Method and mounting frame for manufacturing a vaporizer unit for an inhaler
12102135 ยท 2024-10-01
Assignee
Inventors
- Niklas Romming (Hamburg, DE)
- Lasse Cornils (Hamburg, DE)
- Jan JAKLIN (FELLBACH, DE)
- Thomas M?ller (Hamburg, DE)
Cpc classification
B32B37/02
PERFORMING OPERATIONS; TRANSPORTING
B32B37/14
PERFORMING OPERATIONS; TRANSPORTING
A24F40/42
HUMAN NECESSITIES
B29C45/14
PERFORMING OPERATIONS; TRANSPORTING
Y10T156/1084
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B32B37/12
PERFORMING OPERATIONS; TRANSPORTING
B32B38/18
PERFORMING OPERATIONS; TRANSPORTING
International classification
A24F40/42
HUMAN NECESSITIES
Abstract
A method for manufacturing a vaporizer assembly for an inhaler comprises the steps of providing a plurality of connection stations and performing at least one assembly step at each connection station to produce a vaporizer assembly at each connection station.
Claims
1. A method for manufacturing vaporizer assemblies for inhalers, comprising: providing a plurality of connection stations; and performing at least one assembly step at each connection station to manufacture one vaporizer assembly at each connection station; wherein the plurality of connection stations are interconnected by a metallic assembly framework; wherein the metallic assembly framework is belt-shaped and is advanced in an advancing direction to perform the at least one assembly step; wherein the at least one assembly step comprises connecting a vaporizer support to each connection station and bonding a vaporizer via an adhesive to the vaporizer support connected at each connection station; wherein the metallic assembly framework comprises a plurality of longitudinal webs extending in the advancing direction; wherein the metallic assembly framework comprises, at each connection station, at least one transverse web that extends transversely to the longitudinal webs; and wherein connecting the vaporizer support to each connection station comprises overmolding the at least one transverse web at each connection station with a plastic material.
2. The method according to claim 1, wherein the at least one assembly step further comprises: providing at least one electrically conductive connection surface at each connection station.
3. The method according to claim 2, wherein the at least one assembly step further comprises: electrically connecting and/or wiring each vaporizer to the at least one electrically conductive connection surface at each connection station.
4. The method according to claim 1, wherein the at least one assembly step further comprises: separating an at least partially assembled vaporizer assembly from the metallic assembly framework.
5. The method according to claim 1, wherein the at least one assembly step further comprises one or more of the following assembly steps: placing and/or connecting a wick element in or to each vaporizer assembly; placing at least one sealing element for fluid sealing in or on each vaporizer assembly; placing and/or connecting an identification element in or to each vaporizer assembly; enclosing each vaporizer assembly with a vaporizer housing; connecting a vent to a vent receptacle of each vaporizer assembly; mounting and/or filling a liquid tank to each vaporizer assembly.
Description
BRIEF DESCRIPTION OF THE FIGURES
(1) The invention is explained below by means of preferred embodiments with reference to the accompanying figures. Thereby shows
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DETAILED DESCRIPTION
(17) The assembly framework 10, which is in particular belt-shaped, extends continuously or quasi-endlessly along a longitudinal direction V which corresponds to an advancing direction V when processed in a manufacturing machine.
(18) The assembly framework 10 here comprises, for example, two longitudinal webs 11, 12 extending continuously or quasi-endlessly in the advancing direction, which are advantageously arranged parallel to one another. In other embodiments, only one longitudinal web or more than two longitudinal webs (see
(19) Along the longitudinal or advancing direction of the assembly framework 10, connection stations 14 are formed continuously and at regular intervals. In
(20) Furthermore, at least one transverse web 16 may be provided per connection station 14 which, starting from only one longitudinal web 11, does not extend continuously, i.e. does not extend to the other longitudinal web 12.
(21) Spacers 17 may be provided on the or each continuous transverse web 15, advantageously extending in the longitudinal direction V between each two connection stations 14 and defining and/or maintaining the distance between the respective connection stations 14.
