HK1237606B - A method of assembling a tubular simulated cigarette - Google Patents

Description

Method for assembling tubular simulated cigarette

This application is a divisional application of the invention patent application with application date of March 25, 2014, application number 201480017892.4 (international application number PCT/GB2014/050941), and invention name “Method for assembling tubular simulated cigarettes”.

Technical Field

The invention relates to a method for assembling a simulated cigarette.

Background Art

The applicant has proposed a simulated cigarette having a housing containing a reservoir of an inhalable composition, the reservoir having an outlet selectively closed by a breath-operated outlet valve. The outlet opens to dispense the composition from the reservoir when a user draws on the outlet end.

A simulated cigarette of this type is disclosed in WO 2011/107737. This document requires a wick that fills a substantial portion of the reservoir in order to ensure that sufficient composition is provided to the reservoir outlet regardless of the orientation when the outlet valve is opened.

However, wicks are undesirable because the large surface area presented to the composition by the wick increases the tendency of the wick material to dissolve into the composition.

DE4030257 discloses a tube extending a short distance from the outlet end of a reservoir. The tube is flexible and has a weight at its inlet end such that it is loaded towards the bottom of the reservoir regardless of its orientation. This document does not disclose how to assemble a simulated cigarette in practice.

In order to be a successful commercial product, it is important that the simulated cigarette can be easily assembled in a manner suitable for large-scale production.

Summary of the Invention

The present invention aims to provide a method of assembling cigarettes which solves the problems of the prior art and is suitable for large-scale production.

According to the present invention, there is provided a method for assembling a tubular simulated cigarette, the method comprising:

A method for assembling a tubular simulated cigarette, the method comprising:

a) providing an elongated hollow housing having an intake end and a refill end;

b) inserting an outlet valve tube from the refill port, the outlet valve tube being open at a proximal end thereof and having an outlet orifice at a distal end thereof, such that the outlet orifice is adjacent to the suction port;

c) inserting a dip tube from the refill port such that the distal end of the dip tube is in fluid communication with the proximal end of the outlet valve tube;

d) inserting a support member from the refill end to support the proximal end of the dip tube within the housing;

e) inserting a refill valve into the refill end and securing the refill valve in place such that the housing forms a composition reservoir in the region of the simulated cigarette, the dip tube placing the reservoir in fluid communication with the outlet orifice when the outlet valve tube is open, and the refill valve permitting selective communication with the reservoir;

f) inserting a valve element into a recess in a side of the housing such that the valve element is positioned to selectively close the outlet valve tube;

g) inserting the breath-operated valve actuator into the recess from the side; and

h) Applying a cover to the recess.

The present invention inserts several components into the refill end of the cigarette and inserts several other components through recesses located in one side of the housing. This provides for simple assembly, as the components can be easily guided into position without interfering with each other. Furthermore, the insertion of a support member to support the proximal end of the dip tube provides a simple way to hold the dip tube in the desired position. Thus, the cigarette can be easily assembled with all components securely positioned.

It is possible that one or more of the outlet valve tube, the dip tube, the support member, and the refill valve are integral or assembled as a subassembly prior to insertion into the housing. For example, the outlet valve tube and the dip tube may be integrally formed, or the support member and the refill valve may be inserted as a single unit. However, preferably, steps b) to e) are separate and continuous.

Steps f) to h) may be separate and consecutive. Preferably, however, the valve element and the breath-operated valve actuation mechanism are integral and inserted in a single step.

Steps b) through e) required for inserting components into the refill port can be performed before or after steps f) through h) associated with the side opening. However, step f) is preferably performed after step b) so that the outlet valve tube is in place before the valve element is in place. This prevents the valve element from blocking or potentially damaging the outlet valve tube while it is being inserted.

