Machine and method for producing a cartridge for an electronic cigarette provided with a heat resistor

Description

TECHNICAL FIELD

[0001] The present invention relates to a machine and method for producing an electronic cigarette cartridge.

STATE OF THE ART

[0002] Recently, an electronic cigarette has been proposed (described for example in patent applications WO2014058678A1 and WO2014088889A1) comprising a cylindrical shaped reusable part that is used several times and includes, inter alia, an electric battery (which provides the energy necessary for the operation of the electronic cigarette) and an electronic processor that oversees the operation of the electronic cigarette. In addition, the electronic cigarette includes a disposable cartridge (i.e., to be disposed of after use, and therefore only used once and then replaced) of a cylindrical shape that is screwed into the reusable portion.

[0003] The cartridge comprises a support base which is made of a plastic (electrically insulating) material and is inserted inside a metal base with an internal thread for mechanical connection to the corresponding part of a reusable electronic cigarette. The support base has two power electrodes laterally arranged with a greater axial extent and

A signal electrode positioned centrally (i.e. between the two feed electrodes) and having a smaller axial extent (relative to the two feed electrodes). The heating element is electrically connected to the two power electrodes and comprises a U-bent wick of electrically insulating material and a heat resistor made of a filament spirally wound around the wick; two clamps are formed at the two opposite ends of the fiber which are electrically connected to the respective feed electrodes by welding.

[0004] Between these two supply electrodes is a support body of ceramic (or the like) material which rests transversely on both supply electrodes and is centrally equipped with an electronic circuit which is electrically connected to the signal electrode and contains, inter alia, memory.

[0005] Finally, a hygroscopic cushion (for example a cotton wool cushion) is also placed inside the base, which is impregnated with a liquid viscous substance containing nicotine and optional flavorings. The hygroscopic cushion has a cylindrical tubular shape and surrounds the thermal resistor of the heating element so that, in use, the heat generated by the heating element heats the hygroscopic pad, causing a slow volatilization (evaporation) of the viscous liquid which is saturated with the hygroscopic pad.

[0006] Currently, the manufacture of a cartridge as described above requires the removal of a simple insulated wick (i.e., no folds) provided with a thermal resistor from the wick magazine (where the insulating wicks are loose), and then to support the insulating wick.

On the power electrode of the manufactured cartridge. After an insulating wick is formed on the feed electrodes of the cartridge to be produced, two welds between the terminals of the thermal resistor and the respective power electrodes are formed to establish a stable electrical connection, and then the insulating wick is folded in U on the outer surface of the power electrodes.

[0007] However, it has been observed that said methods of producing this cartridge have the disadvantage that they are not very efficient, since maintaining an acceptable quality of production requires very slow operation (i.e. with a very low hourly output). Moreover, due to a bad (or even no) electrical connection between the power electrodes and the thermal resistance around the insulating wick, damage to the cartridge occurs at a certain frequency. Moreover, during the maneuvering of the electrodes necessary to transfer the electrodes from the magazines to the connecting element, damage to the cartridge occurs with some frequency (substantially undesirable deformation of the electrodes themselves). CN 201758770 U discloses an automatic mounting device for an electronic cigarette cartridge.

DESCRIPTION OF THE INVENTION

[0008] It is an object of the present invention to provide a machine and method for producing an electronic cigarette cartridge, which machine and method enable high productivity levels to be achieved, while being easy and cheap to manufacture.

[0009] According to the present invention, there is provided a machine and method for producing an electronic cigarette cartridge as claimed in the appended claims.

EP 3 025 600 B1

55P41435PL00

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The present invention will now be described with reference to the accompanying drawings, which show a non-limiting embodiment, in which:

Figure 1 is a perspective and schematic view of an electronic cigarette equipped with a cartridge;

Figure 2 is a longitudinal sectional and schematic view of the cartridge of Figure 2;

Figure 3 is a schematic view of a heating element of the cartridge of Figure 2;

Figures 4 and 5 are two different perspective and schematic views of the cartridge of Figure 2 with parts removed for clarity;

Figure 6 is a perspective and schematic view of a production machine for producing the pad of Figure 2 and manufactured in accordance with the present invention;

Figure 7 is a schematic front view of the production machine of Figure 6;

Figure 8 is a schematic plan view of the production machine of Figure 6;

Figure 9 is a schematic front view of the assembly section of the production machine of Figure 6;

Figure 10 is a schematic plan view of the mounting section of Figure 9;

Figure 11 is a schematic front view of some of the assembly section conveyors of Figure 9;

55P41435PL00

Figure 12 is a perspective and schematic view of the conveyors of Figure 11;

Figure 13 is a perspective and schematic view of an assembly station for mounting electric contacts in the assembly section of Figure 9;

Figure 14 shows a view of a detail of Figure 13 on an enlarged scale;

Figure 15 is a perspective and schematic view of an assembly station for assembling the circuits of the assembly section of Figure 9;

Figures 16 and 17 are two different perspective and schematic views of an assembly station for assembling the heating elements of the assembly section of Figure 9;

- Figure 18 is a perspective and schematic detail view of the assembly station for assembling the heating elements of Figures 16 and 17;

- Figures 19 and 20 are two views, on an enlarged scale, of two different details of the assembly station for assembling the heating elements of Figures 16 and 17;

Figure 21 is a perspective and schematic view of the turntable in the mounting section of Figure 9;

Figure 22 is a perspective and schematic view of a mounting station for mounting hygroscopic pads and a subsequent mounting station for mounting the bases of the mounting section of Figure 9;

55P41435PL00 ΕΡ 3 025 600 BI

Figure 23 is a schematic front view showing the feeding of materials at the stations of Figure 22;

Figure 24 is a schematic perspective view that shows the feeding of materials at the stations of Figure 22;

Figure 25 is a schematic perspective view of a mounting station for mounting hygroscopic pads;

- Figures 26, 27 and 28 are three schematic front views of an assembly station for mounting hygroscopic pads in three different working cycles;

Figure 29 is a schematic horizontal section view of a transfer device between a mounting station for mounting hygroscopic cushions and a mounting station for mounting bases; and

Figure 30 is a view of a detail of Figure 29 on an enlarged scale.

