FILL-THROUGH PACKAGING FOR CARTRIDGE DEVICE

Description

BACKGROUND

In fields that involve liquid-filling of a fillable device—including but not limited to personal smoking and vaporization devices such as cartridges—manufacturing efficiency depends on streamlined production workflows that minimize handling steps and reduce process complexity. For example, traditional cartridge filling operations require dedicated fixtures to secure each individual cartridge during automated filling procedures. Each cartridge must be positioned precisely in a filling fixture to ensure proper alignment between the dispensing needle and the cartridge fill port. After the filling operation completes, workers manually remove the filled cartridge from the fixture. The filled cartridge then undergoes additional handling steps as workers transfer it to packaging stations. This sequence of operations introduces multiple opportunities for contamination of the filled product.

The manual handling of filled cartridges presents several technical challenges. Workers must transport cartridges from filling stations to packaging areas without disturbing the filled contents. During this transfer period, the filled cartridges remain vulnerable to leakage if handled improperly. The vaporizable solutions contained in these cartridges can include viscous oils or temperature-sensitive formulations that require careful handling. Any spillage during transfer results in product loss and potential workplace exposure to concentrated substances. Furthermore, each handling step increases the time between filling and final packaging, extending the period during which the product remains exposed to potential contamination sources.

Process complexity increases when manufacturing workflows involve multiple discrete stations. Each transfer point between stations represents a potential source of errors or quality issues. Workers must track which cartridges have been filled and which remain empty during the transfer process. If a filled cartridge becomes mixed with unfilled inventory, quality control problems can arise. The separation of filling and packaging operations also complicates production scheduling. Filling operations must complete before packaging can begin, creating potential bottlenecks when one operation proceeds faster than the other. Inventory of filled but unpackaged cartridges can accumulate between stations, requiring additional storage space and inventory management.

Sterility concerns become particularly acute for products intended for inhalation. Each time a worker handles a filled cartridge, the risk of introducing contaminants increases. Even in controlled manufacturing environments, minimizing handling steps reduces contamination risk. The period between filling and final packaging represents a vulnerable window when the product remains exposed. Traditional workflows cannot eliminate this exposure period because the product must be filled before it can be packaged. Clean room requirements for filling operations add to facility costs, yet the benefits diminish if products undergo extensive handling after filling.

As a result, a need exists for manufacturing processes that reduce the number of handling steps between cartridge filling and final packaging. In addition, a need exists for packaging systems that can serve multiple functions within the manufacturing workflow. A need also exists for methods that eliminate the requirement for separate filling fixtures while maintaining precise alignment during filling operations.

SUMMARY

Examples described herein include fill-through packaging units for fillable devices, methods for filling fillable devices within packaging units, and systems for automated filling operations. The fillable devices can include cartridges, smoking devices, vaporization devices, or other fluid-containing products. The fill-through packaging units can enable filling of the fillable devices after the devices have been positioned within their retail packaging, thereby eliminating manual handling steps between filling and final packaging operations.

An example fill-through packaging unit for a fillable device configured to hold a fluid can include a positioning component and an outer body portion. The positioning component can be shaped to removably accept the fillable device. The positioning component can maintain the fillable device in a predetermined position within the positioning component. The outer body portion can define a plurality of external surfaces. At least one of the plurality of external surfaces can comprise an outer filling location. The outer filling location can be at least one of an aperture or puncturable cover. The outer filling location can be aligned with a device-filling location of the fillable device. The alignment can establish a longitudinal axis that runs through both the outer filling location and the device-filling location.

The fill-through packaging unit can further include a guide component. The guide component can be configured to guide a fill needle along a longitudinal axis that runs through the outer filling location and the device filling location. The guide component can constrain needle movement to prevent misalignment during insertion. The guide component can be positioned between the outer filling location and the device-filling location.

The outer body portion can be shaped to define a viewing window. The fillable device can be viewed from outside the fill-through packaging unit through the viewing window. The viewing window can allow visual inspection of fill level during or after the filling operation. The viewing window can be formed from transparent or translucent material or can simply be a void with no packaging material in the viewing window.

The outer fill location can be positioned on a top or bottom surface of the outer body portion. When a plurality of fill-through packaging units are assembled into a display box, their respective outer filling locations can remain accessible. This configuration can allow multiple units to be filled simultaneously or sequentially without removing them from the display box. The top surface positioning can facilitate automated filling operations.

The fillable device can be at least one of a cartridge or smoking device. For example, the fillable device can be a vaporization cartridge configured to hold oil or e-liquid. The fillable device can include a reservoir for containing fluid and an atomizer for vaporizing the fluid. In some examples, the fillable device includes a mouthpiece for user inhalation.

An example method is also provided for filling a fillable device within a fill-through packaging unit can include inserting the fillable device into a positioning component. The positioning component can be shaped to removably accept the fillable device. The positioning component can maintain the fillable device in a predetermined position within the positioning component. The method can further include associating the positioning component and fillable device with an outer body portion to form a fill-through packaging unit. The association can involve inserting the positioning component into the outer body portion and securing the positioning component to the outer body portion.

The method can include securing the fill-through packaging unit in a fixture. The fixture can hold the fill-through packaging unit in a fixed position during filling operations. For example, the fixture can engage external surfaces of the outer body portion. The method can further include inserting a fill needle through an outer filling location of the fill-through packaging. The fill needle can pass through a device-filling location of the fillable device. In an example, the insertion can occur along a longitudinal axis that runs through both the outer filling location and the device-filling location. The method can include filling the fillable device with a fluid using the fill needle. The fluid flows through the fill needle into the fillable device.

In an example, the outer filling location can be at least one of an aperture or puncturable cover. For example, the puncturable cover can be formed from a self-sealing elastomeric material. The puncturable cover can reseal after the fill needle is withdrawn. The aperture can be an open hole that allows needle passage. The puncturable cover of the fillable device can be a silicon cover. The silicon cover can be configured to close after being punctured by the fill needle. The silicon cover can provide a self-sealing function that prevents fluid leakage after filling. In this way, the silicon cover can maintain package integrity after the needle withdrawal.

Securing the fill-through packaging unit in a fixture can include placing multiple fill-through packaging units into a larger container, also referred to herein as a display box. The filled container can be secured in the fixture. The container can hold multiple fill-through packaging units in an organized array. The method can further include the fixture inverting the container holding the plurality of fill-through packaging units. The fixture can retain the plurality of fill-through packaging units within the container during inversion, such as by using a cover or plate that retains the units but allows for access to the filling locations of each unit. Inversion can facilitate filling by positioning the device-filling locations in an upward orientation. The container can be configured to hold 50 fill-through packaging units. In other examples, the container can be configured to hold 10, 20, 30, 40, or 100 fill-through packaging units.

