Method and apparatus for manufacturing a consumable unit for an inhalation device

Abstract

In a modular apparatus for performing a series of assembly operations on components of an inhalation device, the apparatus comprises a set of workstations, each configured to perform a different assembly operation of the series of operations, and each workstation comprises a machine tray support for positioning a machine tray on which components to be assembled are received, the machine tray support being configured to guide the machine tray positioned on the machine tray support to a predetermined position within the workstation.

Description

Field

[0001] The present invention relates to an apparatus and method for manufacturing a consumable unit for an inhalation device, in particular an apparatus and method for manufacturing a tobacco pod comprising tobacco particle material for use with an inhalation device.The present invention also relates to a consumable unit for an inhalation device, for example a consumable unit comprising tobacco particle material for use with an inhalation device.

[0002] background

[0003] JP2011182710A discloses an apparatus for filling a small container with tobacco material, the small container being a consumable unit for an inhalation device. The filling apparatus includes an auger screw for feeding the tobacco material into a funnel, and a pipe for directing the tobacco material from the funnel to an open end of the container. A suction tube is provided at the opposite end of the container to suck air from the container and ensure that the tobacco material enters the container.

[0004] There is a need to reliably and quickly fill pods with tobacco particle material to provide for efficient production of consumable units for inhalation devices.

[0005] overview

[0006] According to an embodiment of the present invention, there is provided a modular apparatus for performing a sequence of assembly operations on components of an inhalation device, the apparatus comprising: a set of workstations, each workstation configured to perform a different assembly operation of the sequence of operations; Each workstation is A machine tray support is included for placing a machine tray on which components for assembly are received, the machine tray support being configured to guide the machine tray placed on the machine tray support to a predetermined position within the workstation.

[0007] Each workstation is a platform slidably mounted to the machine tray support for movement to an engagement position where an assembly operation is performed on a component received in the machine tray at a predetermined position; Each workstation platform is configured to mount a different assembly mechanism, and when the platform is in the engaged position within the workstation, the workstation's assembly mechanism performs one of a series of assembly operations on components received in a machine tray located at a predetermined position within the workstation.

[0008] The platform of each workstation may be configured to slide between an engaged position and a disengaged position, where the machine tray is insertable into or removable from the machine tray support of the workstation.

[0009] The platform of each workstation may be mounted on a column for linear movement between engaged and disengaged positions.

[0010] The platform of each workstation may be supported by four columns positioned around the periphery of the machine tray support.

[0011] Each machine tray support may include one or more rails configured to support opposing sides of the machine tray such that the machine tray can be inserted into position by sliding the machine tray along the rails.

[0012] Each machine tray support may include a stopper against which the machine tray abuts when inserted into position.

[0013] At least one workstation of the set of workstations may include an actuator configured to move the movable shelf between the engaged and disengaged positions.

[0014] Each machine tray support may further include a proximity switch for determining whether the machine tray is in place.

[0015] Each workstation may include an interface unit, and the modular apparatus further includes a controller configured to control each workstation via said interface unit. Each workstation may include a radio frequency tag reader that detects information identifying a unique radio frequency tag associated with a machine tray inserted into the workstation, which information is communicated to the controller by the interface unit.

[0016] Each workstation may be provided with a set of stop / go lights to indicate to an operator of the workstation whether to proceed to perform an assembly operation on a component received in a machine tray inserted into the workstation, wherein the stop / go lights are configured to provide the indication to the operator upon receiving a command from the controller.

[0017] Each interface unit may be further configured to communicate a completion status of an assembly operation performed on the component to a controller, a positive completion status indicating that the assembly operation was successfully performed, and the controller configured to record the completion status and associate the completion status with information identifying a unique wireless tag of the machine tray.

[0018] At least one workstation of the set of workstations may comprise an inspection unit configured to generate an inspection status, the inspection status including information regarding a status of a component received in a machine tray placed in the at least one workstation, and the interface unit of the at least one workstation is further configured to communicate the inspection status of the component to a controller, the controller being configured to record the inspection status and associate the inspection status with information identifying a unique radio tag of the machine tray in which the component is received.

[0019] The set of workstations comprises first and second workstations for performing first and second assembly operations, respectively, wherein the component can undergo the first assembly operation before undergoing the second assembly operation, and the controller is configured to command a stop / go light of the second workstation to indicate to an operator of the second workstation to proceed only if a unique wireless tag of a machine tray inserted into the second workstation is associated with a positive completion status of the first assembly operation.

[0020] The wireless tag may comprise an RFID tag.

[0021] The set of workstations may be configured to perform a first series of assembly operations to assemble a first type of component for the inhalation device, and the set of workstations can be reconfigured to perform a second series of assembly operations, different from the first series of operations, to assemble a second type of component for the inhalation device.

[0022] Reconfiguring the set of workstations may include rearranging the workstations relative to one another, and / or removing one or more workstations, and / or adding one or more further workstations.

[0023] The step of reconfiguring the set of workstations includes replacing an assembly mechanism of at least one workstation of the set of workstations, the assembly mechanism being a different assembly mechanism configured to perform a first assembly operation on a component of the inhalation device and configured to perform a second assembly operation on a component of the inhalation device different from the first assembly operation.

[0024] According to an embodiment of the present invention, there is provided a workstation for use in a modular apparatus configured to assemble components of an inhalation device, the workstation configured to perform assembly operations on said components, the workstation comprising a machine tray support for placing a machine tray on which the components for assembly are received, the machine tray support configured to guide a machine tray placed on the machine tray support to a predetermined position within the workstation.

[0025] The workstation may further comprise a platform slidably mounted to the machine tray support and moved to an engagement position in which an assembly operation is performed on a component received in the machine tray at a predetermined position, and when the platform is in said engagement position, the assembly mechanism is configured to mount the assembly mechanism such that the assembly operation is performed on a component received in the machine tray at a predetermined position.

[0026] According to an embodiment of the present invention there is provided a method for reconfiguring a modular apparatus as claimed in any one of claims 1 to 19, comprising the steps of rearranging the workstations relative to one another and / or removing one or more workstations and / or adding one or more further workstations.

[0027] A method for reconfiguring a modular device includes replacing an assembly mechanism of at least one workstation of a set of workstations, the assembly mechanism being configured to perform a first assembly operation on a component of an inhalation device, and a different assembly mechanism being configured to perform a second assembly operation on a component of the inhalation device that is different from the first assembly operation. [Brief description of the drawings]

[0028] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] FIG. 1 shows an inhalation device including a consumable unit. [Figure 2A] FIG. 2A shows a consumable unit of the inhalation device of FIG. [Figure 2B] FIG. 2B shows a consumable unit of the inhalation device of FIG. [Figure 3A] FIG. 3A shows the consumable unit of FIG. 2A with the closure removed. [Figure 3B] FIG. 3B shows the consumable unit of FIG. 2B with the closure removed. [Figure 4] FIG. 4 shows a schematic diagram of an apparatus for manufacturing the consumable unit of FIGS. 2A and 2B. [Figure 5A] FIG. 5A shows a machine tray for supporting consumable units via the apparatus of FIG. [Figure 5B] FIG. 5B shows a machine tray for supporting consumable units via the apparatus of FIG. [Figure 6A] FIG. 6A shows a dosing station for providing particulate material to a consumable unit. [Figure 6B] FIG. 6B shows a dosing station for providing particulate material to the consumable unit. [Figure 7A] FIG. 7A shows the dispensing mechanism of the dispensing station of FIGS. 6A and 6B. [Figure 7B] FIG. 7B shows the dispensing mechanism of the dispensing station of FIGS. 6A and 6B. [Figure 7C] FIG. 7C shows the dispensing mechanism of the dispensing station of FIGS. 6A and 6B. [Figure 8A] FIG. 8A shows a closure positioning station for positioning a closure on each consumable unit. [Figure 8B] FIG. 8B shows a closure positioning station for positioning a closure on each consumable unit. [Figure 9] FIG. 9 illustrates a closure support web for use with the closure positioning station of FIGS. 8A and 8B. [Figure 10] FIG. 10 shows the punch of the closure positioning station of FIGS. 8A and 8B. [Figure 11] FIG. 11 shows a closure securing station for securing a closure to a consumable unit. [Figure 12] FIG. 12 shows a schematic diagram of the operation of a first embodiment of the closure fixing station of FIG. [Figure 13] FIG. 13 shows a schematic diagram of the operation of a second embodiment of the closure fixing station of FIG. [Figure 14] FIG. 14 shows an embodiment of a workstation. [Figure 15] FIG. 15 shows a modular assembly machine 150 that includes a set of workstations. Detailed Description

[0029] This patent discloses an apparatus and method for manufacturing components of an inhalation device. In particular, this patent discloses an apparatus and method for manufacturing components of a device for delivering vapor generated without combustion.

