Patent Description:
There exists a need to provide an apparatus and a method for the efficient manufacture of consumable units for inhalation devices which may involve providing a dose of aerosolisable material to a pod of the consumable unit; positioning a closure over an end of the pod; and securing the closure to the pod. These, and other manufacturing steps, may need to be carried out on a plurality of pods in quick succession.

The pods are supplied on a storage tray. The storage tray has pod receiving pockets each of which support an individual pod so that each tray supports a plurality of pods in a structured array. In order to perform various manufacturing steps on the pods, it is necessary to transfer them from the storage trays to a machine cassette. A machine cassette also has pod receiving pockets that correspond to the pod receiving pockets of the storage tray. The machine cassette is configured for insertion into a manufacturing machine to enable one or more of the manufacturing steps to be carried out on the pods whilst they are held in the machine cassette.

Once one or more manufacturing steps have been completed on the pods supported on the machine cassette, they may be transferred from the machine cassette back onto a storage tray.

It is known from <CIT> to provide apparatus for transferring pods, each of which form part of a consumable unit for use with an inhalation device, from a storage tray in which each pod is supported in a pod receiving pocket, to a consumable unit manufacturing device.

Apparatus for transferring pods according to the invention is characterised in that the apparatus transfers pods from said pod receiving pockets to corresponding pod receiving pockets of a machine cassette of said consumable unit manufacturing device, and in that the apparatus comprises
a transfer station to receive the tray and a machine cassette placed over the storage tray and the pods received in the storage tray, the transfer station being configured to rotate the combined tray and machine cassette so that the pods in said pod receiving pockets in the tray are transferred into corresponding pod receiving pockets in the machine cassette.

The apparatus of the invention may comprise a receiving station adjacent to the transfer station. The receiving station may be configured to receive a tray of pods such that, when a machine cassette has been placed on the tray over the pods, the tray is insertable, together with the pods and the machine cassette, from the receiving station into the transfer station.

The tray may be slideable, together with the pods and the machine cassette placed on the tray over the pods, directly from the receiving station into the transfer station.

In certain embodiments, the transfer station comprises a cradle to receive the tray and the machine cassette placed on the tray over the pods.

The cradle may be mounted for rotation about an axis. In particular, the cradle may be configured to rotate about said axis from a first position in which the tray with a machine cassette placed on it is insertable into the cradle, into a second position in which the combined tray and machine cassette inserted into the cradle are inverted.

The cradle may also be configured to rotate in the opposite direction about said axis, from said second position into the first position.

Preferably, the cradle is configured to rotate through an angle of <NUM> degrees between said first and second positions.

The cradle may comprise first and second support plates configured so that a storage tray of pods, with the machine cassette placed on the storage tray, is insertable into said transfer station between said first and second support plates when said cradle is in said first position.

The first and second support plates may be spaced such that, when the cradle is rotated about said axis, a tray of pods together with the machine cassette placed upon it, is supported by the first and second support plates to prevent separation of the tray and the machine cassette.

The cradle may be configured so that the tray of pods, together with the machine cassette placed over it, extends across the axis of rotation of the cradle when the tray of pods with the machine cassette placed over it is inserted into the cradle between the support plates.

The apparatus may comprise a drive member for rotating the cradle about said axis.

The drive member can be manually operable. In certain embodiments, the drive member may be a rotatable hand-wheel. In an alternative embodiment, the drive member may comprise a motor.

The apparatus may comprise an enclosure surrounding the cradle. The enclosure may be a cylindrical drum.

The drum may have a longitudinal axis and it can be configured to rotate together with the cradle about said longitudinal axis.

Preferably, the apparatus comprises a first stationary buffer and a stop element rotatable together with the enclosure. The stop element may be configured so that it contacts the first stationary buffer to prevent the cradle rotating beyond said first position.

The apparatus may additionally comprise a second stationary buffer. The second stationary buffer may be configured such that the stop element rotatable together with the enclosure contacts the second stationary buffer to prevent the cradle rotating beyond said second position.

The apparatus may comprise a slot in the enclosure to enable a tray with a machine cassette placed on it to be inserted into the transfer station through the slot.

In some embodiments, the
transfer station is also configured, after the combined storage tray and machine cassette have been rotated so that the pods in said pod receiving pockets in the tray have been transferred into the corresponding pod receiving pockets in the machine cassette, to rotate the combined machine cassette and storage tray so that the pods in said pod receiving pockets in the machine cassette are transferred back into corresponding pod receiving pockets in the storage tray.