The outer fill location can be positioned on a top surface such that when a plurality of fill-through packaging units are assembled into the container, their respective outer filling locations can remain accessible. This positioning can allow simultaneous or sequential filling of multiple units. The fill-through packaging can comprise a guide component configured to guide a fill needle along a longitudinal axis running through the outer filling location and the device filling location. The method can further include applying a sticker to the fill location of a fill-through package after filling. The sticker can cover the punctured area. The sticker can provide additional sealing and contamination protection. The method can further include applying a sticker sheet to a plurality of fill-through packages at one time. The sticker sheet can apply stickers to each fill location of each fill-through package. The sticker sheet can enable rapid sealing of multiple units. The method can further include heating the fluid before inserting it into the fillable device, to reduce fluid viscosity and facilitate faster filling operations.

An example fill-through packaging unit for a cartridge configured to hold oil can include a packaging insert, a cartridge, and an outer box. The packaging insert can be shaped to removably accept the cartridge. The packaging insert can maintain the cartridge in a predetermined position. The cartridge can be inserted into the packaging insert. The outer box can be configured to hold the packaging insert. The outer box can include a viewing window. The outer box can include an aperture configured to allow access to the cartridge via a fill needle. The aperture can be aligned with a fill port of the cartridge. The packaging insert can comprise a guide portion for guiding the fill needle to the cartridge. The guide portion can direct the fill needle along a predetermined path. The cartridge can include a puncturable silicon cover that self-seals after filling. The silicon cover can close automatically after needle withdrawal. A fill level of the cartridge can be viewable through the viewing window of the outer box. Visual inspection can verify proper fill volume.

Both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the examples, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a fill-through packaging unit for a fillable device according to one or more embodiments herein.

FIG. 2 is a perspective, cross-sectional view of the fill-through packaging unit of FIG. 1.

FIG. 3 is a front view of a fill-through packaging unit for a fillable device according to one or more embodiments herein.

FIG. 4 is a front, cross-sectional view of the fill-through packaging unit of FIG. 3.

FIG. 5 is a flowchart of an example method for preparing and filling a batch of fill-through packaging units.

FIG. 6 provides front and side views of each of a fill-through packaging outer box and a fill-through packaging positioning insert.

FIG. 7 is a perspective view of a fill-through packaging system including a fillable device, insert, outer box, and display box.

FIG. 8 is a perspective view of a display box in various stages of assembly according to one or more embodiments herein.

FIG. 9 is a perspective view of a display box oriented for a filling process, according to one or more embodiments herein.

FIG. 10 is an alternative depiction of the display box of FIG. 9 with all fill-through packaging units removed other than the unit being filled.

FIG. 11 is an alternative view of the fill-through packaging unit of FIGS. 9 and 10.

FIG. 12 is a cross-sectional view of the fill-through packaging unit of FIGS. 9-11.

FIG. 13 is an alternative cross-sectional view of the fill-through packaging unit of FIGS. 9-12.

FIG. 14 is a front view of a cut-out pattern for a display box according to one or more embodiments herein.

FIG. 15 is a front view of cut-out patterns for an insert and an outer box according to one or more embodiments herein.

DETAILED DESCRIPTION

Reference will now be made in detail to the present examples, including examples illustrated in the accompanying drawings.

Examples herein include systems and methods for filling liquid-capable vessels, such as cartridges or smoking devices, while retained in retail packaging. These examples include a fill-through packaging unit for fillable devices and an improved manufacturing process for use in smoking device production. The fill-through packaging unit can include a positioning component, an outer body portion, a puncturable cover, and a guide component. The unit can enable filling operations to occur after the fillable device has been placed in its final retail packaging, such as by providing aligned access from an external surface to an internal filling port. The packaging unit can automatically maintain spatial alignment between the outer filling location and the device filling location, can protect the device during filling operations, and can facilitate batch processing of multiple units simultaneously. The manufacturing system can generate filled, packaged smoking devices based on unfilled devices received in fill-through packaging units.

The fill-through packaging unit may be configured to address inefficiencies in conventional smoking device manufacturing processes. Traditional manufacturing workflows can require separate filling fixtures, manual handling of filled cartridges, and sequential processing steps that increase labor costs and process complexity. The fill-through packaging unit can eliminate the need for separate filling fixtures by serving as both the retail package and the filling fixture. This dual functionality can reduce manufacturing steps, minimize manual handling, and decrease the risk of contamination during the filling process.

Although the systems, devices, and methods described herein are generally directed toward a smoking device or smoking-related item, the same systems, devices, and methods can be used for other types of devices as well. For example, the disclosures herein can apply to any container to be filled with liquids, where the container is placed in packaging before being filled. This can include glass containers with concentrates, such as an oil or perfume.

FIG. 1 provides a perspective view of an example fill-through packaging unit 110 according to one or more embodiments herein. The fill-through packaging unit 110 may be configured to retain a fillable device while enabling filling operations to occur through the packaging structure itself. The unit 110 can include an outer body portion that defines multiple external surfaces. One of these external surfaces may include an outer filling location 120. The outer filling location 120 can be positioned to provide access from the exterior of the packaging unit 110 to an internal filling port of a fillable device retained within the unit 110.

The fill-through packaging unit 110 can also include one or more viewing ports 130. The viewing ports 130 may be transparent or translucent sections of the outer body portion, or it can be a void where no material is present. These ports 130 can allow visual inspection of the fillable device from outside the packaging unit 110. For example, a viewing port 130 can enable verification of fill levels during or after a filling operation. The viewing port 130 can also allow consumers to view the product before purchase.

The packaging unit 110 may further include an interlocking button 140. The interlocking button 140 can be a mechanical feature that facilitates assembly of the packaging unit 110. In some examples, the interlocking button 140 engages with corresponding features on other components of the packaging unit 110. The button 140 can secure different portions of the packaging unit 110 together. For example, an insert can include a protrusion that fits within a aperture in the outer box to interlock the two components together. This can maintain the structural integrity of the unit 110 during handling and filling operations.

The outer filling location 120 may be positioned on a bottom surface of the packaging unit 110 in the example of FIG. 1. This positioning can allow multiple packaging units 110 to be arranged in a container with their respective outer filling locations 120 remaining accessible. The outer filling location 120 can be aligned along a longitudinal axis that runs through the center of a fillable device retained within the unit 110. This alignment can enable a fill needle to pass through the outer filling location 120 and directly into the device filling location without requiring removal of the device from the packaging.

