Patent Application
20230404171
Electronic smoking consumption, or “vaping,” is an activity that has seen a recent increase in popularity. There are currently a large variety of vaping devices and liquids available on the market. One way in which vaping liquids are consumed is by a user inhaling a vaporized aerosol from a cartridge. This vaporized aerosol may be generated by heating a liquid solution stored in the cartridge. Aspects of the invention include an apparatus and method that increases the efficiency of packaging multiple vaping cartridges at one time.
In one aspect, a vaping liquid packaging system is comprised of a first tray formed of deformable material for holding vaping device bodies, the first tray having a plurality of voids, where each of the voids hold a portion of a vaping device body to be filled with a substance. The first tray and the vaping device bodies are covered by a first cover. The system may also include a second tray formed of deformable material for holding vaping device mouthpieces, the second tray having a plurality of voids allowing the vaping device mouthpieces to be vertically aligned with the vaping device bodies of the first tray, with each of the voids holding a portion of a vaping device mouthpiece to cap a corresponding vaping device body. The first tray is capable of being placed over a jig having a plurality of jig voids corresponding to the voids for holding the vaping device bodies. The jig voids comprise a stepped portion within the jig voids, with the stepped portion forming a concentric circle with the jig voids. The second tray is capable of being placed over the first tray to allow a press to exert even pressure on the vaping device mouthpieces of the second tray to press-fit the vaping device mouthpieces onto the corresponding vaping device bodies, where the stepped portion of the jig void is for transferring pressure from the vaping device mouthpieces to a corresponding bottom side of a tank portion of the vaping device bodies when the press exerts even pressure on the vaping device mouthpieces.
According to another aspect, a vaping device packaging system comprises a first tray for holding vaping device bodies, with the first tray having a plurality of voids for holding a portion of a vaping device body to be filled with a substance. The first tray and the vaping device bodies are covered by a first cover. The system also includes a second tray for holding vaping device mouthpieces, the second tray having a plurality of voids allowing the vaping device mouthpieces to be vertically aligned with the vaping device bodies of the first tray. Each of the voids hold a portion of a vaping device mouthpiece to cap a corresponding vaping device body. The first tray is capable of being placed over a jig having a plurality of jig voids corresponding to the voids for holding the vaping device bodies.
According to another aspect, a method is provided for packing vaping devices. A method of packaging vaping devices can comprise selecting a first tray for holding vaping device bodies, the first tray having a plurality of voids, and inserting a portion of a vaping device body into each of the plurality of voids of the first tray. The method may also include covering the first tray and the vaping device bodies with a first cover and selecting a second tray for holding vaping device mouthpieces, the second tray having a plurality of voids. The method may further include inserting a portion of a vaping device mouthpiece into each of the plurality of voids in the second tray.
According to another aspect, a method is provided for filling vaping devices. The method may include selecting a first tray formed of deformable material for holding vaping device bodies, the first tray having a plurality of voids, and each of the voids for holding a portion of a vaping device body to be filled with a substance. The method may also include selecting a second tray formed of deformable material for holding vaping device mouthpieces, the second tray having a plurality of voids allowing the vaping device mouthpieces to be vertically aligned with the vaping device bodies of the first tray. Additionally, the method may include placing the first tray within a jig having a plurality of jig voids corresponding to the voids for holding the vaping device bodies, and wherein the jig voids comprise a stepped portion within the jig voids, the stepped portion forming a concentric circle with the jig voids. Further, the method may include aligning the second tray over the first tray and pressing the vaping device mouthpieces onto the vaping device bodies with a press, where the press exerts even pressure on the vaping device mouthpieces of the second tray to press-fit the vaping device mouthpieces onto the corresponding vaping device bodies, and the stepped portion of the jig void transfers pressure from the vaping device mouthpieces to a corresponding bottom side of a tank portion of the vaping device bodies when the press exerts even pressure on the vaping device mouthpieces. Still further, the method may include inserting a needle through each of the vaping device mouthpieces; puncturing a seal within each of the vaping device bodies using the needle, where the needle exerts even pressure on the seal of the vaping device bodies, the stepped portion of the jig void for transferring pressure from the seal to the corresponding bottom side of the tank portion of the vaping device bodies when the press exerts even pressure on the seal; and injecting the vaping device bodies with the substance.
