Machine and method for producing electronic-cigarette cartridges

Machine and method for producing electronic-cigarette cartridges; being provided: a fill conveyor which feeds bottom shells of the cartridges along a fill path; a filling device located along the fill path to feed a measure of a liquid substance downwards into each bottom shell; an assembly conveyor which feeds bottom shells along an assembly path; a transfer station where the bottom shells are transferred from the fill conveyor to the assembly conveyor; and at least a first assembly device located along the assembly path to fit each bottom shell with a corresponding top cap.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is the U.S. national phase of International Application No. PCT/IB2015/052004, filed Mar. 20, 2015, which claims the benefit of Italian Patent Application No. BO2014A000147, filed Mar. 21, 2014.

TECHNICAL FIELD

The present invention relates to a machine and to a method for producing electronic-cigarette cartridges.

PRIOR ART

Recently electronic-cigarettes cartridges for single use (i.e. disposable) have been proposed inside which a hygroscopic pad is contained (such as a cotton pad) that is impregnated with a viscous liquid substance containing nicotine and possible flavourings. In use, the electronic-cigarette heats the cartridge thus causing the slow volatilization (vapourization) of the viscous liquid substance impregnating the hygroscopic pad.

The production of said cartridges envisages the production of cartridges with an open top end, the insertion of the dry hygroscopic pad into the cartridges, filling the cartridges with a calibrated amount of the liquid substance, and then plugging the cartridges by applying a cap permeable to vapours to the open top end (i.e. a cap that prevents the liquid substance from leaking, but that does not prevent the vapour generated by heating the liquid substance from escaping); once the cap is applied, a corresponding adhesive label is wound around each cartridge to end the production process.

Currently the production of the cartridges is performed manually or with rudimentary machines which provide a continuous use of labour; consequently, the production of the cartridges takes place in a slow manner (that is, with a low productivity) and with very variable and generally low quality.

The patent application DE102011082709A1 describes a machine10for producing containers for pharmaceutical liquids; the machine10comprises: a fill conveyor12which feeds the containers1along a fill path; a filling device40located along the fill path to feed a measure of a liquid substance downwards into each container1(a weighing device42independently for each container2is provided); an assembly conveyor47which feeds the containers1along an assembly path; a transfer station where the containers1are transferred from the fill conveyor12to the assembly conveyor47; and an assembly device43located along the assembly path to fit each container1with a corresponding cap. Both the fill conveyor12, and the assembly conveyor47feed a single container1at a time along the corresponding paths.

DESCRIPTION OF THE INVENTION

The object of the present invention is to provide a machine and a method for producing electronic-cigarette cartridges, which machine and method allow to reach high productivity and are, at the same time, easy and inexpensive to manufacture.

According to the present invention, a machine and a method for producing electronic-cigarette cartridges, as claimed in the appended claims, are provided.

PREFERRED EMBODIMENTS OF THE INVENTION

InFIGS. 1 and 2number1indicates as a whole a machine for producing electronic-cigarette cartridges2.

As shown inFIG. 1, each cartridge2comprises a cylindrical internally hollow bottom shell3inside which a hygroscopic pad4is arranged (for example a cotton pad) that is impregnated with a viscous liquid substance (for example propylene glycol) containing nicotine and possible flavourings; a bottom cap5is fitted to a bottom end of the cylindrical bottom shell3, while a gasket6and a top cap7are fitted to a top end of the cylindrical bottom shell3.

As illustrated inFIGS. 1 and 2, the machine1comprises a feed unit8which receives a mass of unordered bottom shells3(i.e. a mass of bottom shells3arranged in bulk) in a collecting tank9open at the top and manipulates the bottom shells3to arrange the bottom shells3in an ordered succession, a fill unit10which receives bottom shells3arranged by the feed unit8and fills the bottom shells3themselves with the liquid substance to impregnate the corresponding hygroscopic pads4, an assembly unit11which receives the bottom shells3from the fill unit10and applies the corresponding bottom cap5, the gasket6and the top cap7to each bottom shell3, and a labelling unit12which receives the bottom shells3from the assembly unit10and applies a main label13(illustrated schematically inFIG. 18) and a sealing label14(shown schematically inFIG. 17) to each bottom shell3.

As illustrated inFIG. 19, the feed unit8comprises a belt feed conveyor15, which is located completely inside the collecting tank9at the bottom of the collecting tank9itself and is slightly inclined upwards so as to convey the bottom shells3from the bottom upwards along an inclined plane (i.e. an inlet end of the feed conveyor15is lower than an outlet end of the feed conveyor15). In addition, the feed unit8comprises a belt feed conveyor16, which is partially located inside the collecting tank9and is inclined upwards so as to convey the bottom shells3from the bottom upwards along an inclined plane (i.e. an inlet end of the feed conveyor16is arranged lower than an outlet end of the feed conveyor16). In particular, the feed conveyor16is located immediately downstream from the feed conveyor15so that bottom shells3in front of the feed conveyor15are directly transferred to the feed conveyor16; to this purpose, the inlet end of the feed conveyor16is located below the outlet end of the feed conveyor15. Finally, the feed unit8comprises a belt feed conveyor17, which is arranged horizontally and is oriented transversely with respect to the feed conveyor16(i.e. the feed direction of the bottom shells along the feed conveyor17is transverse to the feed direction of the bottom shells3along the feed conveyor16). In particular, the feed conveyor17, is located immediately downstream from the feed conveyor16so that bottom shells3in front of the feed conveyor16are directly transferred to the feed conveyor17; for this purpose, an inlet end of the feed conveyor17is located below the outlet end of the feed conveyor16.