In accordance with yet another embodiment of the invention, there is provided a method for transferring pods, each of which form part of a consumable unit for use with an inhalation device, from a storage tray in which each pod is supported in a pod receiving pocket, to corresponding pod receiving pockets of a machine cassette forming part of a consumable unit manufacturing device, comprising:.

Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings, in which:.

With reference to <FIG>, there is a shown an apparatus <NUM> for transferring a plurality of pods <NUM>, each of which form part of a consumable unit for use with an inhalation device, from a storage tray <NUM> in which each pod <NUM> is supported in a pod receiving pocket 3a, to corresponding pod receiving pockets 4a of a machine cassette <NUM> forming part of a consumable unit manufacturing device <NUM> (see <FIG>). The apparatus <NUM>, according to an embodiment of the invention, may also be used for transferring the pods <NUM>, on which a manufacturing operation has been performed, from the machine cassette <NUM> back into a storage tray <NUM>.

The pods <NUM> are placed in storage trays <NUM> following or during their manufacture at another location. The storage trays <NUM> are suitable for protecting and transporting the pods <NUM>. However, in order to carry out a manufacturing operation on the pods <NUM>, such as filling the pods <NUM> with a particulate material such as tobacco, they need to be transferred to a machine cassette <NUM> which is designed and configured to accurately hold and position the pods <NUM> within a consumable unit manufacturing device <NUM> during the manufacturing steps.

According to an embodiment of the invention, the apparatus <NUM> comprises a receiving station <NUM> and a transfer station <NUM>, which may be mounted to the upper surface 8a of a table <NUM> or other support structure or frame. The table <NUM> has an aperture 8b and the transfer station <NUM> is mounted to the table <NUM> so that a portion of it extends into the aperture 8b below the upper surface 8a. The receiving station <NUM> is mounted to the upper surface 8a adjacent to the aperture 8b.

The receiving station <NUM> comprises a flat surface <NUM> with upstanding guide walls <NUM> along opposite edges that extend away from the transfer station <NUM>. The flat surface <NUM> is a surface onto which one or more storage trays <NUM> of pods <NUM> may be placed and readied prior to moving them into the transfer station <NUM>. The transfer station <NUM> comprises an enclosure <NUM> in the form of a generally cylindrical drum having circular end walls <NUM> and a curved intermediate wall <NUM> extending between the end walls <NUM>. The drum <NUM> is mounted to the table <NUM> such that its longitudinal axis is parallel to, and spaced just above its upper surface 8a, and so that a portion of the drum <NUM> extends through the aperture 8b in the table <NUM>. At least a part of the curved intermediate wall <NUM> extending between the circular end walls <NUM> may be transparent.

Received within the drum <NUM> is a cradle <NUM> which comprises a pair of spaced parallel support plates <NUM>. The cradle <NUM> is mounted for rotation together with the drum <NUM> about the longitudinal axis A-A of the drum <NUM>, although the drum <NUM> could be fixed, in which case the cradle <NUM> would rotate within, and relative to, the drum <NUM>. As will be explained in more detail below, the cradle <NUM> is configured to receive and support a storage tray <NUM> that supports an array of individually spaced pods <NUM>, each pod being loosely received and supported in a pocket 2a in the storage tray <NUM>, together with a machine cassette <NUM> placed on the tray <NUM> over the pods <NUM>. The support plates <NUM> support the storage tray <NUM> and the machine cassette <NUM> placed upon it when the transfer station <NUM> is operated to invert the combined tray <NUM> and machine cassette <NUM> so that the pods <NUM> in said pod receiving pockets 3a in the tray <NUM> are transferred into corresponding pod receiving pockets 4a in the machine cassette <NUM>.

An axle extends along the longitudinal axis A-A of the drum <NUM> through a bearing hub <NUM> at each end of the drum <NUM>. The axle is attached to the drum <NUM>, and to the cradle <NUM>, so that the drum <NUM> and cradle <NUM> rotate in response to rotation of the axle <NUM> about longitudinal axis A-A. Each bearing hub <NUM> is immovably mounted to the table <NUM> via a mounting member <NUM>.

One end of the axle <NUM> extends beyond the edge of the upper surface 8a of the table <NUM> and a drive member <NUM> is attached to a free end of the axle <NUM> to facilitate rotation of the axle by a user. As shown in <FIG>, the drive member <NUM> is a manually rotatable hand wheel 17a. However, it will be appreciated that any other type of drive for rotating the drum <NUM> and the cradle <NUM> may be used, including an electric drive motor.