The outer body portion of the packaging unit 110 may be formed from a rigid or semi-rigid material. For example, the body portion can be constructed from molded plastic, folded paperboard, or a combination of materials. The body portion can provide structural support for the fillable device during shipping and handling. The body portion can also protect the device from physical damage and environmental contamination.

FIG. 2 provides a perspective, cross-sectional view of the fill-through packaging unit 110 of FIG. 1. The cross-sectional view reveals internal structures and spatial relationships that are not visible in the exterior perspective view of FIG. 1. The packaging unit 110 in FIG. 2 can include the same outer body portion described with respect to FIG. 1. The outer body portion can define an internal cavity within which a fillable device 210 may be positioned.

The fillable device 210 may be a smoking device, a cartridge, or any other container configured to hold a fluid. The device 210 can be positioned within the internal cavity of the packaging unit 110. A positioning component within the packaging unit 110 can maintain the fillable device 210 in a predetermined position. The positioning component can be shaped to conform to the outer geometry of the fillable device 210. This conforming shape can prevent the device 210 from shifting or rotating within the packaging unit 110 during handling or transport.

The fillable device 210 can include a device filling location 220. The device filling location 220 may be a port, aperture, or valve through which fluid can be introduced into the interior volume of the device 210. In some examples, the device filling location 220 can be a self-sealing membrane. The membrane can be formed from an elastomeric material such as silicone. The septum can be configured to close automatically after a fill needle is withdrawn. This self-sealing property maintains the integrity of the fluid contained within the device 210 after the filling operation is complete.

The outer filling location 120 is visible in FIG. 2 at an external surface of the packaging unit 110. The outer filling location 120 can be aligned with the device filling location 220 along a longitudinal axis. This longitudinal axis runs through the center of the outer filling location 120 and through the center of the device filling location 220. The alignment along this axis can enable a fill needle to pass through the outer filling location 120 and directly into the device filling location 220 without requiring removal of the device 210 from the packaging unit 110.

The cross-sectional view of FIG. 2 can illustrate the spatial relationship between the outer filling location 120 and the device filling location 220. The positioning component can maintain this spatial relationship by holding the device 210 in a fixed position relative to the outer body portion. The distance between the outer filling location 120 and the device filling location 220 can be predetermined based on the geometry of the packaging unit 110 and the fillable device 210. A fill needle of appropriate length can traverse this distance during a filling operation.

The outer body portion of the packaging unit 110 can provide structural support for the fillable device 210. The outer body portion can protect the device 210 from physical impacts during shipping and handling. The outer body portion can also shield the device 210 from environmental contaminants such as dust, moisture, or airborne particles. The outer body portion can be formed from a rigid or semi-rigid material that maintains its shape under normal handling conditions.

The device filling location 220 can be oriented to face the outer filling location 120. The device 210 can be inserted into the packaging unit 110 in a specific orientation that aligns the device filling location 220 with the outer filling location 120. The positioning component can include features that guide the device 210 into the correct orientation during insertion. For example, the positioning component can include asymmetric surfaces or protrusions that mate with corresponding features on the device 210. These mating features can prevent the device 210 from being inserted in an incorrect orientation.

The positioning component can be an insert that fits within the outer body portion of the packaging unit 110. The insert can be a separate piece that is assembled with the outer body portion during packaging operations. The insert can include a shaped receptacle that conforms to the outer geometry of the fillable device 210. The receptacle can hold the device 210 securely while allowing the device 210 to be removed by an end user after purchase. The insert can be formed from a compliant material such as foam or rubber to provide cushioning and friction for retaining the device 210.

The viewing port 130 in FIG. 2 can be positioned on a side surface of the packaging unit 110. The viewing port 130 can provide a clear line of sight to the fillable device 210 within the internal cavity. The viewing port 130 can extend across a portion of the side surface to allow viewing of the device 210 from multiple angles. The viewing port 130 can be formed by leaving an opening in the outer body portion or by inserting a transparent panel into the outer body portion.

FIG. 3 provides a front view of an example fill-through packaging unit 110 according to one or more embodiments herein. The packaging unit 110 in FIG. 3 can include the fillable device 210 positioned within the internal cavity of the outer body portion. The viewing port 130 may be visible on a front surface of the packaging unit 110. The viewing port 130 can provide a transparent or translucent section through which the fillable device 210 can be observed from outside the packaging unit 110. The viewing port 130 can enable visual inspection of the device 210 without requiring removal of the device 210 from the packaging unit 110.

The viewing port 130 may be formed by an opening in the outer body portion. The opening can be left as a void where no material is present. Alternatively, the viewing port 130 can be formed by inserting a transparent panel into the outer body portion. The transparent panel can be constructed from a clear polymer material such as polyethylene terephthalate, polycarbonate, or acrylic. The panel can be secured to the outer body portion using adhesive, mechanical fasteners, or by being molded as an integral part of the body portion.

The viewing port 130 can extend across a substantial portion of the front surface of the packaging unit 110. The port 130 can be sized to allow viewing of the fillable device 210 from multiple angles. The port 130 can enable verification of the fill level of the device 210 during or after a filling operation. For example, an operator or automated vision system can observe the fluid level within the device 210 through the viewing port 130. The viewing port 130 can also allow consumers to view the product before purchase in a retail environment.

FIG. 4 provides a front, cross-sectional view of the fill-through packaging unit 110 of FIG. 3. The cross-sectional view is taken along a vertical plane that bisects the packaging unit 110. This plane can pass through a longitudinal axis that runs through the outer filling location 120 and the device filling location 220. The cross-sectional view reveals internal structures and spatial relationships that are not visible in the front view of FIG. 3.

The fillable device 210 is visible in the cross-sectional view of FIG. 4. The device 210 can be positioned within the internal cavity of the packaging unit 110. The positioning component can maintain the device 210 in the predetermined position described with respect to FIG. 2. The device 210 can be oriented such that the device filling location 220 faces toward the outer filling location 120. The device filling location 220 may be aligned with the outer filling location 120 along the longitudinal axis. This alignment can be maintained by the positioning component that holds the device 210 in place. The longitudinal axis can extend vertically through the center of the outer filling location 120 at the bottom surface of the packaging unit 110. The axis can continue upward through the internal cavity and through the center of the device filling location 220.

The outer filling location 120 may be visible at the bottom surface of the packaging unit 110 in FIG. 4. The outer filling location 120 can be an aperture or a puncturable cover as described with respect to FIG. 1. The outer filling location 120 can provide an access point through which a fill needle can be inserted. The fill needle can pass through the outer filling location 120 and travel along the longitudinal axis toward the device filling location 220.