As illustrated inFIG. 22, between the outlet end of the feed conveyor15and the inlet end of the feed conveyor16an accumulation area18is defined, in which the bottom shells3coming from the feed conveyor15are accumulated; from the accumulation area18the bottom shells3are subsequently withdrawn by the feed conveyor16. The accumulation area18is delimited at the back by a fixed bottom wall19located between the feed conveyors15and16. It is important to note that the size of the accumulation area18are reduced so as to limit the amount of bottom shells3that are collected in the accumulation area18, and then so as to limit the mechanical stress to which the bottom shells3are subjected in the accumulation area18itself.

According to a preferred embodiment illustrated inFIG. 22, the number of bottom shells3in the accumulation area18is detected by a sensor20(for example by optically measuring the height of the group of bottom shells3in the accumulation area18) and then the feed conveyor15is actuated to keep the number of bottom shells3in the accumulation area18within a desired and predetermined range; in other words, when there is a large number of bottom shells3in the accumulation area18the feed conveyor15is slowed down (even up to the stop), while when there is a reduced number of bottom shells3in the accumulation area18the feed conveyor15is accelerated (possibly re-starting it if previously stopped).

According to a preferred embodiment illustrated inFIG. 22, between the trailing end of the feed conveyor15and the leading end of the feed conveyor16an orienting grid21is arranged, which has the function of guiding in a longitudinal direction the bottom shells3that from the feed conveyor15are passed to the feed conveyor16, i.e. to orient in the longitudinal direction the bottom shells3that are deposited in the accumulation area18. The bottom shells3have a completely random arrangement on the feed conveyor15while it would be desirable for the bottom shells3to show a longitudinal orientation in the feed conveyor16(according to which the central axis of symmetry of the cylindrical bottom shell3is parallel to the feed direction of the feed conveyor16); to facilitate the longitudinal orientation of the bottom shells in the feed conveyor16a rake-shaped orienting grid21is used to allow only the longitudinally oriented bottom shells3to pass through the orienting grid21itself to reach the accumulation area18.

According to a preferred embodiment illustrated inFIG. 22, the feed conveyor16is provided with pockets22, each of which is adapted to contain a corresponding longitudinally oriented bottom shell3; in other words, the belt of the feed conveyor16has a number of pockets22adapted to contain respective longitudinally oriented bottom shells3. To be fed along the feed conveyor16a bottom shell3must necessarily be inserted into a corresponding pocket22, since the high slope of the feed conveyor16prevents a bottom shell3from climbing back along the feed conveyor16if not inserted inside a corresponding pocket22; in this way it is ensured that the bottom shells3are fed by the feed conveyor16towards the feed conveyor17only if they have the desired longitudinal orientation (i.e. only if inserted in corresponding longitudinally oriented pockets22).

According to a preferred embodiment illustrated inFIG. 22, an optical control device23is provided located along the feed conveyor16and is adapted to determine the orientation of the bottom shells3inside the pockets22of the feed conveyor16itself; in other words, the optical control device23checks whether the bottom shells3inside the pockets22of feed conveyor16have or do not have the desired orientation. Furthermore an ejecting device24is provided located along the feed conveyor16downstream from the optical control device23and adapted to eject from the corresponding pocket22of the feed conveyor16each bottom shell3having a wrong orientation (i.e. different from the right orientation); by way of example, the ejecting device24is of pneumatic type and ejects a bottom shell3from the corresponding pocket22of the feed conveyor16by means of a discharge of compressed air directed perpendicularly to the feed conveyor16. A bottom shell3that is ejected from the corresponding pocket22of the feed conveyor16by the action of the ejecting device24lowers by gravity along the feed conveyor16until returning to the accumulation area18.

According to a preferred embodiment illustrated inFIG. 22, the feed conveyor16feeds a row of bottom shells3which is formed by a number of bottom shells3aligned perpendicular to a feed path so as to feed along the feed path itself many bottom shells3at a time; in this way, the feed conveyor16is able to have a high productivity per hour (i.e. the number of bottom shells3feed per unit of time) while presenting a feed rate relatively modest. It is important to note that it is essential for the feed conveyor16to have a relatively modest feed rate, because only if the feed conveyor16has a relatively modest feed rate then the bottom shells3can be inserted at a high rate inside the pockets22of the feed conveyor16at the accumulation area18(i.e. at the inlet end of the feed conveyor16). Furthermore, it is important to specify that the nominal hourly productivity of the feed conveyor16must be adequately greater than the nominal hourly productivity of the machine1, as not all the pockets22of the feed conveyor16are always properly filled by corresponding bottom shells3at the accumulation area18(i.e. at the inlet end of the feed conveyor16); in other words, the feed conveyor16will never be able to operate with its nominal hourly productivity because not all of the pockets of the feed conveyor16are always properly filled by corresponding bottom shells3at the accumulation area18and thus the nominal hourly productivity of the feed conveyor16must be appropriately greater than the nominal hourly productivity of the machine1.

As shown inFIG. 4, the fill unit10comprises a fill conveyor25which feeds the bottom shells3along a straight fill path P1and arranged horizontally with an intermittent motion i.e. a motion that provides a cyclic alternation of motion steps, in which the fill conveyor25is in motion, and rest steps, in which the fill conveyor25is stopped. In the embodiment illustrated inFIG. 3, the fill conveyor25is a belt conveyor having a flexible belt26which is wound ring-like around respective pulleys (known and not illustrated) and supports a number of cartridge-holders27arranged side by side one to the other; each cartridge-holder27is cantilevered fixed to the flexible belt26. As shown inFIG. 5, each cartridge-holder27has a number of cylindrical seats28, each of which is adapted to receive and house a corresponding bottom shell3. In other words, the fill conveyor25feeds along the fill path P1a succession of cartridge-holders27, each of which houses inside an ordered assembly of bottom shells3which are arranged in several rows oriented perpendicularly to the fill path P1; in particular, each row consists of ten bottom shells3and one said cartridge-holder27supports four rows (i.e. a total of forty bottom shells3). In this way, the filling operations of each row of the bottom shells3carried by the same cartridge-holder27are performed in parallel, i.e. occur simultaneously for all the bottom shells3.