The mounting member <NUM> closest to the drive member 17a that rotatably mounts the axle and secures the drum <NUM> to the table <NUM>, is provided with first and second buffers <NUM>, <NUM>. A stop element <NUM> is attached to the end wall <NUM> adjacent to the mounting member <NUM> so that one side of the stop element <NUM> contacts the first buffer <NUM> to prevent further rotation of the drum <NUM> when the drum <NUM> is in a first position, and the other side of the stop element <NUM> contacts the second buffer <NUM> when the drum <NUM> has been rotated into a second position. The angle of rotation between the first and second positions may be in the order of <NUM> degrees.

Operation of the apparatus <NUM> of the embodiment of the invention will now be described in more detail with reference to Figures 2A to 2E.

<FIG> shows a top plan view of the receiving station <NUM> of the apparatus <NUM>. A storage tray <NUM> of pods <NUM> has been placed on the flat surface <NUM> of the receiving station <NUM>, between the guide walls <NUM>.

In <FIG>, two storage trays <NUM> are shown placed on the flat surface <NUM> of the receiving station <NUM> in side-by-side relation, between the guide walls <NUM>. However, it will be appreciated that the apparatus <NUM> may be configured to receive one or more trays <NUM>.

With reference to <FIG>, a machine cassette <NUM> has been placed over each storage tray <NUM>. The machine cassettes <NUM> and the trays <NUM> are configured so that a machine cassette <NUM> locates on the tray <NUM> with each individual pocket 4a in the machine cassette <NUM> located over a corresponding individual pocket 3a containing a pod <NUM> in the storage tray <NUM>. The machine cassette <NUM> has a top and a bottom surface. When the machine cassette <NUM> is inserted into the consumable unit manufacturing device <NUM>, it is is inserted with its top surface uppermost. However, it will be understood that, as shown in <FIG>, the machine cassettes <NUM> are placed over the trays <NUM> in an upside down orientation, i.e. with their top surfaces facing the storage trays <NUM> and the pods <NUM> supported within the storage trays <NUM>.

Once a machine cassette <NUM> has been correctly located over each tray <NUM>, the combined storage tray <NUM>, pods <NUM> and the machine cassette <NUM> are inserted together as a single unit into the transfer station <NUM>. As shown in <FIG>, the combined tray <NUM>, pods <NUM> and the machine cassette <NUM> are slid directly from the flat surface <NUM> of the receiving station <NUM> into the transfer station <NUM> in the direction of arrow A.

In an alternate embodiment, the receving station <NUM> may be omitted. In this case, the machine cassette <NUM> may be placed over the tray <NUM> at another remote location before being inserted directly into the transfer station <NUM>.

To facilitate the insertion of the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM> into the transfer station <NUM>, the curved intermediate wall <NUM> of the drum <NUM> is provided with a slot <NUM> extending in an axial direction between the end walls <NUM>. The slot <NUM> is aligned with the flat surface <NUM> of the receiving station <NUM> when the drum <NUM> is in its first position, i.e. when the stop element <NUM> is against the first buffer <NUM>.

When the drum <NUM> is in its first position, the cradle <NUM> located within the drum <NUM> is positioned so that the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM> are pushed through the slot <NUM> into the cradle <NUM>. More specifically, the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM> are pushed into the space between the spaced, parallel support plates <NUM> of the cradle <NUM>. The support plates <NUM> are parallel and spaced from each other by a distance which is only marginally greater than the total height of a combined tray <NUM> containing the pods <NUM> with a machine cassette <NUM> placed upon it so that the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM> are held between the support plates <NUM> without separating when the transfer station <NUM> is operated to invert the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM>.

Next, as shown in <FIG>, the drive member <NUM> is rotated to rotate the drum <NUM> together with the cradle <NUM> and the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM>, out of its first position and into its second position, in which the stop member <NUM> now contacts the second buffer <NUM>. As a result of rotation from the first into the second position, the storage tray <NUM>, pods <NUM> and the machine cassette <NUM> are inverted.

