The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. A system may include assembly cells each including an assembly track and assembly carriages that ride thereon and which engage components of partially-assembled cartridges. A transfer apparatus may transfer partially-assembled cartridges between the assembly cells. In another example system, cartridges may be assembled on platforms on a rotary track. The platforms may include assembly grippers with sequentially-opening clamps configured to receive the components of the partially-assembled cartridges. Related methods are also provided.

A method for making a smokeless tobacco article can include combining thermoplastic polymer particles with tobacco particles to form a mixture of particles, compressing the mixture of particles within a pressing apparatus to form the mixture into a predetermined shape, separating the mixture from the pressing apparatus such that it retains the predetermined shape, and heating the mixture outside of the pressing apparatus to at least partially melt at least some of the thermoplastic polymer particles and form a matrix of polymer and tobacco particles.

A heating assembly includes an atomizing base and a resistive heating element at least partially embedded in the atomizing base. The resistive heating element includes a heating fence, two connecting portions and two conductive pins arranged along a length direction of the resistive heating element. The heating fence is located in a middle of the resistive heating element. The two connecting portions are respectively located on two opposite sides of the heating fence and are interconnected by the heating fence. The two conductive pins are located at two opposite ends of the resistive heating element and are connected with the two connecting portions respectively. The atomizing base includes a base plate and a side wall extending from a periphery of the base plate. A receiving cavity is formed in the atomizing base. An atomizing opening penetrates through the base plate. The atomizing opening is aligned with the heating fence.

A method of manufacturing a heater for an aerosol-generating device is provided, the method including: forming a heater body including a heater body frame and a heating element, the heater body defining at least a portion of a boundary of a heating chamber configured to receive an aerosol-generating article such that the heating element is configured to heat the heating chamber, at least part of the heater body frame being manufactured by additive manufacturing. A method of manufacturing an aerosol-generating device; and a heater; and an aerosol-generating device are also provided.

A method for making a smokeless tobacco article can include combining thermoplastic polymer particles with tobacco particles to form a mixture of particles, compressing the mixture of particles within a pressing apparatus to form the mixture into a predetermined shape, separating the mixture from the pressing apparatus such that it retains the predetermined shape, and heating the mixture outside of the pressing apparatus to at least partially melt at least some of the thermoplastic polymer particles and form a matrix of polymer and tobacco particles.

A heater assembly for an aerosol-generating device is provided, the heater assembly including: a bushing defining an aperture at a first end of the bushing and a cavity at a second end of the bushing; and an elongate electrical heater extending from the first end of the bushing, in which a portion of the elongate electrical heater extends through the aperture and into the cavity. An aerosol-generating device, and an aerosol-generating system, are also provided.

A method of fabricating a thin film heater includes providing a heating element supported on a surface of a flexible dielectric backing film; and attaching a layer of heat shrink film onto the surface of the dielectric backing film so as to at least partially enclose the heating element between the heat shrink film and the dielectric backing film. The method provides a much more precise and consistent method of assembling the heater assembly and improves the thermal properties and heat transfer to a heating chamber.

A heater assembly for an aerosol-generating device is provided, the heater assembly including a bushing defining an aperture at a first end of the bushing and a cavity at a second end of the bushing; a potting compound disposed within the cavity; and an elongate electrical heater extending from the first end of the bushing, where a portion of the elongate electrical heater extends through the aperture and into the cavity. An aerosol-generating device, an aerosol-generating system, and a method of assembling a heater assembly for an aerosol-generating device are also provided.

Exposure of a leftover material at a cartridge that forms a vapor product is prevented. There is provided a cartridge that is assembled in a part of a vapor product that includes a heating element for heating an aerosol source. The cartridge includes a first component and a second component, at least one of which being formed of resin, and a connection section whose one end is connected to the first component and whose another end is joined or welded to the second component. The second component includes a facing surface that faces the first component, and an outermost edge of the facing surface. The other end of the connection section is joined or welded to the facing surface of the second component, at a position away from the outermost edge.

The present disclosure relates to systems, apparatuses, and methods for assembling cartridges for aerosol delivery devices. A system may include assembly cells each including an assembly track and assembly carriages that ride thereon and which engage components of partially-assembled cartridges. A transfer apparatus may transfer partially-assembled cartridges between the assembly cells. In another example system, cartridges may be assembled on platforms on a rotary track. The platforms may include assembly grippers with sequentially-opening clamps configured to receive the components of the partially-assembled cartridges. Related methods are also provided.