According to another aspect, a method is provided for filling vaping devices. The method may include selecting a first tray formed of deformable material for holding vaping device bodies, the first tray having a plurality of voids, and each of the voids for holding a portion of a vaping device body to be filled with a substance. Additionally, the method may include placing the first tray within a jig having a plurality of jig voids corresponding to the voids for holding the vaping device bodies, and wherein the jig voids comprise a stepped portion within the jig voids, the stepped portion forming a concentric circle with the jig voids. The method may include inserting a needle through each of the vaping device mouthpieces; puncturing a seal within each of the vaping device bodies using the needle, where the needle exerts even pressure on the seal of the vaping device bodies, the stepped portion of the jig void for transferring pressure from the seal to the corresponding bottom side of the tank portion of the vaping device bodies when the press exerts even pressure on the seal; and injecting the vaping device bodies with the substance.
With reference to
A receiver tray or jig 10 may have several holes, or a plurality of jig voids 15, with each hole 15 being configured to hold a single vaping cartridge. A jig or receiver tray 10 can be any shape or size and includes rectangular trays, square trays, or any other structure to hold one or more vaping device bodies and guide the vaping device bodies as they are filled and capped. The jig voids 15 in a receiver tray or jig 10 may be spaced at substantially regular intervals in some embodiments. For example,
In one aspect, each hole or jig void 15 is designed to have a circular cross-sectional profile with varying diameters. In other embodiments, the jig voids 15 have other cross-sectional shapes to hold or partially hold vaping cartridges or all-in-one vaping systems that have varying shapes and sizes. Referring to
Referring to
The stepped portion 20 of the hole 15 may have a diameter that is from about 0.5 mm to about 1 mm, or from about 0.6 mm to about 0.9 mm, or from about 0.7 mm to about 0.8 mm. During a capping or filling process, the bottom side 57 of a vaping device body may be damaged if the capping pressure from the press is transferred to the bottom side 57 of the vaping device body 50. If a stepped portion 20 is provided within the jig void 15, within a special range, the stepped portion 20 can transfer the capping pressure from the press to the bottom side 52 of the vaping device body tank portion 55, rather than the bottom side 57 of the vaping device body 50. This can reduce damage to the bottom side 57 of the vaping device body 50 during capping. As best seen in
The receiver tray or jig 10 may be configured to hold multiple cartridges or vaping device bodies 50 so the vaping device bodies 50 may be filled with vaping solution (also referred to as “vape juice” or “oil(s)”) or other substance. The vaping device bodies 50 may be filled manually, or automatically via a robotic machine.
A robotic machine will typically exert a pressure on the vaping device bodies 50 or a portion of the vaping device bodies 50 during a filling process (e.g., an internal seal, a center post, or other components of the vaping device bodies). For example, a robotic machine may be outfitted with a press equipped with a needle to inject vaping solution into the vaping device bodies 50. Similar to the pressure exerted during a capping process, the bottom side 57 of a vaping device body may be damaged if the pressure from the robotic filling machine is transferred to the bottom side 57 of the vaping device body 50 while filling the vaping device body 50. Incorporating the stepped portion 20 into the jig void 15 allows for a transfer of the filling pressure from the filling machine to the bottom side 52 of the vaping device body tank portion 55, rather than to the bottom side 57 of the vaping device body 50.
In one aspect, the vaping device bodies 50 may be loaded into the receiver tray or jig 10 individually. In another aspect, the vaping device bodies 50 may be preloaded into a first tray 40 (a vaping device body tray) and then placed in the jig 10 or receiver tray 10. The first tray 40 is for holding vaping device bodies 50, or at least a portion of a vaping device body. The first tray 40 may define holes or a plurality of voids 44 that physically and spatially match the hole arrangement on the jig 10 or receiver tray. That is, each of the vaping device bodies 50 in the first tray 40 may correspond to a jig void 15.