As illustrated inFIGS. 20 and 21, the fill unit10comprises a hopper29located alongside a vertical portion of the fill conveyor25and has in the bottom portion a number of vertical channels, each for receiving and conveying a corresponding vertical row of bottom shells3. To the hopper a pusher30is coupled which is movable horizontally through the vertical channels of the hopper29to push a row of bottom shells3out of the vertical channels and then inside the fill conveyor25(in particular in corresponding seats28of a cartridge-holder27carried by the fill conveyor25). A chute31is provided which is arranged horizontally between the hopper29and the fill conveyor25and whereon the bottom shells3are flowing when pushed by the pusher30towards the fill conveyor25.

According to a preferred embodiment, the chute31has a number of controllable hatches32(only one of which is shown schematically inFIG. 21) that are formed through the chute and each of which is individually openable to allow the discharge of a corresponding bottom shell3by deflecting the bottom shell3itself towards a discharge path (typically located below the chute31and then along which the discarded bottom shell3falls by gravity); in other words, when a bottom shell3to be discarded is found (for the presence of defects in materials), the discharge occurs during the travelling of the chute31by opening the corresponding hatch32which by opening deflects the bottom shell3towards the discharge path (and thus the defective bottom shell3does not enter the fill conveyor25). According to a preferred embodiment, to check the presence of defects in the bottom shells3a control station is provided, which is located at the hopper29and comprises at least one optical control device33(for example a CCD camera), which “looks” towards the vertical channels of the hopper29to observe the bottom shells3. The discharge of the deformed bottom shells3(i.e. presenting defects that alter the shape of the bottom shells3) before entering the bottom shells3in the seats28of the cartridge-holders27of the fill conveyor25is very important, as a deformed bottom shell3may get stuck (i.e. wedged by interference) completely or partially inside a seat28without any possibility to be extracted if not by stopping the machine1and thus requiring the manual intervention of an operator.

As illustrated inFIGS. 3 and 4, along a straight horizontal section of the fill conveyor25and at the start of the fill path P1, a coupling station is arranged in which a coupling device34(shown only inFIG. 3) couples each cartridge-holder27of the fill conveyor25with a corresponding measuring element35(best shown inFIG. 6); normally, each measuring element35is simply placed on top of the cartridge-holder27.

As illustrated inFIG. 4, each measuring element35comprises a number of measuring chambers36, each of which is arranged above a corresponding bottom shell3, has a volume sufficient to contain the entire measure of liquid substance (i.e. the entire amount of liquid substance which is to be fed inside of the bottom shell3), and has at the bottom an outlet duct37which flows into the bottom shell3. In other words, each measuring element35has a number of measuring chambers36which are arranged in a row oriented perpendicular to the fill path P1so as to reproduce the arrangement of the bottom shells3in the cartridge-holders27and therefore so that to each bottom shell3housed in a cartridge27corresponds a measuring chamber36.

Downstream from the coupling station S1and along the fill path P1a feed station S2is arranged in which a filling device38is housed that feeds the liquid substance inside each bottom shell3by means of the corresponding measuring chamber36. In other words, in the feed station S2the filling device38feeds the liquid substance in each measuring chamber36so that from the measuring chamber36the liquid substance3descends by gravity into the bottom shell3through the outlet duct37. As illustrated inFIGS. 1 and 2, the liquid substance is fed to the filling device38from a feed station39, which is located behind the measuring conveyor25and supports two removable containers40(i.e. easily and completely replaceable) containing the liquid substance; preferably, each container40(which is completely replaceable) integrates, in its inside, both a feed pump for the extraction of the liquid substance, and agitators which in use are continuously mixing the liquid substance to prevent stratification thereof.

As illustrated inFIGS. 3 and 4, downstream from the feed station S2and along the fill path P1a number of standby stations S3are arranged in succession; the cartridge-holders27containing the bottom shells3, in which the liquid substance is flowing by gravity from the overlying measuring chambers36cross the standby stations S3waiting that all the liquid substance has descended by gravity from each measuring chamber36to the underlying bottom shell3through the outlet duct37.

At the end of the standby stations S3, i.e. downstream from the standby stations S3, and along the fill path P1a removing station S4is provided in which a removing device41(shown only inFIG. 3) removes the corresponding measuring element35from each cartridge-holder27once all the liquid substance has descended by gravity from each measuring chamber36to the underlying bottom shell3through the outlet duct37.

It is important to note that the stations S1-S4and the filling device38are located along a straight horizontal portion of the fill path P1so as to allow the liquid substance to descend by gravity inside each bottom shell3.

For a more detailed description of the construction and operation details of the fill unit10regarding the feeding of the liquid substance reference is made to what is described in the patent application BO2013A000504.

According to a preferred embodiment illustrated inFIGS. 3 and 4, at the start and at the end of the fill path P1(i.e. upstream and downstream from the area in which the filling of the bottom shells3with the liquid substance occurs), two twin weighing devices42are provided, each for weighing each bottom shell3; by weighing each bottom shell3before and after filling the bottom shell3with a liquid substance the amount of liquid substance that was actually erogated inside the bottom shell3can be accurately measured and therefore it can be verified whether the filling of the bottom shell3was performed correctly. According to a preferred embodiment, each weighing device42operates in parallel, i.e. weighs simultaneously all bottom shells3of the same row of bottom shells3contained in a corresponding cartridge-holder27.