[0030] In embodiments disclosed herein, the inhalation device comprises an operating unit sized and shaped to be held by an adult consumer, an atomizer cartridge removably attached to the operating unit, the atomizer cartridge having an atomizer for atomizing a consumable liquid held in the cartridge, a tobacco pod removably attached to the cartridge, the tobacco pod having a container and a mouthpiece, the container containing a charge of aerosolizable material, e.g., tobacco particle material, and a closure for holding the tobacco particle material inside the container.

[0031] The user can replace the atomizer cartridge and the tobacco pod individually when they require replacement, i.e. when the consumable liquid runs out or when the tobacco in the tobacco pod runs out.

[0032] In use, when a consumer inhales air through the inhalation device, the operating unit delivers energy to the atomizer cartridge under the consumer's control. The liquid in the atomizer cartridge is atomized to form an aerosol, and the tobacco particle material in the tobacco pod volatilizes to release the volatile flavor. Thus, the air inhaled from the inhalation device delivers the aerosol of the liquid atomized from the atomizer cartridge to the consumer, along with the vapor generated by heating the tobacco particle material in the tobacco pod. The composition of the evaporable tobacco material and the consumable liquid can be selected to deliver a wide combination of flavors that appeal to consumers.

[0033] By way of example, the present specification describes an apparatus and method for manufacturing tobacco pods for inhalation devices, as described above, which are referred to herein as consumable units 4.

[0034] 1, the inhalation device 1 has three hollow sections made of molded plastic material, a body 2 containing the operating system and mechanisms for the device, an atomizer cartridge 3 containing a volatile liquid flavourant, and a consumable unit 4 containing a dose of particulate material that produces an aerosol when heated. The three sections are removably connected to each other such that the atomizer cartridge 3 and the consumable unit 4 can be separated from each other and from the body 2, respectively, allowing replacement consumable units 4 and atomizer cartridges 3 to fit into the body 2.

[0035] The body 2 is generally cylindrical in shape, axially elongated and flattened to be comfortably held in the hand of an adult consumer. The body 2 is formed from two axially aligned hollow molded sections, an upper section 2a and a lower section 2b. The upper section 2a of the body 2 has an open upper end and a closed lower end wall 5, which define a recess for receiving the atomizer cartridge 3. The lower section 2b of the body is separated from the upper section 2a by the lower end wall 5 of the upper section 2a to provide a firewall. The lower section 2b of the body 2 contains a battery, an electronic circuit board, a puff sensor and other operating components, not shown here, which are activated by an operating button 6 provided on one face of the body 1. An electric light housed in an opening in the body 2 indicates the operating state of the inhalation device 1.

[0036] The atomizer cartridge 3 is removably connected to the body 2 by a press-fit connection within a recess in the upper body section 2a and tapers axially away from the body 2 towards an upper outlet 3a of the atomizer cartridge 3. The atomizer cartridge 3 includes a reservoir filled with a volatile liquid flavourant and a heating element for volatilizing the liquid, the supply of electricity from a battery in the body 2 being controllable by an operating button 6.

[0037] The consumable unit 4 is removably connected to the atomizer cartridge 3 by a press-fit connection within the upper outlet 3a of the atomizer cartridge 3. The outer surface of the consumable unit 4 forms a skirt that continues the tapered shape of the atomizer cartridge 3 axially towards the vapour outlet 7 which is shaped to be held comfortably in the mouth of a consumer.

[0038] 2A and 2B, the consumable unit 4 comprises a mouthpiece 8 and an axially extending open ended container 9. In this embodiment, the container 9 has an elliptical radial cross section. One end of the container 9 resides within a skirt 10 of the mouthpiece 8 and terminates in a plug 11 which is received in a complementary shaped socket 12 formed in the inner surface of the mouthpiece 8 upstream of the vapor outlet 7.

[0039] The mouthpiece 8 may be connected to the container 9 by ultrasonic welding, induction welding or any other suitable method, or the mouthpiece 8 and container 9 may be integrally formed, for example by injection molding.

[0040] In this embodiment, an inner perforated screen 13, integrally molded with the container 9, extends radially across the container 9 to define a vapour permeable barrier a short distance across the container 9 upstream of the vapour outlet 7. As shown in Figure 2B, the inner perforated screen 13 extends across the inner end of the container 9. The other end 15 of the container 9 projects from the skirt 10 of the mouthpiece 8 and is provided with a closure 14. In this embodiment, the closure 14 is in the form of a perforated screen. The closure lid 14 may, for example, be constructed of mesh or foil or a moulded piece of plastic material.

[0041] In an alternative embodiment, the inner perforated screen 13 is integrally molded into the mouthpiece 8 and positioned across the end of the container 9 when the mouthpiece 8 and container 9 are combined.

[0042] The inner perforated screen 13 and closure 14 define the end walls of a chamber 16 within the container 9 in which a dose of particulate material is held. Perforations in the inner perforated screen 13 and closure 14 allow vapour to flow axially downstream through the chamber 16 towards the mouthpiece 8 and vapour outlet 7. The perforations are of a size selected in relation to the particle size of the particulate material to prevent particles from falling out of the container 9 or being drawn into the mouthpiece 8 with inhaled vapour.

[0043] In use, the consumer switches on the inhalation device 1 using the operating button 6 and draws through the mouthpiece 8 to inhale the vapour drawn from the inhalation device 1. When activated, an electronic system in the main body 2 heats the air in the inhalation device 1 and the liquid in the atomiser cartridge 3 sufficiently to cause atomisation. The heated air volatilises flavouring from the particulate material in the container 9 and also entrains the liquid flavouring atomised from the atomiser cartridge 3. This causes the flavouring combination to be delivered to the consumer as an aerosol for inhalation.

[0044] The method of manufacturing the consumable unit 4 includes receiving an empty consumable unit as shown in FIG. 3A, in which the chamber 16 is empty and no closure 14 is present, so that the end 15 of the chamber 16 is open. The method, as shown diagrammatically in FIG. 3B, includes providing a dose of particulate material 17 to the chamber 16 through the open end 15 of the chamber 9, positioning a closure 14 above the end 15 of the chamber 16, and then securing the closure 14 to the container 9. As shown in FIG. 3A, the container 9 initially includes a number of pegs 18 that protrude axially from the end 15 of the container 9. The closure 14 is received between these pegs 18, and as shown in FIGS. 2A and 2B, the pegs 18 are then bent over the closure 14 to secure the closure 14 to the container 9.

[0045] In particular, as shown in Figure 3A, the container 9 defining the chamber 16 includes an end 15 with pegs 18 projecting axially from a radial edge 19 of the end 15 to define a lip 20 at the end of the container 9. As shown in Figure 2B, the closure 14 is positioned against the lip 20 and the pegs 18 are bent outwardly of the closure 14, thereby securing the closure 14 to the container 9.

[0046] As illustrated, the pegs 18 are spaced around the radial edge 19 of the container 9, with the gaps between the pegs 18 allowing them to fold without colliding. The pegs 18 can have different sizes (widths). Narrower pegs 18 are preferably positioned at the portions of the radial edge 19 of the container 9 that have a smaller diameter, allowing the pegs 18 to bend more easily since there are lower stresses and strains at the points where the pegs 18 are bent.

[0047] 4 shows a schematic diagram of an apparatus 21 for manufacturing the consumable unit 4 described with reference to Figures 2A-3B, in particular the consumable unit 4 including the mouthpiece 8 and the container 9 for holding the particulate material 17. The illustrated apparatus 21 includes apparatus for carrying out the following method steps: dispensing particulate material 17 into chamber 16 of consumable unit 4; positioning the closure 14 onto the container 9 of the consumable unit 4; Securing the closure 14 to the container 9 .

