Methods for assembling a cartridge for an aerosol delivery device, and associated systems and apparatuses

Inventors: William Robert Collett (Lexington, MA); Quentin Paul Guenther, Jr. (Winston-Salem, NC); Paul Andrew Brinkley (Winston-Salem, NC); Jeffrey Edward Allgeyer (Gibsonville, NC); Ethan Matthew Bernhardt (Cookeville, TN); Andrew Ross Matthews (Cookeville, TN); Roger Ritter (Büren, CH); Stephen Todd Schafer (Denver, CO); Mathieu Leboeuf (Denver, CO); Martin Lee Maple (Aurora, CO); Trenton S. Noonan (Parker, CO); Kevin Paul Schafer (Lakewood, CO)

Assignee: RAI Strategic Holdings, Inc.

A61M15/06 A24F40/70 B23K26/22 B29C65/08 B29C66/5344 B65B3/14 G01M99/008 H05B3/0014 H05B3/78 A24F40/10 A61M11/042 A61M2205/3334 A61M2205/3553 A61M2205/3693 A61M2207/00 B29L2031/712 B29L2031/7414

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Quick Facts

Patent No.: US 12,564,692
App. No.: 18/655,045
Granted: Mar 3, 2026
Kind: B2

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Abstract

The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. A system may include assembly cells each including an assembly track and assembly carriages that ride thereon and which engage components of partially-assembled cartridges. A transfer apparatus may transfer partially-assembled cartridges between the assembly cells. In another example system, cartridges may be assembled on platforms on a rotary track. The platforms may include assembly grippers with sequentially-opening clamps configured to receive the components of the partially-assembled cartridges. Related methods are also provided.

Claims (22)

1 . An aerosol delivery device cartridge filling system, comprising:

an assembly carriage comprising a plurality of receptacles configured to respectively receive a partially-assembled cartridge including a flow director, the receptacles each including an aperture extending through the assembly carriage;

a filling apparatus configured to dispense an aerosol precursor composition into the cartridge at one or more of the receptacles;

a manifold comprising a plurality of cooperating outlets configured to align with at least a portion of the receptacles; and

an air supply configured to supply a flow of air into the manifold, out of the manifold through the cooperating outlets, into the aperture at each of the receptacles aligned with the cooperating outlets, and through the flow director of the cartridge while the filling apparatus dispenses the aerosol precursor composition.

2 . The aerosol delivery device cartridge filling system of claim 1 , wherein the manifold is configured to direct the flow of air through each of the receptacles.

3 . The aerosol delivery device cartridge filling system of claim 1 , further comprising one or more additional manifolds,

wherein the manifold and the one or more additional manifolds are each configured to direct the flow of air through a portion of the receptacles such that each receptacle receives the flow of air.

4 . The aerosol delivery device cartridge filling system of claim 1 , further comprising an aerosol precursor composition supply.

5 . The aerosol delivery device cartridge filling system of claim 4 , wherein the filling apparatus comprises one or more filling needles configured to direct the aerosol precursor composition from the aerosol precursor composition supply to the cartridges.

6 . The aerosol delivery device cartridge filling system of claim 1 , wherein the flow director defines a channel configured to receive an overflow of the aerosol precursor composition.

7 . The aerosol delivery device cartridge filling system of claim 1 , further comprising an actuator configured to move the manifold into engagement with a bottom of the assembly carriage.

8 . The aerosol delivery device cartridge filling system of claim 1 , wherein the air supply comprises an air compressor.

9 . The aerosol delivery device cartridge filling system of claim 1 , wherein the air supply comprises a flow controller configured to adjust at least one of an air pressure or a flow rate of air through the manifold.

10 . An aerosol delivery device cartridge filling method, comprising:

dispensing an aerosol precursor composition into a partially-assembled cartridge comprising a flow director; and

directing a flow of air through the flow director while dispensing the aerosol precursor composition into the partially-assembled cartridge.

11 . The aerosol delivery device cartridge filling method of claim 10 , wherein directing the flow of air through the flow director comprises directing the flow of air upwardly through the flow director.

12 . The aerosol delivery device cartridge filling method of claim 10 , wherein directing the aerosol precursor composition into the partially-assembled cartridge comprises directing the aerosol precursor composition into contact with a reservoir substrate extending at least partially around the flow director.

13 . The aerosol delivery device cartridge filling method of claim 10 , further comprising positioning the partially-assembled cartridge in an assembly carrier,

wherein directing the flow of air through the flow director comprises directing the flow of air through the assembly carrier.

14 . The aerosol delivery device cartridge filling method of claim 13 , wherein directing the flow of air through the flow director further comprises engaging a manifold with the assembly carrier and directing the flow of air from the manifold to the assembly carrier.

Assignments (5)