Dispenser unit for aerosol precursors

Abstract

A unit for mixing and dispensing an aerosol precursor composition and a container dispensed therefrom. The unit includes a plurality of bulk material filling stations, the plurality of bulk material filling stations having at least one first filling station containing an aerosol former and at least one second filling station containing a flavor material for generating the aerosol precursor. The unit also includes a bulk consumable pack layering a plurality of containers configured to receive the aerosol precursor, and a robot configured to retrieve a container from the bulk consumable pack and move the container across at least two dimensions to stop at at least two of the plurality of bulk material filling stations.

Description

[Technical field]

[0001] The present disclosure relates to custom aerosol precursor compositions and machines configured to eject a container having an aerosol precursor. The present disclosure also relates to a container for receiving the aerosol precursor in the machine. The aerosol precursor may be of a type that incorporates a material that may be produced from tobacco, derived from tobacco, or that may incorporate tobacco. The precursor is intended to be capable of forming an inhalable substance for human consumption when used with an aerosol delivery device, such as a smoking article. The smoking article may be of a type that utilizes electrically generated heat for the generation of the inhalable substance. [Background technology]

[0002] Many smoking devices have been proposed over the years as an improvement or replacement for smoking products that require tobacco to be burned for use. Many of these devices are designed to provide the sensation associated with smoking cigarettes, cigars or pipes, but are said to not deliver significant amounts of incomplete combustion and pyrolysis products resulting from tobacco combustion. To this end, many smoking products, flavor generators and medicinal inhalers have been proposed that utilize electrical energy to vaporize or heat volatile materials or to provide the smoking sensation of cigarettes, cigars or pipes without significant tobacco combustion. See, for example, the various alternative smoking articles, aerosol delivery devices and heat sources described in the background art of Robinson et al., U.S. Pat. No. 7,726,320 and Collett et al., U.S. Pat. No. 8,881,737, which are incorporated herein by reference. Also see, for example, the various types of smoking articles, aerosol delivery devices and electric heat sources referenced by trade names and commercial sources described in Bless et al., U.S. Pat. App. Pub. No. 2015 / 0216232, which is incorporated herein by reference. Additionally, various types of powered aerosol and vapor delivery devices have also been proposed in U.S. Patent Application Publication No. 2014 / 0096781 to Sears et al. and U.S. Patent Application Publication No. 2014 / 0283859 to Minskoff et al., all of which are incorporated herein by reference, as well as U.S. Patent Application No. 14 / 282,768 to Sears et al., filed May 20, 2014, U.S. Patent Application No. 14 / 286,552 to Brinkley et al., filed May 23, 2014, U.S. Patent Application No. 14 / 327,776 to Ampolini et al., filed July 10, 2014, and U.S. Patent Application No. 14 / 465,167 to Worm et al., filed August 21, 2014. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] U.S. Patent No. 7,726,320 [Patent Document 2] U.S. Pat. No. 8,881,737 [Patent Document 3] US Patent Application Publication No. 2015 / 0216232 [Patent Document 4] US Patent Application Publication No. 2014 / 0096781 [Patent Document 5] US Patent Application Publication No. 2014 / 0283859 Summary of the Invention [Problem to be solved by the invention]

[0004] Some of these alternative smoking articles, i.e., aerosol delivery devices, are reusable through the use of replaceable cartridges or refillable tanks of aerosol precursors (e.g., smoke juice, e-liquid, or e-juice). It would be desirable to provide a customizable selection of aerosol precursors for use with these alternative smoking articles. Thus, advances in the generation, mixing, and dispensing of aerosol precursors are desirable. [Means for solving the problem]

[0005] The present disclosure provides a unit for mixing and dispensing an aerosol precursor composition for use by an aerosol delivery device, such as an electronic cigarette. The aerosol precursor dispensed from the unit can generally be customized to a customer's preferred flavor and / or strength. The mixing and dispensing unit may be configured to dispense the composition in the form of a filled or partially filled container that can hold the aerosol precursor composition until it is delivered to a reservoir of the aerosol delivery device. The container may be specially designed to have at least one of child-resistant and tamper-resistant features. Methods of using the mixing and dispensing unit, as well as methods of using the container, are also described.

[0006] In one embodiment, the present disclosure includes a unit for mixing and dispensing an aerosol precursor composition. The unit includes a plurality of bulk material filling stations, the plurality of bulk material filling stations including at least one first filling station having an aerosol former and at least one second filling station having a flavoring material for generating the aerosol precursor. The unit further includes a bulk consumable pack layering a plurality of containers configured to receive the aerosol precursor. The unit further includes a robot configured to pick a container from the bulk consumable pack and move the container across at least two dimensions to stop at at least two of the plurality of bulk material filling stations.

[0007] The above mixing and dispensing unit may further include one or more of the features from the following description, individually as well as in combinations and permutations thereof.

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

[0009] The unit may further include an inspection station configured to measure the amount of the aerosol precursor in the container.

[0010] The unit may further include a labeling station configured to provide an indicia based on the flavor material. The labeling station may provide the indicia by applying a web to the container. The labeling station may include a print head for forming the indicia.

[0011] Each bulk material filling station of the unit may include a pump. The pump may be integrated with a reservoir to form a bulk material pack removable from the bulk material filling station. The pump may include a layering chamber in communication with the reservoir, the layering chamber configured to hold a measured dose of the respective bulk material. An RFID antenna may be attached to a stage of the robot, the RFID antenna configured to read an RFID tag on the bulk material pack. The pump may be configured to dispense a measured dose of the respective bulk material upon each actuation of the pump. The pump may be actuated by being pressed by a portion of the robot or the container.

[0012] The unit may use containers including child-resistant and tamper-resistant features. Each container may include a bottle having a storage volume for holding the aerosol precursor and a cap. The cap may include a nozzle, an inner cover including a tamper-resistant band, and an outer cover provided on the inner cover. The outer cover provides a child-resistant feature that limits the ability to remove the inner cover from the bottle. In the first state, the nozzle, the inner cover, and the outer cover can be simultaneously removed from the bottle. In the second state, the nozzle is substantially permanently fixed to the bottle. Additionally, the bottle may have a neck including male threads. The nozzle may be configured to fit at least partially within the neck, the nozzle having an opening for dispensing the aerosol precursor from the bottle. The inner cover may further include female threads for engaging with the male threads of the neck, and the tamper-resistant band may be disposed within the interior of the inner cover. In the first state, the cap may engage the bottle such that the nozzle is inserted into the neck a first insertion distance I1 and the inner cover is threadedly engaged with the neck a first thread distance T1. In a second state, the cap may be engaged with the bottle such that the nozzle is inserted into the neck a second insertion distance I2 greater than I1 and the inner cover threads with the neck a second thread distance T2 greater than T1. In a third state, the nozzle may be inserted into the neck a second insertion distance I2 and the inner cover does not thread with the neck such that the aerosol precursor in the bottle can be dispensed from the nozzle opening. In a fourth state, the cap is removed from the bottle to allow the storage volume to be at least partially filled with the aerosol precursor.

[0013] The nozzle may further include a detent for snapping onto the inner cover such that the nozzle may be removed from the bottle together with the inner cover. The neck of the bottle may further include a radial flange, where in a first state the tamper-evident band is not activated and in a second state the tamper-evident band is activated by being placed under the radial flange, whereby when the inner cover is removed to achieve a third state the band is damaged as it passes over the radial flange. The tamper-evident band may press against the radial flange in the first state. In the second state the inner cover may abut against a bottle alignment stopper formed on the neck, where the bottle alignment stopper facilitates alignment of the sidewall of the bottle with the sidewall of the cap in the second state if the respective sidewalls are not cylindrical.

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

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

[0016] In another embodiment, the present disclosure provides an automated method for making a custom composition of an aerosol precursor.The method according to one embodiment includes: retrieving a container by a robot; dispensing an aerosol-forming agent into the container at a first location by a first pump; moving the container to a second location by the robot; dispensing at least one flavoring material into the container at the second location by a second pump; capping the container; and mixing the aerosol-forming agent and the at least one flavoring material.

[0017] The method for making a custom composition of aerosol precursors may include one or more of any of the following features individually or in combination.

[0018] The step of removing the container may include using suction to pull the container from a bulk consumable pack that includes a plurality of empty containers.

[0019] The step of dispensing the liquid aerosol forming agent may include actuating a first pump integrated into a reservoir for the liquid aerosol forming agent. Actuating the first pump may include pushing a portion of the first pump substantially vertically upward. The act of pushing may include contacting a portion of the first pump with a container holder having a container bottle held therein and lifting the container holder relative to the first pump. Actuation of the first pump may also cause a drip guard on the first pump to move with the container holder.

[0020] The step of capping the container may include attaching the cap to the bottle. The method may further include removing the cap from the bottle prior to dispensing the liquid aerosol forming agent into the container. The step of removing the cap may include holding the cap and rotating the cap relative to the bottle.

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

[0022] The method of making may also include measuring the amount of the aerosol precursor in the container. Measuring the amount of the aerosol precursor may include measuring a distance between a range finder and a surface of the aerosol precursor using a range finder. The method may involve moving the container to a waste bin if the amount of the aerosol precursor is outside a predetermined range.

[0023] The method of making may also include labeling the container. Labeling the container may include adding a film onto the container. Labeling may further include printing information onto the film. Labeling the container may include printing information onto the container.

[0024] The method of making may also include verifying the at least one flavor ingredient prior to dispensing the at least one flavor ingredient into the container, the verifying step including using an RFID.