(22) The assembly framework 10 advantageously comprises a conductive material, in particular a metal, and is advantageously bendable with respect to workability. In an advantageous embodiment, the assembly framework 10 is made of a sheet metal and is, for example, stamped from a sheet metal and then forms a stamped grid. Non-metallic materials, for example plastic, which may be conductive or metallically coated, are possible for the assembly framework 10.
(23) In the following, the production of vaporizer assemblies 50 is explained with reference to
(24) In a preliminary step, the assembly framework 10 is produced, for example, by rolling. Subsequently, the assembly framework 10 is formed into a shape that can be machined (see
(25) Thereafter, an at least partial surface finishing or electroplating of the assembly framework 10 can optionally be carried out by means of material application, embossing and/or polishing. For example, the stamped assembly framework 10 can be overmolded with plastic and the plastic can then serve as a mask for downstream gold plating by means of electroplating.
(26) In an assembly step according to
(27) After the assembly framework 10 has been overmolded at a connection station 14, the assembly framework 10 continues to be guided in the longitudinal direction V. After leaving the injection mold, the assembly framework 10 shown in
(28) Other methods are possible, for example, the vaporizer support 20 may be prefabricated by injection molding, for example, and clipped into the assembly framework 10 at the corresponding connection station 14. The vaporizer support 20 may also be made of other material, such as ceramic or a composite material.
(29) In a subsequent assembly step according to
(30) The connection of the vaporizer 21 to the vaporizer support 20 can be done, for example, by means of an adhesive 22. In one embodiment, the adhesive 22 can be applied to the vaporizer support 20 in-line, i.e. in the manufacturing process, by means of an application device 23. The application device 23 may comprise, for example, a wheel-shaped print head 24 with a plurality of, for example, four print stamps 25 for pad printing, see
(31) The adhesive 22 may be applied to the vaporizer support 20 (as in
(32) In a subsequent step, the adhesive 22 is cured. This can be done by drying in air or advantageously by applying heat, in particular in an oven. Alternatively, it is also possible to use UV-curable adhesive 22, which is then cured by means of UV radiation. Curing can be carried out batch-wise or in a continuous process, for example in a continuous oven.
(33) After leaving the placement and connection tool, the assembly framework 10 shown in
(34) In an advantageous embodiment, the vaporizer 21 is attached to the rear of the vaporizer support 20. This is best illustrated in
(35) In a subsequent assembly step as shown in
(36) In an optional step according to
(37) At a suitable time in the assembly process, partial singulation of the vaporizer assemblies 50 may optionally be performed as shown in
(38) Advantageously, in a further assembly step as shown in
(39) The wick element 27 is advantageously placed in a wick receptacle 33 or hollow space (cavity) of the vaporizer support 20 in fluid-conducting connection with the vaporizer 21. A nonwoven fabric, for example a glass fiber nonwoven fabric, may optionally be disposed between the wick element 27 and the vaporizer 21. The the wick element 27 may, for example, be made of ceramic. Fixation of the wick element 27 in the wick receptacle 33 may be achieved, for example, by means of a clamp, such as when the wick element 27 comprises an oversize relative to the wick receptacle 33. Alternatively, fixation of the wick element 27 in the wick receptacle 33 may be accomplished by means of an adhesive, for example from the outside, or between the wick element 27 and the wick receptacle 33, or between the wick element 27 and the vaporizer, wherein in the latter case the adhesive advantageously contracts upon curing so that the wick element 27 is permanently pressed against the vaporizer. Where an adhesive is used to fix the wick element 27 in the wick receptacle 33, this is cured in a subsequent step. This can be done by drying in air or advantageously by applying heat, in particular in an oven. Alternatively, it is also possible to use UV-curable adhesive, which is then cured by means of UV radiation. Curing can be carried out batchwise or in a continuous process, for example in a continuous oven.