As illustrated inFIGS. 7, 8 and 9, each weighing device42comprises a number of pushers43(only one of which is shown for simplicity inFIGS. 7, 8 and 9), each of which is located below the fill conveyor25and is movable vertically to enter from the bottom of a corresponding seat28and then push a corresponding bottom shell3upwards until fully ejecting the bottom shell3from the seat28(as shown inFIGS. 8 and 9). Once a pusher43has ejected a bottom shell3from the corresponding seat28(i.e. when the bottom shell3does not touch the walls of the seat28), the pusher43stops its stroke and then a weight sensor44(for example a load cell) integrated in the pusher43detects the weight of the bottom shell3. At the end of weighing, each bottom shell3is again re-inserted in the corresponding seat28by means of a lowering movement opposite to the previous lifting movement. According to a preferred embodiment, each weighing device42operates in parallel, i.e. weighs simultaneously all bottom shells3of the same row of bottom shells3carried by a cartridge-holder25.

According to a preferred embodiment, each pusher43is associated with a corresponding counter-pusher45(or contrast45) which is arranged on the opposite side of the pusher43(i.e. located above the fill conveyor25) and engages a top wall of the corresponding bottom shell3during the lifting of the bottom shell3(i.e. during ejection of the bottom shell3from the corresponding seat28) and during the subsequent lowering of the bottom shell3(i.e. during the subsequent re-insertion of the bottom shell3in the corresponding seat28) to accompany the movement of the bottom shell3itself. In other words, during the lifting and the subsequent lowering each bottom shell3is “pinched” at the bottom and at the top by the corresponding pusher43and counter-pusher45to be always stably and firmly driven, and therefore to prevent unwanted movement of the bottom shell3itself. It is important to note that at the time of weighing (and only at the time of weighing) of each bottom shell3, the corresponding counter-pusher45is detached from the bottom shell3itself (as illustrated inFIG. 9) to avoid influencing the weight measurement.

The assembly of pushers43and of the corresponding counter-pushers45forms a lifting device, which is adapted to lift each bottom shell3thus vertically ejecting the bottom shell itself from the corresponding seat28of the cartridge-holder27and which is connected mechanically with the weight sensor44that detects the total weight of each bottom shell3when the bottom shell3itself is fully ejected from the corresponding seat28. Each pusher43is located below the fill conveyor25, is vertically movable for resting on a lower wall of a corresponding bottom shell3, and is connected mechanically to a corresponding weight sensor44; each counter-pusher45is located above the fill conveyor25, is vertically movable for resting on an upper wall of a corresponding bottom shell3from the opposite side with respect to the corresponding pusher43, and is adapted to be separated temporarily from the upper wall itself during the measuring of the weight of the bottom shell3.

To allow the ejection of the vertical bottom shells3, each cartridge-holder27has a bottom wall provided with a through hole at each seat28; in this manner, each pusher43can enter from below inside the corresponding seat28to push vertically the bottom shell3outside the seat28itself. According to equivalent embodiments, each through hole of the bottom wall of a cartridge-holder can be as large as the seat28(i.e. may have the same diameter of the seat28and in this case below the fill conveyor25a fixed plate is arranged), or can be smaller than the seat28(i.e. may have a diameter smaller than the diameter of the seat28).

According to a preferred embodiment, the weighing device42located upstream from the filling device35also comprises additional control sensors which are adapted to check the correct operation of the electric circuit located inside each bottom shell3(for example to determine whether the electrical circuit has electrical continuity i.e. is not electrically interrupted in an abnormal manner); for example, the electrodes of the control sensors could be integrated into the heads of the pusher43which comes into contact with the bottom wall of each bottom shell3. In this manner, before, during or after weighing each bottom shell3, the weighing device42determines also the proper functioning of the electric circuit located inside each bottom shell3. It is important to note that if before the filling process a bottom shell3with a problem in the electric circuit is detected (i.e. a defective bottom shell3to be discarded) then feeding the liquid substance inside said bottom shell3is avoided.

As illustrated inFIG. 10, the drive assembly11comprises a belt assembly conveyor46which feeds bottom shells3along an assembly path P2(illustrated inFIG. 11) with an intermittent motion, i.e. with a motion that provides a cyclic alternation of motion steps, in which the assembly conveyor46is in motion, and rest steps, in which the assembly conveyor is stopped. In particular, the assembly conveyor46comprises a belt conveyor which is arranged vertically (i.e. is oriented vertically) and supports a number of seats48, each of which adapted to contain and hold a corresponding bottom shell3embracing the cylindrical side wall of the bottom shell3itself; according to a preferred embodiment, the seats48of the assembly conveyor46have a certain elastic deformability, and therefore the bottom shells3are held inside the seats48“fitting” the bottom shells3inside the seats48themselves. According to a preferred embodiment, the belt47of the assembly conveyor46is wound ring-like around two end pulleys (known and not illustrated) having different diameters and arranged horizontally (i.e. rotatable about respective vertical axes of rotation).

One end of the assembly conveyor46is located above a straight horizontal portion of the fill path P1(i.e. above a horizontal straight portion of the fill conveyor25) at a transfer station S5where the bottom shells3are transferred from the fill conveyor25to the assembly conveyor46. As illustrated inFIG. 12, the transfer station S5comprises a lifting device, which is entirely analogous to the lifting devices of the weighing devices42and is adapted for vertically lifting each bottom shell3to transfer the bottom shell3itself from the fill conveyor25to the overlying assembly conveyor46(i.e. from a seat28of a cartridge-holder27of the fill conveyor25to an overlying seat48of the assembly conveyor46). The lifting device of the transfer station S5comprises a number of pushers49(only one of which is shown for simplicity inFIG. 12), each of which is located below the fill conveyor25and is movable vertically to enter from the bottom of a corresponding seat28and then push upwards a corresponding bottom shell3until ejecting the bottom shell3from the seat28and then insert the bottom shell3in a corresponding seat48of the assembly conveyor46. According to a preferred embodiment, the lifting device of the transfer station S5operates in parallel i.e. simultaneously transfers all bottom shells3of the same row of bottom shells3carried by a cartridge-holder25.