[0025] An additional embodiment of the present disclosure provides a child-resistant tamper-evident container. The container includes a bottle having a storage volume for holding liquid contents and a cap. The cap includes a nozzle, an inner cover including a tamper-evident band, and an outer cover disposed on the inner cover, the outer cover providing a child-resistant feature that limits the ability to remove the inner cover from the bottle. In a first state, the nozzle, the inner cover, and the outer cover can be simultaneously removed from the bottle. In a second state, the nozzle is substantially permanently secured to the bottle.

[0026] Embodiments of the child-resistant tamper-evident container may optionally further include one or more of the following features, individually or in various combinations thereof: The bottle may have a neck including male threads. The nozzle may be configured to fit at least partially within the neck, the nozzle having an opening for dispensing liquid contents from the bottle. The inner cover may further include female threads for engaging with the male threads of the neck, and the tamper-evident band may be disposed within the inner cover. In a first state, the cap may engage the bottle such that the nozzle is inserted into the neck a first insertion distance I1 and the inner cover threadably engages with the neck a first thread distance T1. In a second state, the cap may engage the bottle such that the nozzle is inserted into the neck a second insertion distance I2 greater than I1 and the inner cover threadably engages with the neck a second thread distance T2 greater than T1. In a third state, the nozzle may be inserted into the neck a second insertion distance I2 and the inner cover does not thread with the neck such that liquid contents of the bottle can be dispensed from the opening of the nozzle. In a fourth condition, the cap is removed from the bottle allowing the storage volume to be at least partially filled with liquid contents.

[0027] The nozzle may include a detent for snapping onto the inner cover such that the nozzle is removed from the bottle together with the inner cover. The neck may further include a radial flange. In the first state, the tamper-evident band is not activated. In the second state, the tamper-evident band is activated by being disposed under the radial flange such that when the inner cover is removed to achieve the third state, the band is damaged as it passes over the radial flange. The tamper-evident band may press against the radial flange in the first state.

[0028] In the second state, the inner cover may abut against a bottle alignment stopper formed on the neck, the alignment stopper facilitating alignment of the sidewall of the bottle with the sidewall of the cap in the second state if the respective sidewalls are not cylindrical.

[0029] The bottle may have a storage volume of at least about 5 ml, preferably at least about 15 ml.

[0030] Yet another embodiment of the present disclosure includes a method of filling a container with an aerosol precursor. One such method includes separating a cap from a bottle by a machine, the cap including a nozzle, an inner cover, and an outer cover. The method further includes at least partially filling a storage volume of the bottle with the aerosol precursor from a plurality of filling stations, each station including a liquid component of the aerosol precursor, and attaching the cap to the bottle such that the nozzle is substantially permanently fixed to the bottle and a tamper-evident band formed with the inner cover operates under a radial flange extending from the neck of the bottle.

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

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

[0033] The method of filling the container may also include rotating the cap relative to the bottle until the bottle alignment stopper abuts the cap alignment stopper.

[0034] The step of at least partially filling the storage volume may include dispensing a liquid aerosol-forming agent into the container at a first location by a first pump, moving the container to a second location by a robot, and dispensing at least one liquid flavoring material into the container at the second location by a second pump. Dispensing the liquid aerosol-forming agent may include activating a first pump integrated into a reservoir for the liquid aerosol-forming agent. Activating the first pump may include pushing a portion of the first pump substantially vertically upward. The act of pushing may include contacting a portion of the first pump with a container holder having a bottle of the container held therein, and lifting the container holder relative to the first pump.

[0035] The method of filling the container may also include verifying the at least one liquid flavoring material prior to dispensing the at least one liquid flavoring material into the container, the verifying step including using RFID. The method of filling the container may also include moving the container along a plane of a spiral pattern to mix the aerosol precursor liquid. An additional step may also include measuring the amount of aerosol precursor in the container and moving the container to a waste receptacle if the amount of aerosol precursor is outside a predetermined range.

[0036] The present disclosure includes, but is not limited to, the following embodiments.

[0037] Embodiment 1: A unit for mixing and dispensing an aerosol precursor composition, the unit comprising: a plurality of bulk material filling stations including at least one first filling station having an aerosol forming agent and at least one second filling station having a flavoring material for generating an aerosol precursor; a bulk consumable pack layering a plurality of containers configured to receive an aerosol precursor; a robot configured to retrieve a container from a bulk consumable pack and move the container across at least two dimensions to land at at least two of the plurality of bulk material filling stations; Including, units.

[0038] Embodiment 2: The unit of any preceding embodiment, further comprising a capping station configured to remove caps from containers prior to filling the containers at at least two of the plurality of bulk material filling stations and configured to attach caps after filling the containers with the aerosol precursor.

[0039] Embodiment 3: The unit of any preceding embodiment, further comprising an inspection station configured to measure the amount of aerosol precursor in the container.

[0040] Embodiment 4: The unit of any preceding embodiment, further comprising a labeling station configured to provide a label based on a flavor material.

[0041] Embodiment 5: The unit of any preceding embodiment, wherein each bulk material filling station includes a pump.

[0042] Embodiment 6: The unit of any preceding embodiment, wherein the pump is integrated into the reservoir to form a bulk material pack that is removable from the bulk material filling station.

[0043] Embodiment 7: The unit of any preceding embodiment, wherein the pump includes layered chambers in communication with the reservoir, the layered chambers configured to hold measured doses of respective bulk materials.

[0044] Embodiment 8: The unit of any preceding embodiment, further comprising an RFID antenna attached to a stage of the robot, the RFID antenna configured to read an RFID tag on a bulk material puck.

[0045] Embodiment 9: The unit of any preceding embodiment, wherein the pump is configured to dispense a measured dose of the respective bulk material upon each actuation of the pump.

[0046] Embodiment 10: The unit of any preceding embodiment, wherein the pump is actuated by being pressed by a part of a robot or a container.

[0047] Embodiment 11: A unit of any preceding embodiment, wherein each container includes child-resistant and tamper-evident features.

[0048] Embodiment 12: The unit of any preceding embodiment, wherein each container comprises a bottle having a storage volume for holding an aerosol precursor, and a cap, the cap comprising a nozzle, an inner cover comprising a tamper-evident band, and an outer cover provided on the inner cover, the outer cover providing a child-resistant feature that limits the ability to remove the inner cover from the bottle, and wherein in a first state, the nozzle, the inner cover and the outer cover can be simultaneously removed from the bottle, and in a second state, the nozzle is substantially permanently fixed to the bottle.

[0049] Embodiment 13: The unit of any preceding embodiment, wherein the bottle has a neck including male threads, the nozzle is configured to fit at least partially within the neck, the nozzle has an opening for dispensing the aerosol precursor from the bottle, the inner cover further includes female threads for engaging with the male threads of the neck, and a tamper-evident band is disposed inside the inner cover.

[0050] Embodiment 14: The unit of any preceding embodiment, wherein in a first state, the nozzle is inserted into the neck a first insertion distance I1 and the cap engages with the bottle such that the inner cover threads with the neck a first thread distance T1, in a second state, the nozzle is inserted into the neck a second insertion distance I2 greater than I1 and the cap engages with the bottle such that the inner cover threads with the neck a second thread distance T2 greater than T1, and in a third state, the nozzle is inserted into the neck a second insertion distance I2 and the inner cover does not thread with the neck such that the aerosol precursor in the bottle can be dispensed from the opening of the nozzle.

[0051] Embodiment 15: The unit of any preceding embodiment, further comprising a fourth state, wherein in the fourth state, the cap is removed from the bottle, allowing the storage volume to be at least partially filled with the aerosol precursor.

[0052] Embodiment 16: The unit of any preceding embodiment, wherein the nozzle includes a detent for snapping onto the inner cover such that the nozzle is removed from the bottle together with the inner cover.

[0053] Embodiment 17: The unit of any preceding embodiment, wherein the neck further includes a radial flange, and wherein in a first state the tamper-evident band is not activated and in a second state the tamper-evident band is activated by being positioned under the radial flange, such that when the inner cover is removed to achieve a third state, the band is damaged as it passes over the radial flange.

[0054] Embodiment 18: The unit of any preceding embodiment, wherein in the second state, the inner cover abuts against a bottle alignment stopper formed on the neck, the bottle alignment stopper facilitating alignment of the side wall of the bottle with the side wall of the cap in the second state if the respective side walls are not cylindrical.

[0055] Embodiment 19: The unit of any preceding embodiment, comprising a plurality of second bulk ingredient filling stations, each having a bulk ingredient selected from any of nicotine, menthol, fruit flavors, floral flavors, and savory flavors.

[0056] Embodiment 20: The unit of any preceding embodiment, further comprising a user interface configured to receive selection information indicating at which of a plurality of bulk material stations the robot is to stop.

[0057] Embodiment 21: The unit of any preceding embodiment, further comprising a controller having a processor to control the robot to stop at desired bulk material filling stations and dispense a desired amount of bulk material from each bulk material filling station.

[0058] Embodiment 22: An automated method of making a custom composition of an aerosol precursor, the method comprising: removing the container by the robot; Dispensing an aerosol forming agent into a container at a first location with a first pump; moving the container to a second location by the robot; dispensing at least one flavor material into the container at a second location with a second pump; Cap the container; mixing an aerosol forming agent with at least one flavor material; A method comprising:

[0059] Embodiment 23: The method of any preceding embodiment, wherein removing the container comprises using suction to pull the container from a bulk consumable pack comprising a plurality of empty containers.