The distance between the outer filling location 120 and the device filling location 220 can be predetermined based on the geometry of the packaging unit 110 and the fillable device 210. A fill needle of appropriate length can traverse this distance during a filling operation. The fill needle can be inserted through the outer filling location 120 and advanced along the longitudinal axis until the needle tip reaches the device filling location 220.

FIG. 5 provides a flowchart of an example method for preparing and filling a batch of fill-through packaging units according to one or more embodiments herein. The method illustrated in FIG. 5 may be performed in a manufacturing environment where multiple fillable devices are processed simultaneously. The method can enable efficient batch processing of smoking devices or other fillable containers. The flowchart depicts six stages that transform unfilled devices into filled, packaged products ready for shipment and retail sale. Although labeled in sequential fashion, the steps can be performed in various orders where relevant and possible.

Stage 510 can include inserting a cartridge or disposable device into a fill-through packaging insert. The insert may be the positioning component described with respect to FIG. 2. The cartridge can be a smoking device cartridge configured to hold a vaporizable liquid. The disposable device can be a complete smoking device with an integrated cartridge. An operator or automated system can grasp the cartridge and align it with the insert. The insert can include a shaped receptacle that conforms to the outer geometry of the cartridge. The operator can press the cartridge into the receptacle until the cartridge is fully seated. The insert can retain the cartridge through friction fit or mechanical engagement features. The cartridge filling port can be oriented to face a predetermined direction within the insert. This orientation can be maintained by asymmetric features in the insert that prevent incorrect insertion angles. In some examples, this stage includes forming the insert by folding a pre-cut section of paper, cardboard, or similar material.

Stage 520 can include inserting the assembled fill-through packaging insert into a fill-through packaging outer box to form a complete fill-through packaging unit. The outer box may be the outer body portion described with respect to FIG. 1. The insert with the retained cartridge can be slid into the internal cavity of the outer box. The outer box can include guide rails or alignment features that receive corresponding features on the insert. The insert can be pushed into the outer box until it reaches a predetermined position. An interlocking button or snap feature can engage to secure the insert within the outer box. The outer filling location on the outer box can become aligned with the device filling location on the cartridge when the insert is fully seated. This alignment can be maintained by the fixed spatial relationship between the insert and the outer box. The viewing port on the outer box can provide visual access to the cartridge after assembly.

Stage 530 can include inserting fill-through packaging units into a display box until the display box is full. The display box may be a container configured to hold multiple fill-through packaging units in an organized array. An operator or automated system can grasp individual fill-through packaging units and place them into compartments within the display box. The display box can include a grid of compartments arranged in rows and columns. Each compartment can be sized to receive one fill-through packaging unit. The fill-through packaging units can be oriented such that their outer filling locations all face the same direction. For example, all outer filling locations can face upward when the display box is in an upright orientation. The display box can be filled until all compartments contain a fill-through packaging unit. In some examples, the display box can hold fifty fill-through packaging units. In other examples, the display box can hold twenty-five, one hundred, or any other number of units based on the compartment configuration.

Stage 540 can include placing the display box in a filling fixture. The filling fixture may be a mechanical device configured to secure the display box in a predetermined position relative to filling equipment. An operator or automated system can lift the filled display box and position it within the filling fixture. The fixture can include clamps, brackets, or other retention mechanisms that engage with the display box. The fixture can secure the display box to prevent movement during the filling operation. The fixture can be positioned beneath a filling machine that includes one or more fill needles. The fixture can align the display box such that the outer filling locations of the fill-through packaging units are accessible to the fill needles. In some examples, the fixture can include alignment pins that mate with corresponding holes in the display box to ensure precise positioning.

Stage 550 can include a filling machine inverting the display box and filling each fill-through packaging unit by inserting a filling needle through an aperture in the fill-through packaging unit and through a silicone seal of the cartridge or disposable device. The filling machine may be an automated system configured to dispense fluid into multiple cartridges simultaneously or sequentially. The filling machine can activate the fixture to rotate the display box from an upright orientation to an inverted orientation. In the inverted orientation, the outer filling locations can face downward. The fill needles can be positioned below the inverted display box. The filling machine can raise one or more fill needles toward the outer filling locations. Each fill needle can penetrate the puncturable cover at the outer filling location of a fill-through packaging unit.

The needle can continue advancing along the longitudinal axis through the internal cavity of the packaging unit and engage the device filling location on the cartridge. The device filling location can include a silicone seal or septum that yields to permit needle entry. The needle can penetrate through the silicone seal and into the interior volume of the cartridge. The filling machine can activate a pump or pressure source to dispense fluid through the needle into the cartridge. In an example, the fluid can be a nicotine solution, cannabis oil, flavored liquid, or other vaporizable substance. The filling machine can monitor the fill volume using a flow meter, weight scale, or timer. The filling machine can stop fluid flow when the target fill volume is reached. The filling machine can then retract the needle from the cartridge and from the fill-through packaging unit. The silicone seal can close automatically after needle withdrawal to retain the fluid within the cartridge. The filling machine can repeat this process for each fill-through packaging unit in the display box. In some examples, the filling machine can fill multiple units simultaneously using an array of fill needles. In other examples, the filling machine can fill units sequentially using a single needle that moves from position to position.

Stage 560 can include applying a sticker sheet across all fill-through packaging units to conceal the apertures. The sticker sheet may be a single piece of adhesive-backed material with multiple individual stickers arranged in a pattern that matches the arrangement of fill-through packaging units in the display box. An operator or automated system can position the sticker sheet over the inverted display box, or the display box can be returned to its normal un-inverted position before the sticker sheet is applied. The sticker sheet can be aligned such that each individual sticker is centered over the outer filling location of a corresponding fill-through packaging unit. The operator can press the sticker sheet against the display box to adhere the stickers to the fill-through packaging units. Each sticker can cover the aperture or punctured cover at the outer filling location, preventing contamination from entering the fill-through packaging units through the punctured covers or apertures. The sticker sheet can be peeled away from a backing layer before or after application.

The method illustrated in FIG. 5 can enable efficient batch processing of fillable devices. Multiple devices can be assembled into fill-through packaging units and organized into a display box before any filling operations occur. The entire batch can then be filled in a single operation using automated equipment. This approach can reduce labor costs compared to filling devices individually. The method can also reduce the risk of contamination by minimizing manual handling of filled devices. The fill-through packaging units can protect the devices during filling and subsequent handling operations.

