Note: Descriptions are shown in the official language in which they were submitted.
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ELECTRONIC VAPING DEVICE AND KIT
The present disclosure relates to an electronic vaping or e-vaping device
configured to
deliver a pre-vapor formulation to a vaporizer.
An e-vaping device includes a heater element which vaporizes a pre-vapor
formulation to
produce a "vapor." The heater element may include a resistive heater coil,
with a wick
extending therethrough.
The e-vaping device includes a power supply, such as a battery, arranged in
the device.
The battery is electrically connected to the heater, such that the heater
heats to a temperature
sufficient to convert the pre-vapor formulation to a vapor. The vapor exits
the e-vaping device
through a mouthpiece including at least one outlet.
At least one example embodiment relates to a cartridge of an electronic vaping
device
including a roll of material that is coated, impregnated, or coated and
impregnated with at least
one additive.
In at least one example embodiment, a cartridge of an electronic vaping device
includes a
housing extending in a longitudinal direction, a reservoir containing a pre-
vapor formulation, a
heating element in the housing, and a roll of material having a channel
extending longitudinally
therethrough. The heating element is in fluid communication with the
reservoir, and the heating
element is configured to generate a vapor. The housing includes a mouth end
and a connection
end. The reservoir is contained in the housing. The roll of material includes
at least one of a
coating and an impregnated material. The roll of material is positioned in the
housing such that
at least some of the vapor passes through the roll of material. The roll of
material is removable
from the cartridge.
In at least one example embodiment, the roll of material comprises at least
one of a
polymeric film, paper, and a film of reconstituted tobacco material. The roll
of material may be
positioned between the heating element and the mouth end of the housing.
In at least one example embodiment, the coating and the impregnated material
each
include at least one additive, the additive including at least one of a
flavorant, a pH adjusting
agent, a vapor former, tobacco material, and nicotine. In at least one example
embodiment, the
roll of material includes the coating and the impregnated material, and the
coating and the
impregnated material includes different additives.
In at least one example embodiment, the additive is an encapsulated additive.
The
encapsulated additive may include at least one shell layer and an inner core.
The encapsulated
additive may be configured to release the additive in response to one or more
release activation
mechanisms, such as heat and moisture.
In at least one example embodiment, at least one of the at least one shell
layer and the
inner core includes the additive. The encapsulated additive may include a
plurality of capsules.
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The at least one shell layer of some of the plurality of capsules may have
different thicknesses
from the at least one shell layer of others of the plurality of capsules so as
to release the
additives at different times.
In at least one example embodiment, the encapsulated additive may include a
plurality of
capsules. The at least one shell layer of some of the plurality of capsules
formed of different
polymers than the at least one shell layer of others of the plurality of
capsules so as to release
the additives at different times. The different polymers may have different
dissolution rates,
different release rates, or both.
In at least one example embodiment, the encapsulated additive includes a
plurality of
capsules, and each of the plurality of capsules releases the additives at the
same time.
In at least one example embodiment, the encapsulated additive includes
tobacco, tobacco
flavors, or both, and at least one polymer. The polymer includes at least one
of microcrystalline
cellulose, pectin, hydroxypropyl methyl cellulose, and sodium alginate.
In at least one example embodiment, the pre-vapor formulation excludes
nicotine and the
additive includes nicotine.
At least one example embodiment relates to a kit including a plurality of
sheets of
material.
In at least one example embodiment, a kit includes a plurality of sheets of
material
configured to be rolled and placed in a cartridge of an electronic vaping
device. Each of the
plurality of sheets of material includes at least one of a coating and an
impregnated material.
Each of the plurality of sheets of material comprises at least one of a
polymeric film, paper, and
a film of reconstituted tobacco material. The coating and the impregnated
material may each
include at least one additive. The additive may include at least one of a
flavorant, a pH
adjusting agent, a vapor former, tobacco material, and nicotine.
In at least one example embodiment, at least one of the plurality of sheets of
material
includes the coating and the impregnated material, and the coating and the
impregnated
material include different additives.
In at least one example embodiment, the additive is an encapsulated additive.
The
encapsulated additive may be configured to release the additive in response to
at least one of
heat and moisture. The encapsulated additive may include at least one shell
layer and an inner
core. The encapsulation additive may be in the form of matrix encapsulation,
that is, dispersed
within a polymer film, such as a coating.
In at least one example embodiment, each of the plurality of sheets includes
different
additives. In another example embodiment, each of the plurality of sheets
includes the same
additive.
At least one example embodiment relates to a method of enhancing a vapor of an
electronic vaping device.
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In at least one example embodiment, a method of enhancing a vapor of an
electronic
vaping device includes rolling a sheet of material to form a rolled sheet of
material, and inserting
the rolled sheet of material between a heater and a mouth end of a cartridge.
The sheet of
material includes at least one of a coating and an impregnated material.
In at least one example embodiment, the sheet of material comprises at least
one of a
polymeric film, paper, and a film of reconstituted tobacco material. The
coating and the
impregnated material may each include at least one additive, the additive
including at least one
of a flavorant, a pH adjusting agent, a vapor former, tobacco material, and
nicotine.
The various features and advantages of the non-limiting embodiments herein may
become more apparent upon review of the detailed description in conjunction
with the
accompanying drawings. The accompanying drawings are merely provided for
illustrative
purposes and should not be interpreted to limit the scope of the claims. The
accompanying
drawings are not to be considered as drawn to scale unless explicitly noted.