[0060] Embodiment 24: The method of any preceding embodiment, wherein dispensing the liquid aerosol forming agent includes actuating a first pump integrated into a reservoir for the liquid aerosol forming agent.

[0061] Embodiment 25: The method of any preceding embodiment, wherein capping the container comprises attaching a cap to a bottle, and further comprises removing the cap from the bottle prior to dispensing the liquid aerosol forming agent into the container.

[0062] Embodiment 26: The method of any preceding embodiment, wherein mixing comprises moving the container along a plane in a spiral pattern.

[0063] Embodiment 27: The method of any preceding embodiment, wherein mixing further comprises rotating the container about an axis passing through the container.

[0064] Embodiment 28: The method of any preceding embodiment, wherein moving the container in the spiral pattern and rotating the container use the same robot.

[0065] Embodiment 29: The method of any preceding embodiment, further comprising measuring the amount of aerosol precursor in the container.

[0066] Embodiment 30: The method of any preceding embodiment, comprising moving the container to a waste bin if the amount of aerosol precursor is outside of a predetermined range.

[0067] Embodiment 31: The method of any preceding embodiment, further comprising verifying the at least one flavor material prior to dispensing the at least one flavor material into the container, wherein the verifying step comprises using RFID.

[0068] Embodiment 32: A child-resistant, tamper-evident container comprising: 1. A child-resistant, tamper-evident container, wherein the container comprises a bottle having a storage volume for holding liquid contents, and a cap, the cap comprising a nozzle, an inner cover including a tamper-evident band, and an outer cover disposed on the inner cover, the outer cover providing a child-resistant feature that limits the ability to remove the inner cover from the bottle, wherein in a first state, the nozzle, the inner cover and the outer cover can be simultaneously removed from the bottle, and in a second state, the nozzle is substantially permanently secured to the bottle.

[0069] Embodiment 33: A container of any preceding embodiment, wherein the bottle has a neck including male threads, the nozzle is configured to fit at least partially within the neck, the nozzle has an opening for dispensing liquid contents from the bottle, the inner cover further includes female threads for engaging with the male threads of the neck, and a tamper-evident band is disposed inside the inner cover.

[0070] Embodiment 34: A container of any preceding embodiment, wherein in a first state, the cap engages the bottle such that the nozzle is inserted into the neck a first insertion distance I1 and the inner cover threads into the neck a first thread distance T1, in a second state, the cap engages the bottle such that the nozzle is inserted into the neck a second insertion distance I2 greater than I1 and the inner cover threads into the neck a second thread distance T2 greater than T1, and in a third state, the nozzle is inserted into the neck the second insertion distance I2 and the inner cover does not thread into the neck such that the liquid contents of the bottle can be dispensed from the nozzle opening.

[0071] Embodiment 35: A method of filling a container with an aerosol precursor, comprising the steps of: separating the cap, including the nozzle, the inner cover and the outer cover, from the bottle by the machine; at least partially filling a storage volume of the bottle with an aerosol precursor from a plurality of filling stations, each station containing a liquid component of the aerosol precursor; attaching a cap to the bottle such that the nozzle is substantially permanently secured to the bottle and a tamper evident band formed with the inner cover operates beneath a radial flange extending from the neck of the bottle; A method comprising:

[0072] Embodiment 36: The method of any preceding embodiment, wherein separating the cap from the bottle includes simultaneously removing the nozzle, the inner cover, and the outer cover from the bottle.

[0073] These and other features, aspects and advantages of the present disclosure will become apparent from a reading of the following detailed description in conjunction with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four or more of the above-described embodiments, as well as any combination of two, three, four or more features or elements described in the present disclosure, regardless of whether such features or elements are expressly combined in the description of a particular embodiment herein. The present disclosure is intended to be read as a whole such that any separable features or elements of the disclosure, in any of its various aspects and embodiments, appear as intended to be combinable, unless the context clearly dictates otherwise.

[0074] Having described the present disclosure in general terms above, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0075] [Figure 1] 1 shows an external view of a dispenser unit according to an embodiment of the present disclosure. [Diagram 2] 1 shows the dispenser unit with the cover open. [Diagram 3] FIG. 2 is an interior view with a portion of the exterior cutaway of a dispenser unit according to an embodiment of the present disclosure. [Figure 4] FIG. 2 is a detailed view of a robot used in a dispenser unit according to an embodiment of the present disclosure. [Figure 5A] 1 shows a sequence of steps for removing the container. [Figure 5B] 1 shows a sequence of steps for removing the container. [Figure 5C] 1 shows a sequence of steps for removing the container. [Figure 5D] 1 shows a sequence of steps for removing the container. [Figure 5E] 1 shows a sequence of steps for removing the container. [Figure 6] 1 shows a container at a capping station. [Figure 7] FIG. 2 is a detailed view of a capping station according to one embodiment. [Figure 8] 1 shows a container at a first bulk material filling station. [Figure 9] 1 illustrates a bulk material pack for use in a first bulk material filling station according to one embodiment. [Figure 10A] 5 illustrates steps of a filling process according to one embodiment. [Figure 10B] 5 illustrates steps of a filling process according to one embodiment. [Figure 10C] 5 illustrates steps of a filling process according to one embodiment. [Figure 10D] 5 illustrates steps of a filling process according to one embodiment. [Figure 11] 1 shows the container at a second bulk material filling station. [Figure 12] 13 shows a container at an optional third bulk material filling station. [Figure 13] 1 shows a container at an inspection station. [Figure 14A] 1 illustrates details of an inspection station according to one embodiment. [Figure 14B] 1 illustrates details of an inspection station according to one embodiment. [Figure 15] 1 shows the container being returned to the capping station. [Figure 16] 1 shows a container at a labeling station. [Figure 17]1 shows details of a labeling station according to one embodiment. [Figure 18] 1A-1C are top cross-sectional views of a dispenser unit, which are schematic illustrations of container movements provided by a robot to achieve mixing, according to one embodiment. [Figure 19] FIG. 2 is a detailed view of a discharge station according to one embodiment. [Figure 20] 1 illustrates a cross-sectional view of a container in a pre-filled state, according to one embodiment. [Figure 21] 21 shows a cross-sectional view of the container of FIG. 20 in a filled state. [Figure 22] FIG. 21 is an exploded view of a portion of the container of FIG. 20. [Diagram 23] FIG. 21 is an internal detail of the nozzle of the vessel of FIG. 20. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0076] The present disclosure will now be described in further detail with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0077] As described below, embodiments of the present disclosure relate to aerosol precursor compositions, containers for and containing the aerosol precursor compositions, devices for generating the compositions of the aerosol precursors, and devices for discharging one or more containers with the finished aerosol precursor compositions therein. Related methods are also described and understood from the functions of the articles and devices described below. Aerosol precursors (also interchangeably referred to as precursors, aerosol precursor compositions, and aerosol precursor formulations) are consumable liquid compositions that are conventionally used in combination with aerosol delivery devices. Aerosol delivery devices generally use electrical energy to heat the aerosol precursors to form an inhalable substance. The aerosol delivery device may provide some or all of the sensation of smoking a cigarette, cigar, or pipe (e.g., the manner of inhalation and exhalation, the type of taste or flavor, the sensory stimulating effect, the physical feel, the manner of use, the visual stimuli as provided by a visible aerosol, etc.) without substantially burning any components of the article or device.

[0078] Aerosol delivery devices generally include many components. Aerosol delivery devices often include some combination of a power source (i.e., a power source), at least one control component (e.g., a means for activating, controlling, regulating, and stopping the power for heat generation, such as by controlling the flow of current from the power source to other components of the article), a heater or heat generating component (e.g., an electrical resistance heating element or component, commonly referred to as an "atomizer"), and an aerosol precursor composition (e.g., a liquid that can generally generate an aerosol when sufficient heat is applied, commonly referred to as "smoke juice", "e-liquid" and "e-juice"), and a mouth-end region or tip that allows the aerosol delivery device to be drawn for aerosol inhalation (e.g., a defined air flow path through the article so that the generated aerosol can be drawn therefrom by inhalation). The design and component arrangement of various aerosol delivery devices can be understood in consideration of the disclosed or commercially available electronic aerosol delivery devices, such as the representative products incorporated above in this disclosure.

[0079] Referring to FIG. 1, an embodiment of the present disclosure relates to a dispenser unit 100. In one embodiment, the dispenser unit 100 is operated by a customer or a store clerk to dispense a container having therein a custom-blended aerosol precursor composition available in multiple varieties. At a minimum, the custom-blended aerosol precursor composition dispensed from the dispenser unit 100 is available in at least two varieties, at least three varieties, at least five varieties, and preferably ten or more varieties. The upper limit on the number of varieties available may be related to the size of the dispenser unit 100 and any technical limitations of the equipment used in implementing the dispenser unit of the present disclosure. The aerosol precursor compositions are of different varieties if they differ in at least one of flavor and intensity. Intensity may refer to the nicotine content or concentration. Intensity may also refer to the concentration of flavor materials in the aerosol precursor. Preferably, the custom-blended aerosol precursor composition dispensed from the dispenser unit 100 is generated in situ within the dispenser unit 100 by first combining separate components (e.g., aerosol precursor composition components referred to herein as bulk materials). In one embodiment, the initially separated components are first contacted in a container that is dispensed from the dispenser unit 100 to a user (eg, a customer or store attendant).