[0048] As shown in Figure 4, the first step is the input 22 of an empty consumable unit 4. The consumable unit 4 at the input 22 is of the form illustrated in Figure 3A. In particular, the empty consumable unit 4 at the input 22 comprises a mouthpiece 8 and a container 9 having an open end 15. The container 9 includes protruding pegs 18 as shown in Figure 3A for securing the closure 14 after the particulate material 17 has been placed in the chamber 16. The consumable unit passes through a set of workstations comprising a dosing station 23, a closure positioning station 24, and a closure securing station 25.

[0049] After the input 22 of the empty consumable unit 4, the dosing station 23 provides a dose of particulate material 17 to the chamber 16 of the consumable unit 4. Next, the closure positioning station 24 positions the closure 14 on the end 15 of the container 9. Then, the closure fixing station 25 fixes the closure 14 to the vessel 9. In particular, the closure fixing station 25 bends the pegs 18 against the closure 14 to fix the closure 14 to the vessel 9, as shown in Figures 2A and 2B. Completing the consumable unit 4 with the particulate material 17 and then the output 26 from the device 21, as shown in Figures 2A and 2B.

[0050] In the described device 21, the dosing station 23, the closure positioning station 24 and the closure fixing station 25 are arranged separately and adjacent to each other, and the consumable unit 4 can be moved sequentially between the stations 23, 24, 25. The consumable unit 4 can be moved manually or on a conveyor. The use of a conveyor allows for automated production. The conveyor can for example be a so-called "smart conveyor" which allows independent control of individual vehicles along the conveyor track. An example of such a conveyor is the XTS range of conveyors from Beckhoff. In an embodiment employing the use of a conveyor, the dosing station 23, the closure positioning station 24 and the closure fixing station 25 can be arranged such that the consumable unit 4 moves linearly through the dosing station 23, the closure positioning station 24 and the closure fixing station 25.

[0051] In other embodiments, the dosing station 23, the closure positioning station 24, and the closure securing station 25 may be located around a single location where the consumable unit 5 is located, with each station 23, 24, 25 performing its function in sequence on the consumable unit 4. In yet another embodiment, one or more of the stations 23, 24, 25 may be combined such that a single station has tooling for performing one or more of the processes described with respect to Figure 4. For example, the tooling for one or more of the dosing station 23, the closure positioning station 24, and the closure securing station 25 may be located on a rotating turret, with the consumable unit 4 set below the turret that rotates to align the portions of the tooling.

[0052] Each of the dosing station 23, the closure positioning station 24 and the closure securing station 25 will now be described in further detail.

[0053] Figures 5A and 5B show a machine tray 27 holding a number of consumable units 4. The machine tray 27 is provided with a number of empty consumable units 4 at the input 22 of the apparatus 21, and the machine tray 27 is then moved through the apparatus 21 described with reference to Figure 4 such that the consumable units 4 are provided with doses of particulate material 17, and the closures 14 are positioned and secured while the consumable units 4 are held within the machine tray 27.

[0054] The machine tray 27 holds the consumable units 4 in an upright orientation, with the open ends 15 of the containers 9 facing vertically upward, into which the particulate material 17 can be provided and into which the closures 14 can be positioned and secured. As shown in Figure 5A, the machine tray 27 includes an array of support recesses 28, each of which is shaped to receive and support a consumable unit 4. In particular, as shown in Figure 5B, each support recess 28 is shaped to receive and support a mouthpiece 8 of a consumable unit 4, with the open ends 15 of the containers 9 facing upward.

[0055] Optionally, machine tray 27 may include one or more handles for manually lifting and moving machine tray 27. Alternatively, if apparatus 21 includes a conveyor, machine tray 27 may be mounted to the conveyor for movement through apparatus 21, as described above. Machine tray 27 may be removably mounted to such a conveyor.

[0056] 6A and 6B show a dosing station 23 for dosing particulate material 17 into each container 9 of the consumable unit 4.

[0057] The dosing station 23 includes a machine tray support 29 with rails 30 that support a machine tray 27, shown in FIG. 5A, with a plurality of consumable units. The machine tray 27 can be inserted into the dosing station 23 by sliding the machine tray 27 onto the rails 30 that support opposite sides of the machine tray 27. The machine tray support 29 also includes stops against which the machine tray 27 abuts when the machine tray 27 is inserted into the machine tray support 29. The machine tray support 29 ensures that the machine tray 27 and consumable units 4 are accurately and securely positioned and supported within the dosing station 23.

[0058] The dosing station 23 may include a proximity switch to verify that the machine tray 27 is properly positioned on the machine tray support 29. Alignment pins may additionally or alternatively be provided to ensure accurate positioning.

[0059] The dosing station 23 also includes a movable shelf or platform 31. The movable shelf 31 is slidably mounted on posts 33 via slide bearings 34 such that the movable shelf 31 can be moved up and down relative to the machine tray support 29 and relative to the machine tray 27 and the consumable unit 4. An actuator (not shown) may be provided to move the movable shelf 31 or it may be moved manually, for example, by a handle 32. The movable shelf 31 is positioned above the machine tray support 29. The movable shelf 31 includes a dosing mechanism 35 for dosing particulate material into a receptacle 9 of the consumable unit 4 on the machine tray 27, as described further below. The movable shelf 31 is movable between a disengaged position and an engaged position. In the engaged position, the movable shelf 31 is adjacent the machine tray 27 and the consumable unit 4 and is in a position to dosing particulate material 17 into the receptacle 9. In the disengaged position, the movable shelf 31 is spaced apart from the machine tray 27 and the consumable unit 4 such that the machine tray 27 can be inserted or removed from the machine tray support 29.

[0060] The dosing station 23, and in particular the dosing mechanism 35, dispenses the particulate material 17 into multiple containers 9 on the machine tray 27 simultaneously, and preferably the dosing station 23 dispenses the particulate material 17 into all containers 9 on the machine tray 27 simultaneously.

[0061] The dosing mechanism 35 shown in Figures 7A-7C is embedded within the movable shelf 31, as also shown in Figures 6A and 6B. As shown, the dosing mechanism 35 includes a hopper member 36 that includes a hopper 37 in which the particulate material 17 is received. The hopper 37 has a planar lower wall 38 that includes an array of openings 39 extending through the lower wall 38. The array of openings 39 in the hopper 37 corresponds to the array of consumable units 4 held within the machine tray 27, as shown in Figure 5A. The hopper 37 includes an inclined surface 40 between the openings 39 such that the particulate material 17 is directed toward the openings 39. A vibrator 41, shown in Figure 6B, can be attached to the hopper member 36 or the movable shelf 31 to vibrate the hopper member 36 to keep the particulate material 17 from clogging or bridging and to encourage the particulate material 17 to move into the openings 39.

[0062] The bottom wall 38 of the hopper 37 is planar and below the bottom wall 38 is a dosing device, in this embodiment a dosing plate 42. The dosing plate 42 is slidably mounted and can slide linearly between the position shown in FIG. 7A and the position shown in FIG. 7C via the position shown in FIG. 7B. The dosing plate 42 includes an arrangement of dosing cavities 43 corresponding to the openings 39 in the hopper 37 and the arrangement of the consumable units 4 in the machine tray 27. An actuator 44 for moving the dosing plate 42 is shown in FIG. 6B. The actuator 44 is configured to move the dosing plate 42 in the plane of the dosing mechanism 35 and the movable shelf 31, parallel to the machine tray 27 held on the machine tray support 29 below the movable shelf 31.

[0063] The alignment member 45 is arranged below the dosing plate 42. The alignment member 45 also has an arrangement of openings 46 corresponding to the arrangement of the openings 39 in the hopper 37, the dosing cavities 43 in the dosing plate 42, and the consumable units 4 in the machine tray 27. The openings 46 of the alignment member 45 are aligned with the containers 9 of the consumable units 4 of the machine tray 27, as shown in Figures 7A-7C. The alignment member 45 is in a fixed position on the movable shelf 31 and does not move with the dosing plate 42. As shown, the openings 46 of the alignment member 45 are offset from the openings 39 of the hopper 37, so that depending on the position of the dosing plate 42, the dosing cavities 43 of the dosing plate 42 are aligned with the openings 39 of the hopper 37 as shown in Figure 7B, or aligned with the openings 46 of the alignment member 45 as shown in Figure 7C, but cannot be aligned with both the openings 39 of the hopper 37 and the openings 46 of the alignment member 45 at the same time.