PREFERRED EMBODIMENTS OF THE INVENTION

[0011] In Figure 1, the reference numeral 1 designates as a whole an electronic cigarette of a known type (described for example in the patent applications WO2014058678A1 and WO2014088889A1).

[0012] The electronic cigarette 1 comprises a reusable cylindrical portion 2 that is used several times and includes, inter alia, an electric battery (which provides the energy necessary to operate

55P41435EN00 ΕΡ 3 025 600 BI of the electronic cigarette 1) and the electronic processor that supervises the operation of the electronic cigarette 1. Furthermore, the electronic cigarette 1 comprises a disposable cartridge 3 (i.e., disposed of after being used once, and therefore used only once and then replaced) and in a cylindrical shape which is screwed into the reusable part 2.

As shown in Figure 2, the cartridge 3 of the electronic cigarette 1 comprises a support base 4 which is made of a plastic (electrically insulating) material and is at least partially press-fitted (i.e. fitted with a slight interference) inside the metal. a base 5 with female thread for mechanical connection with the corresponding part 2 of a reusable electronic cigarette 1. This support base 4 is provided with two laterally spaced power electrodes 6 having a greater axial extent and a signal electrode 7 centrally located (i.e. between the two power electrodes 6) and having a smaller axial extent (relative to the two power electrodes 6). To these two feed electrodes 6 is electrically connected a heating element 8 (better shown in Figure 3) which comprises a U-shaped folded wick 9 of electrically insulating material and a thermal resistor 10 formed by a filament spirally wrapped around the wick 9; two clamps 11 are formed at the two opposite ends of the fiber, which are electrically connected to the respective feed electrodes 6 by welding.

[0014] A support body 12 of material is positioned between the two supply electrodes 6

A ceramic (or the like) that rests laterally on both supply electrodes 6 and is centrally equipped with an electronic circuit 13 that is electrically connected to the signal electrode 7 and contains, inter alia, memory. The support body 12 also has the function of an insulating spacer for holding the two power electrodes 6 apart from each other. Finally, inside the base 5 is also placed a hygroscopic cushion 14 (for example a cotton wool cushion) which is impregnated with a liquid viscous substance containing nicotine and possibly aromatic substances. The hygroscopic pad 14 has a tubular cylindrical shape and surrounds the thermal resistor 10 of the heating element 8 so that, in use, the heat generated by the heating element 8 heats up the hygroscopic pad 14, causing a slow volatilization (evaporation) of a viscous liquid saturating the hygroscopic pad 14. In particular, in the embodiment shown in Figure 2, a hygroscopic pad 14 is positioned (wrapped) around two feed electrodes 6 (i.e. external to the feed electrodes 6). Preferably, and as better described below, the hygroscopic cushion 14 is obtained by rolling an initially flat piece of hygroscopic material into a ring.

[0015] In Figures 6, 7 and 8, reference number 15 designates as a whole a manufacturing machine for the production of the electronic cigarette cartridges 2 described above.

[0016] The manufacturing machine 15 comprises a mounting section 16 in which the materials constituting the inserts 2 are assembled to produce the inserts 2 and a feeding section 17 in which the materials constituting the inserts 2 are received and guided towards the mounting section 16.

55P41435PL00

[0017] The feeding section 17 of the production machine 15 comprises a feeding device 18 for feeding the support legs 4, which receives the disordered mass of the support legs 4 (i.e. the mass of the loose support legs 4) into the open-top collection tank 19 and manipulates the support legs 4. to arrange the support legs 4 in an orderly series which is then fed by a mechanical type pneumatic conveyor, for hopper 20 assembly section 16 production machine 15.

The feeding section 17 comprises a feeding device 21 for feeding the bases 5, which receives the disordered mass of the bases 5 (i.e. the mass of the loose bases 5) into the open-top collection tank 22 and manipulates the bases 5 to arrange the bases 5 in an ordered series. which is then fed, by a mechanical type pneumatic conveyor, to the hopper 23 of the assembly section 16 of the production machine 15.

[0019] The feeding section 17 of the production machine 15 comprises two feeding devices 24 for feeding the electronic circuits 13 which are twinned for alternating use (i.e., one feeding device 24 is always used at a time). Each delivery device 24 receives a disordered mass of electronics 13 (i.e., a mass of loose electronics 13) into an open-top collection tank 25 and manipulates electronics 13 to arrange electronics 13 in an ordered series which is then fed by an overhead. pneumatic type conveyor, to the assembly section 16 of the production machine 15.

[0020] The feeding section 17 of the production machine 15 comprises two feeding devices 26 for feeding the support bodies 12, which are twin devices for alternating use (i.e., one feeding device 26 is always used at a time) . Each feeding device 26 receives the disordered mass of supporting bodies 12 (i.e., the mass of loose supporting bodies 12) into the open-top storage tank 27 and manipulates supporting bodies 12 to arrange supporting bodies 12 in an ordered series which is then fed by means of an overhead pneumatic type conveyor, to the assembly section 16 of the production machine 15.