[0080] The dispenser unit 100 according to an embodiment of the present disclosure is intended to be relatively small in size and potentially capable of being placed on a desk or counter for operation by a retail associate or an appropriately selected customer. However, the size of the dispenser unit 100 may be increased as desired in light of the present disclosure. The dispenser unit 100 may include a user interface 102 located on or adjacent to the exterior of the dispenser unit in any location that is easy to identify and operate. The user interface 102 may be configured to allow a user to make a selection (e.g., provide selection information) so that a preferred aerosol precursor is delivered to the user. For example, the user may customize the flavor and / or strength (e.g., nicotine content) of the aerosol precursor using multiple options and menus displayed on the user interface 102. The user interface 102 may be a touch screen. Alternatively, the user interface 102 may include a display separate from an input device such as a keypad.

[0081] The dispenser unit 100 may also include an opening 104 connected to a chute for dispensing filled containers to a user. The opening 104 may include a door, flap, valve, drawer or other structure that selectively opens when the filled containers are ready to be removed or received by a user. The door may be opened manually by a user or automatically via control by the dispenser unit 100.

[0082] As shown in FIG. 2, the dispenser unit 100 may have an access door 106. The access door 106 allows maintenance personnel or retailers to access the interior of the dispenser unit 100 to maintain, update, or at least refill the dispenser unit 100 with bulk materials and empty containers necessary to perform the operation of the unit. The access door 106 is not limited to a hinged door and may include any other suitable closure. Although the access door 106 is shown on the front of the dispenser unit 100, the access door 106 may be located in any other suitable location based on the desire to provide access to the internal workings of the dispenser unit 100. Thus, the configuration of the access door 106 may be influenced by the arrangement and packaging of the internal components and stations within the dispenser unit 100. Although a single access door 106 is shown in FIG. 2, it should be appreciated that the dispenser unit 100 may include multiple separate access doors 106 to provide the necessary interior access.

[0083] As seen in FIG. 1, the exterior of the dispenser unit 100 may include various other ports, plugs, scanners, readers and other devices operably accessible to a user. For example, in addition to or instead of the user interface 102, the dispenser unit 100 may include a reader 108, such as a scanner, sensor, camera, etc. for barcodes, QR codes, magnetic strips, radio frequency identification (RFID), near field communication (NFC) and other optical and electromagnetic identification that may be used to provide information to the dispenser unit 100. In one embodiment, the dispenser unit 100 may be configured to determine the identity of a user through an identification card, such as a driver's license or employee badge. The dispenser unit 100 may include a camera that records the user to help prevent theft or apprehend vandals. The dispenser unit 100 may have a reader for codes on coupons or other pamphlets. For example, a store may want to promote an employee's favorite aerosol precursor recipe. These recipes may be indicated by a barcode that the user can scan to cause the dispenser unit 100 to create the predetermined recipe. The user may store their preferences on a key tag or other internal or external storage medium, e.g., memory, that the dispenser unit 100 can read to facilitate the automatic vending of the customer's preferred aerosol precursor. In one example, a customer recipe may be created using a website or mobile application. The customer's smartphone may then be programmed to display a corresponding barcode that can be read by a barcode reader in operative communication with the dispenser unit 100. The customer's recipe may be incorporated within the mobile application such that the application can transmit the recipe information to the dispenser unit 100 via a short-range wireless technology such as Bluetooth. The mobile application may facilitate other functions in combination with the user profile, such as storing purchase history, facilitating reward programs, to wirelessly facilitate payment for aerosol precursors.Other readers may facilitate direct purchase of the desired product directly from the dispenser unit 100 using credit card readers, cash acceptors or other devices for accepting payment as known in the art.

[0084] In one embodiment, the dispenser unit 100 may include a port or plug that allows a user to recharge the power unit of the aerosol delivery device while the dispenser unit is preparing its customized precursor.

[0085] The dispenser unit 100 may also have one or more ports, plugs, or devices to facilitate operation of the dispenser unit that are not intended to be user-accessible or user-facing. These may include products such as a power cord to power the dispenser unit 100, or an Ethernet port to allow the unit to network with a remote database on the World Wide Web or as part of a retail store's operations. For example, the dispenser unit 100 may be linked to a store's register so that the unit will only dispense a desired product after a customer has paid for the product or after a salesperson has verified the user's age or other identifying characteristic.

[0086] The dispenser unit 100 itself may be able to store consumer preferences to streamline the dispensing process. The dispenser unit 100 may be networked to other similar units, networked to the Internet, or equipped with reader technology so that a customer may receive a preferred precursor without returning to the same unit each time or making a set of selections on the user interface 102.

[0087] 2 shows the dispenser unit 100 with the access door 106 open. The discharge chute 110 may be mounted to swing with the access door 106. A removable waste bin 112 may also move with the access door 106. The waste bin 112 is configured to receive products produced by the dispenser unit 100 that do not meet the preferred standards. Also shown is an optional inner door 114 to conceal and protect moving parts within the dispenser unit 100. The ingredient drawer 116 may be configured to slide out to facilitate refilling the drawer with empty containers or bulk material components of the aerosol precursor.

[0088] FIG. 3 is an interior view with a portion of the exterior cut away of the dispenser unit 100 to reveal the internal arrangement of stations, features and components according to one embodiment of the disclosure. The raw material drawer 116 may include a bulk consumable pack 118 layering a plurality of containers 120 configured to be filled with a custom blended aerosol precursor composition. The containers 120 in the bulk consumable pack 118 may be empty or partially filled with the components of the custom blended aerosol precursor composition. The bulk consumable pack 118 may take many forms, such as a tray, hopper or other configuration with cells for receiving the containers 120 that facilitates removal of one container 120 from a group. The raw material drawer 116 may have a plurality of additional compartments 122 configured to receive components for use in making the precursors. Each compartment 122 is configured to receive a bulk material pack 124 to create a bulk material filling station 126 for the containers 120.

[0089] The aerosol precursors originating from the container 120 visiting two or more of the bulk material filling stations 126 are not particularly limited. Some optional features of representative precursors are discussed below. Aerosol precursors are composed of a combination or mixture of various components (i.e., constituents). The selection of the particular aerosol precursor components and the relative amounts of these components used may be altered based on user input at the user interface 102 to control the overall chemical composition of the mainstream aerosol generated by the nebulizer of the aerosol delivery device. Of particular interest are aerosol precursors that can be characterized as generally liquid in nature. For example, representative generally liquid aerosol precursors may have the form of a solution, a mixture of miscible components, or a liquid incorporating suspended or dispersed components. Typical aerosol precursors can vaporize when exposed to heat under conditions experienced during use of the aerosol delivery device that is a feature of the present disclosure, thus producing a vapor and an aerosol that can be inhaled.

[0090] The aerosol precursor may incorporate so-called "aerosol former" components that may be provided in one or more of the first filling stations 126a. Such materials have the ability to produce a visible aerosol when vaporized upon exposure to heat under conditions experienced during normal use of the nebulizers featured in this disclosure. Such aerosol-forming materials include various polyols or polyhydric alcohols (e.g., glycerin, propylene glycol, and mixtures thereof). Many embodiments of the present disclosure incorporate aerosol precursor components that can be characterized as water, moisture, or aqueous liquids. Under normal conditions of use of certain aerosol delivery devices, water incorporated within these devices can vaporize to provide a component of the generated aerosol. Thus, for purposes of this disclosure, water present within the aerosol precursor may be considered to be an aerosol-forming material.

[0091] Various flavoring agents or flavoring materials that change the sensory characteristics or properties of the mainstream aerosol to be inhaled may constitute the second major component of the aerosol precursor and may be provided in the second filling stations 126b. Each of the second filling stations 126b may provide a unique flavoring material. Additionally, the most popular flavors may be provided in multiple second filling stations 126b. Flavoring agents may be selectively added into the aerosol precursor to change the flavor, aroma and organoleptic properties of the aerosol. Certain flavoring agents may be provided from sources other than tobacco. Exemplary flavoring agents may be of natural or artificial nature and may be used as concentrates or flavor packages.

[0092] Exemplary flavors include vanillin, ethyl vanillin, cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach, and citrus flavors including lime and lemon), floral flavors, savory flavors, maple, menthol, mint, peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom, ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla, cocoa, licorice, and flavors and flavor packages of the type and characteristics conventionally used in cigarette, cigar, and pipe tobacco flavorings. Also, syrups such as high fructose corn syrup can be used. Certain flavors may be incorporated into the aerosol-forming materials prior to formulation of the final aerosol precursor mixture (e.g., certain water-soluble flavors can be incorporated into water, menthol can be incorporated into propylene glycol, and certain composite flavor packages can be incorporated into propylene glycol).

[0093] In an aerosol delivery device characterized as an e-cigarette, the aerosol precursor most preferably incorporates tobacco or tobacco-derived components (referred to herein as "nicotine sources"). These nicotine sources may be present in one or more third filling stations 126c. The third filling station 126c may be referred to as a nicotine station. In one respect, the tobacco may be provided as tobacco parts or pieces, such as finely ground, crushed, or powdered tobacco flakes. In another respect, the tobacco may be provided in the form of an extract, such as a spray-dried extract, that incorporates many of the water-soluble components of tobacco. Alternatively, the tobacco extract may have the form of a relatively high concentration nicotine-containing extract that also incorporates small amounts of other extracted components derived from tobacco. In another respect, the tobacco-derived components may be provided in a relatively pure form, such as certain flavoring agents derived from tobacco. In one respect, a component derived from tobacco that may be used in a highly purified or essentially pure form is nicotine (e.g., pharmaceutical grade nicotine).