The first tray may 40 be formed of any suitable material and in some configurations the material is a deformable material, such as a foam, etc., to provide cushioning for the vaping device bodies 50 during transportation, filling, and capping. The plurality of voids 44 in the first tray 40 may be sized and shaped to receive a portion of a vaping device body 50, or a portion of a cartridge body. A pictorial representation of a complete set of vaping device bodies 50 being loaded or placed over a jig 10 using a first tray 40 is shown in
The first tray 40 may be loaded or filled with vaping device bodies 50 such that the bottom portion 57 of the vaping device body 50 (for being placed into the jig voids 15 of the jig 10) extend below the first tray 40, and the top portion of the vaping device body 50 (for having mouthpieces capped over) extend above the first tray 40.
The first tray 40, along with the vaping device bodies 50 loaded into the first tray 40, can be provided with a cover (not illustrated). In some embodiments, the cover may simply be a box for receiving the first tray 40 loaded with vaping device bodies 50. In some embodiments, the cover may be a sealed cover to protect the vaping device bodies 50 from any dust, etc., during transport. For example, a sealed plastic cover may surround the first tray 40 and the vaping device bodies 50 loaded into the first tray 40. This may also simplify packaging to facilitate the filling and capping process. In other configurations, the cover may be a foam lid, or formed of other materials that protect the vaping device bodies during transport from any damage, dust etc.
Once the jig 10 has been fully loaded with the vaping device bodies of the first tray 40, an optional step is to place an alignment plate or stabilizer plate 59 on top of the vaping device bodies 50. In one aspect, the stabilizer or alignment plate 59 is a rigid plate (e.g., a plastic or metal plate) that may be configured with holes that physically and spatially match the hole arrangement on the receiver tray 10. Each hole on the stabilizer plate 59 may be diametrically matched with the diameter of a cartridge or vaping device body 50. Each hole on the stabilizer plate 59 may also physically grasp (i.e., fasten on to) an area towards the top end of each cartridge and hold the cartridge in place. The stabilizer plate 59 ensures that each cartridge is substantially immobile with respect to each other cartridge and the receiver tray 10. In combination, the stabilizer plate 59 and the receiver tray 10 provide a rigid support for an array of cartridges to be processed (i.e., filled and capped).
Once the alignment plate 59 has been installed, the vaping device bodies 50 may be filled. The filling process may be accomplished manually or automatically (e.g., by using a robotized filling machine).
Each vaping device body 50 or cartridge may be designed to be consistent with the filling process. For example, a cartridge may have an annular cylindrical cavity that accepts the vaping solution. For this process, the needle of a robotized filling machine may be inserted into the annular cylindrical cavity, as shown in
As before, during the filling process, the needle of the robotized filling machine may apply pressure to the vaping device bodies 50 in order to fill the annular cylindrical cavity. For example, the needle of the robotized filling machine may puncture a seal (e.g., a self-sealing seal) covering the annular cylindrical cavity in order to fill the cavity. When the vaping device bodies 50 are arranged within the jig 10 and the jig voids 15, this puncture pressure is transferred (via the stepped portion 20) from the filling machine to the bottom side 52 of the vaping device body tank portion 55, rather than to the bottom side 57 of the vaping device body 50.
The bottom side 57 of the vaping device body 50 is placed facing downwards in the jig voids 15 of the jig 10. The threaded portion of the bottom end 57 may be used to interface (i.e., screw into) a power source, battery, etc. The tank portion 55 can also have a metal band surrounding the bottom 52 of the tank portion 55, or a cylindrical metallic portion of the cartridge at the lower end of the cartridge. This band or metallic portion is configured to be wider than the threaded portion of the bottom end 57 of the cartridge 50. That is, the tank portion 55 of the vaping device body 50 is wider than the threaded bottom portion 57 of the vaping device body 50.
