Disposable Cartridge Assembly Line With Elliptical Forming Path

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Solution Overview

Problem

Current methods for producing disposable cartridges for electronic cigarettes are inefficient and labor-intensive, resulting in low productivity and variable quality due to manual or rudimentary manufacturing processes, which can lead to damage of components during handling.

Innovation Solution

A manufacturing machine with an elliptical forming path and multiple processing stations that automates the assembly of disposable cartridges, including feeding systems for precise component placement, welding, and substrate application, allowing for high-speed and high-quality production without operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual or rudimentary manufacturing machines are used for assembling disposable cartridges, then the process is simple to implement, but productivity is low and quality is variable

Engineering Contradiction:

Improvehourly productivityVSAvoidmachine complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The manufacturing machine is divided into multiple independent operating units (first operating unit for electrode assembly, second operating unit for substrate assembly, third operating unit for final assembly) that work in parallel along the elliptical forming path, enabling high-speed production while maintaining manageable complexity through modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces an elliptical forming path that adds a spatial dimension to the assembly process, allowing components to be fed and assembled from different directions and planes simultaneously, thereby increasing productivity without proportionally increasing mechanical complexity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If manual handling and assembly operations are used, then the device complexity is low, but the risk of damaging components (especially substrate and electrodes) is high

Engineering Contradiction:

Improvecomponent integrityVSAvoidhandling system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The substrate is designed to be self-assembling through elastic deformation: it is elastically enlarged to fit around the electrodes, then released to automatically adhere to them through elastic return, eliminating the need for manual positioning and reducing damage risk

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The substrate is pre-deformed to a larger dimension before assembly, and the electrodes are pre-positioned in the support base, allowing the substrate to self-assemble onto the pre-positioned electrodes without manual intervention, thereby protecting component integrity

Inventive Principle:

Principle #10Preliminary action

3Strength

If force is applied to fit the substrate around the electrodes to achieve mechanical interference coupling, then the assembly is secure, but the substrate may be damaged

Engineering Contradiction:

Improvemechanical coupling strengthVSAvoidsubstrate integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent changes the physical parameter of the substrate by elastically deforming it to a larger dimension during assembly, then allowing it to return to its natural state through elastic recovery, creating a secure mechanical interference coupling without applying damaging force

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The elastic deformation of the substrate, which could be seen as a vulnerability, is converted into a beneficial self-assembling mechanism that secures the substrate to the electrodes through elastic return, eliminating the need for forceful assembly that could cause damage

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Productivity

If automated high-speed assembly is implemented, then productivity increases to 300 cartridges per minute, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveproduction speedVSAvoidmanufacturing complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The single manufacturing machine performs multiple functions (electrode assembly, substrate assembly, final cartridge assembly) through different operating units along the elliptical forming path, achieving high productivity while consolidating complexity into one multi-functional device rather than multiple separate machines

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11191305B2Manufacturing machine for the production of disposable cartridges for electronic cigarettes

Publication Date: 2021.12.07 GD SPA

AI summary

A manufacturing machine for the production of disposable cartridges for electronic cigarettes provided with a base; a support body, coupled to the base and is provided with a number of electrodes; a heating member electrically connected to the electrodes; and a substrate which surrounds the heating member. The manufacturing machine is provided with feeding conveyor, which feeds a semi-finished disposable cartridges along a forming path; and a number of operating stations arranged along the first forming path to alternatively carry out the supplying of a corresponding component of the semi-finished disposable cartridges or to carry out a processing of the components of the semi-finished disposable cartridges. The feeding conveyor has an annular guide arranged in a fixed position along the forming path; and a number of slides, each of which is coupled to a respective carriage designed to house the semi-finished disposable cartridges.