FIG. 6 provides front and side views of an example fill-through packaging outer box 620 and a fill-through packaging insert 610 according to one or more embodiments herein. The insert 610 may be the positioning component described with respect to FIG. 2. The outer box 620 may be the outer body portion described with respect to FIG. 1. The views in FIG. 6 can illustrate the separate components before assembly into a complete fill-through packaging unit 110.

The fill-through packaging insert 610 may be visible in both front and side views in FIG. 6. The insert 610 can be a three-dimensional structure configured to receive and retain a fillable device 210. The insert 610 can include a shaped receptacle that conforms to the outer geometry of the fillable device 210. The receptacle can be formed by walls or surfaces that define a cavity sized to accept the device 210. The insert 610 can be constructed from a foldable material such as paperboard or cardstock. The insert 610 can be formed by folding a flat cutout pattern along predetermined fold lines. The fold lines can create edges and corners that define the three-dimensional shape of the insert 610.

The insert 610 may include retention features that engage with the fillable device 210. The retention features can be tabs, flaps, or protrusions that extend inward from the walls of the receptacle. The retention features can apply friction forces to the device 210 to prevent movement within the insert 610. The insert 610 can be shaped to orient the device 210 in a predetermined position. The predetermined position can align the device filling location 220 with a longitudinal axis that runs through the center of the insert 610.

The fill-through packaging outer box 620 may be visible in both front and side views in FIG. 6. The outer box 620 can be a three-dimensional structure configured to receive and enclose the insert 610. The outer box 620 can define an internal cavity sized to accept the insert 610 with the fillable device 210 retained therein. The outer box 620 can be constructed from a foldable material such as paperboard or cardstock. The outer box 620 can be formed by folding a flat cutout pattern along predetermined fold lines. The fold lines can create edges and corners that define the three-dimensional shape of the outer box 620.

The outer box 620 may include an outer filling location 120 and a viewing port 130 as described previously. It can also include an interlocking button 140 or other mechanical feature that facilitates assembly with the insert 610. The interlocking button 140 can be a protrusion or tab that extends from a wall of the outer box 620. The interlocking button 140 can engage with a corresponding feature on the insert 610. For example, the insert 610 can include an aperture or slot that receives the interlocking button 140 when the insert 610 is pushed into the outer box 620. The engagement between the interlocking button 140 and the corresponding feature on the insert 610 can secure the insert 610 within the outer box 620.

The insert 610 and outer box 620 in FIG. 6 are shown as separate, unassembled components. The views illustrate the individual structures before they are combined to form a complete fill-through packaging unit 110. The insert 610 can be assembled by folding a flat cutout pattern into its three-dimensional shape. The outer box 620 can be assembled by folding a separate flat cutout pattern into its three-dimensional shape. The fillable device 210 can be inserted into the assembled insert 610. The assembled insert 610 with the device 210 can then be inserted into the assembled outer box 620 to form the complete fill-through packaging unit 110.

FIG. 7 provides a perspective view of an example fill-through packaging system including multiple components in an exploded or separated arrangement according to one or more embodiments herein. The system illustrated in FIG. 7 may demonstrate the relationship between individual components and their assembly into progressively larger organizational units. The view can show how a fillable device 710 may be integrated with packaging components to form a complete fill-through packaging unit. The view can also illustrate how multiple fill-through packaging units may be organized into a larger container for batch processing operations.

The fillable device 710 is visible as a separate component in FIG. 7. The device 710 can be a smoking device, cartridge, or other fluid-containing vessel as described previously. An insert 720 is also visible as a separate component in FIG. 7. The insert 720 can be the positioning component described with respect to FIG. 2 and also shown in FIG. 6. The insert 720 can include a shaped receptacle configured to receive and retain the fillable device 710. The receptacle may conform to the outer geometry of the device 710. The insert 720 can be constructed from folded paperboard, molded plastic, or other suitable material. The insert 720 may include retention features such as tabs, flaps, or friction surfaces that engage with the device 710. The insert 720 can be shaped to orient the device 710 in a predetermined position when the device 710 is inserted into the receptacle.

The outer box 730 may be visible as a separate component in FIG. 7. The outer box 730 can be the outer body portion described with respect to FIG. 1 and shown in detail in FIG. 6. The outer box 730 can define an internal cavity sized to receive the insert 720 with the fillable device 710 retained therein. The outer box 730 may include multiple external surfaces as described previously. One of these external surfaces can include an outer filling location as described with respect to FIG. 1. The outer box 730 can also include a viewing port as described with respect to FIG. 1. The outer box 730 may include an interlocking button or other mechanical feature that facilitates assembly with the insert 720.

A display box 740 is also shown in an assembled state in FIG. 7. The display box 740 can be a container configured to hold multiple fill-through packaging units in an organized array. In an example, the display box 740 may include a grid of compartments or other guide components arranged in rows and columns. Each compartment can be sized to receive one fill-through packaging unit formed by the assembly of the device 710, insert 720, and outer box 730. The display box 740 can be constructed from corrugated cardboard, folded paperboard, or molded plastic. The display box 740 may include structural features such as dividers, walls, or partitions that define the individual compartments.

The arrows between components in FIG. 7 illustrate the assembly sequence for forming a complete fill-through packaging system. The fillable device 710 can be inserted into the insert 720 as a first assembly step. The insert 720 with the retained device 710 can then be inserted into the outer box 730 as a second assembly step. This assembly forms a complete fill-through packaging unit. Multiple fill-through packaging units can then be placed into the compartments of the display box 740 as a third assembly step. This arrangement enables batch processing of multiple devices simultaneously during filling operations.

The display box 740 in FIG. 7 may be shown in a fully assembled configuration. The box 740 can include a bottom panel, side walls, and optional top flaps or cover. The compartments within the display box 740 may be visible from the perspective view. The compartments can be arranged in a regular grid pattern. For example, the display box 740 can include a five-by-ten grid of compartments for holding fifty fill-through packaging units. In other examples, the display box 740 can include a five-by-five grid for twenty-five units, a ten-by-ten grid for one hundred units, or any other suitable arrangement. The filling process can proceed after the arrangement in FIG. 7 is completed.

FIG. 8 provides a perspective view of a display box in various stages of assembly according to one or more embodiments herein. The figure illustrates the progression from a flat cutout pattern to a fully assembled display box containing multiple fill-through packaging units. The display box may be configured to organize and secure multiple fill-through packaging units during batch filling operations. The various stages shown in FIG. 8 can demonstrate how the display box transitions from an unassembled state to a functional container ready for use in manufacturing processes.