The outer surface of the housing and the outer surface of the cover can themselves provide the outer surface of the simulated cigarette. However, preferably, after step h), the method further comprises adhering a packaging to the assembly, the packaging comprising: a paper or paper-like layer; and a polymer film protecting the paper or paper-like layer. With this packaging, the cover can be fixed to the housing without being separately fixed, as the cover can be held in place by the packaging, although it is preferred that the cover is at least temporarily fixed in place before the packaging is applied. More preferably, the cover is permanently fixed by adhesive, welding, or other physical or chemical bonding. As disclosed in WO2011/117580, this packaging gives the simulated cigarette the look and feel of a cigarette.

The components inserted at the refill end may be fixed in place separately. However, preferably, the step of fixing the refill valve in place maintains the support, the dip tube and the outlet valve in place. Thus, there is no need to fix these components separately.

The refill valve may be held in place by welding, adhesive or snap-fitting into place.Preferably, the refill valve is sonic welded to the housing to form an airtight seal.

The outlet valve tube may be provided with an orifice into which the valve element selectively enters to effectively operate as a gate valve. However, preferably, the outlet valve tube is a deformable tube, and the valve element is arranged to selectively squeeze the outlet valve tube. Such a squeeze valve provides a simple and reliable way of controlling flow from the reservoir.

The breath operated valve actuation mechanism may be of any suitable design but preferably comprises a diaphragm which is indented by the user drawing on the outlet port.

Because the support member allows the proximal end of the diptube to be supported within the reservoir, its position can be fixed for optimal efficiency. The proximal end of the diptube can be supported toward the refill end of the housing to maximize the amount of composition dispensed in the "top-down" orientation, the most common inhalation position. However, preferably, the proximal end of the diptube is positioned so that the major axis of the simulated cigarette passes through it, and so that the diptube inlet is positioned axially at the center of the reservoir's volume, i.e., at the center of 50% of the reservoir's volume. This positions the tube orifice inlet toward the center of the reservoir, allowing approximately 50% of the liquid to be dispensed regardless of the cigarette's orientation. This allows approximately the same amount of composition to be dispensed each time the reservoir is refilled, regardless of the cigarette's orientation. This provides a consistent dosage for the user.

Preferably, the dip tube is flexible and the interior of the support has a tapered surface at the distal end of the support to guide the proximal end of the dip tube to a desired position.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of a method of assembling a simulated cigarette according to the present invention will now be described with reference to the accompanying drawings, in which:

FIG1 is an axial cross-sectional view of a simulated cigarette;

FIG2 is a view similar to FIG1 in a “top down” configuration;

FIG3 is a view similar to FIG1 and FIG2 in a “top-up” configuration;

FIG4 is an axial cross-sectional view showing the right side portion of FIG1 in more detail;

FIG5 is an end view of the tube support; and

FIG6 is an exploded perspective view showing an assembly process of the second embodiment; and

FIG7 is a cross-sectional view of the second embodiment.

DETAILED DESCRIPTION

The basic layout of the simulated cigarette is as described in WO2011/107737. Thus, the assembled simulated cigarette has a generally cylindrical shape and approximates the dimensions of a cigarette. The assembled simulated cigarette comprises a housing 1 with an outlet end 2 and a refill end 3, the housing 1 having a reservoir 4. At the outlet end 2 is a blade 5 having a valve element 6 in the form of teeth that squeezes an elastic tube 7 to close the tube. As described in WO2011/107737 and in more detail in UK application 1215278.1, the outlet valve 5 further comprises a blade co-molded with a diaphragm 8 to open the valve element 6 against the action of a spring 9 when a user draws on the outlet end.

At the opposite end of the reservoir 4 is a refill valve element 10, which is essentially a non-return valve that can be operated against the action of a second spring 11. This non-return valve is the subject of GB 1305486.1. The second spring 11 and the refill valve element 10 are held in a retainer 12 having a plurality of openings so that the space within the retainer 12 forms part of the reservoir 4.