[0094] The aerosol precursor may also include components exhibiting acidic or basic characteristics (e.g., organic acids, ammonium salts, or organic amines). These components may be included in the general description of flavoring materials for purposes of this disclosure. For example, in an aerosol precursor formulation incorporating nicotine, certain organic acids (e.g., levulinic acid, succinic acid, lactic acid, and pyruvic acid) may be included, preferably up to equimolar amounts with nicotine (based on total organic acid content). For example, the aerosol precursor may include about 0.1 to about 0.5 moles of levulinic acid per mole of nicotine, about 0.1 to about 0.5 moles of succinic acid per mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per mole of nicotine, or various permutations and combinations thereof, up to a concentration where the total amount of organic acids present is equimolar to the total amount of nicotine present in the aerosol precursor.

[0095] As a non-limiting example, a representative aerosol precursor produced by the dispenser unit 100 upon user demand is: About 70% to about 90% glycerin by weight, often about 75% to about 85% glycerin, About 5% to about 20% water, often about 10% to about 15% water, About 1% to about 10% propylene glycol, often about 4% to about 8% propylene glycol; About 0.1% to about 6% nicotine, often about 1.5% to about 5% nicotine, an optional flavoring agent in an amount of up to about 6%, often about 0.1% to about 5% flavoring agent; The compound may have the form of a mixture of the above. For example, a representative aerosol precursor may have the form of a formulation incorporating, by weight, more than about 76% glycerin, about 14% water, about 7% propylene glycol, about 1% to about 2% nicotine, and less than about 1% flavoring material. For example, a representative aerosol precursor may have the form of a formulation incorporating, by weight, more than about 75% glycerin, about 14% water, about 7% propylene glycol, about 2.5% nicotine, and less than about 1% flavoring material. For example, a representative aerosol precursor may have the form of a formulation incorporating, by weight, more than about 75% glycerin, about 5% water, about 8% propylene glycol, about 6% nicotine, and less than about 6% flavoring material.

[0096] Representative types of aerosol precursor components and formulations are also described and characterized in U.S. Pat. No. 7,726,320 to Robinson et al. and U.S. Pat. Appl. Pub. No. 2013 / 0008457 to Zheng et al., U.S. Pat. Appl. Pub. No. 2013 / 0213417 to Chong et al. and U.S. Pat. Appl. Pub. No. 2014 / 0060554 to Collett et al., U.S. Pat. Appl. Pub. No. 2015 / 0020823 to Lipowicz et al. and U.S. Pat. Appl. Pub. No. 2015 / 0020830 to Koller, and WO 2014 / 182736 to Bowen et al., the disclosures of which are incorporated herein by reference. Other aerosol precursors that may be used include the aerosol precursors incorporated in RJ Reynolds Vapor Company's VUSE® products, Lorillard Technologies' BLU products, Mistic Ecigs' MISTIC MENTHOL products, and CN Creative Ltd.'s VYPE products. So-called "smoke juice" for e-cigarettes available from Johnson Creek Enterprises LLC is also desirable. Effervescent material embodiments may be used with the aerosol precursor, for example, as described in U.S. Patent Application Publication No. 2012 / 0055494 to Hunt et al., which is incorporated herein by reference. Further, the use of foamable materials is described, for example, in U.S. Pat. No. 4,639,368 to Niazi et al., U.S. Pat. No. 5,178,878 to Wehling et al., U.S. Pat. No. 5,223,264 to Wehling et al., U.S. Pat. No. 6,974,590 to Pather et al., and U.S. Pat. No. 7,381,667 to Bergquist et al., as well as U.S. Patent Application Publication No. 2006 / 0191548 to Strickland et al., U.S. Patent Application Publication No. 2009 / 0025741 to Crawford et al., U.S. Patent Application Publication No. 2010 / 0018539 to Brinkley et al., and U.S. Patent Application Publication No. 2010 / 0170522 to Sun et al., and PCT Publication No. WO 97 / 06786 to Johnson et al., all of which are incorporated herein by reference.

[0097] In addition to the bulk material filling stations, the dispenser unit 100 also includes a robot 130. As best seen in FIG. 4, the robot 130 may include a stage 132 (referred to as a container holder) for holding the containers 120 and moving the containers across at least two dimensions. For example, the stage 132 may be driven by a first actuator 134 to move along an X-axis as guided on a rail 136. A second actuator 138 may drive the stage 132 to move along a Y-axis as guided on a support 140. The actuators 134, 138 may be guided by a controller 142 having a processor in operative communication with the actuators 134, 138 and the user interface 102. Based on the preferred precursor composition and the inventory levels at each bulk material filling station 126, the controller 142 is configured to stop the stage 132 at each of the appropriate bulk material filling stations and draw an appropriate amount of each bulk material into the container 120.

[0098] 3 shows a stage 132 of the robot 130 positioned beneath the bulk consumable pack 118 as a container receiving station 144. The stage 132 may be signaled by the controller upon actuation of the dispenser unit 100, such as by completion of a precursor selection and purchase transaction, to report to the container receiving station 144 and retrieve an empty container 120.

[0099] One exemplary process for removing an empty container 120 from a bulk consumable pack 118 is illustrated in FIGS. 5A-5E, where only a partial view of the bulk consumable pack 118 is shown for ease of illustration. The robot 130 may have an extendable suction cup 146 that can be raised to contact the bottom of the empty container 120. Suction may be applied to grip the bottom of the container 120, as shown in FIG. 5B. Once suction is applied, the suction cup 146 may be lowered to pull the container 120 from the bulk consumable pack 118, as shown in the progression of FIGS. 5C and 5D. The bulk consumable pack 118 may be gravity fed such that once an empty container 120 is removed, the next container 120a above drops into a ready position. The bottom of the bulk consumable pack 118 may include a friction tab 148 to prevent additional containers from being removed if the pulling force of the suction cup 146 is not applied. As can be seen in FIG. 5E, after one container 120 has been removed, the next container 120a is correctly positioned for the next run of the dispenser unit 100.

[0100] A gravity-fed bulk consumable pack 118 with a suction-activated pull-down take-out is just one possible configuration for selecting an empty container 120 and engaging it with a stage 132 of the robot 130. For example, instead of the bulk consumable pack 118 being part of the ingredient drawer 116, the bulk consumable pack 118 may be formed as a separate tray within the dispenser unit 100. Alternatively, the bulk consumable pack 118 may be provided below the robot 130. The container receiving station 144 need not be in a single location or multiple adjacent locations. Instead, the container receiving station 144 may be anywhere within the dispenser unit 100 that corresponds to available empty containers, for example if the empty containers 120 are located a step beyond the trays placed below the robot 130.

[0101] As discussed further below, the bulk consumable pack 118 may be configured to receive an empty container 120 that includes both a bottle 150 and a cap 152 (see FIG. 7) pre-attached to one another. In other embodiments, the bottles 150 and caps 152 may be provided in separate bulk consumable packs, in which case the dispenser unit 100 is configured to combine the bottles 150 with their respective caps 152 only after the bottles have been filled with the aerosol precursor composition.

[0102] If the container 120 initially includes a cap 152, the robot 130 may be actuated to move the container from the container receiving station 144 to a capping station 154, the movement being indicated by a horizontal bold arrow in FIG. 6. An example of the capping station 154 is shown in FIG. 7. The capping station 154 may include a cap retainer 156. At the capping station 154, the robot 130 aligns the container 120 with the cap retainer 156. In the illustrated example, at least one of the container 120 and the cap retainer 156 moves vertically along the Z axis to engage the cap retainer with the cap 152 of the container. In one embodiment, the robot 130 and / or the stage 132 are configured to lift the container 120 into engagement with the cap retainer 156. The engagement may be facilitated by vacuum pressure, friction, a detent mechanism or other known means that allows the cap retaining device 156 to grip the cap 152 and temporarily hold the cap while the remainder of the container 120 (e.g., the bottle 150) is released. In the illustrated embodiment, the cap 152 is removed from the bottle 150 by rotation. Thus, the capping station 154 may further include a rotational actuator 158 that rotates the cap 152 relative to the bottle 150 in relation to the cap retaining device 156. The cap retaining device 156 may be driven to rotate by a motor, directly or indirectly, by using a belt system or a gear system. Those skilled in the art will appreciate that in other embodiments, the stage 132 may have a mechanism for rotating the bottle 150 while the cap 152 and the cap retaining device 156 remain substantially stationary relative to the dispenser unit 100.

[0103] 8, stage 132 moves from capping station 154 to first bulk material filling station 126a, as indicated by bold arrow A. Bottle 150 is ready to receive precursor components. Again, cap 152 may have been initially separated from bottle 150 or may have been separated from the bottle by capping station 154. As noted above, first filling station 126a may provide an aerosol forming agent. An aerosol forming agent is included in virtually every aerosol precursor composition. However, the aerosol forming agent is not necessarily the first component dispensed into bottle 150.

[0104] As mentioned above, the first filling station 126a may include a first bulk material pack 124a. An exemplary bulk material pack 124 removed from the compartment 122 is shown in FIG. 9. The bulk material pack 124 is shown in a bag-in-a-box configuration having a shell 160 with a bladder bag 162 disposed therein. The shell 160 may include a cardboard portion and a plastic portion. The hard plastic portion of the shell 160 may be used to engage the respective compartment 122 in the ingredient drawer 116. The bladder bag 162 provides a reservoir 164 for the bulk material components of the aerosol precursor composition. The reservoir 164 may have a volume of at least about 500 ml for some bulk materials. The reservoir 164 for other bulk material packs 124 may have a volume of at least about 2000 ml. An RFID tag 166 may be attached to the shell 160 for use as discussed below.