The cutout 810 for the display box may be visible in FIG. 8 as a flat pattern. The cutout 810 can be a single piece of material that has been die-cut or laser-cut to include predetermined fold lines and connection tabs. The material can be corrugated cardboard, folded paperboard, or other suitable sheet material. The cutout 810 can include multiple panels that will form the walls and bottom of the display box when folded. The cutout 810 can also include flaps or tabs that will interlock or adhere to secure the box structure. The fold lines can be scored or perforated to facilitate accurate folding along predetermined axes.

The partially assembled display box 820 may be shown in an intermediate stage of construction. The display box 820 can represent the cutout 810 after some folding operations have been performed. For example, the bottom panel can be folded upward and side walls can be erected to form a three-dimensional structure. The partially assembled display box 820 can have some connection points secured while others remain open. The box 820 can be in a configuration where additional folding or securing operations are still required to complete the assembly. The partially assembled state can allow for easier handling during automated or manual assembly processes.

The assembled display box 830 may be shown filled with fill-through packaging units 840. The display box 830 can represent the fully assembled container after all folding and securing operations have been completed. The box 830 can define an internal cavity divided into multiple compartments. Each compartment can be sized to receive one fill-through packaging unit 840. The compartments can be arranged in a regular grid pattern such as rows and columns. For example, the display box 830 can include a five-by-ten grid of compartments for holding fifty fill-through packaging units 840. In other examples, the display box 830 can include different grid configurations based on manufacturing requirements.

The fill-through packaging units 840 are visible within the assembled display box 830. Each fill-through packaging unit 840 can be the complete assembly described with respect to FIG. 7. The units 840 can be oriented such that their outer filling locations all face the same direction. For example, all outer filling locations can face upward when the display box 830 is in an upright orientation as shown in FIG. 8. This uniform orientation can enable simultaneous or sequential filling operations to be performed on all units 840 within the display box 830. The units 840 can be retained within the compartments through friction fit or mechanical engagement features.

The sticker sheet 850 is shown as a separate component in FIG. 8. The sticker sheet 850 can be a single piece of adhesive-backed material with multiple individual stickers arranged in a pattern. The pattern can match the arrangement of fill-through packaging units 840 in the display box 830. Each individual sticker can be sized to cover the outer filling location of one fill-through packaging unit 840. The sticker sheet 850 can include a backing layer that is removed before or during application. The stickers can be formed from paper, polymer film, or laminated materials. The adhesive can be pressure-sensitive adhesive that bonds to the surface of the fill-through packaging units 840 upon contact.

The final assembly 860 of the display box may be shown with the sticker sheet 850 applied and the top lid closed. The final assembly 860 can represent the display box 830 after filling operations have been completed and the sticker sheet 850 has been adhered to cover all outer filling locations. The stickers can seal the punctured or penetrated covers at the outer filling locations. This sealing can prevent contamination from entering the fill-through packaging units 840 through the access points used during filling. In an example, the final assembly 860 is ready for shipment to retail locations or distribution centers.

FIG. 9 provides a perspective view of a display box 830 oriented for a filling process according to one or more embodiments herein. The display box 830 may be positioned in an inverted orientation relative to the upright orientation shown in FIG. 8. The inverted orientation can facilitate access to the outer filling locations 120 of multiple fill-through packaging units 840 retained within the display box 830. A fill needle 910 may be visible in FIG. 9 approaching or engaging with one of the fill-through packaging units 840.

The display box 830 in FIG. 9 can be the same display box 830 described with respect to FIG. 8. The box 830 can be rotated approximately 180 degrees from the upright orientation to the inverted orientation. In the inverted orientation, the outer filling locations 120 of the fill-through packaging units 840 can face downward. This downward orientation can allow fill needles 910 to be positioned below the display box 830 and raised upward to engage the outer filling locations 120.

The fill-through packaging units 840 may remain retained within the compartments of the display box 830 during the inversion process. In one example, compartments within the display box 830 provide sufficient retention force to prevent the units 840 from falling out when the box 830 is inverted. The retention force can be generated by friction between the walls of the compartments and the outer surfaces of the fill-through packaging units 840. The retention force can also be generated by mechanical engagement features such as tabs, lips, or undercuts in the compartment walls that engage corresponding features on the fill-through packaging units 840. In another example, a cover (not shown) can be pressed against the exposed surfaces of the units 840 during the inversion process. The cover can include apertures or openings aligned with the filling locations of each unit 840, such that the cover can remain in place during the filling process without interfering with the fill needle 910.

The fill needle 910 is visible in FIG. 9 positioned below the inverted display box 830. The needle 910 can be part of an automated filling machine as described with respect to FIG. 5. The needle 910 can be a hollow tube with a sharpened tip configured to penetrate the puncturable cover at the outer filling location 120 and/or the fillable device. The needle 910 can be constructed from stainless steel or other biocompatible material. In an example, the needle 910 can have an outer diameter in the range of 0.5 mm to 3 mm. The needle 910 can have a length sufficient to traverse the distance from the external surface of the fill-through packaging unit 840 through the outer filling location 120 and into the device filling location 220 of the fillable device 210.

The fill needle 910 may be aligned with one of the fill-through packaging units 840 in FIG. 9. For example, the needle 910 can be positioned along the longitudinal axis that runs through the outer filling location 120 and the device filling location 220 of that particular unit 840. The filling machine can include positioning mechanisms that align the needle 910 with each fill-through packaging unit 840 in sequence. The positioning mechanisms can include linear actuators, stepper motors, or servo motors that move the needle 910 in X, Y, and Z directions. The positioning mechanisms can also include rotary actuators that rotate the display box 830 or the needle 910 to align different units 840 with the needle 910.

The display box 830 in FIG. 9 can be secured in a filling fixture as described with respect to stage 540 of FIG. 5. The fixture can include clamps, brackets, or other retention mechanisms that engage with the display box 830. The fixture can prevent movement of the display box 830 during the filling operation. The fixture can maintain the inverted orientation of the display box 830 throughout the filling process. The fixture can be constructed from metal such as aluminum or steel to provide rigidity and stability.

The outer filling locations 120 of the fill-through packaging units 840 may be visible in FIG. 9 facing downward. The outer filling locations 120 can be positioned on the bottom surfaces of the units 840 when the units 840 are in their normal upright orientation. When the display box 830 is inverted as shown in FIG. 9, these bottom surfaces become the top surfaces and the outer filling locations 120 face downward. This arrangement can allow the fill needle 910 to approach the outer filling locations 120 from below and be raised upward to engage the puncturable covers.