[0064] In a preferred embodiment, the alignment member 45 engages the container 9 of the consumable unit 4, particularly the end 15 of the container 9 where the peg 18 is located, as shown in FIG. 3A. After the machine tray 27 is inserted into the machine tray support 29, the movable shelf 31 can move downward into an engagement position, whereby the alignment member 45 engages the container 9. The underside of each opening 46 in the alignment member 45 can include a recess that engages the container 9. Preferably, the openings 46 are smaller (e.g., have a smaller diameter) than the container 9, such that the flow of the particulate material 17 is directed into the container 9 and is not captured at the edge of the container 9. Alternatively, the openings 46 of the alignment member 45 can be larger than the container 9, such that the container 9 is inserted into the openings 46. Alternatively, the alignment member 45 is positioned proximate to the container 9 in the engagement position of the movable shelf 31.

[0065] Figures 7A-7C illustrate diagrammatically the dosing mechanism 35. It will be appreciated that the plates (hopper plate 36, dosing plate 42, alignment member 45) abut one another in use, or the plates 36, 42, 45 are closely adjacent one another so that no gaps as shown in Figures 7A-7C exist.

[0066] The operation of the dosing mechanism 35 will now be described. Figure 7A illustrates an initial position of the dosing plate 42 when the machine tray 27 and consumable unit 4 are initially inserted into the dosing station 23. As described above, the particulate material 17 is set into the hopper 37 and moves downward into the opening 39 by gravity, possibly assisted by vibration from the vibrator 41. In the initial position of Figure 7A, the dosing cavity 43 in the dosing plate 42 is not aligned with the opening 39 in the hopper 37, so that the dosing plate 42 prevents the particulate material 17 from leaving the opening 39 in the hopper 37.

[0067] Next, as shown in Figure 7B, the dosing plate 42 is moved by the actuator (44, see Figure 6B) so that the dosing cavity 43 in the dosing plate 42 is aligned with the opening 39 in the hopper 37. In this position, the particulate material 17 can move downwards within the dosing cavity 43 in the dosing plate 42. It can be seen that the dosing cavity 43 in the dosing plate 42 is completely filled with the particulate material 17 from the hopper 37. Vibrations from the vibrator (41, see Figure 6B) can facilitate and promote the movement of the particulate material 17 into the dosing cavity 43 of the dosing plate 42.

[0068] Once the dosing cavities 43 in the dosing plate 42 have been filled with the particulate material 17, the dosing plate 42 is moved to the position shown in Figure 7C. In this position, the dosing cavities 43 in the dosing plate 42 are aligned with the openings 46 in the alignment member 45, allowing the particulate material 17 to fall through the openings 46 in the alignment member 45 and into the container 9. In this manner, the particulate material 17 is dispensed into the container 9.

[0069] As the dosing plate 42 moves from the position shown in Figure 7C back to the position shown in Figure 7A, it passes the position shown in Figure 7B and some particulate material 17 may move into the dosing cavity 43 of the dosing plate 42. At the start of the next dosing process, the dosing plate 42 is moved to the position of Figure 7B, as described above. This arrangement is advantageous as it ensures that the dosing cavity 43 is exposed twice to the hopper 37 and filled with particulate material 17, and that a full dose of particulate material 17 is provided to the dosing cavity 43 of the dosing plate 42.

[0070] In an alternative arrangement, the dosing plate 42 is moved between the position shown in Figure 7B (where a dose of particulate material 17 is received in the dosing cavity 43) and the position shown in Figure 7C (where the particulate material 17 is transferred to the consumable unit 4 via an opening 46 in the alignment member 45). That is, the dosing plate 42 does not necessarily have to be moved to the position shown in Figure 7A.

[0071] In some embodiments, the dosing plate 42 is moved a small distance from the position shown in Figure 7C and then returned to the position shown in Figure 7C. This action ensures that the particulate material 17 is shaken off or removed from the dosing cavities 43 in the dosing plate 42. The dosing plate 42 can be tapped against a hard stop to remove the particulate material 17.

[0072] When the tobacco particulate material 17 includes tobacco, such a tapping action may be beneficial, since the tobacco particulate material may have a variable particle size, is sticky, and prone to clumping. The volume of each dosing cavity 43 in the dosing plate 42 may match the volume of the granular material 17 to be dosed in each container 9 of the consumable unit 4. In this way, one movement cycle of the dosing plate 42 provides each consumable unit 4 with a desired dose of the granular material 17. Alternatively, the volume of each dosing cavity 43 in the dosing plate 42 may be half the volume of the granular material 17 to be dosed in each container 9 of the consumable unit 4, and the dosing process is repeated twice for each tray of the consumable unit 4 inserted in the dosing station 23. In other embodiments, the volume may be 1 / 3 or 1 / 4, requiring three or four doses, respectively. The thickness of the dosing plate 42 may be varied to provide different volumes of doses.

[0073] In some embodiments, the size (e.g. diameter) of the dosing cavity 43 is larger than the size (e.g. diameter) of the opening 39 of the hopper 37. This can prevent the edges of the dosing plate 42 from slowing down the flow of the granular material 17 into the dosing cavity 43. Similarly, the opening 46 in the alignment member 45 can be larger (e.g. have a larger diameter) than the dosing cavity 43, such that the flow of the granular material 17 from the dosing cavity through the opening 46 in the alignment member 45 is not slowed down.

[0074] In some embodiments, the number of openings 39, dosing cavities 43 and openings 46 is doubled and they are arranged at half the pitch of the movement of the dosing plate 42 between the position shown in Fig. 7B and the position shown in Fig. 7C. In this way, two sets of openings 39, dosing cavities 43 and openings 46 are arranged at half the pitch from each other. Thus, when one set of openings 39, dosing cavities 43 and openings 46 is in the position shown in Fig. 7B, the other set of openings 39, dosing cavities 43 and openings 46 is in the position shown in Fig. 7C. In this way, the granular material 17 can be dispensed into more containers 9 with fewer movements.

[0075] An inspection unit may be provided on the dosing station 23 to inspect the consumable units 4 in the machine tray 27. In one embodiment, the optical scanning system can take a height measurement of the entire machine tray 27 when it is removed from the dosing station 23 after dosing of the granular material 17, and the inspection system can determine the fill height of the granular material 17 in each container 9 to ensure that sufficient granular material 17 has been dispensed into each container 9.

[0076] Figures 8A and 8B show the closure positioning station 24. The closure positioning station 24 positions the closures 14 on each consumable unit 4, on the lip 20, and between the posts 18, as shown in Figure 3A.

[0077] The closure positioning station 24 includes a machine tray support 29 similar to the machine tray support 29 of the dosing station 23 described above. In particular, the machine tray support 29 includes rails 30 that support a machine tray 27, shown in FIG. 5A, with a plurality of consumable units. The machine tray 27 can be inserted into the closure positioning station 24 by sliding the machine tray 27 onto the rails 30 that support opposite sides of the machine tray 27. The machine tray support 29 also includes stops against which the machine tray 27 abuts when the machine tray 27 is inserted into the machine tray support 29. The machine tray support 29 ensures that the machine tray 27 and the consumable units 4 are accurately and reliably positioned and supported within the closure positioning station 24.

[0078] The closure positioning station 24 may include a proximity switch to verify that the machine tray 27 is properly positioned on the machine tray support 29. Alignment pins may additionally or alternatively be provided to ensure accurate positioning.

[0079] The closure positioning station 24 also comprises a movable shelf 31 similar to the movable shelf 31 of the dosing station 23. In particular, the movable shelf 31 is slidably mounted on posts 33 via plain bearings 34 so as to be movable up and down relative to the machine tray support 29 and relative to the machine tray 27 and the consumable unit 4. An actuator 47 may be provided for moving the movable shelf 31 or it may be moved manually, for example by a handle. The movable shelf 31 is positioned above the machine tray support 29.

