Method And Apparatus For Manufacturing A Liquid-Filled Capsule

Abstract

A method of manufacturing liquid-filled capsules for use in smoking articles includes providing a capsule shell defining a cavity and having an open end; dispensing a volume of liquid into the cavity through the open end of the shell, whereby a clearance is left between an upper surface of the liquid dispensed into the cavity and the open end of the shell and sealing the open end of the shell with a portion of sheet material to provide a liquid-filled capsule containing the volume of liquid. An apparatus for manufacturing liquid-filled capsules includes a holder for holding one or more capsule shells; a conveyor for moving or transporting the holder; a filling station for dispensing a liquid into a cavity of each of the capsule shells; and a sealing station for covering and sealing an open end of each capsule shell. A liquid-filled capsule is also provided.

1 . A method of manufacturing liquid-filled capsules for use in smoking articles, the method comprising the steps of:
 providing a capsule shell defining a cavity and having an open end;   dispensing a volume of liquid into the cavity through the open end of the shell, whereby a space or clearance is provided between an upper surface of the liquid dispensed into the cavity and the open end of the shell; and   sealing the open end of the shell with a portion of sheet material to provide a liquid-filled capsule containing the volume of liquid.   
     
     
         2 . A method according to  claim 1 , wherein the clearance is at least 0.4 mm. 
     
     
         3 . A method according to  claim 1 , wherein the step of dispensing the liquid into the shell comprises providing the capsule with a filling ratio above a predetermined minimum, whereby the filling ratio of the capsule is a ratio of the volume of liquid dispensed to a filling capacity of the cavity, and wherein the predetermined minimum of the filling ratio is 0.5. 
     
     
         4 . A method according  claim 1 , wherein the step of sealing the open end of the shell comprises:
 covering the open end of the capsule shell with the portion of sheet material;   fusing or bonding the portion of sheet material to seal said end of the shell; and   cutting excess sheet material from the portion of sheet material at the sealed end of the shell.   
     
     
         5 . A method according to  claim 1 , further comprising the steps of:
 inspecting the liquid-filled capsule or a component thereof for a manufacturing defect;   identifying the capsule as defective if a manufacturing defect is detected; and   rejecting a capsule identified as defective.   
     
     
         6 . A method according to  claim 5 , further comprising the steps of:
 providing a holding device to hold the capsule shell; and   conveying the holding device together with the capsule shell between at least two steps selected from the steps of: dispensing the liquid into the cavity, sealing the open end of the shell, inspecting the capsule or a component thereof, identifying the capsule as defective, and rejecting a capsule identified as defective.   
     
     
         7 . A method according to  claim 6 , wherein the holding device is configured to hold a plurality of capsule shells and wherein the method includes the steps of:
 positioning a plurality of capsule shells on the holding device;   referencing a position of each individual shell relative to the holding device; and   conveying the holding device with a position reference conveyor system between at least two steps selected from the steps of: dispensing the liquid into the cavity, sealing the open end of the shell, inspecting the capsule or a component thereof, identifying the capsule as defective, and rejecting a capsule identified as defective.   
     
     
         8 . A method according to  claim 1 , wherein the step of sealing the open end of the shell comprises the steps of:
 covering the open end of each of a plurality of capsule shells with the portion of sheet material;   fusing or bonding the portion of sheet material to seal said end of each of the plurality of shells; and   cutting excess sheet material from the portion of sheet material at the sealed end of each shell.   
     
     
         9 . An apparatus for manufacturing liquid-filled capsules for use in smoking articles, comprising:
 a holder for holding one or more capsule shells;   a conveyor for moving or transporting the holder with the one or more capsule shells;   a filling station for dispensing a liquid into a cavity of each of the capsule shells held by the holder, wherein the filling station is configured to leave a pre-defined space or clearance between the liquid dispensed into the cavity and an open end of each shell; and   a sealing station for covering and sealing the open end of each capsule shell with a sheet material to form a capsule.   
     
     
         10 . An apparatus according to  claim 9 , wherein the filling station comprises one or more nozzles in fluid connection with a supply reservoir of the liquid, wherein each nozzle is configured to dispense a predetermined volume of the liquid to a respective one of the shells. 
     
     
         11 . An apparatus according to  claim 9 , wherein the sealing station comprises: a supply roll of the sheet material, a heat-sealing device for fusing the sheet material to a rim at the open end of each shell, and a cutting device for cutting excess sheet material from the rim at the end of each capsule. 
     
     
         12 . An apparatus according to  claim 9 , wherein the holder for holding one or more capsule shells comprises a tray. 
     
     
         13 . A liquid-filled capsule for use in smoking articles, the capsule comprising: a capsule shell defining a cavity and having an end providing a filling opening; a volume of liquid contained within the cavity; and a cap which covers and seals the end;
 wherein a pre-defined clearance is provided between an upper surface of the liquid contained in the cavity and the end of the shell.   
     
     
         14 . A capsule according to  claim 13 , wherein the pre-defined clearance  49  is at least 0.5 mm. 
     
     
         15 . A capsule according to  claim 13 , wherein an end region of the shell comprises a pre-defined rupture region at which the shell is configured to break preferentially. 
     
     
         16 . A method according to  claim 3 , wherein the step of dispensing the liquid into the shell further comprises providing the capsule with the filling ratio within a pre-defined range from 0.5 to 0.9. 
     
     
         17 . An apparatus according to  claim 11 , wherein the sealing station further comprises a feed roller to drive the supply roll of the sheet material. 
     
     
         18 . An apparatus according to  claim 9 , wherein the conveyor for moving or transporting the holder comprises one or more of a robotic conveyor arm, a conveyor belt, and a turntable. 
     
     
         19 . An apparatus according to  claim 9 , further comprising a rejecting station at which any defective capsule is able to be removed. 
     
     
         20 . A capsule according to  claim 13 , wherein a filling ratio of the capsule is above a predetermined minimum, whereby the filling ratio of the capsule is a ratio of the volume of liquid contained to a filling capacity of the cavity, and wherein the predetermined minimum of the filling ratio is 0.5.