In one aspect, the bottom 52 of the tank portion 55 of the vaping device body 50 is used to bear a force associated with a capping process, to prevent any damage to the threaded portion 57 of the cartridge or bottom side of the vaping device body 50. In one aspect, when a vaping device body 50 is inserted into a jig void 15 in the jig 10, the bottom side 52 of the tank portion 55 of the vaping device body 50 rests on the stepped portion 20 of the jig void 15. In other words, the bottom side 52 of the tank portion 55 rest on the surface where the first portion 28 of the jig void 15 transitions to the second portion 32 of the jig void 15. During a capping process, when a vertical force is exerted on a cap to affix the vaping device mouthpiece onto the vaping device body 50, the force is transmitted to bottom side 52 of the tank portion 55 that rests on the stepped portion 20 or circular edge surface, rather than on the threaded portion 57 (which would be the case if the stepped portion 20 or circular edge surface was not present). The bottom side 52 of the tank portion 55 of the vaping device body 50 is better able to bear the force of the capping process, and that this reduces damage to the threaded portion 57 of the cartridge 50.
In some embodiments, after the vaping device bodies 50 have been filled, the next stage is to install a cap (vaping device mouthpiece) on each vaping device body 50.
In some embodiments, the vaping device bodies 50 are filled after they have been capped with vaping device mouthpieces 85. The vaping device mouthpieces 85 may be press-fit onto the vaping device bodies 50 using a press that is capable of exerting even pressure onto the vaping device mouthpieces 85. In other embodiments, the vaping devices may come from the manufacturer with the mouthpieces 85 already in place. The vaping device mouthpieces 85 may include a vapor outlet that is fluidly connected with the annular cylindrical cavity of the vaping device bodies 50. A needle may be inserted through the vapor outlet of the vaping device mouthpieces 85 to fill the annular cylindrical cavity with vaping solution. The needle may be inserted using a press or filling machine that is also capable of exerting even pressure through the vaping device mouthpieces 85.
During this filling process, the needle of the robotized filling machine may apply pressure to the vaping device bodies 50 in order to fill the annular cylindrical cavity. For example, the needle of the robotized filling machine may puncture a seal (e.g., a self-sealing seal) covering the annular cylindrical cavity in order to fill the cavity. When the vaping device bodies 50 are arranged within the jig 10 and the jig voids 15, this puncture pressure is transferred (via the stepped portion 20) from the press or filling machine to the bottom side 52 of the vaping device body tank portion 55, rather than the bottom side 57 of the vaping device body 50.
Air within the annular cylindrical cavity may exit through the center lumen 53 as it is displaced by fluid filling the annular cylindrical cavity. Specifically, the center lumen 53 may include one or more voids in fluid communication with the annular cylindrical cavity. Air within the annular cylindrical cavity may pass through the one or more voids of the center lumen 53, through an interior channel of the center lumen 53, and out of the vapor outlet of the vaping device mouthpieces 85.
In some embodiments, the jig 10 with the capped vaping device bodies 50 may be inverted or flipped over, such that the vaping device mouthpieces 85 are downwardly oriented. The capped vaping device bodies 50 can then be filled using the same process, where a needle is inserted through the vaping device mouthpieces 85 (now in a downward or inverted position) to fill the annular cylindrical cavity with vaping solution. Inverting the capped vaping device bodies 50 may better facilitate an exit flow of air during the filling process. This inversion filling can also simplify the process of capping, as capping can be done by the manufacturer rather than the local filler.
In one aspect, a mechanical press may be used to fasten each vaping device mouthpiece 85 onto a corresponding vaping device body 50. The second tray 80 is capable of being placed over the first tray 40 to allow a press to exert even pressure on the vaping device mouthpieces 85 of the second tray 80 to press-fit the vaping device mouthpieces 85 onto the corresponding vaping device bodies 50. During the press, in embodiments with stepped portions 20 of the jig void 15, the stepped portion 20 of the jig void 15 transfers pressure from the vaping device mouthpieces 85 to a corresponding bottom side 52 of a tank portion 55 of the vaping device bodies 50 when the press exerts even pressure on the vaping device mouthpieces 85.
In some embodiments, the number of vaping device bodies 50 present in the first tray 40 (and the corresponding number of vaping device mouthpieces 85 present in the second tray 80) may be optimized based on the pressure need to cap the vaping device bodies 50. For example, some vaping device bodies 50 require from about 15 pounds per vaping device body to about 17 pounds per vaping device body 50. A standard press is able to exert a varying amount of force based on how the press is adjusted. In one embodiment, the press is adjusted to exert between around 800 pounds to around 1000 pounds per press. For vaping devices bodies 50 that require from about 15 pounds per vaping device body to about 17 pounds per vaping device body, the number of vaping devices present in the first tray 40 may be 50 to ensure that all 50 devices will be capped by a single press, but also not exert undue excess force on the vaping device bodies 50. It has been found that undue capping force on the vaping device bodies 50 can cause structural damage, leading to leaks and malfunctions.