(40) After leaving the placement device, the assembly framework 10 shown in
(41) In the embodiment shown in
(42) For assembly, the wick element 27 is first placed in the receptacle 33 of the vaporizer support 20. Then, to seal a liquid inlet opening 36 of the lower shell 32, an elastomeric sealing element 34, for example in the form of a sealing ring, may be arranged in a hollow space 35 around the liquid inlet opening 36. Subsequently, the assembly of vaporizer support 20 with vaporizer 21 can be placed on the lower shell 32, for example by lowering or bending the assembly framework 10. Alternatively, the lower shell 32 can be attached to the vaporizer support 20, for example by an assembly robot. When assembled, the sealing element 34 advantageously exerts a permanently elastic force on the wick element 27 against the vaporizer 21.
(43) The wick element 27 may be round in cross-section or comprise any other suitable cross-sectional shape. The cross-sectional shape of the wick element 27 may be adapted to the shape of the vaporizer 21. The lower shell 32 may be bonded to the vaporizer support 20 for sealing purposes. The identification element 29 can thereby be encapsulated in a tamper-proof manner.
(44) In a subsequent assembly step as shown in
(45) For assembly, the vaporizer housing 37 is advantageously slidable over the vaporizer assembly 50, as shown in
(46) To seal the vaporizer housing 37 against the vaporizer support 20, for example, an adhesive can be applied to the vaporizer housing 37 and/or the vaporizer support 20 before insertion, in particular over a large area. Alternatively, an adhesive can be applied or pressed locally into a groove provided in the vaporizer support 20, for example, through the vent opening 47 in the vent mount 41, or through an additional opening in the liquid tank 44. Furthermore, a sealing groove can be welded locally around the wick element 27 preferably from the outside by heat treatment, for example by ultrasonic or thermosonic welding. The welding can be done efficiently, for example, by radiating through the liquid tank 44 by means of a laser beam. Sealing of the vaporizer housing 37 against the vaporizer support 20 ensures that vaporization liquid can only flow into the space around the wick element 27. On the vaporizer side, tightness is established by pores of the vaporizer 21.
(47) In an alternative embodiment according to
(48) As an alternative to the two-component vaporizer housing 37, 19 design, a separate sealing ring may be provided as the sealing element 19, which is squeezed through the vaporizer housing 37, for example.
(49) The insertion of the vaporizer assemblies 50 into the vaporizer housings 37 can be done individually, serially or batch-wise. In the case of series production, a plurality of vaporizer housings 37 are preferably connected by webs and produced at the spacing corresponding to the connection stations 12, for example by injection molding.
(50) To complete a vaporizer cartridge 52, a vent 42 is connected to the corresponding vent receptacle 41 of the vaporizer unit 51, for example inserted therein, and then a liquid tank 44 is slid over the vent 42 and the vaporizer unit 51 and connected in a liquid-tight manner to an end flange 40, for example by welding or bonding. The liquid tank 44 is advantageously cylindrical and preferably comprises a shell element 45 and an end face part 46 for closing the end face of the shell element 45 opposite the vaporizer unit 51 or the vaporizer-side interface 40 and/or for holding the end of the vent 42 opposite the vaporizer unit 51, see
(51) Finally, there follows a step of singulating the vaporizer units 51 by separating them from the assembly framework 10 or longitudinal web(s) 11, thereby obtaining individual vaporizer assemblies 50, individual vaporizer units 51, or individual vaporizer cartridges 52 as in
(52) The embodiment according to
(53) The vaporizer 21 is advantageously designed as a microelectromechanical system (MEMS), for example with conduction or microchannels, as described in DE 10 2016 120 803 A1, the disclosure content of which is incorporated to that extent in the present application. Advantageously, this involves a flat silicon heater provided with microchannels, possibly doped. Bionic or capillary-like heater structures, such as bionic meshes, are also possible for the vaporizer 21. Vaporizers 21 with heating structures as described in DE 10 2017 111 119 A1 are also possible, the disclosure content of which is to that extent incorporated in the present application. In general, the invention is not bound to a specific type of vaporizer 21.
EMBODIMENTS
(54) Embodiment 1. Method for manufacturing a vaporizer assembly (50) for an inhaler, characterized by providing a plurality of connection stations (14) and performing at least one assembly step at each connection station (14) to manufacture a vaporizer assembly (50) at each connection station (14).