[0021] The feeding section 17 of the production machine 15 comprises two feeding devices 28 for the respective sheet metal strips 29 (shown schematically in Figure 8) which, as better described below, are made of a metallic material and are used to form the electrodes 6 and 7; the two feeding devices 28 are twin and are used alternately (i.e., one feeding device 28 is always used at a time). Each feed device 28 houses a corresponding coil in which the sheet metal strip 29 is wound and uncoils the sheet metal strip 29 from the roll for feeding towards the assembly section 16 of the production machine 15.

The feeding section 17 of the production machine 15 comprises a single feeding device 30 for feeding the heating elements 8. The feeding device 30 houses two turns that are used alternately (i.e., one turn is always used at a time) and on each roll. of them, a series of heating elements 8 is wound; the feeding device 30 unwinds the web at a given moment at

To feed further heating elements 8 towards the mounting section 16 of the production machine 15.

[0023] The feeding section 17 of the production machine 15 comprises a single feeding device 31 for feeding the hygroscopic pads 14. The feeding device 31 houses two rolls which are used alternately (i.e., one spool is always used at a time) and on each of them a continuous strip of hygroscopic material is wound; the feeding device 31 unwinds the web at a given moment in order to feed a continuous strip of hygroscopic material towards the assembly section 16 of the production machine 15.

[0024] As shown in Figures 9 and 10, the assembly section 16 of the production machine 15 comprises a receiving station SI of the supporting bases 4, a pair of assembly stations S2 (backup to each other) for mounting electrodes 6 and 7, a pair of assembly stations S3 (backup to each other) for assembling electronic circuits 13, a pair of assembly stations S4 (reserve relative to each other) for assembling supporting bodies 12, S5 assembly station for mounting heating elements 8, S6 rotating station, S7 assembly station for mounting hygroscopic cushions 14 and S8 assembly station for mounting bases 5.

As shown in Figures 11 and 12, the assembly section 16 of the production machine 15 comprises a conveyor 32 that includes a plurality of pockets 33 (better illustrated in Figure 12) for receiving support bases 4 in an intermittent (stepwise) motion along the transfer path PI in a U-shape that extends from the receiving station S1 towards the connection station S7; in particular, the PI transfer path includes two

Rectilinear sections (one above the other and of different length) connected to each other by a semicircular portion. 55P41435PL00 ΕΡ 3 025 600 BI. The intermittent (stepping) motion provides cyclically alternating steps of movement during which the conveyor 32 moves the pockets 33 and resting steps during which the conveyor 32 keeps the pockets 33 stationary. In the embodiment illustrated in the accompanying figures, the conveyor 32 is a belt conveyor and comprises a flexible belt supporting pockets 33 and is looped around two end pulleys (at least one of which is driven).

According to a preferred embodiment, a companion conveyor 34 is provided which is arranged adjacent to the conveyor 32 from assembly station S4 to assembly station S7, it moves synchronously with companion conveyor 34 and includes a plurality of pockets 35 (better illustrated). in Figure 12) to provide support for the support bodies 12 which extend cantilevered from the respective support bases 4, mounted on pockets 33 of conveyor 32. In the embodiment shown in the accompanying figures, conveyor 34 is a conveyor belt and includes a flexible belt that supports the pockets 35 and is closed in a loop around two end pulleys (at least one of which is driven).

[0027] As shown in Figures 11 and 12, a stationary restriction element 36 is provided around the initial portion of the PI transfer path, which is U-shaped and holds the support bases 4 within the respective pockets 33 of the conveyor 32. Furthermore, in an intermediate portion of the PI transfer path is out

Another companion conveyor 37 is located above the conveyor 32 and holds the support bases 4 inside the respective pockets 33 of the conveyor 32 itself. In the embodiment shown in the accompanying figures, the companion conveyor 37 is a belt conveyor and comprises a flexible belt which is enclosed in loops around two end pulleys (at least one of which is driven).

[0028] As shown in Figure 11, the transfer path P1 begins at the lower outlets of the hopper 20; reciprocating along a direction perpendicular to the transfer path PI cyclically pushes the plurality of support bases 4 out of the lower outlets of hopper 20 into the respective pockets 33 of the conveyor 32 by a number of pushers (e.g., ten pushers positioned side by side).

As shown in Figure 11, the receiving station S1 comprises an optical control device 38 (e.g., a CCD camera) that observes the support legs 4 to determine the orientation of each support seat 4 (in particular to determine the orientation of the electric connecting holes of the support seat 4). made to receive electrodes 6 and 7). Moreover, as shown in Figure 11, the receiving station S1 comprises a guide device 39 which is controlled as a function of the elements detected by the optical control device 38 and, if necessary, rotates each support seat 4 to give the support seat itself 4 the desired and in advance. specific orientation (especially in order to send

The desired and predetermined orientation to the electrical connection openings in the support base 4 provided to receive electrodes 6 and 7). According to a possible embodiment, the guide device 39 comprises a pivot fork that is axially slidable to fit into the electrical connecting holes of the support base 4 to grip the support base 4 and thereby allow the support base 4 itself to pivot. Due to the combined operation of the optical control device 38 and the guide device 39 at the entrance of the mounting station S2 of electrodes 6 and 7, all support bases 4 have a predetermined desired orientation, which simplifies the insertion of electrodes 6 and 7 into the support bases 4 themselves.

As shown in Figures 13 and 14, the assembly station S2 for mounting electrodes 6 and 7 is located along the conveyor 32 (i.e. along the transfer path PI) and includes three gripper devices 40 each designed to grip the respective electrode 6. or 7, and an actuator 41 that cyclically moves each gripping device 40 forwards and backwards along an assembly direction D1 perpendicular to the transfer path PI such, to carry electrode 6 or 7 gripped by gripping device 40 to engage the respective support base 4 (i.e., to insert the corresponding electric connection hole of support base 4 into the interior) during the forward stroke and disengagement of gripping device 40 from electrode 6 or 7 connected to the support plate 4 on the return stroke. According to a preferred embodiment shown in the attached figures, each gripper device 40 comprises a gripper consisting of two opposing and hinged jaws.