In other examples, the press can be adjusted to provide from about 1.5 tons to about 2 tons of pressure. Other vaping device bodies 50 may require a higher force to cap. For example, some vaping device bodies 50 that include a battery (commonly known as an “all-in-one”) may require a higher force to cap and are also designed to withstand a higher capping pressure. For instance, some vaping device bodies may need about 65 pounds to about 70 pounds of pressure per vaping device body 50 (30 kg). These vaping device bodies 50 may be provided in a first tray 40 having approximately 30 voids (65-70 lbs×30 vaping device bodies per pack equals 1950 pounds of pressure required for a single press to cap all 30 vaping device bodies 50).
To fill a cartridge, blunt tip needle may be inserted into the space between the center airway tube and the inner wall of the cartridge (i.e., into the annular cylindrical cavity). A recommended oil temperature range at time of filling may be 90° F.-130° F. In one aspect, 1.4 mm may be a preferred needle width, with 1.63 mm being the maximum needle width allowed. An 18-gauge needle is 1.27 mm wide. For polyresin cartridges, 14-gauge needles may be used.
For polyresin cartridges, care must be taken so as to not fill above the bottom of the metal band on the open end (top) of the cartridge. For glass cartridges, a user may need to make sure there is no fluid in the top 4 mm of the glass tank. As cautionary measures, a user must ensure that:
A user may need to be aware that the silicone end cap (e.g., a mouthpiece) can be punctured when too much pressure is applied during capping.
Immediately after filling, the cartridge may be capped with the mouthpiece until the mouthpiece is fully seated. In one aspect, a filled cartridge may need to be capped within three minutes after it has been filled. A shorter time may be recommended for thinner oils. Failure to cap within the appropriate amount of time can lead to leakage and clogging.
Cartridges should be allowed to stand for at least 30 minutes before use. During this time, fluid is priming the atomizer. The rate that the atomizer saturates is dependent upon the viscosity of the fluid. More viscous fluids will require more time. The appropriate aperture setting must be used according to the viscosity of the fluid.
In one aspect, cartridges made from different materials may require different workflows. Instructions to cap different cartridges are as follows.
After filling, the mouthpiece is pressed into the cartridge until it is fully seated. Mechanical assistance is required to fully seat the mouthpiece. About 45 kgF of force is needed to cap a single cartridge. The cartridge must be upright and centered with the mouthpiece when pressing down. Do not use a hammer or mallet. Once the mouthpiece is fully seated, it cannot be removed without damaging the cartridge or the mouthpiece. Caution: failure to insert the mouthpiece immediately after filling may cause leakage. Do not twist or rotate the mouthpiece while it is being inserted. A misaligned cartridge or pressing at an angle will cause uneven pressure which may lead to leakage. Make sure the cartridge is centered to the arbor press.
After filling, screw-on the mouthpiece until it is fully seated. When using a mechanical capping tool for threaded mouthpieces, the torque must be below 3.5 kgF/cm. Caution: failure to cap the mouthpiece immediately after filling may cause leakage. Excessive torque may pull the center airway tube off of the base.
After filling, insert the mouthpiece, pressing lightly to align it on the center post. After making sure the mouthpiece is properly aligned and straight, press the mouthpiece down vertically (not at an angle) using level, even pressure until a click is heard indicating that it is fully seated. It is possible to seat the mouthpiece by hand, but a light-duty arbor press and jig is recommended. Do not use a hammer or mallet. About 7-8 kg F of force is needed to cap a single cartridge. A misaligned mouthpiece, off-center arbor press, or pressing at an angle can cause the mouthpiece hooks to not engage onto the center post. This can lead to damage, improper seal, leakage, and/or cracking of the glass tank. Once the mouthpiece is fully seated, it cannot be removed without damaging the cartridge or the mouthpiece. Caution: Do not reuse a mouthpiece that failed to seat on the first try. Do not twist or rotate the mouthpiece while it is being inserted. Do not press down even at a slight angle.