According to a preferred embodiment, to each pusher49a corresponding counter-pusher50(or contrast50) is associated which is arranged on the opposite side of the pusher49(i.e. located above the assembly conveyor46) and engages a top wall of the corresponding bottom shell3during the lifting of the bottom shell3(i.e. during ejection of the bottom shell3from the corresponding seat28) to accompany the movement of the bottom shell3itself. In other words, during the lifting each bottom shell3is “pinched” at the bottom and at the top by the corresponding pusher49and counter-pusher50to be always stably and firmly driven, and therefore preventing unwanted movements of the bottom shell3itself.

Each pusher49is located below the fill conveyor25and is vertically movable for resting on a lower wall of a corresponding bottom shell3; each counter-pusher50is located above the fill conveyor25and is vertically movable for resting on an upper wall of a corresponding bottom shell3from the opposite side with respect to a corresponding pusher49.

As illustrated inFIGS. 10 and 11, along the assembly path P2and around a circular portion of the assembly conveyor46an assembly device51for fitting each bottom shell3with a corresponding gasket6, an assembly device52for fitting each bottom shell3with a corresponding top cap7, and an assembly device53for fitting each bottom shell3with a corresponding bottom cap5are arranged in succession.

As illustrated inFIGS. 1 and 2, the gaskets6are fed to the assembly device51from a storage unit54by means of a corresponding feed conveyor55, the top caps7are fed to the assembly device52from a storage unit56by means of a corresponding feed conveyor57, and the bottom caps5are fed to the assembly device53from a storage unit58by means of a corresponding feed conveyor59.

As illustrated inFIGS. 13-16, the assembly device51comprises a support plane60, which is located above the assembly conveyor46, is movable horizontally (i.e. it moves to the right and to the left while staying at the same distance from the assembly conveyor46), provides a temporary support to the gasket6before fitting the seal6itself to a corresponding bottom shell3, and moves to allow fitting the corresponding seal6to the bottom shell3. Moreover, the assembly device51comprises an inserter element61, which is located above the support plane60, is movable vertically (i.e. towards and away from the assembly conveyor46) and moves downwards with a first stroke to engage the seal6resting on the support plane60and with a subsequent second stroke for fitting the seal6to the bottom shell3after the support plane60has moved freeing access to the bottom shell3itself.

When a bottom shell3arrives at the level of the assembly device51, the feed conveyor55deposits a corresponding gasket6on the support plane60that is located above the bottom shell3itself (as shown inFIG. 13). At this point, the inserter element61is lowered making the first stroke downwards to engage a center hole of the gasket6, i.e. to fit inside the central hole of the gasket6(as illustrated inFIG. 14); preferably a bottom end of the inserter element61is point-shaped to have a self-centering function with respect to the central hole of the gasket6. Thus, the support plane60moves laterally to free access to the underlying bottom shell3while the gasket6remains in the same position as engaged by the inserter element61(as shown inFIG. 15). Finally, the inserter element61is further lowered making the second downwards stroke to insert the seal6into the bottom shell3(as shown inFIG. 16).

The assembly device52is entirely similar to the assembly device51and therefore comprises a support plane62, which is located above the assembly conveyor46, is movable horizontally (i.e., it moves to the right and to the left while staying at the same distance from the assembly conveyor46), provides a temporary support to the top cap7before fitting the top cap7itself to a corresponding bottom shell3, and moves to allow the fitting of the bottom shell3with a corresponding top cap7. Furthermore, the assembly device53comprises an inserter element63, which is located above the support plane62, is vertically movable (i.e. towards and away from the assembly conveyor46) and moves downwards with a first stroke for engaging the top cap7resting on the support floor62and with a subsequent second stroke for fitting the top cap7to the bottom shell3after the support plane62has moved freeing access to the bottom shell3itself.

The assembly device53is similar to the assembly devices51and52and comprises a support plane64, which is located below the assembly conveyor46, is fixed, and provides a temporary support to the bottom cap5before the application of the bottom cap5itself to a corresponding bottom shell3overhead. Furthermore, the assembly device53comprises an inserter element65, which is located below the support plane64, is vertically movable (i.e. towards and away from the assembly conveyor46) and moves upwards with a single stroke to engage the bottom cap5resting on the support plane64and then fit the cap bottom5to the bottom shell3by passing through the support plane64.

According to a preferred embodiment, immediately upstream from the assembly device53a control device is arranged adapted to determine the correct operation of the electric circuit located inside each bottom shell3(for example to determine whether said electric circuit has electric continuity i.e. is not prematurely electrically interrupted). In this way, before applying the bottom cap5to each bottom shell3, the proper operation of the electric circuit located inside each bottom shell3is checked. It is important to note that if before the assembly process a bottom shell3with a problem in the circuit is detected (i.e. a defective bottom shell3to be discarded), then the caps5and7and the seal6are not fitted with said defective bottom shell3.

According to a preferred embodiment, along the assembly conveyor46and downstream from the assembly devices51-53an optical control device (such as a CCD camera) is arranged that verifies the correct conformation of bottom shells3identifying any defective bottom shells3(e.g. bottom shells wherein the cap5and/or the cap7are not arranged correctly or damaged bottom shells3).