As the pods <NUM> are supported in the pockets 3a in the storage tray <NUM> under their own weight, inversion of the storage tray <NUM> results in each pod <NUM> transferring to a corresponding pocket 4a in the machine cassette <NUM> so that the pods <NUM> are now supported, the other way up, in the machine cassette <NUM>. <FIG> shows a cross section through a portion of a machine cassette <NUM> having a support pocket 4a and a pod <NUM> received in the pocket 4a following transfer from a storage tray <NUM> using the apparatus <NUM> according to an embodiment of the invention. Inversion of the storage tray <NUM> may occur when the combined storage tray <NUM>, pods <NUM>, and machine cassette <NUM> are turned over, i.e. rotated through an angle of <NUM> degrees. However, rotation through less than <NUM> degrees may be sufficient for the weight of the pods <NUM> to be transferred from the storage tray <NUM> to the machine cassette <NUM>.

It will be understood that, when a machine cassette <NUM> is placed over a tray <NUM>, the pods <NUM> supported in the pod receiving pockets 3a of the storage tray <NUM> may each extend from a pocket into a pocket of the machine cassette <NUM>, i.e. a part of each pod may be received in a pocket 3a in the storage tray <NUM> and, at the same time, another part of the pod <NUM> may be received in a corresponding pocket 4a in the machine cassette <NUM>. This means that, when the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM> are inverted, there is little or no movement of the pods <NUM> and their weight is simply transferred from the storage tray <NUM> to the machine cassette <NUM>. However, it is also possible for a pod <NUM> to move, i.e. drop out of a pocket 3a in which it is supported on the storage tray <NUM>, and into a corresponding pocket 4a in the machine cassette <NUM>, when the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM> are inverted using the apparatus <NUM>.

When the pods <NUM> are in the machine cassette <NUM>, they are held in an upright orientation, with their open ends <NUM> directed vertically upwards so that they can be provided with particulate material and a closure <NUM> (see <FIG>) can be positioned on, and secured to, the pods <NUM>. <FIG> shows how one supporting pocket 4a is shaped to receive and support a pod <NUM>. In particular, each supporting pocket 4a is shaped to receive and support a mouthpiece portion 2a of a pod <NUM> so that the open end <NUM> of the pod <NUM> is directed upwards.

Optionally, the machine cassette <NUM> may include one or more handles <NUM> for manual lifting and moving of the machine cassette <NUM>.

Once the storage tray <NUM>, pods <NUM> and machine cassette <NUM> have been inverted using the transfer station <NUM> of the apparatus <NUM>, the combined storage tray <NUM>, pods <NUM> and machine cassette <NUM> may be slid back out of the transfer station <NUM> onto the flat surface <NUM> of the receiving station <NUM>. As the weight of the pods <NUM> is no longer supported by the storage tray <NUM>, the storage tray <NUM> may be lifted away to leave the machine cassette <NUM> with the pods <NUM> supported therein. The machine cassette <NUM> together with the pods <NUM> may now be removed from the receiving station <NUM> and inserted into the consumable unit manufacturing device <NUM> so that a manufacturing operation may subsequently be performed on each of the pods <NUM> supported by the machine cassette <NUM>.

It will be appreciated that, once the manufacturing operation or operations have been completed, the pods <NUM> may also be transferred from the machine cassette <NUM> back onto the storage trays <NUM> using the same apparatus <NUM>, should this be required.

The pods <NUM> may form part of a consumable unit of an inhalation device which is of a size and shape suitable to be held by an adult consumer. The consumable unit may comprise a removable atomizer cartridge which has an atomizer for atomizing a consumable liquid held in the cartridge, and a charge <NUM> of particulate aerosolisable tobacco. A charge of tobacco <NUM> may be received in a pod <NUM> having a mouthpiece portion 2a, to which a closure <NUM> for retaining the charge of tobacco <NUM> within the pod <NUM> is attached, as demonstrated by <FIG>.

The user is able to change the atomizer cartridge and the charge of tobacco <NUM> when they need replacement, i.e. when the consumable liquid runs out, or when the charge of tobacco is exhausted.

In use, an operating unit delivers energy to the atomizer cartridge under the control of the consumer as the consumer draws air through the inhalation device. The liquid in the atomizer cartridge is atomized to form an aerosol and the particulate tobacco material is volatilized, releasing volatile flavours. The air inhaled from the inhalation device therefore delivers an aerosol of atomised liquid from the atomizer cartridge to the consumer together with the vapour generated by heating the particulate tobacco material.

In addition to a mouthpiece portion 2a, the pod <NUM> of <FIG> comprises an axially-extending open-ended section <NUM>. In this example, the open-ended section <NUM> has an elliptical radial cross-section. The mouthpiece portion 2a is connected to the open-ended section <NUM> by ultrasonic welding, induction welding or any other suitable method. Alternatively, the mouthpiece portion 2a may be integrally formed with the open-ended section <NUM>, for example by injection moulding.