Also within reservoir 4 is a flexible dip tube 20 having an internal aperture 21. Aperture 21 has an outlet 22 positioned adjacent to one end of elastic tube 7. Dip tube 20 can be placed against elastic tube 7 ( FIGS. 1-3 ) or within elastic tube 7 ( FIG. 7 ), such that composition can only reach elastic tube 7 through aperture 21. As is apparent from the figures, either the side wall of dip tube 20 or the end wall of dip tube 20 ( FIGS. 1-3 ), but preferably both, are sealed to elastic tube 7 ( FIG. 7 ). If dip tube 20 is located within elastic tube 7, the two tubes are sealed to each other, and elastic tube 7 is sealed to the housing. It can also be seen from the figures that the right side of elastic tube 7, located between valve element 6 and dip tube 20, is also part of the reservoir.

At the inlet end 25 of the tube 20, the bore 21 has an inlet 26. As shown in FIG4, the inlet end 25 is supported by a support 30 so that the inlet end 25 of the bore 21 (preferably the inlet 26 of the bore 21) is located on the main axis X of the housing 1.

As best shown in FIG4 , the support member 30 abuts against the valve retainer 12 at the end of the support member 30 closest to the refill end 3. The support member 30 and the valve retainer 12 can be fabricated as a single component. At the opposite end, the support member 30 has a tapered surface 31 facing the outlet end 2. The outer diameter 32 of this end has a similar diameter corresponding to the inner diameter of the reservoir 4 at that point, so that the support member 30 forms an interference fit within the reservoir 4. Four openings 34, as shown in FIG5 , allow liquid in the reservoir 4 to flow freely through the support member 30 and into the inlet 26.

The assembly of the simulated cigarette will now be described with reference to Figure 6, which shows the components of the simulated cigarette in an exploded view.

The simulated cigarettes are manufactured in a cleanroom environment (preferably a cleanroom class 8 or higher according to BS EN ISO 14644-1:1999). The assembly line can consist of one or more manual and/or semi-automatic or fully-automatic assembly stations, which can be independent or modularly integrated into the same assembly line. In the most preferred design, the cigarettes are assembled as described below.

At the first station, the refill valve subassembly is assembled by fitting together the retainer 12, spring 11, refill valve element 10, valve sealing gasket 27, and end cap 28 to form a single-piece component known as a retainer valve. This can be formed at another station in the production line, rather than as a pre-formed subassembly. The retainer valve can be leak-tested and further assembled with the support member 30 before being integrated at the next assembly station.

At the second assembly station, the housing 1 is placed in a nest and the elastomeric tube 7 is inserted into the housing 1, followed by the dip tube 20. The sub-assembled retainer valve and support 30 are then placed into the housing 1, and an ultrasonic cycle is started to weld the end cap 28 to the housing 1, thereby clamping and sealing all previously inserted components in place.

At the third station, the valve assembly, comprising the blade 5, co-injected diaphragm 8, and valve element 6, is loaded onto the housing 1 from the side and ultrasonically welded in place. The spring 9 is then loaded into the recess of the blade 5, and a cover 29 is placed in place over the valve assembly to hold the spring 9 in place and seal the cylindrical housing. The cover 29 is then ultrasonically welded to the housing 1.

Quality control may be appropriate at each individual step as well as at final assembly.

The device may be packaged and may be moved to another subassembly assembly station where a label L is applied to the device.

As will be appreciated from the above description and from the accompanying drawings, reservoir 4 has a complex shape. The right-hand portion has a generally cylindrical configuration that occupies the majority of the device's diameter, while the left-hand portion of the reservoir may simply be the internal bore 21 of the tube, or the reservoir may have portions located on either side of the tube. Furthermore, in the right-hand portion, the volume of the reservoir is reduced by the inlet end portion of the tube 20, the sealing gasket 27, the support member 30, the valve retainer 12, the second spring 11, and the portion of the refill valve element 10 located within the reservoir. Thus, while the volume of reservoir 4 can be determined by measuring these components, it can be more easily determined experimentally.

The operation of the apparatus will now be described with reference to FIG. 1 to FIG. 3 .