As illustrated inFIGS. 11 and 18, the labelling unit12comprises a labelling device66, which is located downstream from the assembly conveyor46and applies around a side surface of each bottom shell3a corresponding main label13. The labelling device66comprises a labelling wheel67, which rotates with continuous motion around a horizontal axis of rotation68, is tangent to the assembly conveyor46, and receives bottom shells3directly from the assembly conveyor46itself (so by passing from the assembly conveyor46to the labelling wheel67the bottom shells pass from intermittent motion of the assembly conveyor46to continuous motion of the labelling wheel67). The labelling wheel67is provided with a number of suction seats69, each of which is formed at a cylindrical side surface of the labelling wheel67and is adapted to retain a corresponding main label13provided with glue (which is applied to the main label13upstream from the labelling wheel67) and a corresponding bottom shell3which is subsequently placed over the main label13.

Furthermore, the labelling unit12comprises a rolling plate located alongside the labelling wheel67to define a rolling channel71inside which each bottom shell3is made to rotate on itself by rolling on the outer surface of the labelling wheel67so as to determine the wrapping around the bottom shell3of the corresponding main label13. According to a preferred embodiment, the rolling plate70comprises a tooth72, which is located at a front end of the rolling channel71(or the inlet of the rolling channel71), protruding internally to the rolling channel71locally reducing the size of the rolling channel71itself, and is mounted radially movable against the thrust of elastic means73; the function of the tooth72is to slightly compress each bottom shell3at the inlet of the rolling channel71so as to facilitate the ejection of the bottom shell3from the corresponding seat69of the labelling wheel67and then start the rolling of the bottom shell3itself. The presence of the elastic means73is particularly useful, since the bottom shells3are not substantially elastically compressible and therefore it is preferable that is the tooth72to yield moving inwards when a bottom shell3enters the rolling channel71and therefore impacts against the tooth72.

According to a preferred embodiment the labelling device66comprises a resetting drum74located alongside the labelling wheel67immediately downstream from the rolling plate70and has a series of teeth76which engage the bottom shells3exiting from rolling channel71to arrange the bottom shells3itself in a predetermined relative position with respect to labelling wheel67, or to arrange bottom shells3inside the corresponding seats69of the labelling wheel67once exited from the rolling channel71.

According to a possible embodiment, it may be necessary to ensure a certain relative position between each bottom shell3and the corresponding main label13(normally when the main label13has a through hole that must be aligned with an underlying opening formed in the cylindrical lateral surface of the bottom shell3); in this case, the assembly conveyor46is coupled to an orienting device that optically detects the angular position of each bottom shell3, and then acts mechanically on the bottom shell3by imparting a rotation to the bottom shell3to put the bottom shell3itself in a desired and predetermined angular position. In this way, the bottom shells3enter into the labelling wheel67always and only with the desired and predetermined angular position which ensures the respect of the desired relative position between each bottom shell3and the corresponding main label13.

As illustrated inFIG. 17, the labelling unit12comprises a labelling device77, which is located downstream from the labelling device66and apply on a top wall of each bottom shell3(i.e. over the corresponding top cap7) a corresponding sealing label14. The labelling device77comprises a labelling wheel78, which rotates with continuous motion around a vertical axis of rotation79, is tangent to the labelling wheel67, and receives the bottom shells3directly from the labelling wheel67itself. The labelling wheel78is provided with a number of suction seats80, each of which is formed at a cylindrical lateral surface of the labelling wheel78and is adapted to retain a corresponding bottom shell3. Furthermore, the labelling device77comprises an application wheel81, which is located above the labelling wheel78, is oriented perpendicularly to the labelling wheel78, and rotates with continuous motion around a horizontal axis of rotation82. The application wheel81is provided with a number of suction seats83, each of which is formed at a cylindrical lateral surface of the application wheel81and is adapted to retain a corresponding sealing label14. In use, each suction seat83of the application wheel81receives a corresponding label14and then applies the sealing label14itself on a top wall of each bottom shell3(i.e. over the corresponding top cap7) carried by a seat80of the labelling wheel78. The labelling wheel78is coupled to a movable folding device (not shown) provided with two degrees of freedom, which is located downstream from the application wheel81in the rotation direction of the labelling wheel78and L-folds each sealing label14completely to adhere the sealing label14itself to the corresponding bottom shell3.

According to a preferred embodiment illustrated inFIG. 17, the main labels13are self-adhesive, i.e. originally already provided with glue on an inner face, and are withdrawn by two corresponding tapes84that are used alternatively to ensure operation continuity (i.e. when tape84is exhausted the other tape84is used and in the meantime the exhausted tape84is replaced with a new tape84). According to a preferred embodiment illustrated inFIGS. 1 and 2, the tapes84are unwound from corresponding spools supported by an unwinding device85of known type. According to a preferred embodiment illustrated inFIG. 17, the sealing labels14are self-adhesive, or are originally already provided with glue on an inner face, and are withdrawn by two corresponding tapes86that are used alternatively to ensure the continuity of the operation (i.e. when a tape86is exhausted the other tape86is used and in the meantime the exhausted tape86is replaced with a new tape86). According to a preferred embodiment illustrated inFIGS. 1 and 2, the tapes86are unwound from corresponding spools supported by an unwinding device87of known type.

According to a preferred embodiment, downstream from the labelling devices66and77an optical control device (such as a CCD camera) is arranged that verifies the correct conformation of the cartridges2identifying any defective cartridges2.

According to a preferred embodiment, downstream from the labelling devices66and77a discharge station of known type is arranged in which the cartridges2that have been recognized as defective by the control devices located upstream (i.e. the cartridges2whose bottoms shells7, caps5and7, and/or labels13and14show functional and/or visible defects) are discarded or eliminated from the production process.