The fill needle 910 may be connected to a fluid delivery system that supplies the liquid to be dispensed into the fillable devices 210. The fluid delivery system can include a reservoir that holds a bulk quantity of the liquid. The reservoir can be a tank, bottle, or bag constructed from materials compatible with the liquid. The fluid delivery system can also include a pump that draws liquid from the reservoir and delivers it through tubing to the fill needle 910. The pump can be a peristaltic pump, gear pump, syringe pump, or other type of positive displacement pump. The pump can be controlled by the filling machine to dispense precise volumes of liquid.

The filling machine can include sensors that monitor the filling process. The sensors can include flow meters that measure the volume of liquid dispensed through the fill needle 910. The sensors can also include weight scales that measure the weight of the fill-through packaging unit 840 before and after filling to determine the mass of liquid added. The sensors can further include optical sensors that detect the fill level of the fillable device 210 through the viewing port 130. The filling machine can use data from these sensors to control the filling process and ensure that each fillable device 210 receives the correct amount of liquid.

FIGS. 10-13 provide various views of the fill-through packaging unit 840 during a filling operation according to one or more embodiments herein. These figures collectively illustrate the spatial relationships between the display box 830, the fill-through packaging unit 840, and the fill needle 910 during the filling process. The figures also reveal internal structures such as the guide component 1210 and the puncturable membrane 1220 that facilitate accurate needle insertion and fluid delivery.

FIG. 10 provides an alternative depiction of the display box 830 of FIG. 9 with all fill-through packaging units removed except for the unit 840 being filled (for illustrative purposes). The display box 830 is shown in the inverted orientation described with respect to FIG. 9, while the fill needle 910 is shown inserted into he unit 840.

FIG. 11 provides an alternative view of the fill-through packaging unit 840 of FIGS. 9 and 10. The view in FIG. 11 is a perspective view from a slightly different angle than FIG. 10. The display box 830 is visible in the inverted orientation, and the fill-through packaging unit 840 may be visible within the display box 830. The fill needle 910 is visible in relation to the fill-through packaging unit 840.

The fill-through packaging unit 840 in FIGS. 10 and 11 is shown with the outer filling location facing downward toward the fill needle 910. The outer body portion of the unit 840 can define the external surfaces described with respect to FIG. 1. The positioning component within the unit 840 can maintain the fillable device in the predetermined position described with respect to FIG. 2. The viewing port may be visible on a side surface of the unit 840. The viewing port can allow observation of the fillable device and verification of the fill level during or after the filling operation.

The fill needle 910 in FIGS. 10 and 11 is shown at a particular stage of the filling process. The needle 910 is aligned with the longitudinal axis that runs through the outer filling location and the device filling location. The needle 910 may be connected to fluid delivery tubing that supplies liquid from a reservoir. The needle 910 can be supported by a positioning mechanism that controls the needle movement in three-dimensional space.

FIGS. 12-13 provide cross-sectional views of the fill-through packaging unit 840 during the filling operation described with respect to FIGS. 9-11. These cross-sectional views reveal internal structures that facilitate the filling process. The views in FIGS. 12-13 may be taken along different planes to show various aspects of the internal geometry and component relationships. The display box 830 is visible in the inverted orientation described with respect to FIG. 9. The fill-through packaging unit 840 may be retained within a compartment of the display box 830 or by a cover held by a fixture. The fill needle 910 is shown inserted through the outer filling location and extending toward or into the device filling location of the fillable device.

The guide component 1210 is visible in FIGS. 12-13. The guide component 1210 can be a structural element configured to direct the fill needle 910 along the longitudinal axis described with respect to FIG. 2. The guide component 1210 may extend from the outer filling location toward the device filling location. The guide component 1210 can be a tubular structure with an internal passage. The internal passage can be sized to receive the fill needle 910 with minimal clearance. For example, the internal passage can have a diameter that exceeds the outer diameter of the fill needle 910 by 0.5 mm to 2 mm. This clearance can allow the needle 910 to pass through the guide component 1210 while constraining lateral movement of the needle 910.

The guide component 1210 may be formed as an integral part of the positioning component described with respect to FIG. 2. The guide component 1210 can be molded or formed from the same material as the positioning component. In other examples, the guide component 1210 can be a separate piece that is assembled with the positioning component. The guide component 1210 can be constructed from a rigid polymer material such as polypropylene, polyethylene, or acrylonitrile butadiene styrene. The material can provide sufficient rigidity to resist deflection when the fill needle 910 contacts the inner surfaces of the guide component 1210.

The guide component 1210 may include a funnel-shaped entry at the end proximate to the outer filling location. The funnel-shaped entry can have a larger diameter than the internal passage. The funnel can taper from the larger diameter to the diameter of the internal passage. This taper can facilitate capture of the fill needle 910 even if the needle 910 is not perfectly aligned with the longitudinal axis at the moment of initial contact. The funnel can redirect the needle 910 toward the center of the internal passage as the needle 910 advances.

The guide component 1210 may have a length sufficient to provide effective guidance of the fill needle 910. For example, the guide component 1210 can have a length in the range of 5 mm to 50 mm. The length can be selected based on the distance between the outer filling location and the device filling location. A longer guide component 1210 can provide more constraint on the needle trajectory. A shorter guide component 1210 can reduce material usage and simplify manufacturing. The optimal length can be determined based on the specific geometry of the fill-through packaging unit 840 and the fillable device.

The guide component 1210 may terminate at a location proximate to the device filling location 220. The terminus of the guide component 1210 can be positioned within 1 mm to 10 mm of the device filling location 220. This proximity can ensure that the fill needle 910 remains aligned with the device filling location 220 as the needle 910 exits the guide component 1210. The terminus can be shaped to avoid interference with the fillable device or the device filling location 220. For example, the terminus can be chamfered or radiused to prevent sharp edges from contacting the fillable device.

The puncturable membrane 1220 is visible in FIG. 12. The membrane 1220 may be positioned at the outer filling location on the external surface of the fill-through packaging unit 840. The membrane 1220 can be a thin layer of elastomeric material. The material can be silicone rubber, butyl rubber, or another self-sealing elastomer. In an example, the membrane 1220 has a thickness in the range of 0.5 mm to 3 mm. This thickness can provide sufficient resistance to accidental puncture while allowing intentional penetration by the fill needle 910.

The puncturable membrane 1220 may be aligned with the longitudinal axis described with respect to FIG. 2. The center of the membrane 1220 can be positioned on the longitudinal axis. This alignment can ensure that the fill needle 910 penetrates the membrane 1220 at the optimal location. Penetration at the center of the membrane 1220 can minimize the risk of tearing or incomplete sealing after needle withdrawal. The membrane 1220 can be configured to self-seal after the fill needle 910 is withdrawn. The elastomeric material can elastically recover to close the puncture site. The material can have sufficient elastic memory to return to its original shape after deformation.