Aspect 1: A vaping device packaging system comprising:
Aspect 2: The vaping device packaging system of Aspect 1, wherein the plurality of jig voids have a diameter sized to receive a bottom side of the vaping device body and wherein the stepped portion of the jig void has a diameter to receive a tank bottom side.
Aspect 3: The vaping device packaging system of Aspect 1 or Aspect 2, wherein the stepped portion of the jig void has a diameter of from about 0.7 mm to about 0.9 mm.
Aspect 4: The vaping device packaging system of any one of Aspects 1-3, wherein the second tray and the vaping device mouthpieces are covered by a second cover.
Aspect 5: The vaping device packaging system of any one of Aspects 1-4, wherein the jig voids are circular.
Aspect 6: The vaping device packaging system of any one of Aspects 1-5, further comprising at least one first tray in a first package, at least one second tray in the first package, and at least one jig in the first package.
Aspect 7: The vaping device packaging system of any one of Aspects 1-6, wherein the second tray is capable of being placed over the first tray to allow a press to exert even pressure on the vaping device mouthpieces of the second tray to one-way press-fit the vaping device mouthpieces onto the corresponding vaping device bodies.
Aspect 8: The vaping device packaging system of any one of Aspects 1-7, wherein the first tray comprises five rows of ten voids.
Aspect 9: The vaping device packaging system of any one of Aspects 1-8, wherein the first tray is capable of holding a number of vaping device bodies to allow the press to exert from around 200 pounds of pressure to around 900 pounds of pressure per press to press-fit the vaping device mouthpieces onto the corresponding vaping device bodies with a single press.
Aspect 10: A vaping device packaging system comprising:
Aspect 11: The vaping device packaging system of Aspect 10, wherein at least one of the plurality of jig voids comprises a stepped portion forming a concentric circle within the plurality of jig voids.
Aspect 12: The vaping device packaging system of Aspect 10 or Aspect 11, wherein the second tray is capable of being placed over the first tray to allow a press to exert even pressure on the vaping device mouthpieces of the second tray to press-fit the vaping device mouthpieces onto the corresponding vaping device bodies.
Aspect 13: The vaping device packaging system of any one of Aspects 10-12, wherein the stepped portion of the jig void prevents pressure from being transferred from the vaping device mouthpieces to a bottom side of the vaping device bodies when the press exerts an even pressure on the vaping device mouthpieces.
Aspect 14: The vaping device packaging system of any one of Aspects 10-13, wherein a distance from an outer diameter of the jig void to an inner diameter of the stepped portion is about 0.7 mm to about 0.9 mm.
Aspect 15: The vaping device packaging system of any one of Aspects 10-14, wherein the voids of the second tray are vertically alignable with the corresponding voids of the first tray.
Aspect 16: The vaping device packaging system of any one of Aspects 10-15, wherein the second tray and the vaping device mouthpieces are wrapped in a second cover.
Aspect 17: The vaping device packaging system of any one of Aspects 10-16, wherein the first tray and second tray are formed of deformable material.
Aspect 18: A method of packaging vaping devices, the method comprising:
Aspect 19: A system for filling and capping vaping devices, the system comprising:
Aspect 20: The system of Aspect 19, further comprising an alignment plate defining a plurality of voids, each of the plurality of voids for holding a portion of the vaping device bodies, the plurality of voids aligning vertically with the plurality of voids of the first tray and the jig.
This application is a continuation of U.S. application Ser. No. 18/074,422, now U.S. Pat. No. 11,744,294, filed Dec. 2, 2022 and entitled “CARTRIDGE PACKAGING SYSTEMS AND METHODS,” (the '422 Nonprovisional Application) which claims priority to U.S. Provisional Patent Application No. 63/285,323 filed Dec. 2, 2021 (the '323 Provisional Application). The entire disclosures of the '422 Nonprovisional Application and '323 Provisional Application are incorporated herein.
| Number | Date | Country | |
|---|---|---|---|
| 63285323 | Dec 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 18074422 | Dec 2022 | US |
| Child | 18241533 | US |