55P41435PL00

In other words, each gripping device 40 grips, by the methods described below, the respective electrode 6 or 7, then the actuator 41 makes a forward stroke to transfer the electrode 6 or 7 gripped by the gripping device 40 to engage with it. a suitable supporting base 4 (i.e. inserting a suitable electrically connecting hole of the supporting base 4 inside) after connecting the electrode 6 or 7, gripped by the gripping device 40, with the respective supporting base 4, the gripping device 40 releases the electrode 6 or 7, and finally the actuator 41 performs a return stroke to disconnect the gripping device 40 from the electrode 6 or 7 connected to the respective supporting base 4. According to a preferred embodiment, the actuator 41 is only one and common to all three gripping devices 40; in particular, actuator 41 comprises a slider that is slidably mounted along the mounting direction D1 with all three gripping devices 40 seated side by side, and is connected to an actuator that gives a reciprocating movement.

[0032] The assembly station S2 for mounting the electrodes 6 and 7 receives the sheet metal strip 29 by means of a corresponding feeding device 28; for feeding the sheet metal strip 29 through the assembly station S2 for mounting the electrodes 6 and 7, a fixed guide 42 is provided inside which an edge 43 of the sheet metal strip 29 runs; in other words, the stationary guide 42 comprises an inner recess in which an edge 43 of the sheet metal strip 29 runs and which has a lateral slot through which the remainder of the sheet metal strip 29 projects from the stationary guide 42, protruding cantilevered from the stationary guide 42 itself.

55P41435PL00

A tool 44 is positioned in front (viewed in the working direction) of the stationary guide 42 (and thus in front of the gripping device 40), which periodically punches blanks in the sheet metal strip 29 to form electrodes 6 and 7 in the sheet metal strip 29, leaving a portion of each. electrodes 6 or 7 in contact with the rest of the sheet metal strip 29 (i.e. in contact with the edge 43 of the sheet metal strip 29). In other words, the working tool 44 cyclically carries out a cold working of the sheet metal strip 29 by separating a predetermined flat piece with a punch and die, suitably constructed and inserted into a more complex structure known as a mold. According to a preferred embodiment, the punch and die of the tool 44 are shaped to also shape the sheet metal strip 29 such that portions of each electrode 6 or 7 are folded (as detailed in Figure 5); in other words, the tool 44 also performs the folding of some portions of each electrode 6 or 7 to give the electrode 6 or 7 the desired shape (as shown in detail in Figure 5).

Behind (viewed in the working direction) the gripping devices, what remains of the sheet metal strip 29 (i.e. the edge 43 and the projections from which the electrodes 6 and 7 previously extended) are processed in the grinding device for grinding and then collected and disposed of (and fully recycled).

Each gripping device 40 is accompanied by a corresponding cutting device 45 that cooperates with the gripping device 40 to separate the electrode 6 or 7 from the rest of the sheet metal strip 29 when the gripping device 40 holds the electrode 6 or 7 itself. In other words,

55P41435PL00 ΕΡ 3 025 600 BI each gripping device 40 grips electrode 6 or 7, while electrode 6 or 7 is still in one piece with the sheet metal strip 29 and in connection with said gripping (or immediately after said gripping) a corresponding cutting device 45 performs a separating cut electrode 6 or 7 gripped by gripper device 40 from the rest of the sheet metal strip 29. According to a preferred (but non-binding) embodiment, each cutting device 45 is separate and independent from the respective gripper device 40 to separate electrodes 6 or 7 from the rest of the sheet metal strip 29 only after gripping device 40 only grips electrode 6 or 7; an optimal (i.e. very precise positioning) electrode holder 6 or 7 is thus always ensured by a suitable gripping device 40.

[0036] According to a preferred embodiment, an operating tool 44, punching blanks in the sheet metal strip 29, produces at an edge 43 of the sheet metal strip 29 a series of guide through holes 46 (shown schematically in Figure 13); in this regard, it should be noted that the sheet metal 29 is initially completely smooth (i.e. free of any notches) and the guide holes 46 and the electrodes 6 and 7 are completely formed from scratch by the tool 44. According to the possible embodiment shown in Figure 13, when the working tool 44 forms guide holes 46 in the edge 43 of the sheet metal strip 29, it also forms small through cuts 46a that are arranged transversely and have the function of increasing the flexibility of the sheet metal strip 29 to facilitate its subsequent handling. (especially with regard to the correct centering of the electrodes 6 and 7 attached to the sheet metal strip 29 with respect to the respective support bases 4); as shown in Figure

55P41435PL00 ΕΡ 3 025 600 BI

13, the small through cuts 46a align with the guide holes 46 and extend all the way to the guide holes 46, but alternatively these small through cuts 46a (or at least some of them) need not line up with the guide holes 46 and / or they do not need to extend all the way to the pilot holes 46.

[0037] The feeding device 28 comprises two sprockets 47 which are positioned downstream (viewed in the working direction) of the working tool 44 in the gripping devices 40 and guide the feeding of the sheet metal strip 29 by engaging their teeth with through-holes 46 of the sheet metal strip 29 itself. The function of the sprocket 47 is to ensure perfect synchronization of the space between the electrodes 6 and 7 formed in the sheet metal strip 29 and the gripping devices 40, and then preferably the sprockets 47 are placed adjacent to the gripping devices 40. According to a preferred embodiment shown in the attached figures, the through-holes 46 formed in the edge 43 of the sheet metal strip 29 are round and the teeth of the sprockets 47 are hemispherical in shape; in this way, the teeth of the sprockets 47 are self-centering within the guide holes 46 formed in the edge 43 of the sheet metal strip 29.