FIG. 14 provides a front view of a cutout pattern 1410 for a display box according to one or more embodiments herein. The cutout pattern 1410 may be a flat, two-dimensional template configured to be folded and assembled into the three-dimensional display box 830 described with respect to FIG. 8. The pattern 1410 can be formed from a single sheet of material. The material can be corrugated cardboard, folded paperboard, or other suitable sheet material with sufficient rigidity to support multiple fill-through packaging units 840 when assembled.

The cutout pattern 1410 may include multiple panels arranged in a planar layout. The panels can be connected by fold lines that define the edges where the material will be bent during assembly. The fold lines can be scored, perforated, or otherwise marked to facilitate accurate folding along predetermined axes. The panels can include a bottom panel that will form the base of the display box 830. The bottom panel can be positioned centrally within the cutout pattern 1410. Side panels can extend from the edges of the bottom panel. The side panels can be configured to be folded upward to form the vertical walls of the display box 830.

The cutout pattern 1410 may also include flaps or tabs extending from the edges of the side panels. The flaps can be configured to interlock or adhere to adjacent panels during assembly. For example, a flap extending from one side panel can be folded inward and secured to an adjacent side panel using adhesive, mechanical fasteners, or friction fit. The flaps can provide structural reinforcement at the corners of the assembled display box 830. The flaps can also provide surfaces for applying adhesive to bond the panels together.

The cutout pattern 1410 may be produced by die-cutting, laser cutting, or mechanical cutting processes. The cutting process can create the outer perimeter of the pattern 1410 as well as any internal cutouts or apertures. The fold lines can be created simultaneously with the cutting process by using scoring blades or perforating tools. The cutout pattern 1410 can be produced in large quantities on a continuous web of material that is later separated into individual patterns.

FIG. 15 provides a front view of cutout patterns for an insert 1520 and an outer box 1510 according to one or more embodiments herein. The cutout patterns may be flat, two-dimensional templates configured to be folded and assembled into the three-dimensional insert 720 and outer box 730 described with respect to FIG. 7. The patterns can be formed from separate sheets of material. The material can be paperboard, cardstock, or thin polymer sheet with sufficient rigidity to maintain shape when folded.

The outer box cutout pattern 1510 may include multiple panels arranged in a planar layout. The panels can be connected by fold lines that define the edges where the material will be bent during assembly. The fold lines can be scored or perforated to facilitate accurate folding. The panels can include a bottom panel that will form the base of the outer box 730. Side panels can extend from the edges of the bottom panel. The side panels can be configured to be folded upward to form the vertical walls of the outer box 730. Top flaps can extend from the upper edges of the side panels. The top flaps can be configured to fold inward to close the top of the outer box 730.

The outer box cutout pattern 1510 may include an aperture or cutout corresponding to the outer filling location 120 described with respect to FIG. 1. The aperture can be positioned in the bottom panel of the pattern 1510. The aperture can be circular, rectangular, or any other suitable shape. The aperture can be sized to accommodate the puncturable membrane 1220 described with respect to FIG. 12. The puncturable membrane 1220 can be adhered to the inner surface of the bottom panel, covering the aperture from the inside of the assembled outer box 730.

The outer box cutout pattern 1510 may also include cutouts corresponding to the viewing ports 130 described with respect to FIG. 1. The cutouts can be positioned in the side panels of the pattern 1510. The cutouts can be rectangular or shaped to match the contours of the fillable device 210. The cutouts can be left as voids, or transparent panels can be inserted into the cutouts during assembly. The transparent panels can be secured using adhesive or by folding tabs around the edges of the panels.

The outer box cutout pattern 1510 may include tabs or flaps for assembly. The tabs can extend from the edges of the panels. The tabs can be configured to be folded and adhered to adjacent panels to secure the outer box 730 in its assembled configuration. For example, a tab extending from a side panel can be folded inward and glued to an adjacent side panel. The tabs can provide structural reinforcement at the corners and edges of the outer box 730.

The outer box cutout pattern 1510 may include features corresponding to the interlocking button 140 described with respect to FIG. 1. The features can be protrusions, tabs, or cutouts that will engage with corresponding features on the insert 720 when the insert 720 is inserted into the outer box 730. For example, the pattern 1510 can include a tab that will be folded to create a protrusion extending inward from a side panel. This protrusion can engage with a slot or aperture in the insert 720 to secure the insert 720 within the outer box 730.

The insert cutout pattern 1520 may include multiple panels arranged in a planar layout. The panels can be connected by fold lines that define the edges where the material will be bent during assembly. The panels can include a base panel that will form the bottom of the insert 720. Side panels can extend from the edges of the base panel. The side panels can be configured to be folded upward to form the walls of a receptacle that will receive the fillable device 210. The receptacle can be shaped to conform to the outer geometry of the fillable device 210.

The insert cutout pattern 1520 may include shaped cutouts or contours that define the receptacle geometry. The cutouts can be curved or angled to match the shape of the fillable device 210. For example, if the fillable device 210 has a cylindrical body, the side panels of the insert 720 can include curved edges that will form a cylindrical receptacle when folded. The receptacle can be sized to provide a friction fit with the fillable device 210. The dimensions of the receptacle can be slightly smaller than the outer dimensions of the fillable device 210 to ensure secure retention.

The insert cutout pattern 1520 may include tabs or flaps for assembly. The tabs can extend from the edges of the panels. The tabs can be configured to be folded and adhered to adjacent panels to secure the insert 720 in its assembled configuration. The tabs can also provide surfaces for applying adhesive to bond the insert 720 to the inner surfaces of the outer box 730. For example, a tab extending from the base panel of the insert 720 can be adhered to the inner surface of the bottom panel of the outer box 730.

The insert cutout pattern 1520 may include features corresponding to the guide component 1210 described with respect to FIG. 12. The features can be panels or flaps that will be folded to form a tubular structure extending from the base panel toward the location where the device filling location 220 will be positioned. The tubular structure can be formed by folding multiple panels into a cylindrical or conical shape. The panels can include tabs that interlock or overlap to secure the tubular structure. The inner diameter of the tubular structure can be sized to receive the fill needle 910 with minimal clearance.

Other examples of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the examples disclosed herein. Though some of the described methods have been presented as a series of steps, it should be appreciated that one or more steps can occur simultaneously, in an overlapping fashion, or in a different order. The order of steps presented are only illustrative of the possibilities and those steps can be executed or performed in any suitable fashion. Moreover, the various features of the examples described here are not mutually exclusive. Rather any feature of any example described here can be incorporated into any other suitable example. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the disclosure being indicated by the following claims.