsule 1300 in Figures 9 to 11. From the capping drum 530', capsule 1300' is transported to a post-capping inspection drum (e.g., post-capping inspection drum 540 in Figure 35) for inspection, and then to a post-capping rejection drum 550'. Here, capsule 1300' that are found to be defective or otherwise unsuitable are discharged to a rejection chute 526'.

[0124] Figure 40 is an enlarged view of a capping station according to an exemplary embodiment, including a post-capping inspection drum. Referring to Figure 40, the carriage 530-20 of the capping drum 530 begins to move from a lowered position to an raised position prior to the transport point where the capsules are transported from the drum ring 530-10 to the post-capping inspection drum 540. Returning to the raised position, the carriage 530-20 of the capping drum 530 is configured to receive additional caps (e.g., first end caps 1310) from the cap supply drum 520, and the capping process is repeated with more capsule casings (e.g., capsule casings 1370). From the capping drum 530, the capsules are transported to the post-capping inspection drum 540, where they are inspected by a post-capping inspection device 560 (e.g., for improper capping, damage, defects in appearance or aesthetics, etc.). The capsules are then transported to a post-capping rejection drum 550, which may be assisted by a transport guide 545.

[0125] Figure 41 is an enlarged view of a capping station according to an exemplary embodiment, including a post-capping inspection drum and a post-capping rejection drum. Referring to Figure 41, capsules transported from the capping drum 530 to the post-capping inspection drum 540 are inspected by the post-capping inspection device 560 and then transported to the post-capping rejection drum 550. In the post-capping rejection drum 550, capsules determined to be defective or otherwise unacceptable by the post-capping inspection device 560 are discharged into the rejection chute 526. Any remaining capsules on the post-capping rejection drum 550 are discharged into the recovery station 700.

[0126] Figure 42 is a photograph showing how capsules are transported from the post-capping rejection drum to the recovery station according to an exemplary embodiment. Referring to Figure 42, capsules 1300' on the post-capping inspection drum 540' are transported to the post-capping rejection drum 550'. In the illustrated exemplary embodiment, the post-capping inspection drum 540' rotates counterclockwise and the post-capping rejection drum 550' rotates clockwise, and capsules 1300' move to the recovery station 700' following an S-shaped path. On the post-capping rejection drum 550', capsules 1300' that are deemed defective or otherwise unacceptable (by the post-capping inspection device) are discharged to the opening of the rejection chute 526'. For any remaining capsules 1300' on the rejection drum 550' after capping, a terminal interface (wall, barrier, etc.) can be positioned near a point downstream of the rejection chute 526' on the rejection drum 550' after capping (e.g., a removal point or a recovery point). This prevents sufficient clearance for the capsules 1300' moving on the rejection drum 550' after capping to pass through the terminal interface. As a result, the capsules 1300' moving on the rejection drum 550' after capping collide with the terminal interface, detach, and fall into the recovery station 700'. Alternatively (or in addition to) a terminal barrier, the suction for holding the capsules 1300' on the rejection drum 550' after capping can be temporarily interrupted or stopped at a point or section downstream of the rejection chute 526'. This causes the capsules 1300' to separate or detach from the rejection drum 550' after capping by centrifugal force and accumulate in the recovery station 700'.

[0127] Figure 43 is an enlarged view including a recovery station according to an exemplary embodiment. Referring to Figure 43, the transport drum 510, capping drum 530, post-capping inspection drum 540, post-capping rejection drum 550, and cap supply station 600 are labeled, which provides a clearer context regarding the location, size, and configuration of the recovery station 700. Therefore, for the sake of brevity, the details of the transport drum 510, capping drum 530, post-capping inspection drum 540, post-capping rejection drum 550, and cap supply station 600, which have already been described herein, will not be repeated below. As shown in Figure 43, the distal end of the rejection chute 526 is positioned to guide capsules rejected by the post-capping rejection drum 550 to the rejection bin 528.