[0105] The bulk material packs 124 may further include a pump 168 integrated into the reservoir 164. The pump 168 may include a layering chamber 170 between the reservoir 164 and an outlet 172 (see FIG. 10A). The layering chamber 170 may be configured to hold a measured dose of the respective bulk material such that each actuation of the pump 168 releases a measured dose of the bulk material from the outlet 172. In some embodiments, a drip guard 174 may be provided to selectively cover the outlet 172 when the bottle 150 is not preparing to receive bulk material from the respective bulk material pack 124. The drip guard 174 may be moved by the stage 132 to access the bottle 150. In some embodiments, the pump 168 may be protected during transport by having a storage position in which the pump is at least partially retracted within the shell 160.

[0106] The bulk material pack 124 is configured to be disposable and easily removable from the compartment 122 of the ingredient drawer 116. Thus, when the reservoir 164 is empty, the entire bulk material pack 124 can be replaced. By integrating the pump 168 as part of the bulk material pack 124, cross-contamination of ingredients is minimized or eliminated. Additionally, the need for flushing and clean-up lines that would be required if an external electric pump were used is eliminated. Nevertheless, if desired, the pump 168 may instead be provided as an element of the container 122, and the bulk material pack 124 may be configured to engage the pump 168 in substantially the above-described configuration when the bulk material pack 124 is inserted into the container 122.

[0107] The bulk material filling stations 126 are further described with reference to FIG. 8 and FIGS. 10A-10D. The robot 130 may be actuated to provide the stage 132 and bottle 150 to the desired bulk material filling station 126, where the bottle is aligned under the corresponding pump 168, as shown in FIG. 10A. The stage 132 may include an RFID antenna 176 configured to read the RFID tag 166 on the bulk material pack 124 at the corresponding filling station 126 to verify proper placement of the stage. The use of RFID may be optional. The controller 142 may be pre-programmed with the coordinates of the stage 132 to correspond to each compartment 122. When stocking the dispenser unit 100, a user may program the controller 142 using the user interface 102 to teach the dispenser unit 100 which bulk material is to be placed in each compartment 122 or provided to each filling station 126.

[0108] Once the robot 130 has placed the bottle 150 at the appropriate filling station 126 for the preferred precursor recipe, the stage 132 may be raised vertically so that a portion of the stage engages a portion of the pump 168, as shown in FIG. 10B. In other embodiments, the bottle 150 itself may engage a portion of the pump 168. In the illustrated embodiment, the stage 132 is shown with a pair of alignment posts 178 configured to contact a portion of the pump 168, such as by engaging a pair of alignment openings 180 formed in a flange 181 of the pump. Once the alignment posts 178 engage the alignment openings 180, the upward movement of the stage 132 continues as shown by the bold arrow in FIG. 10C, pushing the pump 168 upward to expel the bulk material from the outlet 172 into the bottle 150. Actuation of the pump 168 may also be accomplished by a rotating cam.

[0109] Once a certain amount of bulk material, such as a measured dose from the layering chamber 170, has been received, the bottle 150 may be retracted and the pump 168 may be disengaged. In some cases, the desired precursor may include multiple doses of bulk material from a single filling station 126. Thus, the stage 132 may be retracted from the pump 168 just enough to recharge the pump without fully disengaging from the pump. The stage 132 may then be pushed up again to extract an additional amount of bulk material. Once the bottle 150 has received the desired amount of bulk material from this filling station 126, the stage 132 may disengage the pump 168, for example, by moving the stage down along the Z axis.

[0110] 11 and 12 show the stage 132 and the bottle 150 stopped at the second filling station 126b and the third filling station 126c, respectively. At the second filling station 126b, the bottle 150 may receive one or more doses of flavoring material. The flavoring material may be released from the corresponding bulk material pack 124b in much the same manner as described above. Similarly, at the third filling station 126c, the bottle 150 may receive one or more doses of nicotine material. The nicotine material may be released from the corresponding bulk material pack 124c in much the same manner as described above. The movement of the stage 132 and the bottle 150 from the first filling station 126a to the second filling station 126b and the third filling station 126c is represented by thick arrows in the respective figures. Those skilled in the art will understand that this movement is provided by the robot 130 as described above.

[0111] Upon visiting the appropriate filling stations 126 and receiving a deemed appropriate amount of bulk material from each station, the robot 130 may move the bottle 150 to an inspection station 182. FIG. 13 shows the stage 132 placing the bottle 150 at the inspection station 182. The inspection station 182 is shown in more detail in FIGS. 14A and 14B. The inspection station 182 may include equipment that is combined with the capping station 154 in the module. The optional inspection station 182 is configured to measure the amount of aerosol precursor in the bottle 150. The inspection station 182 provides a quality control function to ensure that the correct volume of aerosol precursor is dispensed to the user. In one example, the dispenser unit 100 may be configured to provide 15 ml or more.

[0112] In one embodiment, the inspection station 182 has an ultrasonic range finder 184. As shown in FIG. 14B, a beam 186 or wave is emitted from the range finder 184 to the bottle 150. The beam 186 then reflects off a surface 188 of the aerosol precursor composition and returns to the range finder 184. The ultrasonic range finder 184, alone or in combination with the controller 142, can determine the distance the beam 186 has traveled. This distance can then be compared to a preferred distance once the bottle 150 is filled to a desired height. If the beam 186 has traveled too far, i.e., the volume of aerosol precursor is outside of an acceptable range, the bottle 150 may be returned to one or more of the filling stations 126 to receive additional bulk material. In another embodiment, if the bottle 150 is not fully filled, the container 120 may be discarded in a waste receptacle 112 as seen in FIG. 2 instead of being provided to a customer. Because the inspection station 182 cannot determine which of the aerosol precursor components is missing the final composition resulting in an insufficient total volume, it may be preferable to discard the insufficiently filled container 120. In one embodiment, the robot 130 may move the bottle 150 to the inspection station 182 after visiting each filling station 126. However, inspecting the volume of the bottle 150 after each component is added individually may increase the processing time of the dispenser unit 100 to an unacceptable extent.

[0113] Depending on the reliability of the pump 168, it may be important to provide an inspection station 182 to ensure volume control. If the bulk material pack 124 is used until it is completely emptied of bulk material, the volume in the bottle 150 may also be insufficient, in which case one or more uses of the pack 124 when the reservoir 164 is nearly empty may result in only a partial dose being released from the outlet 172. The controller 142 may be configured to track the number of times a particular bulk material pack 124 has been actuated to release a dose of bulk material. For example, the controller 142 may record the number of visits to a particular bulk material pack 124 using the RFID tag 166 and RFID antenna 176 described above. This tracking capability may allow the bulk material pack 124 to be removed from use and replaced before the performance quality of the bulk material pack 124 is predicted to deteriorate.

[0114] The inspection station 182 has been described as including an ultrasonic distance meter 184. Those skilled in the art will appreciate that the inspection station 182 can provide the same or substantially equivalent functionality as other laser or optical distance meters, or other measurement techniques known in the art. A laser-based meter may be used to ensure access through the narrow neck of the bottle 150. In another example, the stage 132 may include a mass scale. The mass scale may have a tare weight equal to the empty bottle 150 and may be sufficient to estimate the total volume of the precursor. The scale may also be capable of estimating the volume of each component being added based on the change in mass of the bottle 150 at each filling station 126. The scale may allow sufficient stations to be monitored to reduce or eliminate the need to discard the container 120 or provide a separate inspection step at the end of the filling process.

[0115] FIG. 15 shows the bottle 150 returned to the capping station 154 after the volume of the bottle's contents has been tested as at the inspection station 182. If the contents have an acceptable volume, the bottle 150 may be moved to the capping station 154. If the bottle 150 is set to be discarded, the bottle may be returned to the capping station 154 to contain the precursor in the container 120 in the waste receptacle 112. The capping station 154 functions to return the cap 152 to the bottle 150. It is expected that placing the cap 152 on the bottle 150 will occur in much the same manner as the cap is removed from the bottle. Once the bottle 150 is aligned with the cap 152, the cap retainer 156 may simply rotate in the opposite direction. Additional features of the capping station 154 will become apparent in view of the detailed description of the container structure provided below.

[0116] The dispenser unit 100 may further include a labeling station 190. FIG. 16 shows a container 120 being moved from the capping station 154 to the labeling station 190. The labeling station 190 is not limited to use after the bottle 150 is filled or after the cap 152 is secured to the bottle. The labeling station 190 may be used immediately after removing the container 120 from the bulk consumable pack 118. In other embodiments, any necessary markings or information may be pre-placed on the container 120 such that additional labeling at the labeling station 190 is not necessary.

[0117] Information provided on the container 120 may include signage providing trademarks or text in compliance with government regulations. The text may specifically or generally indicate a recipe to be used for the precursor contained therein. The text or symbols may provide instructions regarding use of the container 120 or the precursor. Information may include bar codes, QR codes, etc. that are scanned during purchase for inventory control, pricing, etc.

[0118] The label contents, collectively referred to as information, may be pre-placed in whole or in part on the container 120. The contents may be applied in whole or in part by a labeling station 190. The information may be applied directly to the bottle 150, or to the cap 152 of the container 120. The information may be provided on the container 120 via a web 192 or film, such as an adhesive-backed film or a direct heat transfer label. The information may be provided on the web 192 before or after the web is attached to the container 120.

