Method for assembling a cartridge for a smoking article

• US 10,609,961 B2
• Filed: 11/01/2017
• Issued: 04/07/2020
• Est. Priority Date: 02/13/2014
• Status: Active Grant

• Current Assignee: RAI STRATEGIC HOLDINGS, INC. (British American Tobacco PLC)
• Original Assignee: RAI STRATEGIC HOLDINGS, INC. (British American Tobacco PLC)
• Inventors: Ampolini, Frederic Philippe, Nestor, Timothy Brian, Flinchum, Jr., Jack Gray, Brown, Wayne Douglas, Watson, Nicholas Harrison, Novak, III, Charles Jacob, Brinkley, Paul Andrew, Covino, James Robert, DePiano, John, Dickinson, Edward Louis, Harris, Eugene R., Keough, Kevin Edward, Smith, David Jay, Hook, John, LaCourse, Michael, Metcalf, Robert, Hart, Steven, Pelletier, David, Bourque, Marc, Cambray, Nathaniel, Wolber, John William, McClellan, James William, Mongillo, Steven R., Silveira, Frank S., Laine, Michael, Guenther, Jr., Quentin Paul
• Primary Examiner(s): Travers, Matthew P
• Application Number:
  US15/800,943
• Publication Number:
  US 20180077969A1
• Time in Patent Office: 888 Days
• CPC Class Codes: A24C 5/34 Examining cigarettes or the rod, e.g. for regulating the feeding of tobacco; Removing defective cigarettes
• CPC Class Codes: A24F 40/10 Devices using liquid inhalable precursors
• CPC Class Codes: A24F 40/46 Shape or structure of electric heating means
• CPC Class Codes: A24F 40/50 Control or monitoring
• CPC Class Codes: A24F 40/70 Manufacture
• CPC Class Codes: A24F 40/80 Testing
• CPC Class Codes: A61M 11/042 electrical
• CPC Class Codes: A61M 15/06 Inhaling appliances shaped like cigars, cigarettes or pipes
• CPC Class Codes: A61M 2205/3334 Measuring or controlling the flow rate
• CPC Class Codes: A61M 2205/43 making noise when used correctly
• CPC Class Codes: A61M 2205/8206 battery-operated
• CPC Class Codes: A61M 2207/00 Methods of manufacture, assembly or production
• CPC Class Codes: A61M 2207/10 Device therefor
• CPC Class Codes: B23P 11/005 by expanding or crimping
• CPC Class Codes: B23P 19/04 for assembling or disassembling parts
• CPC Class Codes: B23P 21/004 the units passing two or more work-stations whilst being composed
• CPC Class Codes: B25J 11/005 Manipulators for mechanical processing tasks
• CPC Class Codes: B25J 15/0047 for internally gripping hollow or recessed objects
• CPC Class Codes: B61B 13/04 Monorail systems
• CPC Class Codes: B65G 2201/0267 Pallets
• CPC Class Codes: H01C 17/04 : adapted for winding the resistive element
• CPC Class Codes: H01C 3/08 : Dimension or characteristic of resistive element changing gradually or in discrete steps from one terminal to another
• CPC Class Codes: H01C 3/16 : including two or more distinct wound elements or two or more winding patterns
• CPC Class Codes: H05B 2203/037 : Heaters with zones of different power density
• CPC Class Codes: Y10T 29/49913 : by constricting outer annulus

Abstract

The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. The cartridges may be assembled by transporting carriages between various substations at which parts are added to a base. In another assembly method, the base may be moved between a plurality of robots which direct the base downwardly into contact with components to couple the components therewith. An inspection system may inspect the cartridges at various stages of completion.

Claims

1. A method for assembling an atomizer for an aerosol delivery device, the method comprising:

providing a first heating terminal, a second heating terminal, and a heating element wherein the heating element comprises;

a wire defining a plurality of coils and comprising two contact portions, a center portion, and two outer portions positioned outside of the contact portions, the two contact portions and the center portion of the wire defining the heating element,

wherein the two contact portions define a first coil spacing, the center portion defines a second coil spacing, and the outer portions define a third coil spacing, the third coil spacing being greater than the second coil spacing and the second coil spacing being greater than the first coil spacing;

determining a position of the first heating terminal and the second heating terminal;

determining a position of the heating element; and

affixing the heating element to the first heating terminal and the second heating terminal based on the position of the first heating terminal and the second heating terminal and the position of the heating element.

2. The method of claim 1, wherein determining the position of the first heating terminal and the second heating terminal comprises determining a midpoint between a first heating terminal tab and a second heating terminal tab.

3. The method of claim 2, wherein the two contact portions of the heating element comprise a first contact portion and a second contact portion, and

wherein determining the position of the heating element comprises determining a midpoint between the first contact portion and the second contact portion.

4. The method of claim 3, further comprising aligning the midpoint between the first heating terminal tab and the second heating terminal tab with the midpoint between the first contact portion and the second contact portion;

engaging the first contact portion with the first heating terminal tab; and

engaging the second contact portion with the second heating terminal tab.

5. The method of claim 4, further comprising clamping the first heating terminal and the second heating terminal such that the first heating terminal tab and the second heating terminal tab are substantially coplanar.

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

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

8. The method of claim 7, wherein directing the laser beam at the first heating terminal tab and at the second heating terminal tab comprises directing the laser beam at a backside of the first heating terminal tab and the second heating terminal tab opposite from the heating element.

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

10. The method of claim 1, wherein providing the heating element comprises:

supplying the heating element from a substantially continuous heating element input; and

controlling a tension in the substantially continuous heating element input.

11. The method of claim 1, further comprising coupling the heating element to a liquid transport element.

12. The method of claim 11, wherein coupling the heating element to the liquid transport element comprises inserting an end of the heating element through the liquid transport element and rotating at least one of the heating element and the liquid transport element such that the heating element winds about the liquid transport element.

13. The method of claim 1, wherein providing the first heating terminal and the second heating terminal comprises:

supplying the first heating terminal from a substantially continuous first heating terminal input; and

supplying the second heating terminal from a substantially continuous second heating terminal input.

14. The method of claim 1, wherein the plurality of coils of the heating element are wound about a liquid transport element.

15. The method of claim 14,

wherein affixing the heating element to the first heating terminal and the second heating terminal comprises affixing the contact portions to the first heating terminal and the second heating terminal.