[0128] Figure 44 is another enlarged view including a recovery station according to an exemplary embodiment. Referring to Figure 44, the recovery station 700 may include an upper recovery chute 710, a lower recovery chute 720, a lifting assembly 730, a recovery container 740, and a transport assembly 750. Capsules that have been transported from the post-cap inspection drum 540 to the post-cap rejection drum 550 and have not been discharged to the rejection chute 526 first move to the upper recovery chute 710, then to the lower recovery chute 720, and finally reach the recovery container 740 of the recovery station 700. The lower recovery chute 720 may be configured to allow capsules to descend in a spiral path to mitigate potential problems associated with the vertical drop of capsules into the recovery container 740 (e.g., detachment of aerosol-forming substrate particles from the capsules, damage to the capsules).

[0129] Figure 45 is a block diagram of a method for filling a capsule casing with an aerosol-forming substrate according to an exemplary embodiment. Referring to Figure 45, Method 2000 is a method for filling a capsule casing with an aerosol-forming substrate. Method 2000 may comprise a feeding step 2100, an engagement step 2200, a vibration step 2300, and an suction step 2400. In one exemplary embodiment, Method 2000 may be carried out using an automated production line 1000 described herein.

[0130] In the supply step 2100, method 2000 may include supplying an aerosol-forming substrate to a filled receptacle defining a vacuum port array. In one exemplary embodiment, the supply step 2100 may be performed using at least the substrate supply station 100 described herein.

[0131] In engagement step 2200, method 2000 may include engaging the capsule casing with the lower part of the filling receptacle and the vacuum port array. The capsule casing may have an open upper end and a permeable lower end. In an exemplary embodiment, engagement step 2200 may be performed using at least the capsule casing supply station 200, pre-fill inspection station 300, and / or filling station 400 described herein.

[0132] In vibration step 2300, method 2000 may include providing vibrations that increase the particle motion of the aerosol-forming substrate within the filling receptacle. In one exemplary embodiment, vibration step 2300 may be carried out using at least the filling station 400 described herein.

[0133] In the suction step 2400, method 2000 may include suction toward the permeable lower end of the capsule casing such that the aerosol-forming substrate in the filling receptacle is drawn toward the open upper end of the capsule casing via the vacuum port array. In one exemplary embodiment, the suction step 2400 may be carried out using at least the filling station 400 described herein. It should be understood that method 200 may include further steps relating to the capping station 500, cap supply station 600, and / or recovery station 700 described herein.

[0134] Additional details and / or alternatives relating to machines, aerosol generating devices, capsules, and / or aerosol-forming substrates are described in U.S. Patent Nos. 9,963,260, 9,968,131, 10,562,748, 10,858,137, 11,576,440, U.S. Patent Application No. 17 / 151,340 (filed January 18, 2021), and U.S. Patent Application No. 17 / 981,973 (filed November 7, 2022), the entirety of which is incorporated herein by reference.

[0135] As discussed herein, an aerosol-forming substrate is a material or combination of materials capable of generating an aerosol. An aerosol relates to a substance produced or output by the disclosed apparatus, the apparatus described in the claims, or an equivalent apparatus. This material may contain compounds (e.g., nicotine, cannabinoids). When this material is heated, an aerosol containing the compound is produced. Heating may be carried out below the combustion temperature to produce an aerosol without significant thermal decomposition of the aerosol-forming substrate or significant production of combustion byproducts (if any). Thus, in one embodiment, no thermal decomposition occurs during heating and the resulting aerosol production. In other examples, some thermal decomposition and combustion byproducts may occur, but to a relatively minor degree and / or can be considered merely incidental.