[0119] 17 shows a labeling station 190 in the form of a print head 194. The print head 194 may be biased, for example spring loaded, to maintain pressure on the container 120 as the container moves past the print head. A robot 130 may be used to move the container 120 past the print head 194. The container 120 may be rotated as needed to facilitate application of a pre-printed label thereon and / or to facilitate printing on multiple surfaces of the container.

[0120] With reference to FIG. 18, one or more additional steps may occur within the dispenser unit 100 before the product (e.g., the precursor-filled container) is finalized. For example, the aerosol-forming agents and flavoring materials often used to generate the precursors of the present disclosure are not necessarily mixed easily and simply when added to the same bottle 150. However, to provide a consistent product, these precursor components must be thoroughly mixed before use. One option is to provide instructions on the label, for example, prompting the user to "shake well." In the embodiment shown in FIG. 18, the mixing step occurs within the dispenser unit 100. FIG. 18 shows a schematic top cross-sectional view of the dispenser unit 100. A mixing path 196 is shown in the form of a spiral pattern. The robot 130 may be configured to move the container 120 along a spiral mixing path in the XY plane. Alternatively or additionally, the mixing path 196 may be a pseudo-random pattern. Alternatively or additionally, the stage 132 may be configured to move the container 120 out of the XY plane along the Z axis. The motion along the Z axis is in the same direction as the motion that may be used to engage and disengage the capping station 154. The container 120 may be moved along the Z axis relatively slowly as it follows the helical mixing path 196. Alternatively, the container 120 may be actively rocked up and down. Additionally or alternatively, the stage 132 may be configured to impart a rotational motion to the container 120 about an axis that passes through the container, such as the Z axis. In yet other embodiments, rotational mixing may occur within the capping station 154. The cap retainer 156 may rotate the container 120 as a whole, and the bottle 150 may be temporarily removed from the stage 132 or at least allowed to rotate freely relative to the stage 132.

[0121] 19, an exemplary discharge chute 110 is shown. The discharge chute 110 may include an entrance 200. The robot 130 may be configured to place the container 120 within the entrance 200. A stage 132 or other structure may be used to elevate the container 120. A deflection surface 202 may push the container 120 along a desired discharge path 204. The discharge chute 110 may direct the container 120 into and / or out of the opening 104 of the access door 106 after release from the stage 132.

[0122] With the dispenser unit 100, some possible stations therein, and their respective representative functions thus far described, the method and process resulting from the use of the dispenser unit 100 will be understood by those skilled in the art. The use of the dispenser unit 100 may be described as an automated method of making custom compositions of aerosol precursors. The method may include removing an empty container 120 by a robot 130. The method may then include dispensing a liquid aerosol forming agent into the container 120 at a first location by a first pump 168, moving the container 120 to a second location by the robot 130, and dispensing at least one liquid flavoring material into the container 120 at the second location by a second pump. The container 120 may be sealed or closed by a cap 152. The aerosol precursor components may then be mixed to complete the aerosol precursor composition, which may then be expelled from the dispenser unit 100.

[0123] 20-23, an example of a container 120 for use with the dispenser unit 100 is shown in detail. In one embodiment, the container 120 dispensed by the dispenser unit 100 has one or more "child-resistant" features. A "child-resistant" feature is generally understood by those skilled in the art to require a combination of two or more different actions to restrict access to the contents of the container 120. One example includes applying a squeezing action while rotating the cap 152. Other conventional child-resistant caps require a squeezing force during rotation. Still other conventional child-resistant caps require alignment of certain elements before the cap can be removed.

[0124] In one embodiment, the container 120 includes one or more tamper-resistant features. The tamper-resistant features are intended to change the appearance or function of the container 120 after it is first accessed, so that the user knows if the container has been opened before. For example, some bottle caps have a button that pops up after the container is first broken. In a preferred embodiment, the container 120 containing the aerosol precursor received from the dispenser unit 100 has both child-resistant and tamper-resistant features.

[0125] FIG. 20 shows a cross-sectional view of the container 120 in a first state. The first state generally corresponds to a pre-filled state (i.e., before being filled or filled, and thus substantially empty or unfilled). In the first state, the container 120 may be present in a bulk consumable pack 118 ready for retrieval by the robot 130. The container 120 includes a bottle 150 and a cap 152. The bottle 150 includes a storage volume 210 for holding liquid contents, such as an aerosol precursor. The storage volume 210 may be at least about 5 ml, preferably at least about 15 ml. Since the dispenser unit 100 is preferably configured as a countertop device with a significant number of containers 120 therein, the storage volume 210 is not expected to exceed 100 ml. In many cases, the storage volume 210 is large enough to accommodate enough aerosol precursor for multiple uses in the aerosol delivery device. In other words, the reservoir of the aerosol delivery device, for example provided in a cartridge, may be half or larger than the storage volume 210 of the bottle 150 .

[0126] The bottle 150 may include a neck 212 having external threads 214 that at least partially assist in attaching the cap 152 to the bottle 150. The neck 212 may include a radial flange 216 between the threads 214 and the storage volume 210.

[0127] The cap 152 may include a nozzle 220 having an opening 222 for dispensing the aerosol precursor from the storage volume 210. The nozzle 220 may fit at least partially within the neck 212. The cap 152 may also include an inner cover 224. The inner cover 224 may include internal threads 226 configured to engage with the external threads 214 of the neck 212. The inner cover 224 may provide a tamper evident feature in the form of a tamper evident band 228 disposed on the interior of the inner cover 224.

[0128] In the first, pre-fill position, the tamper-evident band 228 is not activated. Thus, removing the cap 152 to allow the bottle 150 to be filled with precursor does not destroy the tamper-evident band 228. As shown in FIG. 20 , the tamper-evident band 228 may press against the top of the radial flange 216 in the first state. This press fit between the band 228 and the top of the radial flange 216 may help ensure that the cap 152 does not come loose from the bottle 150 during transportation or stowage of the empty container 120.

[0129] The cap 152 may also include an outer cover 230 configured to be disposed over the inner cover 224. Selected movement between the inner cover 224 and the outer cover 230 may provide favorable child resistance features for the container 120. For example, the outer cover 230 may need to be radially compressed against the inner cover 224 to rotate the inner cover 224 relative to the neck 212. Alternatively, the outer cover 230 may need to be pressed down onto the inner cover 224 toward the bottle 150 to rotate the inner cover relative to the neck 212.

[0130] 20 includes the cap 152 partially attached to the bottle 150. For example, the nozzle 220 is inserted into the neck 212 a first insertion distance I1. The inner cover 224 threadably engages the neck 212 a first threaded distance T1. In the first state, the cap 152 can be completely removed from the bottle 150 without activating the tamper evident feature such that the bottle 150 can receive the aerosol precursor composition components. Complete removal of the cap 152 prior to filling may include simultaneously removing the nozzle 220, the inner cover 224 and the outer cover 230.

[0131] FIG. 21 shows the cap 152 fully attached to the bottle 150 in a second state. The second state generally occurs after the aerosol precursor fills the bottle 150. FIG. 21 shows the tamper-evident band 228 intact and activated, which would occur before a user uses the aerosol precursor for the first time. In the second state, the cap 152 engages the bottle 150 such that the nozzle 220 is inserted into the neck 212 a second insertion distance I2 that is greater than I1. In the second state, the inner cover 224 threads into the neck 212 a second thread distance T2 that is greater than T1. When the inner cover 224 is fully threaded onto the neck 212, the tamper-evident band 228 is activated by being positioned under the radial flange 216. When the band 228 is activated, the band is damaged (e.g., permanently deformed or broken) as it passes the radial flange 216 if the inner cover 224 is removed from the nozzle 220.

[0132] In the first state shown in FIG. 20, the first insertion distance I1 is configured to provide a loose fit for the nozzle 220 in the neck 212. When the inner cover 224 is unscrewed from the neck 212 to access the bottle 150 for filling, the nozzle 220 is carried along with the inner cover 224 and maintained by the cap 152. In one example, the nozzle 220 has a detent 232 for snap-fitting into the inner cover 224 by interacting with a protrusion 234. The detent 232 and the protrusion 234 allow the nozzle 220 to follow the inner cover 224 only when the nozzle is loosely inserted into the neck 212. In other words, the detent 232 allows the cap 152 to be completely removed from the bottle 150 in a single step at the capping station 154 when in the first state. This avoids the need to separately remove the nozzle 220 from the bottle 150 and possibly add it to the bottle separately.

[0133] However, in the second state shown in FIG. 21 , the second insertion distance I2 is configured to provide a tight, substantially permanent press fit of the nozzle 220 into the neck 212. The nozzle 220 may include a shoulder 236 set under a step 238 of the inner cover 224. When the inner cover 224 is fully threaded onto the neck 212, the step 238 of the inner cover 224 may press against the shoulder 236 of the nozzle 220 to press the nozzle into the second insertion distance I2. In the second position, the retention between the neck 212 and the nozzle 220 is significantly greater than the retention between the detent 232 and the protrusion 234. Thus, when the second state is achieved, the inner cover 224 is configured to be threadably removable from the bottle 150 while the nozzle 220 remains engaged with the neck 212.

[0134] When the nozzle 220 is inserted into the neck 212 a second insertion distance I2 and the inner cover 224 does not threadably engage the neck, the container 120 may be said to be in a third state. In the third state, the precursor contents of the bottle 150 can be dispensed through the opening 222 of the nozzle 220.