The closure <NUM> may be in the form of a perforated screen. The closure <NUM> is composed for example of a mesh or foil or a moulding of plastics material. Perforations in the closure <NUM> allow vapour to pass in the axial direction downstream through the pod <NUM> towards the mouthpiece portion 2a.

The manufacturing steps carried out on pods <NUM> whilst they are supported in a machine cassette <NUM> may include providing the pod <NUM> with a dose of particulate material through the open ended section <NUM>, positioning a closure <NUM> over the open-ended section <NUM> of the pod <NUM>, and securing the closure <NUM> to the pod <NUM>.

The manufacturing steps may be carried out on a number of empty pods <NUM> using the manufacturing device <NUM> shown in <FIG>, or a series of devices <NUM> similar to that shown in <FIG>. For example, one device <NUM> may be a dosing station, a second device <NUM> may be a closure positioning station, and a third device <NUM> may be a closure securing station. The machine cassette <NUM> supporting a plurality of pods <NUM> is inserted into each device <NUM> in turn so that a charge of tobacco <NUM> may be dosed into the pod <NUM>, a closure <NUM> may be positioned on the open-ended section <NUM> of the pod <NUM>, and the closure <NUM> may be secured to the pod <NUM>.

The manufacturing device <NUM> of <FIG> may comprise, for example, a machine cassette support <NUM> that comprises rails <NUM> to support the machine cassette <NUM> supporting a plurality of pods <NUM>. The machine cassette <NUM> can be inserted into the dosing station by sliding the machine cassette <NUM> onto the rails <NUM>, which support opposing sides of the machine cassette <NUM>. The machine cassette support <NUM> may also include a stop against which the machine cassette <NUM> abuts when inserted into the machine cassette support <NUM>. The machine cassette support <NUM> ensures that the machine cassette <NUM>, and the pods <NUM>, are accurately and reliably positioned and supported within the manufacturing device <NUM>. <FIG> shows a part of the dosing station of <FIG>, with a machine cassette <NUM> supported on the rails <NUM> of the machine cassette support <NUM>.

The machine cassette <NUM> provided with a plurality of empty pods <NUM> is moved through the apparatus of <FIG> so that the pods <NUM> are provided with a dose of particulate material and the closures <NUM> are positioned and secured while the pods <NUM> are held in the machine cassette <NUM>.

As used herein, reference to a charge of tobacco refers to a material that includes tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The particulate material may also include a non-tobacco material. In some examples, the charge is a charege of particulate material that is powder-like, and in alternative examples may be formed by cutting of shredding a material into smaller particles. In some examples, the charge of tobacco may include a so-called 'cut rag', which is formed by shredding or cutting tobacco into small particles. The charge of tobacco may be produced by extruding a tobacco slurry and cutting the extruded material into particles.

It will be appreciated that the pods <NUM> described above may be used in devices other than a inhalation device as described. For example, the device may releases compounds from the charge of tobacco without burning, such as tobacco heating products. The inhalation device may be a heating device which releases compounds by heating, but not burning, a substrate material, for example the charge of tobacco.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention as defined by the appended claims may be practiced and provide for superior method and apparatus for transferring pods, each of which form part of a consumable unit for use with an inhalation device, from a storage tray in which each pod is supported in a pod receiving pocket, to corresponding pod receiving pockets of a machine cassette forming part of a consumable unit manufacturing device. The advantages and features of the disclosure are of a representative sample of embodiments only.

Claim 1:
Apparatus for transferring pods (<NUM>), each of which form part of a consumable unit for use with an inhalation device, from a storage tray (<NUM>) in which each pod (<NUM>) is supported in a pod receiving pocket (3a), to a consumable unit manufacturing device (<NUM>),
characterised in that the apparatus is adapted to transfer pods from said pod
receiving pockets to corresponding pod receiving pockets of a machine cassette of said consumable unit manufacturing device, and in that
the apparatus comprises:
a transfer station (<NUM>) to receive the storage tray (<NUM>) and a machine cassette (<NUM>) placed over the storage tray (<NUM>) wherein the pods (<NUM>) are received in the storage tray (<NUM>), the transfer station (<NUM>) being configured to rotate the combined storage tray (<NUM>) and machine cassette (<NUM>) so that the pods (<NUM>) in said pod receiving pockets (3a) in the tray (<NUM>) are transferred into corresponding pod receiving pockets (4a) in the machine cassette (<NUM>).