[0136] The aerosol-forming substrate may be a fibrous material. For example, the fibrous material may be a plant-based material. The fibrous material is configured to release a compound upon heating. The compound may be a natural component of the fibrous material. For example, the fibrous material may be a plant-based material such as tobacco, and the released compound may be nicotine. The term "tobacco" includes all tobacco plant materials, including tobacco leaves, tobacco plugs, reconstituted tobacco, compressed tobacco, molded tobacco, powdered tobacco, and combinations thereof from one or more tobacco plants (such as Nicotiana rustica and Nicotiana tabacum).

[0137] In some embodiments, the tobacco material may include material from any species of the genus Nicotiana. Furthermore, the tobacco material may contain a blend of two or more different tobacco varieties. Suitable usable tobacco materials include, but are not limited to, flue-cured tobacco, burley, dark tobacco, Maryland tobacco, Oriental tobacco, rare tobacco, specialty tobacco, and blends thereof. The tobacco material can be provided in any suitable form, such as tobacco lamina, processed tobacco material (volume-expanded tobacco, puffed tobacco, etc.), processed tobacco stem (cut-rolled stem, cut-puffed stem, etc.), reconstituted tobacco material, and blends thereof. In some embodiments, the tobacco material is in the form of substantially dried tobacco lumps. Furthermore, in some cases, the tobacco material may be mixed and / or combined with propylene glycol, glycerin, partial combinations thereof, or at least one of these combinations.

[0138] The released compounds may be natural components of medicinal plants with medically recognized therapeutic effects. For example, the medicinal plant may be a cannabis plant, and the compounds may be cannabinoids. Cannabinoids interact with receptors in the body, producing a wide range of effects. As a result, cannabinoids have been used for various medical purposes (e.g., pain, nausea, epilepsy, and mental illness). The fibrous material may contain leaf and / or flower material from one or more cannabis plants, such as Cannabis sativa, Cannabis indica, and Cannabis ruderalis. In some cases, the fibrous material is a mixture of 60-80% (e.g., 70%) Cannabis sativa and 20-40% (e.g., 30%) Cannabis indica.

[0139] Examples of cannabinoids include tetrahydrocannabinol (THCA), tetrahydrocannabinol (THC), cannabidiolic acid (CBDA), cannabidiol (CBD), cannabinol (CBN), cannabicyclol (CBL), cannabichromene (CBC), and cannabigerol (CBG). Tetrahydrocannabinol (THCA) is a precursor of tetrahydrocannabinol (THC), and cannabidiolic acid (CBDA) is a precursor of cannabidiol (CBD). Tetrahydrocannabinol (THCA) and cannabidiolic acid (CBDA) can be converted to tetrahydrocannabinol (THC) and cannabidiol (CBD), respectively, by heating. In one exemplary embodiment, decarboxylation may occur due to heat from a heater, converting tetrahydrocannabinol (THCA) in the capsule to tetrahydrocannabinol (THC) and / or cannabidiolic acid (CBDA) in the capsule to cannabidiol (CBD).

[0140] When both tetrahydrocannabinol (THCA) and tetrahydrocannabinol (THC) are present in a capsule, decarboxylation and the resulting conversion will decrease the amount of tetrahydrocannabinol (THCA) and increase the amount of tetrahydrocannabinol (THC). During heating of the capsule, at least 50% (e.g., at least 87%) of the tetrahydrocannabinol (THCA) may be converted to tetrahydrocannabinol (THC). Similarly, when both cannabidiolic acid (CBDA) and cannabidiol (CBD) are present in a capsule, decarboxylation and the resulting conversion will decrease the amount of cannabidiolic acid (CBDA) and increase the amount of cannabidiol (CBD). During heating of the capsule, at least 50% (e.g., at least 87%) of the cannabidiolic acid (CBDA) may be converted to cannabidiol (CBD).