[0038] According to the preferred embodiment shown in the attached figures and clearly visible in Figures 9 and 10, two mounting stations S2 are provided for mounting electrodes 6 and 7, which stations are twin, redundant and independent from each other and arranged one behind the other along the length of the PI transfer paths; each assembly station S2 has its own gripping devices 40 (and therefore its own corresponding cutting devices 45), its own

Actuator 41, its own feeding device 28 and its own working tool 44. Consequently, the two assembly stations S2 are twin and completely autonomous from one another. Typically only one assembly station S2 is used and only one dispensing device 28 is used at a time, while the second assembly station S2 and the second dispensing device 26 are stationary and can therefore be serviced even while the production machine 15 is running; moreover, in the stationary feeding device 28 (i.e. not working) it is possible to perform a reel change of the sheet metal strip 29. Alternatively, the two assembly stations S2 may be used together and in an alternating manner (i.e., the feeding station S2 performs the insertion while the second feeding station S2 performs the next insertion) to halve its effective operating speed.

[0039] The assembly station S2 for mounting electrodes 6 and 7 is particularly effective and efficient as removing the electrodes 6 and 7 directly from the sheet metal strip 29 in which the electrodes 6 and 7 have been formed in-line (i.e. by the punching action of the working tool 44) it is possible to operate quickly (i.e. with a very high hourly output) while ensuring both high-precision positioning of electrodes 6 and 7, as well as very gentle treatment of electrodes 6 and 7, which completely preserves the integrity of electrodes 6 and 7 themselves (thus ensuring excellent overall production quality). Particularly useful in this regard is the presence of guide openings 46 which, due to their simultaneous formation with the electrodes 6 and 7, make it possible to synchronize the spatial positions of the gripping devices 40 with the positions of the electrodes 6 and 7 in a very precise manner.

55P41435PL00 ΕΡ 3 025 600 BI

[0040] As shown in Figure 15, the assembly station S3 for assembling the electronics 13 includes an insertion device 48 that pushes the electronics 13 axially towards the respective support base 4 attached to the pocket 33 of the conveyor 32; in the support base 4, the electronics 13 rests on horizontal supports that protrude from the feed electrodes 6, and is electrically connected to the signal electrode 7. A transfer device 49 is provided that receives electronics 13 from the corresponding delivery device 24, and then pushes the electronics 13 transversely so as to sequentially stack the electronics 13 upstream of the insertion device 48, which in turn pushes them along the same axial path. towards the respective support plates 4. The transfer device 49 includes a pusher that is cyclically moved back and forth with a single rotation (i.e., with one degree of freedom). Instead, the insertion device 48 comprises a pusher that is cycled back and forth by means of a rotational displacement provided by an articulated quadrilateral (i.e. with two degrees of freedom).

[0041] According to the preferred embodiment shown in the attached figures and clearly visible in Figures 9 and 10, two assembly stations S3 are provided for assembling electronic circuits 13, which are twin, redundant and independent from each other, and are arranged one behind the other along the conveying path PI. The two S3 assembly stations are identical and completely autonomous from each other. Usually only one position is used

Assembly S3 and only one feeding device 24 at a time is in use while the second assembly station S3 and the second feeding device 24 are stationary and can therefore be serviced even while the production machine 15 is running; alternatively, the two assembly stations S3 may be used alternately (i.e., feeding station S3 performs the insertion while the second feeding station S3 performs the next insertion) to halve its effective operating speed.

The assembly station S4 for assembling support bodies 12 (not shown in detail) is very similar to the assembly station S3 for assembling electronics 13 and includes an insertion device (similar to insertion device 48 of assembly station S3) which axially pushes the support body 12 into the direction of the respective support base 4 attached to the pocket 33 of the conveyor 32, and a transfer device 49 (similar to the transfer device 49 of the assembly station S3) that receives the support bodies 12 from the respective feeding device 26 and then pushes the support bodies 12 transversely so as to sequentially arrange the support bodies 12 in front of the insertion device which in turn pushes them axially towards the respective supporting chocks 4.

[0043] According to the preferred embodiment shown in the attached figures and clearly visible in Figures 9 and 10, two assembly stations S4 are provided for assembling the support bodies 12, which are twin, redundant and independent from each other, and arranged one behind the other along the conveying path. PI. These two S4 assembly stations are

55P41435PL00 ΕΡ 3 025 600 BI twin and fully autonomous from one another. Typically only one assembly station S4 is used and only one feeding device 26 is used at a time, while the second assembly station S4 and the second feeding device 26 are stationary and therefore can be serviced even while the production machine 15 is running; alternatively, the two assembly stations S4 may be used together and in an alternating manner (i.e., the feeding station S2 performs the insertion while the second feeding station S2 performs the next insertion) to halve its effective operating speed.

[0044] As shown in Figures 16, 17 and 18, the assembly station S5 for assembling the heating elements 8 includes a connecting unit 50 that connects the heating element 8 to the power electrodes 6 of each support base 4, while the support base 4 is placed in the corresponding support base. pocket 33 of the conveyor 32. Moreover, the assembly station S5 for assembling the heating element 8 comprises a welding device 51 arranged along the conveyor 32 to form, in each support base 4, a weld between the two terminals 11 of the thermal resistor 10 of the heating element 8 and the corresponding power electrodes 6.

[0045] The connecting assembly 50 includes a feed conveyor 52 disposed upstream of conveyor 32 and includes a plurality of grippers 53 that are fed along U-shaped feed path P2 over a distance parallel to and facing the conveying path PI. As more clearly shown in Figures 19 and 20, each gripper 53 includes two opposing jaws 54 that can move between an open position.