[0080] The movable shelf 31 of the closure positioning station 24 includes a closure positioning mechanism 48 that positions a closure 14 on each bin 9 on the machine tray 27, as will be described below. The movable shelf 31 is movable between a disengaged position and an engaged position. In the engaged position, the movable shelf 31 is adjacent to the machine tray 27 and the consumable unit 4 and is positioned to position a closure 14 on each bin 4. In the disengaged position, the movable shelf 31 is spaced from the machine tray 27 and the consumable unit 4 to allow the machine tray 27 to be inserted and removed from the machine tray support 29.

[0081] The closures 14 are provided to the closure positioning station 24 in a closure support web 50 shown in Figure 9. The closure support web 50 comprises a support structure 51 and a plurality of closures 14 arranged in an array. The closures 14 are removably attached to the support structure 51, for example, via connecting tabs. Individual closures 14 can be removed from the closure support web 50 by pushing the closures 14 out of the plane of the closure support web 50, as shown.

[0082] The connection tabs that attach the closure 14 to the support structure 51 are preferably configured to break at the closure 14 and not at the support structure 51. Thus, when the closure is removed from the closure support web 50, the connection tabs remain on the support structure. In one embodiment, the connection tabs are narrower at the closure than they are at the support structure 51.

[0083] The movable shelf 31 of the closure positioning station 24 includes support surfaces 52 and clamps 49 that hold the closure support webs 50 together, as shown in FIG. 10. The support surfaces 52 and clamps 49 of the movable shelf 31 hold the closure support webs 50 in position over the consumable units 4 in the machine tray 27 such that the closures 14 in the closure support webs 50 are aligned with each consumable unit 4 in the machine tray 27. In a preferred embodiment, the movable shelf 31 includes alignment pins that engage holes in the closure support webs 50 as the movable shelf 31 moves toward the consumable units 4. This ensures alignment between the closures 14 and the containers 9 of the consumable units 4.

[0084] The closure positioning station 24 also includes a punch 53 configured to push the closures 14 from the closure support web 50 into the consumable units 4, as shown in FIG. 10. The punch 53 includes an actuator that moves a punch head 54. The punch head 54 includes a plurality of protrusions 55 arranged in an arrangement that matches the arrangement of the closures 14 in the closure support web 50, and also matches the arrangement of the consumable units 4 in the machine tray 27. The protrusions 55 push the closures 14 out of the closure support web 50 and into the consumable units 4. In this manner, a single movement of the punch head 54 can simultaneously position the closures 14 into each consumable unit 4.

[0085] In a preferred embodiment, the closure support web 50 carries two or more sets of closures 14, and after one set of closures 14 is moved into the consumable unit 4, the closure support web 50 is moved to align the other set of closures 14 with the next machine tray 27 of the consumable unit 4. This has the advantage of reducing the number of times the closure support web 50 needs to be replaced. It should be understood that the number of closures 14 in each set is equal to the number of support recesses 28 in the machine tray 27.

[0086] As illustrated in Figure 10, when the actuator moves the punch head 54 downward toward the consumable unit 4, each protrusion 55 on the punch head 54 contacts a closure 14 in the closure support web 50. The movement of the punch head 54 separates the closure 14 from the closure support web 50 and pushes the closure 14 into the consumable unit 4. As previously described with reference to Figure 3A, the container 9 of each consumable unit 4 includes an end face 15 that defines a lip 20 and a peg 18 protruding from the end face 15. The closure 14 is positioned between the pegs 18 and disposed between the lip 20, as shown in Figure 3A.

[0087] As shown in FIG. 10, the support surface 52 of the movable shelf 31 provides support under the closure support mesh 50 opposite the punch head 54. The support surface 52 may extend under the closure support mesh 50 only as far as necessary to allow the clamps 49 to hold the closure support mesh 50 in place, or alternatively, the support surface 52 may extend further under the closure support mesh and include an array of openings 56 for the punch 53 to move through as it pushes the individual closures 14 from the closure support web 50 into the consumable unit 4. Preferably, each protrusion 55 on the punch head 54 has a size and shape that closely matches the size and shape of the openings 56 in the closures 14 and support surface 52 to help prevent bending and movement of the closure support web 50 and closures 14 during operation. To prevent the punch head 54 from catching on the support surface 52, the tolerances of the size of the openings 56 in the support surface 52 and the size of the punch head 54 are set so that the punch head 54 is smaller than the openings 56.

[0088] 10, each opening 56 in the support surface 52 may include a recess 57 that engages with a container 9, and particularly a stake 18, when the movable shelf 31 is in the engaged position. This helps ensure a smooth transfer of the closure 14 from the closure support web 50 to the consumable unit 4.

[0089] Similar to the dosing station 23, as described above, the closure positioning station 24 may include an inspection unit for inspecting the consumable units 4 in the machine tray 27 as they are removed from the machine tray support 29. As shown in Figures 8A and 8B, the scanner 58 may be positioned above the machine tray support 29 such that the laser / optical system of the scanner 58 can make height measurements across the machine tray 27 and the inspection system can check for the presence and correct seating of the closures 14 in each container 4.

[0090] Figure 11 shows the closure fixing station 25. The closure fixing station 25 fixes the closure 14 to the consumable unit 4 by bending it over the pegs 18, as shown in Figures 2A and 2B.

[0091] The closure fixation station 25 includes a machine tray support 29 similar to the machine tray support 29 of the dosing station 23 and the closure positioning station 24. In particular, the machine tray support 29 includes rails 30 that support a machine tray 27, shown in FIG. 5A, with a plurality of consumable units. The machine tray 27 can be inserted into the closure fixation station 25 by sliding the machine tray 27 onto the rails 30 that support opposite sides of the machine tray 27. The machine tray support 29 also includes stops against which the machine tray 27 abuts when the machine tray 27 is inserted into the machine tray support 29. The machine tray support 29 ensures that the machine tray 27 and the consumable units 4 are accurately and reliably positioned and supported in the closure fixation station 25.

[0092] The closure securing station 25 may include a proximity switch to verify that the machine tray 27 is properly positioned on the machine tray support 29. Alignment pins may additionally or alternatively be provided to ensure accurate positioning.

[0093] As illustrated in Figure 11, the closure fixing station 25 includes a press 59. The press 59 bends the posts 18 of the container 9 against the closure 14 to fix the closure 14 to the container 9, as shown in Figures 2A and 2B.

[0094] The closure securing station 25 includes a movable shelf 31 similar to the movable shelf 31 of the dosing station 23 and the closure positioning station 24, as shown in Figure 11. In this embodiment, the movable shelf 31 is provided with a press head 60 of a press 59, which will be described below. The support posts 33 and slide bearings 34 of the movable shelf 31 guide the movable shelf 31 and the press head 60 to ensure reliable and accurate operation of the press head 60. In other embodiments, the closure securing station 25 does not include a movable shelf 31, and the press head 60 is a separate component.

[0095] 11, includes an actuator 61 that acts to move a press head 60 vertically. The press head 60 has a number of individual presses arranged in an array that matches the array of the consumable units 4 in the machine tray 27. In this manner, a number or all of the consumable units 4 can be processed simultaneously to bend the pegs 18 and secure the closures 14 to the consumable units 4.

[0096] In one embodiment, the press head 60 includes a first set of presses 62 for performing the first bending step and a second set of presses 63 for performing the second bending step. The first and second sets of presses 62, 63 may each be arranged to occupy one half of the press head 60. In an alternative arrangement, the first set of presses 62 are provided at a separate station from the second set of presses 63.

[0097] Figure 12 shows the sequence in which a first set of presses 62 and a second set of presses 63 move from left to right, bending the pegs 18 against the closure 14. Figure 12 shows the consumable unit 4 received at the closure fixation station 25 with the pegs 18 extending upward and the closure 14 received between the pegs 18.

[0098] As shown, the first press 64 of the first set of presses 62 includes an angled pressing surface 66 that partially bends the peg 18. In particular, in this embodiment, the angled pressing surface 66 is angled 45 degrees from the horizontal, such that the peg 18 is bent 45 degrees in the first bending step. However, it should be understood that angles other than 45 degrees may be used for the angled pressing surface 66, as long as the angle is less than about 80 degrees and greater than about 20 degrees. In some embodiments, the pressing surface 66 may be concave, meaning that the angle of the pressing surface 66 from the horizontal varies across the width of the pressing surface 66.