[0141] Furthermore, the released compounds may be or may contain non-naturally derived additives. These additives are introduced into the fibrous material in a later step. For example, the fibrous material may include cotton, polyethylene, polyester, rayon, combinations thereof, or similar materials (e.g., in the form of gauze). In another example, the fibrous material may be a cellulose material (e.g., non-tobacco and / or non-cannabis material). In either case, the introduced compounds may include nicotine, cannabinoids, and / or flavorings. Flavorings are obtained from naturally derived sources such as plant extracts (e.g., tobacco extract, cannabis extract) and / or from artificial sources. In yet another example, if the fibrous material contains tobacco and / or cannabis, the compound may contain or additionally contain one or more flavorings (e.g., menthol, mint, vanilla). Therefore, compounds in the aerosol-forming substrate may contain naturally derived components and / or non-naturally derived additives. In this regard, it should be understood that the level of naturally derived components in the aerosol-forming substrate can be increased by supplementation. For example, the level of nicotine in a given amount of tobacco can be increased by supplementing with a nicotine-containing extract. Similarly, the level of one or more cannabinoids in a given amount of cannabis can be increased by supplementing with an extract containing such cannabinoids.

[0142] In at least one exemplary embodiment, the aerosol-forming substrate, for example when contained within a capsule, has a resistance to draw (RTD) of about 30 mmH2O or more (for example, about 40 mmH2O or more, about 50 mmH2O or more, about 60 mmH2O or more, about 70 mmH2O or more, about 80 mmH2O, about 90 mmH2O or more, about 100 mmH2O or more, about 110 mmH2O or more, or about 120 mmH2O or more). In at least one exemplary embodiment, the RTD is about 130 mmH2O or less (for example, about 120 mmH2O or less, about 110 mmH2O or less, about 100 mmH2O or less, about 90 mmH2O or less, about 80 mmH2O or less, about 70 mmH2O or less, about 60 mmH2O or less, about 50 mmH2O or less, or about 40 mmH2O or less). In at least one exemplary embodiment, the RTD is in the range of about 60 mmH2O to about 80 mmH2O (for example, in the range of about 65 mmH2O to about 75 mmH2O, about 67 mmH2O to about 73 mmH2O, or about 69 mmH2O to about 71 mmH2O).

[0143] In at least one exemplary embodiment, the aerosol-forming substrate has a bulk density of about 0.2 g / cm 3 , 3 , 3 , 3 , 3 , 3 , 3 , 3 or more (for example, about 0.25 g / cm 3 or more, about 0.3 g / cm 3 , about 0.35 g / cm 3 or more, about 0.4 g / cm 3 or more, about 0.45 g / cm 3 or more, about 0.5 g / cm 3 or more, about 0.55 g / cm 3 [[ID=2)]], about 0.6 g / cm 3 or more, about 0.65 g / cm " 3 or more, about 0.7 g / cm 3 or more, about 0.75 g / cm 3 bor more). In at least one exemplary embodiment, the bulk density is about 0.8 g / cm 3 or less (for example, about 0.75 g / cm 3 [[ID=]) or less, about 0.7 g / cm 3 or less, about 0.65 g / cm 3 or less, about 0.6 g / cm 3Below, about 0.55g / cm 3 Below, about 0.5g / cm 3 Below, approximately 0.45g / cm 3 Below, approximately 0.4g / cm 3 Below, approximately 0.35g / cm 3 Below, about 0.3g / cm 3 The following, or approximately 0.25 g / cm³ 3 The following applies: In at least one exemplary embodiment, the bulk density is approximately 0.3 g / cm³. 3 Approximately 0.5 g / cm³ 3 The range (for example, approximately 0.35 g / cm³) 3 Approximately 0.45 g / cm³ 3 , or approximately 0.37 g / cm³ 3 Approximately 0.43 g / cm³ 3 (This is within the range of)