When the user draws on the outlet end 2, the blade 5 lifts. If the inlet 26 of the hole 21 is below the liquid level L of the liquid in the reservoir, the liquid will travel along the hole 21 and will be atomized downstream of the outlet valve element 6 to form a smoke stream for inhalation. Figures 1 to 3 show the center of mass C of the liquid body filling the reservoir 4. The inlet 26 of the hole 21 is located near this center of mass. In the specific embodiment shown in Figure 1, the inlet 26 is displaced 1.3mm from the center of mass C toward the refill end 3. In the horizontal orientation shown in Figure 1, all the liquid above the liquid level L (which represents approximately 50% of the total liquid in the reservoir) can be inhaled from the cigarette. When the cigarette is in the top-down configuration shown in Figure 2, because the inlet 26 is displaced from the center of mass C as described above, the available liquid is slightly more than that shown in Figure 1. In contrast, in the top-up configuration, the available liquid for inhalation is slightly less. In different arrangements, the inlet 26 is located at the center of mass C, so that there is essentially no distribution difference between the three positions. It is presently preferred that the inlet 26 be displaced slightly from the centroid C toward the refill end as shown, as this allows for more liquid to be dispensed in the more common top-down configuration.

Once the liquid level reaches position L shown in Figures 1 to 3, the liquid can be refilled through the refill valve 10 at the discretion of the user.

Claims (12)

1. A method for assembling a tubular simulated cigarette, the method comprising: a) Provide an elongated, hollow shell with an intake end and a refill end; b) Insert an outlet valve tube from the refill end, the outlet valve tube opening at its proximal end and having an outlet orifice at its distal end, such that the outlet orifice is adjacent to the suction end. c) Insert the suction tube from the refill end such that the distal end of the suction tube is in fluid communication with the proximal end of the outlet valve tube; d) Insert the support from the refill end to support the proximal end of the extraction tube within the housing; e) Insert the refill valve into the refill end and secure the refill valve in place, wherein the housing has a composition reservoir, the draw tube allows the reservoir to be in fluid communication with the outlet orifice when the outlet valve tube is open, and the refill valve allows selective communication with the reservoir; f) Insert the valve element into a recess located on one side of the housing, such that the valve element is positioned to selectively close the outlet valve tube; g) Insert the breathing operation valve actuation mechanism into the recess from the side; and h) Apply the cover to the recess. 2. The method according to claim 1, wherein steps b) to e) are separate but consecutive steps. 3. The method according to claim 1 or 2, wherein the valve element and the breathing operation valve actuation mechanism are integral and inserted in a single step. 4. The method according to claim 1 or 2, wherein steps b) to e) are performed before steps f) to h). 5. The method according to claim 1 or 2, further comprising, after step h), adhering a package to the outer surface of the housing and the outer surface of the cover, wherein the package comprises: a paper or paper-like layer; and a polymer film protecting the paper or paper-like layer. 6. The method according to claim 1 or 2, wherein the support and the refill valve are inserted as an integral component. 7. The method of claim 1, wherein the step of securing the refill valve in place maintains the support, the intake tube, and the outlet valve tube in place. 8. The method according to claim 1 or 2, wherein the refill valve is acoustically welded to the housing. 9. The method according to claim 1 or 2, wherein the outlet valve tube is a deformable tube, and the valve element is arranged to selectively compress the outlet valve tube. 10. The method according to claim 1 or 2, wherein the breathing operation valve actuation mechanism includes a diaphragm, and air is arranged to flow over the housing above the diaphragm to open the valve element against a bias member. 11. The method according to claim 1 or 2, wherein the proximal end of the draw tube is held such that the main axis passes through the proximal end of the draw tube, so that the inlet of the draw tube is positioned in the axial direction at the center of the volume of the reservoir, i.e. at the center of 50% of the volume of the reservoir. 12. The method of claim 1 or 2, wherein the suction tube is flexible and the interior of the support has a tapered surface at the distal end of the support to guide the proximal end of the suction tube to a desired position.