55P41435PL00 ΕΡ 3 025 600 B1 (shown in part of Figure 20), where both jaws 54 are relatively spaced apart, and a closed position (shown in Figure 19 and part of Figure 20) where both jaws 54 are relatively close to each other in to clamp the heating element 8 bent in the shape of the U-shape. Moreover, as better shown in Figures 19 and 20, each gripper 53 includes a stationary center support 55 which is U-shaped and is positioned between two jaws 54 to provide both jaws 54 alone with an opposing hold such that each arm of the heating element 8, bent in a U-shape, is gripped between the jaw 54 and the corresponding wall of the central support 55. Preferably, in each gripper 53, the jaws 54 are hinged to the gripper 53 itself, and the rotation of the jaws 54 is transmitted by a cam actuated system.

[0046] According to a preferred embodiment, each gripper 53 is hinged to the supply conveyor 52 to rotate with respect to the supply conveyor 52 about an axis of rotation 56 perpendicular to the supply path P2; rotation of each gripper 53 relative to the feed conveyor 52 and about the rotation axis 56 is controlled by a cam actuated system. Each gripper 53 rotates relative to the supply conveyor 52 in the area where the gripper 53 is connected from above to the corresponding pocket 33 on the conveyor 32 to position the U-folded heating element 8 on the supply electrodes 6 of the support base 4 seated in the pocket 33; in addition, each gripper 53 pivots relative to the supply conveyor 52 in the area where the gripper 53 disengages to disengage upwardly from the respective pocket 33 of the conveyor 32. The function of rotating each gripper 53 relative to the supply conveyor 52 is to allow the gripper 53 to fit

From the top to the corresponding pocket 33 of the conveyor 32 and separating upwards from the pocket 33 of the conveyor 32 without mechanical collision and without subjecting the heating element 8 and / or the supply electrodes 6 to undesirable mechanical stresses.

As shown more clearly in Figure 18, the link unit 50 cooperates with (includes) a bending device 57 located above the supply conveyor 52, receives simple heating elements 8 (i.e., no bends) from the supply device 30, and engages each heating element. 8 into the corresponding gripper 53 of the infeed conveyor 52, simultaneously bending the heating element 8 into a "U" shape. In other words, during the movement of each heating element 8 into a respective gripper 53 of the feed conveyor 52, the heating element 8 is bent into a letter shape. ^ŁAT^Łthereby assuming the final folded configuration; thus it is evident that the heating elements 8 are bent into a 'U' shape (wide) before connecting each heating element 8 to the feed electrodes 6 of the respective support base 4. According to a preferred embodiment, the bending device 57 comprises a pusher 58 which pushes each heating element 8 perpendicular to the feed path P2 to drive the heating element 8 into the respective gripper 53 and simultaneously fold the heating element 8 into a 'U' shape.

[0048] The interconnection unit 50 comprises twin redundant handling devices 59 on opposite sides of the bending device 57, each designed to feed a series of straight heating elements 8 (i.e. without bends) towards the bending device 57. Each equipment

The handling device 59 receives a chain of heating elements 8 from the feeding device 30 (in particular from one of two coils attached to the feeding device 30) and includes a cutter 60 for cutting the chain crosswise, and then separates the heating element 8 from this chain. According to a preferred embodiment, each handling device 59 comprises a plurality of opposing rollers (both horizontally and vertically positioned) which are positioned in front of (viewed in the working direction) of cutter 60 and have the function of straightening the chain to eliminate, at least partially, the curvature. imposed by previous winding of the coil. Once separated from the chain, each straight heating element 8 is pushed by a pusher 58 of the bending device 57 towards the gripper 53 of the feed conveyor 52 for bending into a letter. ^ŁU 'when entering the gripper 53 itself. Typically, only one handling device 59 is used, while the other handling device 59 is stationary and can then be serviced even while the production machine 15 is running; moreover, a safe change of the roll connected to the fixed handling device 59 can be performed.

[0049] According to the preferred embodiment shown in the accompanying figures and clearly visible in Figures 19 and 20, each pocket 33 of the conveyor 32 comprises a pair of resistance elements 61 which are located on opposite sides of the pocket 33 and rest on the heating element 8 to hold the heating element. 8 when folded into a letter ^ŁAT^Ł. In other words, the two stop elements 61 of each pocket 33 of the conveyor 32 block the U-shaped heater 8, preventing any kind of desired elastic return of the heater 8 itself.

55P41435PL00

[0050] As shown in Figures 16 and 17, the welding device 51 includes a series of four spot welding guns 62, each of which includes two opposing jaws engaging on two opposing sides of the heating element 8 and adapted to be moved vertically to engage and disengage. with heating element 8. Preferably, the sealing device 51 is mounted so that it moves parallel to the PI transfer path and moves back and forth along the PI transfer path itself, accompanying the pockets 33 with which it cooperates along a portion of the PI transfer path (corresponding to the four feeding steps). ). In particular, the four spot welding guns 62 are mounted on a common support 63 which is mounted to slide along a stationary rail 64 oriented parallel to the transfer path P1; thus, the four spot welding guns 62 can move parallel to the PI transfer path in a cyclic back and forth motion to accompany the respective pockets 33 of the conveyor 32 along a portion of the PI transfer path.

In other words, the welding device 51 engages the heating elements 8 of the four adjacent pockets 33 (by means of four respective spot welding guns 62) and follows the movement of the four adjacent pockets 33 along a portion of the transfer path P1 along the same path. the transfer path P1 in synchronization with the four adjacent pockets 33; once the welding of the ends 11 of the heating elements 8 has been completed, the welding device 51 disengages from the heating elements 8 and quickly returns to its starting position to start a new welding cycle with the other four adjacent pockets 33.