[0144] In at least one exemplary embodiment, the aerosol-forming substrate is in a granular form with an average particle size (e.g., diameter) of about 270 μm or more (e.g., about 280 μm or more, about 290 μm or more, about 300 μm or more, about 310 μm or more, about 320 μm or more, about 330 μm or more, about 340 μm or more, about 350 μm or more, about 360 μm or more, about 370 μm or more, about 380 μm or more, about 390 μm or more, about 400 μm or more, or about 410 μm or more). In at least one exemplary embodiment, the average particle diameter is about 415 μm or less (for example, about 410 μm or less, about 400 μm or less, about 390 μm or less, about 380 μm or less, about 370 μm or less, about 360 μm or less, about 350 μm or less, about 340 μm or less, about 330 μm or less, about 320 μm or less, about 310 μm or less, about 300 μm or less, about 290 μm or less, or about 280 μm or less).

[0145] In at least one exemplary embodiment, the aerosol-forming substrate has a 10th percentile diameter in the range of about 160 μm to about 225 μm. In at least one exemplary embodiment, the aerosol-forming substrate has a 50th percentile diameter (or median particle size) in the range of about 260 μm to about 385 μm. In at least one exemplary embodiment, the aerosol-forming substrate has a 90th percentile diameter in the range of about 390 μm to about 635 μm.

[0146] In this specification, the capsule 1300 is disclosed to include a heater 1340, but it should be understood that the embodiments are not limited thereto. For example, the capsule 1300 may not have a heater, but instead be provided as part of an aerosol generator that receives the capsule 1300. In other examples in which the heater 1340 is present within the capsule 1300, the heater 1340 may include a first end 1342, an intermediate section 1344, and a second end 1346. The intermediate section 1344 of the heater 1340 may have a planar bend shape, such as a compressed wavy or zigzag, comprising a plurality of parallel sections (e.g., 8 to 16 parallel sections). In one exemplary embodiment, the two outermost parallel sections of the intermediate section 1344 may be wider than the inner parallel sections (e.g., 0.60 mm for the outer section and 0.30 mm for the inner section) to relieve thermal stress and improve mechanical stiffness. The inner parallel section of the intermediate section 1344 may be positioned closer to the first opening 1312 of the first end cap 1310 and the second opening 1322 of the second end cap 1320 than the outer parallel section of the intermediate section 1344. Such a configuration can facilitate heating at the center of the capsule 1300. However, it should be understood that the intermediate section 1344 of the heater 1340 may have other shapes (e.g., spiral, flower-like).

[0147] The ends of the first end 1342 and the second end 1346 may be oriented perpendicular to the plane of the intermediate section 1344. Each of the first end 1342 and the second end 1346 may include a section having a lateral J-shape. Furthermore, each of the first end 1342 and the second end 1346 may include opposing finger-like or claw-like structures. The finger-like or claw-like structures may function as positioning features for manufacturing equipment (e.g., overmolding tools). As a result, the first end 1342 and the second end 1346 can be embedded relatively securely within the second end cap 1320 while providing a pair of electrical contact surfaces.

[0148] In other examples, the dimensional change may be small or nonexistent in the transition from the intermediate section 1344 to the first end section 1342 and the second end section 1346 (for example, when the width is uniform, unlike a broadly formed thermal stress relaxation / low resistance section). Furthermore, the first end section 1342 and the second end section 1346 may include tab sections that are simplified as anchor and electrical contact structures, respectively.

[0149] In this specification, the aerosol-forming substrate 1860' is a loose, unformed form (e.g., particles, fibers, pulverized material, fragments, or small pieces) that does not have a predetermined shape and is configured to conform to the shape of the available space in the chamber when introduced into the capsule. Specifically, during assembly or filling, the loose form of the aerosol-forming substrate 1860' is positioned to partially or completely occupy the available space in the capsule chamber and to be located to the sides of each intermediate portion of the heater (e.g., to surround and contact the intermediate portion 1344 of the heater 1340). For example, the loose form of the aerosol-forming substrate 1860' may be used to fill the remaining space in a chamber in which a consolidated form of the aerosol-forming substrate has already been introduced (e.g., to top off the chamber). As another example, the loose form of the aerosol-forming substrate 1860' may be used to fill the entire chamber of the capsule. Furthermore, the aerosol-forming substrate 1860' can be introduced into a capsule (e.g., capsule 1300) via an aspiration-assisted process.