[0135] In some embodiments, the sidewall 240 of the bottle 150 and the sidewall 242 of the cap 152 may not be cylindrical. Thus, threading the cap 152 onto the bottle 150 may result in misalignment between the sidewall 242 of the cap 152 and the sidewall 240 of the bottle 150. To address this potential issue and to help ensure that the respective sidewalls are aligned when the cap 152 is fully threaded onto the bottle 150, the neck 212 may be provided with a bottle alignment stopper 244. The bottle alignment stopper 244 may be best seen in FIG. 22. The inner cover 224 may also have a cap alignment stopper 246, which may be best seen in FIG. 23. When the cap 152 is threaded onto the bottle 150, the bottle alignment stopper 244 abuts the cap alignment stopper 246 in a second state, at which point the sidewalls 240, 242 of the container 120 are aligned.

[0136] Having thus far shown and described the structure of the container 120 according to one embodiment, methods and processes for using or filling the container will be apparent to those skilled in the art. In one example, the container 120 may be used as part of a method for filling a container with an aerosol precursor liquid. The method may include separating the cap 152 from the bottle 150 by a machine, the cap having a nozzle 220, an inner cover 224, and an outer cover 230. The method may then include at least partially filling the storage volume 210 of the bottle 150 with the aerosol precursor liquid from a number of filling stations 126, each station containing a liquid component of the aerosol precursor. The method may continue by attaching the cap 152 to the bottle 150 such that the nozzle 220 is substantially permanently fixed to the bottle and a tamper-evident band 228 formed with the inner cover 224 operates under a radial flange 216 extending from the neck 212 of the bottle.

[0137] The above description of the use of the dispenser unit 100 and the container 120 may be applied to the various embodiments described herein through minor modifications that may be apparent to one of ordinary skill in the art in light of the further disclosure provided herein. However, the above description of use is not intended to limit the use of the articles, but is provided to comply with all necessary disclosure requirements of the present disclosure.

[0138] Many modifications and other embodiments of the present disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. It is to be understood, therefore, that the present disclosure is not limited to the specific embodiments disclosed herein, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. 1. A unit for mixing and dispensing an aerosol precursor composition, the unit comprising: a robot configured to remove a container from a bulk consumable pack; a plurality of bulk material filling stations including at least one first bulk material pack having a first reservoir with a first pump integrated with the first reservoir, the first bulk material pack having an aerosol forming agent, and at least one second bulk material pack having a second reservoir with a second pump integrated with the second reservoir, the second bulk material pack having a flavoring material for generating an aerosol precursor; Including, The bulk consumable pack includes a plurality of containers arranged in a layered manner, each container including child-resistant and tamper-evident features and configured to receive an aerosol precursor; the robot is configured to move the container across at least two dimensions to stop at at least two of the plurality of bulk material filling stations and to engage a first pump and a second pump with a portion of the robot or a portion of the container to dispense respective materials therefrom into the container; Each container further comprises: a bottle having a storage volume for holding an aerosol precursor; a cap, the cap comprising: A nozzle; an inner cover including a tamper evident band; an outer cover disposed over the inner cover, the outer cover providing a child resistance feature that limits the ability to remove the inner cover from the bottle; In a first state, the nozzle, the inner cover and the outer cover can be simultaneously removed from the bottle; In the second condition, the unit has the nozzle substantially permanently secured to the bottle.

2. 10. The unit of claim 1, further comprising a capping station configured to remove caps from containers prior to filling the containers at at least two of the plurality of bulk material filling stations and configured to attach caps after filling the containers with the aerosol precursor.

3. 3. The unit of claim 1 or claim 2, further comprising an inspection station configured to measure the amount of aerosol precursor in the container.

4. The unit of claim 1 further comprising a labeling station configured to provide a label based on a flavor material.

5. 10. The unit of claim 1, wherein the pump includes layered chambers in communication with the reservoir, the layered chambers configured to hold measured doses of respective bulk materials.

6. The unit of claim 1 , further comprising an RFID antenna attached to a stage of the robot, the RFID antenna configured to read RFID tags on the first bulk material pack and the second bulk material pack.

7. 10. The unit of claim 1, wherein the pumps are configured to dispense a measured dose of the respective bulk ingredient upon each actuation of the pump.

8. The unit of claim 1 , wherein the first pump and the second pump are actuated by being pressed by a robot or a portion of the container.

9. the bottle having a neck including male threads; a nozzle configured to fit at least partially within the neck, the nozzle having an opening for dispensing the aerosol precursor from the bottle; The inner cover is further comprising female threads for engaging the male threads of the neck; 10. The unit of claim 1, wherein the tamper evident band is disposed inside the inner cover.

10. In a first state, the cap engages the bottle such that the nozzle is inserted into the neck a first insertion distance I1 and the inner cover is threadedly engaged with the neck a first thread distance T1; In a second state, the cap engages the bottle such that the nozzle is inserted into the neck by a second insertion distance I2 greater than I1 and the inner cover is threadedly engaged with the neck by a second thread distance T2 greater than T1; The unit of claim 1, wherein in a third state, the nozzle is inserted into the neck a second insertion distance I2 and the inner cover does not thread onto the neck so that the aerosol precursor in the bottle can be dispensed from the nozzle opening.

11. 11. The unit of claim 10, further comprising a fourth state, wherein in the fourth state, the cap is removed from the bottle to allow the storage volume to be at least partially filled with the aerosol precursor.

12. 12. The unit of claim 11, wherein the nozzle includes a detent for snap-fitting onto the inner cover such that the nozzle may be removed from the bottle together with the inner cover.

13. the neck further includes a radial flange; In the first state, the tamper evident band is not activated, 11. The unit of claim 10, wherein in the second condition, the tamper evident band is activated by being placed under the radial flanges such that when the inner cover is removed to achieve the third condition, the band is damaged as it passes over the radial flanges.

14. 10. The unit of claim 1, wherein in the second state, the inner cover abuts against a bottle alignment stopper formed on the neck, the bottle alignment stopper facilitating alignment of a side wall of the bottle with a side wall of the cap in the second state if the respective side walls are not cylindrical.

15. 10. The unit of claim 1, comprising a plurality of second bulk ingredient filling stations each having a bulk ingredient selected from any of nicotine, menthol, fruit flavors, floral flavors, and savory flavors.

16. The unit of claim 1 , further comprising a user interface configured to receive selection information indicating at which of a plurality of bulk material stations the robot is to stop.

17. 10. The unit of claim 1, further comprising a controller having a processor for controlling the robot to stop at desired bulk material filling stations and dispense a desired amount of bulk material from each bulk material filling station.

18. 1. An automated method for making a custom composition of an aerosol precursor, the method comprising: removing the container by the robot; placing a container relative to a first bulk material pack, the first bulk material pack including a first reservoir having a first pump integral with the first reservoir; Engaging at least one of a portion of the robot or a portion of the container with a first pump; dispensing an aerosol forming agent from a first bulk material pack into a container with a first pump; positioning, by the robot, a container relative to a second bulk material pack, the second bulk material pack including a second reservoir having a second pump integral with the second reservoir; Engaging at least one of a portion of the robot or a portion of the container with a second pump; dispensing at least one flavor ingredient from a second bulk ingredient pack into the container with a second pump; applying a cap to a container, the cap including attaching a cap to a bottle, the cap including a nozzle, an inner cover, and an outer cover, the nozzle being inserted into the container, and the inner cover and the outer cover being threaded onto the container; mixing an aerosol forming agent with at least one flavor material; A method comprising:

19. 20. The method of claim 18, wherein removing the container comprises using suction to pull the container from a bulk consumable pack that includes a plurality of empty containers.

20. 20. The method of claim 18 or claim 19, wherein dispensing the aerosol forming agent comprises activating a first pump integrated into a reservoir for the aerosol forming agent.

21. 20. The method of claim 18, wherein mixing comprises moving the container along a plane in a spiral pattern.

22. 22. The method of claim 21, wherein mixing further comprises rotating the container about an axis passing through the container.

23. 23. The method of claim 22, wherein moving the container in the spiral pattern and rotating the container use the same robot.

24. 20. The method of claim 18, wherein the method further comprises measuring the amount of the aerosol precursor in the container.

25. 25. The method of claim 24, comprising removing the container to a waste bin if the amount of aerosol precursor is outside a predetermined range.

26. 20. The method of claim 18, further comprising verifying the at least one flavor material prior to dispensing the at least one flavor material into the container, the verifying step comprising using an RFID.

27. The container includes a cap and a bottle, 20. The method of claim 18, further comprising removing the cap from the bottle prior to dispensing the liquid aerosol forming agent into the container.

28. The cap includes a nozzle, an inner cover, and an outer cover; 28. The method of claim 27, wherein separating the cap from the bottle includes simultaneously removing the nozzle, the inner cover, and the outer cover from the bottle.

29. at least one of the first pump or the second pump includes a layered chamber configured to hold a measured dose of a respective bulk material; 20. The method of claim 18, wherein dispensing from the first or second bulk material packs comprises dispensing a measured dose of the respective bulk material after engaging the respective pump.

30. The method further comprises: Positioning the container relative to a labeling station; labeling the container with an indicia based on the flavor material; 20. The method of claim 18, comprising:

31. The method of claim 18, wherein the mixing comprises moving the container along a Z-axis relative to the XY plane.

32. 32. The method of claim 31, wherein the mixing comprises moving the container in a random pattern about a combination of at least two of the X, Y, and Z axes.

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