[0099] The second press 65 of the second set of presses 63 then has a flat pressing surface 67 which bends the peg 18 over the remaining portion thereof into contact with the closure 14 and secures it to the container 9 .

[0100] The arrangement of the first and second sets of presses 64, 65 causes the pile 18 to bend in two stages, thereby ensuring that the pile 18 can be bent without breaking.

[0101] In some embodiments, the first and / or second presses 64, 65 are heated, or the entire press head 60 is heated to facilitate bending of the pegs 18. In some embodiments where the closure 14 is or includes a metal, an induction heating system may be deployed to heat the closure 14, which in turn heats the periphery of the container 9 including the pegs 18. It will be appreciated that this will depend on the material of the container 9 and the pegs 18. For example, if the pegs 18 are made of a thermoplastic material, a heated press may facilitate the bending process.

[0102] 13 illustrates an alternative press in which a first press 68 and a second press 69 are arranged concentrically. As shown, in this embodiment, the first press 68 has an inclined pressing surface 70 and a central bore 71. Within the central bore 72 is a second press 69 that is movable within the bore 71. Thus, as illustrated, the first press 68 can be moved first to initiate bending of the peg 18 by the inclined pressing surface 70. The second press 69 can then be moved to bend the peg 18 against the closure 14 to secure the closure to the container 9.

[0103] 13 arrangement, the press head 60 can include a first plate with a protrusion forming a first press 68 and an opening forming a bore 71 for the first press 68, and a second plate can include a protrusion forming a second press 69 that passes through the opening in the first plate. The first and second plates can be positioned adjacent to one another and separate actuators can move the first and second plates to perform the process illustrated in FIG 13. In this embodiment, all of the consumable units 4 can be processed simultaneously by a single closure fixture station 25.

[0104] In some embodiments, the first and second presses 68, 69 are heated, or the entire press head 60 is heated, to facilitate bending of the pegs 18. It will be appreciated that this will depend on the materials of the container 9, and in particular the pegs 18. For example, if the pegs 18 are made from a thermoplastic material, a heated press may facilitate the bending process.

[0105] In alternative configurations, the closure securing station 25 may comprise alternative means for securing the closure 14 to the consumable unit 4. For example, the closure securing station 25 may include a welding station, such as an ultrasonic welding station, that welds the closure 14 to the container 9 of the consumable unit 4. In other embodiments, the closure securing station 25 may comprise a press that presses the closure 14 into the chamber 16 of the consumable unit 4 to secure the closure 14 to the container 9 of the consumable unit 4.

[0106] Like the dosing station 23 and the closure positioning station 24, the closure securing station 25 may include an inspection unit for inspecting the consumable units 4 in the machine tray 27 as they are removed from the machine tray support 29, as described above. In particular, a scanner may be positioned above the machine tray support 29 such that a laser / optical system of the scanner can make height measurements across the machine tray 27 and such that the inspection system can check for the presence and correct seating of closures 14 in each container 9, as well as the presence and correct position of pegs 18 to ensure that the closures 14 are properly secured.

[0107] Removal from the closure securing station 25 completes the manufacture of the consumable unit 4. The consumable unit 4 can then be removed from the machine tray 27 and proceed to the packaging and dispensing process. The machine tray 27 can be returned to the start of the process and reused.

[0108] It will be appreciated that the set-dosing station 23, the closure positioning station 24 and the closure securing station 25 of the workstations have many common features. For example, each workstation 23, 24, 25 includes a machine tray support 29 and a movable shelf or platform 31 mounted on posts 33 for vertical movement. This allows the workstations 23, 24, 25 to be modularly located within a larger apparatus, such as, for example, an apparatus for packaging consumable units 4 and / or an apparatus for assembling or forming empty consumable units 4 as shown in FIG. 3A.

[0109] It should be understood that although the above described apparatus and method relate to the assembly of tobacco pods or consumable units 4, the apparatus may additionally or alternatively be adapted for the manufacture of consumable units 4, other components of an inhalation device, such as, for example, an atomizer cartridge 3.

[0110] Common features of each workstation 23, 24, 25 can be carried over to create alternative sets of workstations adapted to perform different sequences of assembly operations on successive batches of components.

[0111] The movable shelf 31 of each workstation may be adapted to support an assembly mechanism in place of the dosing mechanism 35, closure positioning mechanism 48 or press head 60 of workstations 23, 24, 25. Additional workstations may be added as needed so that the set of stations includes the number of workstations required for the particular component being assembled.

[0112] Similarly, the machine tray 27 can be adapted to hold components of different sizes and shapes. What is important is that the machine tray remains compatible with the machine tray support 29 that is common to each workstation. For example, the machine tray 27 can hold the same overall dimensions regardless of the component it is configured to hold.

[0113] Accordingly, an embodiment of the present invention provides a modular assembly apparatus including a series or multiple workstations. An example of a workstation 140 is shown in FIG. 14. Each workstation 140 carries the same reference number and includes the common features described above including a machine tray support 29 for placing a machine tray 27 for holding components of an inhalation device and guiding the machine tray 27 to a predetermined position to allow specific assembly operations to be performed on the components held on the machine tray 27. Each workstation 140 also includes a shelf 31 or platform 31 movable between a non-engaged position and an engaged position, in which the machine tray 27 can be placed and removed from its predetermined position and in which an assembly operation is performed on said components while the machine tray 27 is in its predetermined position.

[0114] In FIG. 14, the movable shelf 31 is concealed by a safety cover 141 to protect the operator of the workstation 140. However, it should be understood that the movable shelf 31 of each workstation of the present invention is substantially as shown and described in connection with the workstations 23, 24, 25 described above. The purpose of FIG. 14 is merely to illustrate other features for enhancing compatibility of the example workstation 140 with modular assembly equipment not shown and described in connection with the workstations 23, 24, 25 described above. However, it should be further understood that the example workstation 140 encompasses the workstations 23, 24, 25 and consumable liquid filling station described above. Thus, any feature described in connection with the example workstation 140 may be applied to any other workstation described herein, and vice versa.

[0115] In Figure 14, two workstations 140 are shown in a back-to-back relationship, however, other configurations of workstations are contemplated.

[0116] A modular assembly machine 150 with a set of workstations 151 according to an embodiment of the workstations 140 is shown diagrammatically in Figure 15. In the illustrated embodiment, the set of workstations 151 comprises three workstations 140, although it will be appreciated that the number of workstations 140 in the set of workstations 151 may vary depending, among other things, on the type of components being assembled.

[0117] Any of the workstations 140 described herein may be manually operated; that is, each workstation 140 may be operated by an individual human operator. Accordingly, each workstation 140 is further provided with a bench 142 (as shown in connection with the embodiment of the workstation 140 in FIG. 14) that allows the human operator to interact with the workstation in a standing or seated position.

[0118] Manual operation increases the flexibility of the modular assembly line 150 because workstations 140 can be added, removed, or replaced without having to integrate changes with the automated conveyor. However, manual operation presents other challenges, such as ensuring that each machine tray 27 moves through the workstations 140 in the correct order to perform a sequence of assembly operations.

[0119] To further enhance the modular aspect of the apparatus 150, each workstation 140 is provided with an interface unit 143 for communicating with a central controller 152. The controller 152 is configured to track the progress of the machine trays 27 through the assembly apparatus 150 and ensure that the assembly operations are performed in the correct order.

[0120] Additionally, each workstation includes a radio frequency tag reader 144 configured to detect information identifying a unique radio frequency tag (not shown) associated with a machine tray 27 inserted into the workstation 140, the radio frequency tag reader 144 configured to read the radio frequency tag. The radio frequency tag may include any type of radio frequency tag, such as an optical tag, a Bluetooth tag, or an RFID tag. RFID tags are particularly preferred as they provide unique radio frequency identification with minimal cost, complexity, and footprint. The information is communicated by the interface unit 143 to the controller 152. The controller 152 is thus able to determine whether a particular machine tray 27 has passed through the workstation 140.

[0121] When the machine tray 27 is inserted into the work station 140, it is supported by rails 30 on the machine tray supports 29 as described with reference to stations 23, 24, 25. A proximity switch may be provided to indicate when the machine tray 27 is in position so that an assembly operation can be performed.