[0150] To reduce or eliminate the electrical insulating effect of the metal oxide layer, the electrical contact structure may be configured to concentrate the forces acting between the connection structures over a relatively small surface area. This increases the likelihood of penetrating the metal oxide layer (e.g., mechanically and / or electrically), improving the quality and reliability of the electrical connection with the underlying metal. In one exemplary embodiment, the electrical contact pad is manufactured or modified to introduce at least one surface discontinuity to form one or more concentrated contact points (e.g., edges) with the corresponding connector when electrically connected. A surface discontinuity should be understood as a disturbance in an otherwise smooth and continuous surface. Each surface discontinuity (or each surface discontinuity) is approximately 0.2 mm in size. 2 ~0.80mm 2 (For example, 0.4mm) 2 ~0.6mm 2 It can occupy a continuous region of ).

[0151] The contact pad may be provided with surface discontinuities (or multiple surface discontinuities) to enhance the electrical connection between at least one connector pin and the contact pad. In one exemplary embodiment, the surface discontinuity may take the form of at least one opening on the surface of the contact pad. The opening may be circular, or other shapes may be available. The opening may be provided as a recess or indentation (e.g., a dimple) in the contact pad. Alternatively, the opening may be provided as a through hole that penetrates the contact pad completely. With regard to manufacturing, to form one or more openings as surface discontinuities, the contact pad may be punched, stamped, drilled, etched, or otherwise machined before the capsule is assembled. Alternatively, techniques such as drilling may be performed after the capsule is assembled. The surface discontinuities of the contact pad create mechanically fragile (e.g., structurally fragile) portions through the edges or ends of the openings. This increases the likelihood that the corresponding connector pins will physically penetrate, damage, or otherwise break through this relatively weak point or portion of the outer oxide film, thereby establishing a reliable and stable electrical connection with the underlying metal of the contact pad.

[0152] A shear surface approach is also available, in which case the contact pad is provided with a projection such as a chamfer (e.g., R0.1 chamfer) as a surface discontinuity to enhance the electrical connection with the connector pin. The contact pad may be machined to form the chamfer, but the embodiment is not limited to this. The connector pin may be provided with a flat contact tip to concentrate the bonding force on the chamfer, thereby increasing the likelihood that the connector pin penetrates the outer layer of metal oxide and directly contacts the underlying metal, resulting in a more reliable electrical connection. Only one chamfer and corresponding connector pin are described here, but the embodiment is not limited to this, and additional chamfers and corresponding connector pins may be provided in other cases.

[0153] Although described with reference to specific embodiments and drawings, those skilled in the art can modify, add to, and substitute exemplary embodiments in various ways based on the description herein. For example, the described techniques may be performed in a different order than described, and / or the elements of the described systems, architectures, devices, circuits, etc., may be connected or combined in different ways than described above. Alternatively, suitable results may be achieved by other elements or equivalents.

Claims

1. A filling station for aerosol generating capsules, A filling receptacle is configured to accept an aerosol-forming substrate, defining a first series of vacuum ports, A plurality of carriages positioned below the filling receptacle, each of which defines a second series of vacuum ports and is configured to receive and hold a capsule casing for filling with the aerosol-forming substrate, A filling station comprising at least one vacuum source configured to draw a vacuum through the capsule casing such that the aerosol-forming substrate is drawn through the first vacuum port array in the filling receptacle and introduced into the capsule casing below.

2. In the filling station according to claim 1, The filling receptacle and the plurality of carriages are configured to be rotatable and have a common axis of rotation. A filling station in which the plurality of carriages are configured to be movable in the axial direction relative to the rotation axis.