In this way, each spot welding gun 62 has a relatively long time available to complete the welding of the ends 11 of the respective heating element 8.

The assembly station S5 for assembling the heating elements 8 is particularly effective and efficient, because by bending each heating element 8 into a 'U' shape before connecting the heating element 8 to the feed electrodes 6, and in particular before welding the ends 11 of the heating element 8 itself. with the corresponding supply electrodes 6, it allows a significant reduction of the mechanical stress (and thus undesirable deformations) to which the terminals 11 are exposed, feed electrodes 6 and welds between the tips 11 and feed electrodes 6. Consequently, it is possible to operate quickly (i.e. with a very high hourly capacity) while still ensuring a good electrical connection (i.e. stable and durable and thus not subject to accidental breakage) between supply electrodes 6, and tips 11 of each heating element 8.

[0053] As shown in Figure 21, the turntable S6 comprises a rotating device 65 which engages each support base 4 seated in a respective pocket 33 on the conveyor 32 (obviously the support seat 4 is provided with pre-mounted electrodes 6 and 7, the electronics 13, support body 12 and heating element 8) and 180 ° pivots support base 4 (i.e. turns upside down). Said rotation of the four supporting bases 4 is not strictly required, but allows more efficient subsequent mounting of the hygroscopic pillows 14 (depending on the mounting methods described below); especially,

Said rotation of the support bodies 4 allows the rear of the respective support bodies 12 to be exposed towards the apex, which is smooth and substantially cylindrical and thus provides a support base that is more secure and stable for the hygroscopic cushions 14.

[0054] According to a preferred embodiment, between the heating element mounting station S5 8 and the rotary station S6 there is a control device 66 which performs an electrical continuity check to verify the correct functioning of both the heating elements 8 and the electronic circuits 13; in particular, the control device 66 comprises terminals which are inserted into the respective electric connection openings in each support base 4 and check the correct operation of both the heating element 8 and the electronic system 13. The control device 66 controls the discharge device located behind (viewed in the direction of operating device) of the controller 66 and rejects the defective cartridge 2. In addition to the control device 66 between the heating element mounting station S5 8 and the turntable S6, there may be other control devices (generally of the optical type) which also control the discharge device.

[0055] As shown in Figures 22, 23 and 24, the assembly station S7 for mounting the hygroscopic pads 14 includes a conveyor 67 which is shaped as a drum rotatably mounted about a central pivot axis 68 and supports a plurality of grippers 69, each of which is designed to be used. positioning the corresponding support base 4 (fitted with the pre-mounted

Electrodes 617, electronics 13, support body 12 and heating element 8). The conveyor 67 is positioned above the conveyor 32 such that each support base 4 (provided with pre-mounted electrodes 6 and 7, electronics 13, support body 12 and heating element 8) can be carried vertically from bottom to top through the pocket 33 of conveyor 32 to gripper 69 of conveyor 67.

[0056] As shown in Figures 22, 23 and 24, the assembly station S8 for assembling the bases 5 includes a conveyor 70 which is shaped as a drum pivotally mounted about a central pivot axis 71 and supports a plurality of seats 72 each intended to be placed appropriate base 5. The conveyor 70 is positioned next to the conveyor 67 (the two pivot axes 68 and 71 are parallel to each other) and partially coincides with the conveyor 67 such that the support base 4 (equipped with pre-mounted electrodes 6 and 7, electronics 13, carrying body 12 , the heating element 8 and the hygroscopic pad 14) can be moved axially (i.e., movement parallel to the axis of rotation 68 and 71) by the gripper 69 of the conveyor 67 into the seat 72 of the conveyor 70. Connected to the conveyor 70 is a hopper 23 which receives the bases 5 from the feeding device 21 for feeding the base 5; the lower hopper outlets 23 are positioned around the periphery of the conveyor 70 and there are tappets (e.g., ten juxtaposed tappets) that are reciprocating along a direction parallel to the rotation axis 71 of the conveyor 70 and cyclically push a plurality of bases 5 from the bottom outlets hopper 23 until it is inserted into the corresponding seats 72 of the conveyor 70.

55P41435PL00 ΕΡ 3 025 600 BI

As shown more clearly in Figure 25, connected to each gripper 69 of the conveyor 67 is a pocket 73 which is radially outermost of the gripper 69 to receive and hold a corresponding hygroscopic pillow 14 rectangular in shape and initially flat. so that the hygroscopic pad 14 is placed in front of the gripper 69. In the embodiment illustrated in the accompanying figures, each pocket 73 includes two opposing tabs that hinge to the conveyor 67 and hold a corresponding flat hygroscopic pad 14 against the outer surface of the conveyor 67 itself.

[0058] An insertion device 74 is provided which is placed on the upper periphery of the conveyor 67 and is intended to insert the flat hygroscopic pads 14 successively into the respective pockets 73; the handling device 74 receives from the delivery device 31 for the delivery of hygroscopic pads 14 a continuous strip of hygroscopic material coming from the roll and cyclically cuts the continuous strip of hygroscopic material to separate a series of flat hygroscopic pads 14 which are introduced into the respective pockets 73.

As shown in Figure 25, the assembly station S7 for assembling the hygroscopic cushions 14 includes an insertion device 75 for inserting each support base 4 (provided with pre-mounted electrodes 6 and 7, electronics 13, support body 12 and heating element 8) with pockets 33 of the conveyor 32 inside the respective gripper 69 of the conveyor 70 so as to catch the hygroscopic pad 14 which is placed inside the respective pocket

55P41435PL00 ΕΡ 3 025 600 BI 73 and is folded into a letter ^ŁAT^Ł around the heating element 8 engaging the gripper 69.