[0122] Thus, when the proximity switch is activated, the RFID tag reader 144 identifies the unique RFID tag of the machine tray 27 in place. The interface unit 143 then communicates this information to the controller 152. It should be understood that the operation of the RFID tag reader 144 is not necessarily dependent on the proximity switch being activated. In another embodiment, the RFID tag reader 144 continuously monitors for the presence of an RFID tag. In such an embodiment, the RFID tag reader 144 can identify the unique RFID tag of the machine tray 27 placed on the machine tray support 29, regardless of whether the machine tray 27 is in place or not.

[0123] The interface unit 143 is configured to communicate to the controller 152 a completion status of an assembly operation performed on a machine tray 27 holding components for an inhalation device. A positive completion status indicates that the assembly operation was performed successfully. The controller 152 is configured to record the completion status and associate the completion status with information identifying the unique RFID tag of the machine tray 27 of components.

[0124] Each workstation is provided with a set of stop / go lights 145 (as shown in FIG. 14 ) to indicate to an operator of the workstation 140 whether to perform an assembly operation on the machine tray 27 of a component inserted at the workstation 140. The stop / go lights 145 are configured to provide said indication to the operator upon receiving a command from the controller 152.

[0125] The stop-go light 145 will be described with reference to a first and a second workstation 140a, 140b of the set of workstations 140. The first and second workstations 140a, 140b perform first and second assembly operations, respectively. The first assembly operation must be performed before the second assembly operation. In this respect, the first and second assembly operations may be similar to the assembly operations performed on the consumable unit 4 at stations 23 and 24, respectively.

[0126] The controller 152 is configured to command the stop / go light 145 of the second workstation 140b to indicate to an operator of the second workstation 140b to proceed only if the unique RFID tag of the machine tray 27 inserted in the second workstation 140b is associated with a positive completion status for the first assembly operation. Thus, the stop / go light 145 prevents the operator from performing a second assembly operation on the machine tray 27 of components that were not the subject of the first assembly operation.

[0127] Each workstation 140 may further include an inspection unit 146 configured to generate an inspection status. Any suitable inspection 146 unit may be used. For example, inspection unit 146 may be similar to any of those described in connection with stations 23, 24, and 25. The inspection status indicates whether any components in machine tray 27 require rejection. A positive inspection status indicates that none of the components require rejection. A negative inspection status indicates that at least one component requires rejection.

[0128] The inspection status is communicated to the controller 152 via the interface unit 143. The controller 152 then records the inspection status and associates the inspection status with information identifying the unique RFID tag of said machine tray 27.

[0129] It is therefore possible to prevent the machine tray 27 associated with the negative inspection status from undergoing further assembly operations. When the machine tray 27 associated with the negative inspection status is inserted into the further workstation 140, the controller 152 identifies the presence of the machine tray 27 by the unique RFID tag, for example when a proximity switch is activated. The controller 152 then activates the stop / go light 145 of the further workstation 140 to indicate to an operator that no further assembly operations should be performed. The operator can then remove the machine tray 27 from the assembly line 150.

[0130] To further verify that the assembly operations performed at each workstation 140 are successfully completed, each workstation 140 may also include a second proximity sensor (not shown) for determining when the movable shelf 31 is in the engaged position. The second proximity sensor is configured such that when the movable shelf 31 is moved to the engaged position, the second proximity sensor is activated and sends a signal to the controller 152 indicating that the movable shelf 31 has been moved to the engaged position.

[0131] During operation of the workstation 140, the controller 152 determines the presence of the machine tray 27 in the workstation 140 by the unique RFID tag, as described above. When the movable shelf 31 is moved to the engagement position, the controller 152 associates the unique RFID tag with a signal from the second proximity sensor indicating that the machine tray 27 has been moved to the engagement position. If the movable shelf 31 is not moved to the engagement position, the controller 152 associates the unique RFID tag with an incomplete assembly operation. Thus, it is possible to determine not only that the machine tray 27 has been received at the workstation 140, but also that the movable shelf 31 has been moved to the engagement position to perform the corresponding assembly operation. This is particularly advantageous when the movable shelf 31 is moved manually by a human operator, which is the case in the embodiment of the dosing station 23 described above.

[0132] Since the controller 152 records the incomplete assembly operation, it is possible to prevent the machine tray 27 associated with the incomplete assembly operation from undergoing a subsequent assembly operation. In particular, when the same machine tray 27 is inserted into a subsequent workstation 140, the controller 152 determines the presence of the machine tray 27 by the unique RFID tag. Furthermore, the controller 152 determines that the machine tray 27 is associated with an incomplete assembly operation and activates the stop / go light 145 of the workstation 140 to indicate to the operator that no further assembly operations should be performed. The operator can then remove the machine tray 27 from the assembly line.

[0133] The controller 152 may also be configured to measure the duration of time between a machine tray 27 being received at a first workstation 140 and the same machine tray 27 being received at a subsequent second workstation 140, and associate said duration of time with the unique RFID tag of the machine tray 27. This may be accomplished by determining that a machine tray 27 is received at the first workstation 140, and then measuring the time until a machine tray 27 having the same unique RFID tag is received at the second workstation 140. The duration may be measured from the activation of a proximity switch of the machine tray support 29 of the first workstation 140 to the activation of a proximity switch of the machine tray support 29 of the second workstation 140. Alternatively, the time is measured from the activation of a second proximity switch of the first workstation 140 to the activation of a second proximity switch of the second workstation 140. Alternatively, the time from when the movable shelf 31 of the first workstation 140 is moved to the engagement position until when the movable shelf 31 of the second workstation 140 is moved to the engagement position is determined.

[0134] Additionally, the controller 152 can be configured to compare the measured time duration with a predefined time and, if the measured time is greater than the predefined time, to associate an error code with the unique RFID tag of the corresponding machine tray 27. This may be necessary, for example, if a second assembly operation must be performed within a predefined time of a first assembly operation.

[0135] The stop / go light system 145 may be integrated with an automatic cutout that prevents assembly operations from being performed at a respective workstation 140. Thus, if the controller 152 determines that a workstation 140 associated with a negative inspection status has a machine tray 27 inserted or has not yet undergone a required preceding assembly operation, the controller 152 may activate the automatic cutout to prevent operation of the workstation 140.

[0136] In yet another embodiment, the workstation 140 may be configured to actively retract into position when the machine tray 27 is placed on the machine tray support 29. In such an embodiment, the machine tray 27 may include a bushing or other simple mechanical fixture designed to rest over a pin on the machine tray support 29. The pin is attached to a linear actuator, which retracts the machine tray into position within the workstation. Activation of the linear actuator may be automatic, i.e., the linear actuator may be activated when an operator places the machine tray 27 on the machine tray support 29. This may be accomplished, for example, by providing electrical contacts on the pin and bushing that make an electrical connection when the bushing is placed on the pin. The electrical connection sends a signal to the controller 152, which in turn activates the linear actuator to retract the machine tray 27 into the workstation 140.

[0137] By providing a controller 152 to track the progression of the machine trays 27 through the assembly line, it is possible to ensure that the assembly operations are performed in the correct order, regardless of the use of a human operator. This provides a flexible modular assembly line 150 in which workstations 140 can be added or removed without the need to integrate changes with the automated conveyor. The use of workstations 140 with a high degree of commonality also contributes to the flexibility of the system. Workstations 140 can be quickly adapted to perform additional or alternative assembly operations and can be dropped into an existing set of workstations 140 without the need to adapt other workstations 140. Human operators also quickly become accustomed to new workstations, with minimal retraining required. This combination of flexibility and reliability is superior to anything the applicant is aware of for the assembly of components for inhalation devices.

[0138] As used herein, the term "aerosolizable material" means that when heated, the aerosolizable material generates an aerosol. For example, the aerosolizable material may be or include a flavor substrate. The flavor substrate may comprise a flavoring substance, such as tobacco flavor or other flavor, and / or may comprise glycerol or other additives or enhancers instead of or in addition to glycerol. The flavor substrate, with or without glycerol or other additives, may be heated to generate an aerosol.

[0139] In general, an aerosol is a colloid of fine solid particles or liquid droplets in air or other gas, where it is noted that a colloid is a substance in which microscopically dispersed insoluble particles are suspended throughout another substance. A vapor, on the other hand, is a substance in the gas phase at a temperature below its critical temperature, meaning that the vapor can be condensed into a liquid, for example, by increasing the pressure without decreasing the temperature. It should be understood that the term aerosol as used herein includes aerosol and / or vapor.