(55) Embodiment 2. Method according to embodiment 1, characterized in that the connection stations (14) are interconnected by an assembly framework (10).
(56) Embodiment 3. Method according to any of the preceding embodiments, comprising the following assembly step:
(57) Connecting a vaporizer support (20) to the or each connection station (14), in particular by overmolding the assembly framework (10) with a plastic material.
(58) Embodiment 4. Method according to any of the preceding embodiments, comprising the following assembly step:
(59) Bonding a vaporizer (21) to the or each connection station (14), in particular by means of an adhesive (22).
(60) Embodiment 5. Method according to any one of the preceding embodiments, comprising the following assembly step:
(61) Providing at least one electrically conductive connection surface (18) at each connection station (14).
(62) Embodiment 6. Method according to embodiment 5, comprising the following assembly step:
(63) electrically connecting and/or wiring the vaporizer (21) to the or each electrically conductive connection surface.
(64) Embodiment 7. Method according to any one of the preceding embodiments, comprising the following assembly step:
(65) at least partially singulating the at least partially assembled vaporizer assembly (50), in particular by separating it from the assembly framework (10).
(66) Embodiment 8. Method according to any of the preceding embodiments, comprising one or more of the group of following assembly steps: placing and/or connecting a wick element (27) in or to the or each vaporizer assembly (50); placing at least one sealing element (19, 34) for fluid sealing in or on the or each vaporizer assembly (50); placing and/or connecting an identification element (29) in or to the or each vaporizer assembly (50); enclosing the or each vaporizer assembly (50) with a vaporizer housing (37); connecting a vent (42) to a vent receptacle (41) of the or each vaporizer assembly (50); mounting and/or filling a liquid tank (44) to the or each vaporizer assembly.
(67) Embodiment 9. Method according to any one of the preceding embodiments, characterized in that the assembly framework (10) is belt-shaped, preferably provided in a substantially endless manner, and is advanced to perform assembly steps, preferably in a work-clocked manner.
(68) Embodiment 10. Assembly framework (10) for use in at least one assembly device for carrying out the assembly method according to any of the preceding embodiments.
(69) Embodiment 11. Assembly framework (10) according to embodiment 10, characterized in that the assembly framework (10) is metallic, belt-shaped and/or rollable/unrollable.
(70) Embodiment 12. Assembly framework according to embodiment 10 or 11, characterized in that the assembly framework (10) comprises at least one, advantageously several, longitudinal webs (11, 12) extending in an advancing direction, wherein the connection stations (14) are advantageously arranged in one or more rows parallel to the longitudinal webs (11, 12).
(71) Embodiment 13. Assembly framework according to embodiment 12, characterized in that guide elements or openings (13) are provided at periodic distances on or in at least one longitudinal web (11, 12).
(72) Embodiment 14. Assembly framework according to embodiment according to one of the embodiments 9 to 12, characterized in that the assembly framework (10) comprises at each connection station (14) at least one transverse web (15, 16) which extends transversely starting from at least one longitudinal web (11, 12).
(73) Embodiment 15. Assembly framework according to embodiment 14, characterized in that at least a part of the at least one transverse web (15, 16) remains permanently on or in the vaporizer assembly (50) and advantageously forms at least one electrical connection (48) for electrical contacting of the vaporizer (21).
LIST OF REFERENCE SIGNS
(74) 10 assembly framework 11 longitudinal web 12 longitudinal web 13 guide opening 14 connection station 15, 16 transverse web 17 spacer 18 connecting surface 19 sealing element 20 vaporizer support 21 vaporizer 22 adhesive 23 application device 24 print head 25 print stamp 26 air channel 27 wick element 28 electrical line 29 digital identification element 30 end face opening 31 liquid reservoir 32 lower shell 33 wick receptacle 34 sealing element 35 hollow space 36 liquid inlet opening 37 vaporizer housing 38, 39 end faces 40 flange 41 vent receptacle 42 vent 43 shell part 44 cartridge housing 45 shell element 46 end face part 47 vent opening 48 electrical connections 49 electrical interface 50 vaporizer assembly 51 vaporizer unit 52 vaporizer cartridge 53 longitudinal web