[0060] As shown in Figures 25-28, each gripper 69 is tubular in shape and is formed by two shell members 76 (semicircular in cross-section) that are movable relative to each other between an open position, wherein the two shells 76 are positioned in a certain section. distances from each other, and a closed position where both shells 76 are positioned in contact with each other. In particular, in each gripper 69, the two shell members 76 are hinged to the conveyor 70 to move relative to each other by respective rotations.

[0061] The shell members 76 of each gripper 69 are positioned in the open position to allow radial entry of the support base 4 (provided with pre-mounted electrodes 6 and 7, electronics 13, support body 12 and heating element 8) connected to the hygroscopic pad 14, folded in the shape of a letter ^ŁAT^Ł and are moved to the closed position after insertion to fold the hygroscopic pad 14 into a tube around the heating element 8. In other words, in each gripper 69, the initially flat hygroscopic pad 14 is gripped by the support base 4 which moves vertically upwards and then, entering the gripper 69 (with the shell elements 76 in the open position), is bent into a letter. 'U' around support base 4; after the support base 4 has fully entered the gripper 69, the shell members 76 of the gripper 69 are brought into a closed position to fold the hygroscopic pad 14 into a tube around the heating element 8.

55P41435PL00 ΕΡ 3 025 600 BI

[0062] As shown in Figures 29 and 30, between the assembly station S7 for assembling the hygroscopic cushions 14 and the assembly station S8 for assembling the bases 5, there is defined a transfer station S9 in which the handling device 77, which pulls out the support base 4 (equipped, among others, into the heating element 8 and the hygroscopic pad 14) bent into a tube, axially from the gripper 69, while the shell elements 76 of the gripper 69 are still in the closed position.

[0063] In the transfer station S9, each seat 72 of the conveyor 70 is axially aligned with the respective gripper 69 of the conveyor 67 so that the support base 4 (equipped with, inter alia, a heating element 8 and a hygroscopic pad 14 bent into a tube) is pulled out. axially from the gripper 69 of the conveyor 67 and driven axially into the base 5 mounted in the seat 72 of the conveyor 70 by operation of the conveying device 77. According to a preferred embodiment, each gripper 69 of the conveyor 67 has a flared inner shape that is progressively reduced at the discharge end through which the support base 4 protrudes from the gripper 69 itself. During the transfer of the support seat 4, the respective gripper 69 of the conveyor 67 is kept fully closed until the support seat 4 comes near the outlet end and is partially opened when the support seat 4 comes near the outlet end; thus the flared shape of each gripper 69 is used to radially compress the composite hygroscopic pad 14 (which has the ability to flexibly deform without being damaged) to facilitate entry into the corresponding base 5, while the flared shape of each gripper 69 is not used when inserting the base support 4 in the base

5, because the support seat 4 is not capable of being elastically deformed without being damaged.

[0064] According to the preferred embodiment shown in the attached figures, the handling device 77 comprises a pusher 78 which passes through the gripper 69 of the conveyor 67 so as to axially push the support base 4 (provided with, inter alia, a heating element 8 and a hygroscopic cushion bent into a tube). 14), and an opposing follower 79, opposite and aligned with the follower 78, passes through the seat 72 of the conveyor 70 for accompaniment, on the side opposite to the pusher 58, an axial movement of the supporting base (provided, inter alia, with a heating element 8 and a hygroscopic cushion 14 bent into a tube).

[0065] According to a possible embodiment, the transferring station S9 also comprises a pivot device that is coupled to each seat 72 of the conveyor 70 and is designed to cause the respective base 5 to rotate in the transfer station S9 during the axial insertion of the support base 4 (provided with, inter alia, a heating element 8 and a hygroscopic pillow 14) bent into a tube; the rotation of the base 5 in the transfer station S9 makes it possible to facilitate the axial insertion of the support base 4 (provided inter alia with a heating element 8 and a hygroscopic cushion 14 bent into a tube).

[0066] As shown in Figure 22, the conveyor 70 is connected to a pinching device 80 which is positioned downstream (viewed in the working direction) of the transfer station S9 and deforms one edge of the base 5 to mechanically fix the support base 4 to the base itself. 5.

55P41435PL00

The assembly station S7 for mounting the hygroscopic cushions 14 is particularly effective and efficient because, starting with the hygroscopic cushions 14, which are initially bent into a 'U' shape when inserted into the open, respective grippers 69, and are then bent into a tube by closing the grippers 69, it is possible to operate quickly (i.e. with a very high hourly capacity) while ensuring both high accuracy in the positioning of the hygroscopic cushions 14 and a very gentle treatment of the hygroscopic cushions 14, which fully preserves the integrity of the hygroscopic cushions 14 themselves (thus ensuring the overall high quality of production i).

[0068] Also, the assembly station S8 for assembling the bases 5 is particularly effective and efficient, thus allowing rapid operation (i.e. with a very high hourly output) while ensuring the integrity of all the components of the cartridges 2.

[0069] The production machine 15 described above has many advantages.

[0070] First, the production machine 1 described above enables a high hourly output (i.e. the number of pieces produced per unit time) to be obtained while at the same time ensuring a high quality standard of the refills 2.

[0071] Moreover, the above-described production machine 1 is also easy and inexpensive to produce as it consists of structurally simple elements requiring little and easy maneuvering.

[0072] Finally, the above-described production machine 1 provides adequate maneuvering space around each

55P41435PL00

The component ΕΡ 3 025 600 BI, therefore both the initial assembly of the components and the subsequent servicing of the components themselves are simplified (from simple cleaning to replacement).

GD Societa 'per Azioni

Proxy:

55P41435PL00

ΕΡ 3 025 600 BI