3. In the filling station according to claim 1, A filling station comprising a plurality of carriages configured to engage with the filling receptacle by raising the capsule casing to facilitate the filling of the aerosol-forming substrate, and to lower the capsule casing after filling.

4. In the filling station according to claim 1, A filling station in which the first vacuum port array within the filling receptacle has a shape corresponding to the cross-section of the capsule casing.

5. In the filling station according to claim 1, The first vacuum port array is arranged in a ring shape within the filling receptacle of the filling station.

6. In the filling station according to claim 1, A filling station in which the plurality of carriages are configured to raise the capsule casing so that the capsule casing is inserted into the first vacuum port array within the filling receptacle.

7. In the filling station according to claim 1, A filling station in which each vacuum port in the first vacuum port array within the filling receptacle has its lower end chamfered such that its bottom opening is larger than the corresponding upper opening.

8. In the filling station according to claim 1, A filling station wherein the second vacuum port array is configured to align with the permeable lower end of the capsule casing.

9. In the filling station according to claim 1, A filling station comprising a plurality of carriages, each carriage of which is configured to hold the capsule casing relative to the plurality of carriages when suction is performed by the at least one vacuum source, further defining a third series of vacuum ports.

10. In the filling station according to claim 1, A filling station wherein the at least one vacuum source is configured to perform suction such that the filling density of the aerosol-forming substrate drawn into the capsule casing is greater than that introduced by gravity.

11. In the filling station according to claim 1, A filling station further comprising at least one motor configured to generate vibrations for promoting particle motion of the aerosol-forming substrate within the filling receptacle.

12. In the filling station according to claim 11, A filling station further comprising at least one baffle configured to adjust the distribution of the aerosol-forming substrate within the filling receptacle.

13. In the filling station according to claim 12, A filling station in which at least one baffle is configured to vibrate in response to at least one motor.

14. In the filling station according to claim 12, A filling station in which the filling receptacle and the plurality of carriages are configured to rotate, and the at least one baffle is configured to remain fixed relative to the rotation of the filling receptacle and the plurality of carriages.

15. In the filling station according to claim 14, The filling station is configured such that at least one baffle directs the aerosol-forming substrate toward the first vacuum port array during rotation of the filling receptacle.

16. In the filling station according to claim 12, A filling station in which the at least one baffle includes a first baffle, a second baffle, a third baffle, and a fourth baffle.

17. In the filling station according to claim 16, A filling station wherein the first baffle is configured to facilitate the initial filling of the aerosol-forming substrate within the capsule casing, and the third baffle is configured to facilitate the subsequent filling of the aerosol-forming substrate within the capsule casing.

18. In the filling station according to claim 16, A filling station wherein the second baffle is C-shaped or U-shaped and is positioned higher than the first baffle, the third baffle, and the fourth baffle from the surface of the filling receptacle.

19. In the filling station according to claim 16, A filling station wherein the second baffle is configured to temporarily store the aerosol-forming substrate for the purpose of determining a suitable pace for supplying the aerosol-forming substrate to the filling receptacle.

20. In the filling station according to claim 16, A filling station wherein the fourth baffle is configured to wipe away excess aerosol-forming substrate from the first vacuum port array and guide the excess aerosol-forming substrate toward the inner portion of the filling receptacle.

21. A method for filling a capsule casing with an aerosol-forming substrate, The steps include supplying the aerosol-forming substrate to a filled receptacle that defines the arrangement of vacuum ports, The steps include engaging the capsule casing, which has an open upper end and a breathable lower end, with the lower part of the filling receptacle and the vacuum port array, The steps include: applying vibrations within the filled receptacle to increase the particle motion of the aerosol-forming substrate; A method comprising the step of applying suction to the permeable lower end of the capsule casing such that the aerosol-forming substrate in the filled receptacle is drawn through the vacuum port array into the open upper end of the capsule casing.

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