From what has been described above and well-illustrated inFIG. 10, in the fill unit10the fill conveyor25feeds along the fill path P1a row of bottom shells3with intermittent motion, which consists of ten bottom shells3(i.e. by at least two bottom shells3) aligned perpendicularly to the fill path P1so as to feed along the fill path P1itself ten bottom shells3(i.e. at least two bottom shells3) at a time; each row of ten bottom shells3is housed in corresponding seats28of a cartridge-holder27of the fill conveyor25. Instead, in the assembly unit11the assembly conveyor46feeds along the assembly path P2a single bottom shell3at a time with intermittent motion. Obviously, at each feed step of the fill conveyor25the assembly conveyor46has to make ten feed steps, as in the transfer station S5the assembly conveyor46receives ten bottom shells3at a time from the fill conveyor25. Finally, in the labelling units12the labelling wheels67and78move with continuous motion a single bottom shell3at a time.

From what has been described above and well-illustrated inFIG. 10, the assembly path P2of the assembly conveyor46is arranged perpendicularly to the fill path P1of the fill conveyor25. Furthermore, the assembly path P2of the assembly conveyor46extends in a vertical plane and the fill path P1of the fill conveyor25extends in a horizontal plane.

In summary, machine1for producing electronic-cigarette cartridges2; the machine comprising: a fill conveyor25which feeds bottom shells3of the cartridge2along a fill path P1; a filling device38located along the fill path P1to feed a measure of a liquid substance downwards into each bottom shell3; an assembly conveyor46which feeds bottom shells3along an assembly path P2; a transfer station S5in which the bottom shells3are transferred from the fill conveyor25to the assembly conveyor46; and at least a first assembly device52located along the assembly path P2for fitting each bottom shell3with a corresponding top cap7; in the machine1the fill conveyor25feeds along the fill path P1a row of bottom shells3comprising at least two bottom shells3aligned perpendicularly to the fill path P1so as to feed along the fill path P1itself at least two bottom shells3at a time; and the assembly conveyor46feeds along the assembly path P2a single bottom shell3at a time.

The assembly path P2is arranged perpendicular to the fill path P1.

The assembly path P2extends in a vertical plane and the fill path P1extends in a horizontal plane.

The fill conveyor25comprises a first belt conveyor26and a number of cartridge-holders27, each of which is fixed to the first belt conveyor46and has at least one row of seats28arranged perpendicular to the fill path P1to house a corresponding row of bottom shells3that are simultaneously fed along the fill path P1itself.

Each cartridge-holder27has a bottom wall provided with a through hole at each seat28.

The filling device38is located along a straight horizontal portion of the fill path P1; a first weighing device42is provided which is adapted to weigh each bottom shell3and is located upstream from the filling device38along the straight horizontal portion of the fill path P1; a second weighing device42is provided which is adapted to weigh each bottom shell3and is located downstream from the filling device38along the straight horizontal portion of the fill path P1; and each weighing device42comprises a first lifting device, which is adapted to lift each bottom shell3vertically ejecting the bottom shell3itself from the corresponding seat28of the cartridge-holder27and, which is connected mechanically with a weight sensor44which detects the total weight of the bottom shell3when the bottom shell3is fully ejected from the corresponding seat28.

The first lifting device of each weighing device42comprises: a first pusher43which is located below the fill conveyor25, is vertically movable for resting on a lower wall of a corresponding bottom shell3, and, which is connected mechanically to the weight sensor44; and a first counter-pusher45which is located above the fill conveyor25, is vertically movable for resting on a top wall of a corresponding bottom shell3from the opposite side with respect to the first pusher43, and is adapted to be separated temporarily from the top wall itself during the measuring of the weight of the bottom shell3.

One end of the assembly conveyor46is located above a straight horizontal portion of the fill path P1; and the transfer station S5comprises a second lifting device, which is adapted to vertically lift each bottom shell3to transfer the same bottom shell3from the fill conveyor25to the overlying assembly conveyor46.

The second lifting device of the transfer station S5comprises: a second pusher49which is located below the fill conveyor25and is vertically movable for resting on a lower wall of a corresponding bottom shell3; and a second counter-pusher50which is located above the fill conveyor25and is vertically movable for resting on a top wall of a corresponding bottom shell3from the opposite side of the second pusher49.

The assembly conveyor46comprises a second belt conveyor47that is arranged vertically and supports a number of seats48, each of which is adapted to contain and hold a corresponding bottom shell3.

The first assembly device52comprises: a support plane62, which is located above the assembly conveyor46, is horizontally movable, provides a temporary support to the top cap7before applying the top cap7itself to a corresponding bottom shell3, and moves to allow fitting the bottom shell3with a corresponding top cap7; an inserter element63, which is located above the support plane62, is vertically movable and moves downwards with a first stroke for engaging the top cap7resting on the support plane62and with a subsequent second stroke for fitting the top cap7with the bottom shell3after the support plane62has moved freeing access to the bottom shell3itself.

The machine1further comprising: a second assembly device51located along the assembly path P2upstream from the first assembly device52for fitting each bottom shell3with a corresponding insert6; and a third assembly device53located along the assembly path P2for fitting each bottom shell3with a corresponding bottom cap5arranged on the opposite side of the top cap7.

The machine1further comprising a first labelling device66, which is located downstream from the assembly conveyor46and applies around a lateral surface of each bottom shell3a corresponding first label13.

The first labelling device66comprises: a first labelling wheel67provided with a number of suction seats69, each of which is adapted to retain a corresponding first label13provided with glue and a corresponding bottom shell3which is placed over the first label13; and a rolling plate70located alongside the first labelling wheel67to define a rolling channel71inside which each bottom shell3is made to rotate on itself by rolling on the outer surface of the first labelling wheel67so as to determine the wrapping of the corresponding first label13around the bottom shell3.