[0140] As previously explained, the aerosolizable material can include tobacco. For example, the aerosolizable material can be a tobacco particle material.

[0141] As used herein, the term "tobacco" or "tobacco particle material" refers to a material that includes tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The particle material may also include non-tobacco materials. In some examples, the "particulate material" is powder-like, and in alternative examples, the "particulate material" is formed by shredding or cutting the material into smaller particles. In some examples, the "tobacco particle material" may include so-called "cut rags" that are formed by crushing or cutting tobacco into small particles. Tobacco particle material may be produced by extruding a tobacco slurry and cutting the extruded material into particles.

[0142] It will be appreciated that the above-described examples of the consumable unit can be used in devices other than the inhalation device described with reference to Figure 1. For example, the inhalation device may be a device that releases compounds from particulate matter without combustion, e.g., a tobacco heating product. In one embodiment, the inhalation device is a heating device that releases compounds by heating, but not burning, a substrate material, e.g., a particulate material. The particulate matter may be, for example, tobacco or other non-tobacco products that may or may not contain nicotine. In one embodiment, the inhalation device is a tobacco heating device.

[0143] In another embodiment, the tobacco industry product is a hybrid system that generates an aerosol by heating rather than combustion, producing a combination of a substrate material, e.g., the contents of an atomizer cartridge, and a particulate material in a consumable unit. The substrate material in the atomizer cartridge and the particulate material in the consumable unit can comprise, for example, a solid, liquid, or gel, which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and a solid substrate. The solid substrate can be, for example, tobacco or other non-tobacco product, which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and tobacco.

[0144] In order to address various problems and advance the art, the entirety of this disclosure illustratively illustrates various embodiments that may implement the claimed invention and provide an improved method and apparatus for manufacturing a consumable unit for use with an inhalation device. The advantages and features of the present disclosure are only representative samples of embodiments and are not exhaustive and / or exclusive. They are presented only to aid in the understanding and teaching of the claimed features. It should be understood that the advantages, embodiments, examples, features, features, structures, and / or other aspects of the present disclosure are not to be considered limitations of the present disclosure as defined by the claims or equivalent limitations to the claims, and that other embodiments may be utilized and modified without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or essentially consist of various combinations of the disclosed elements, components, features, parts, steps, means, etc. Additionally, the present disclosure includes other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A modular apparatus for performing a series of assembly operations on components of an inhalation device, comprising: The apparatus comprises: a set of a plurality of stations, each station configured to perform a different assembly operation of the sequence of operations; Each station is a machine tray support for positioning a machine tray on which components for assembly are received, the machine tray support being configured to guide the machine tray to a predetermined position within the station; Each station includes an interface unit, the modular apparatus further comprising a controller configured to control each station via the interface unit.

2. Each station further comprises a movable shelf; the movable shelf is slidably mounted to the machine tray support for movement to an engaged position in which an assembly operation is performed on a component received in the machine tray at the predetermined position; 2. The modular apparatus of claim 1, wherein the movable shelf at each station is configured to accommodate a different assembly mechanism, such that when the movable shelf is in the engaged position within the station, the assembly mechanism at that station performs one of a set of assembly operations on components received in the machine tray located in a predetermined position within that station.

3. 3. The modular apparatus of claim 2, wherein the movable shelf at each station is configured to slide between the engaged and disengaged positions, where the machine tray is insertable into or removable from the machine tray support at the station.

4. 4. The modular apparatus of claim 3, wherein the movable shelf at each station is mounted on a post for linear movement between the engaged and disengaged positions.

5. 5. The modular apparatus of claim 4, wherein the movable shelf at each station is supported by four posts disposed around a periphery of the machine tray support.

6. 6. A modular apparatus as claimed in any one of claims 1 to 5, wherein each machinery tray support comprises one or more rails configured to support opposite sides of a machinery tray, such that the machinery tray can be inserted into position by sliding the machinery tray along the rails.

7. A modular apparatus as claimed in any preceding claim, wherein each machinery tray support includes a stopper against which the machinery tray abuts when inserted into position.

8. 8. The modular apparatus of claim 3, wherein at least one station of the set of stations comprises an actuator configured to move a movable shelf between the engaged and disengaged positions.

9. A modular apparatus as claimed in any preceding claim, wherein each machine tray support further comprises a proximity switch which determines whether the machine tray is in position.

10. A modular apparatus as claimed in any one of claims 1 to 9, wherein each station comprises a radio frequency tag reader which detects information identifying a unique radio frequency tag associated with a machine tray inserted into the station, said information being communicated to the controller by the interface unit.

11. 11. The modular apparatus of claim 10, wherein each station comprises a set of stop / go lights to indicate to an operator of the station whether or not to begin performing an assembly operation on a component received in a machine tray inserted into the station, the stop / go lights configured to provide the indication to an operator upon receiving a command from the controller.

12. 12. The modular apparatus of claim 11, wherein each interface unit is further configured to communicate a completion status of an assembly operation performed on the component to the controller, a positive completion status indicating that the assembly operation was successfully performed, and wherein the controller is configured to record the completion status and associate the completion status with information identifying a unique wireless tag of the machine tray.

13. 13. The modular apparatus of claim 11 or 12, wherein at least one station of the set of stations comprises an inspection unit configured to generate an inspection status, the inspection status including information regarding a status of a component received in a machine tray placed in the at least one station, and the interface unit of the at least one station is further configured to communicate the inspection status of the component to the controller, the controller being configured to record the inspection status and associate the inspection status with information identifying a unique wireless tag of the machine tray on which the component is received.

14. 14. The modular apparatus of claim 12 or 13, wherein the set of multiple stations comprises a first station and a second station for performing a first assembly operation and a second assembly operation, respectively, the component is subjected to the first assembly operation before being subjected to the second assembly operation, and the controller is configured to indicate a stop / go light of the second station to indicate proceed to an operator of the second station only if a unique wireless tag of a machine tray inserted at the second station is associated with a positive completion status for the first assembly operation.

15. The module device according to any one of claims 10 to 14, wherein the wireless tag is an RFID tag.

16. A modular apparatus according to any one of claims 2 to 15, wherein the set of stations is configured to perform a first series of assembly operations to assemble a first type of component for an inhalation device, and the set of stations can be reconfigured to perform a second series of assembly operations different from the first series of assembly operations to assemble a second type of component for an inhalation device.

17. 17. The modular apparatus of claim 16, wherein reconfiguring the set of stations includes rearranging stations relative to one another and / or removing one or more stations and / or adding one or more further stations.

18. 18. The modular apparatus of claim 16 or 17, wherein reconfiguring the set of stations includes replacing an assembly mechanism of at least one station of the set of stations, the assembly mechanism being configured to perform a first assembly operation on a component of an inhalation device, and a different assembly mechanism being configured to perform a second assembly operation on a component of an inhalation device that is different from the first assembly operation.

19. 1. A station for use in a modular apparatus configured to assemble components of an inhalation device, the station being configured to perform an assembly operation on the components, the station comprising: a machine tray support for placing a machine tray on which components for assembly are received, the machine tray support being configured to guide the machine tray placed on the machine tray support to a predetermined position within the station; The station further includes an interface unit, the interface unit configured to communicate with a controller of the modular device.

20. a station further comprising a movable shelf slidably mounted relative to said machine tray support for movement to an engagement position where an assembly operation is performed on a component received in said machine tray at a predetermined position, 20. The station of claim 19, wherein the movable shelf is configured to mount an assembly mechanism, the assembly mechanism performing an assembly operation on components received in the machine tray in a predetermined position when the movable shelf is in the engaged position.

21. A method of reconfiguring a modular apparatus according to any one of claims 1 to 18, comprising the steps of rearranging the stations relative to one another and / or removing one or more stations and / or adding one or more further stations.

22. A method for reconfiguring a modular apparatus according to any one of claims 2 to 18, comprising the step of replacing the assembly mechanism of at least one station of the set of stations, the assembly mechanism being configured to perform a first assembly operation on a component of an inhalation device and a different assembly mechanism being configured to perform a second assembly operation on a component of an inhalation device that is different from the first assembly operation.

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