The rolling plate70comprises a tooth72, which is located at a front end of the rolling channel71, protrudes inside the rolling channel71locally reducing the size of the rolling channel71itself, and is mounted radially movable against the thrust of elastic means73.

The first labelling device66comprises a resetting drum74located alongside the first labelling wheel67immediately downstream from the rolling plate70and has a series of teeth which engage the bottom shells3exiting the rolling channel71to arrange the bottom shells3itself in a predetermined relative position with respect to the first labelling wheel67.

The machine1further comprising a second labelling device77, which is located downstream from the first labelling device66and applies on an top wall of each bottom shell3a corresponding second label14.

The second labelling device77comprises: a second labelling wheel78, which is provided with a number of suction seats28, each of which is adapted to retain a corresponding bottom shell3; and an application wheel81, which is located above the second labelling wheel78, is oriented perpendicularly to the second labelling wheel78, and is provided with a number of suction seats83, each of which is adapted to retain a corresponding second label14to apply the second label14itself on a top wall of each bottom shell3carried by the second labelling wheel78.

The machine1further comprising a hopper29located alongside a vertical portion of the fill conveyor25, and having at the bottom part a number of vertical channels, each for receiving and conveying a corresponding stack of bottom shells3; and comprises a pusher30which is movable horizontally through the vertical channels of the hopper29to push a row of bottom shells3out of the vertical channels inside the fill conveyor25.

The machine1further comprising a chute31which is horizontally located between the hopper29and the fill conveyor25and whereon the bottom shells3slide when they are pushed by the pusher30towards the fill conveyor25; and comprises a number of controllable hatches32which are obtained through the chute31and each of which is individually openable to allow the discharge of a corresponding bottom shell3by deflecting the bottom shell3itself towards a deviation path.

The machine1further comprising a first feed belt conveyor17which feeds bottom shells3from the top inside the hopper29; and it comprises a second feed belt conveyor16which ends above the first feed conveyor17and feeds the bottom shells3from the first feed conveyor17itself.

The second feed conveyor16is arranged horizontally inclined to feed the bottom shells3from the bottom upwards along an inclined plane.

The second feed conveyor16, is provided with pockets22, each adapted to contain a corresponding bottom shell3.

The machine1further comprising an optical control device23located along the second feed conveyor16and is adapted to determine the orientation of the bottom shells3inside the pockets22of the second feed conveyor16itself; and comprises an ejecting device24that is located along the second feed conveyor16downstream from the optical control device23and is adapted to eject from the corresponding pocket22of the second feed conveyor16each bottom shell3which is wrongly oriented.

The machine1further comprising a third belt feed conveyor15that ends above the second feed conveyor16to feed the bottom shells3from the top to the first feed conveyor17itself.

The third feed conveyor15is arranged horizontally inclined to feed the bottom shells3from the bottom upwards along an inclined plane.

The third feed conveyor15and an initial portion of the second feed conveyor16are located inside a collecting tank9open at the top and adapted to receive a mass of bottom shells3arranged in bulk.

An orienting grid21is located between a trailing end of the third feed conveyor15and a leading end of the second feed conveyor16.

The present invention also relates to a method for producing electronic-cigarette cartridges2; the method comprises the steps of: feeding the bottom shells3of the cartridges2along a fill path P1of the fill conveyor25; feeding a measure of a liquid substance inside each bottom shell3by means of a filling device38located along the fill path P1; transferring the bottom shells3from the fill conveyor25to an assembly conveyor46at a transfer station S5; feeding the bottom shells3along an assembly path P2by means of the assembly conveyor46; and fitting each bottom shell3with at least one corresponding top cap7by means of an assembly device52located along the assembly path P2; the fill conveyor25feeds along the fill path P1a row of bottom shells3comprising at least two bottom shells3aligned perpendicularly to the fill path P1so as to feed along the fill path P1itself at least two bottom shells3at a time; and the assembly conveyor46feeds along the assembly path P2one single bottom shell3at a time.

The machine1described above has numerous advantages.

First, the machine1described above allows to achieve high productivity (that is, a number of pieces produced in the time unit) while ensuring a high quality standard of the cartridges2. This result is obtained thanks to the fact of making the fill unit10operate in parallel, i.e. by feeding along the fill path P1itself at least two bottom shells3at a time which are processed simultaneously, and to operate the assembly unit11and the labelling unit12in series, i.e. feeding along the assembly path P2one single bottom shell3at a time; in this way, all processes (filling, assembling, labelling) can take place in the most favorable conditions. In fact, the filling of bottom shells3requires a long enough time to take place in an optimal way, and then is performed in parallel (i.e. by filling more bottom shells3at a time the available time for the filling each bottom shell3is multiplied); it is important to note that by having a lot of time available the liquid substance can enter in the bottom shells3by gravity (i.e. at atmospheric pressure without over-pressures) and in this way, the filling of bottom shells is done in an optimal way allowing to obtain a perfect impregnation of the hygroscopic pads4, avoiding unwanted deformations of the bottom shells3and/or of the hygroscopic pads4, and avoiding leakage of the liquid substance from bottom shells3. Instead, the assembly and labelling operations can be done in a much more rapid way (while retaining effectiveness and quality) and would be very complex to be performed in parallel having the need to fit the solid elements (i.e. non-liquid, that is, the gaskets6, caps5and7and the labels13and14) external to the bottom shells3.

In addition, the machine1described above is also easy and inexpensive to manufacture, as it is composed of structurally simple elements performing few movements and easy to implement.

Finally, the machine1described above provides adequate space for maneuvering around each component, and then both the initial assembly of the components and the subsequent maintenance (from simple cleaning to the replacement) of the components themselves are simplified.