For purposes of
clarity, various dimensions of the drawings may have been exaggerated.
FIG. 1 is a side view of an e-vaping device according to at least one example
embodiment.
FIG. 2 is a cross-sectional view along line II-II of the e-vaping device of
FIG. 1.
FIGS. 3A and 3B are perspective views of rolls of material according to at
least one
example embodiment.
FIG. 4 is a top view of a sheet of material that forms a roll of material
according to at least
one example embodiment.
FIG. 5 is a cross-sectional view along line V-V of the material of FIG. 4.
FIG. 6 is a cross-sectional view of a flavor capsule impregnated in, coated
on, or
impregnated in and coated on a sheet of material according to at least one
example
embodiment.
FIG. 7 is a cross-sectional view of a flavor capsule impregnated in, coated
on, or
impregnated in and coated on a sheet of material according to at least one
example
embodiment.
FIG. 8 is a cross-sectional view of a flavor capsule in the form of an
encapsulated matrix
according to at least one example embodiment.
FIG. 9A a perspective view of a kit including a plurality of sheets of
material according to
at least one example embodiment.
FIG. 9B is a perspective view of a roller for inclusion in the kit of FIG. 9A
according to at
least one example embodiment.
FIG. 90 is a side view of an inflexible guide for inclusion in the kit of FIG.
9A according to
at least one example embodiment.
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FIG. 10 is a flow chart illustrating a method of enhancing a vapor of an
electronic vaping
device.
Some detailed example embodiments are disclosed herein. However, specific
structural
and functional details disclosed herein are merely representative for purposes
of describing
example embodiments. Example embodiments may, however, be embodied in many
alternate
forms and should not be construed as limited to only the example embodiments
set forth herein.
Accordingly, while example embodiments are capable of various modifications
and
alternative forms, example embodiments thereof are shown by way of example in
the drawings
and will herein be described in detail. It should be understood, however, that
there is no intent to
limit example embodiments to the particular forms disclosed, but to the
contrary, example
embodiments are to cover all modifications, equivalents, and alternatives
falling within the
scope of example embodiments. Like numbers refer to like elements throughout
the description
of the figures.
It should be understood that when an element or layer is referred to as being
"on,"
"connected to," "coupled to," or "covering" another element or layer, it may
be directly on,
connected to, coupled to, or covering the other element or layer or
intervening elements or
layers may be present. In contrast, when an element is referred to as being
"directly on,"
"directly connected to," or "directly coupled to" another element or layer,
there are no
intervening elements or layers present. Like numbers refer to like elements
throughout the
specification.
It should be understood that, although the terms first, second, third, and so
forth may be
used herein to describe various elements, components, regions, layers or
sections, these
elements, components, regions, layers, or sections should not be limited by
these terms. These
terms are only used to distinguish one element, component, region, layer, or
section from
another element, component, region, layer, or section. Therefore, a first
element, component,
region, layer, or section discussed below could be termed a second element,
component,
region, layer, or section without departing from the teachings of example
embodiments.
Spatially relative terms (for example, "beneath," "below," "lower," "above,"
"upper," and
the like) may be used herein for ease of description to describe one element
or feature's
relationship to another element or feature as illustrated in the figures. It
should be understood
that the spatially relative terms are intended to encompass different
orientations of the device in
use or operation in addition to the orientation depicted in the figures. For
example, if the device
in the figures is turned over, elements described as "below" or "beneath"
other elements or
features would then be oriented "above" the other elements or features.
Therefore, the term
"below" may encompass both an orientation of above and below. The device may
be otherwise
oriented (rotated 90 degrees or at other orientations) and the spatially
relative descriptors used
herein interpreted accordingly.
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The terminology used herein is for the purpose of describing various example
embodiments only and is not intended to be limiting of example embodiments. As
used herein,
the singular forms "a," "an," and "the" are intended to include the plural
forms as well, unless the
context clearly indicates otherwise. It will be further understood that the
terms "includes,"
"including," "comprises," and "comprising," when used in this specification,
specify the presence
of stated features, integers, steps, operations, elements, or components, but
do not preclude
the presence or addition of one or more other features, integers, steps,
operations, elements,
components, or groups thereof.
Example embodiments are described herein with reference to cross-sectional
illustrations
that are schematic illustrations of idealized embodiments (and intermediate
structures) of
example embodiments. As such, variations from the shapes of the illustrations
as a result, for
example, of manufacturing techniques or tolerances, are to be expected.
Therefore, example
embodiments should not be construed as limited to the shapes of regions
illustrated herein but
are to include deviations in shapes that result, for example, from
manufacturing.
Unless otherwise defined, all terms (including technical and scientific terms)
used herein
have the same meaning as commonly understood by one of ordinary skill in the
art to which
example embodiments belong. It will be further understood that terms,
including those defined
in commonly used dictionaries, should be interpreted as having a meaning that
is consistent
with their meaning in the context of the relevant art and will not be
interpreted in an idealized or
overly formal sense unless expressly so defined herein.
FIG. 1 is a side view of an e-vaping device according to at least one example
embodiment.
In at least one example embodiment, as shown in FIG. 1, an electronic vaping
device (e-
vaping device) 60 may include a replaceable cartridge (or first section) 70
and a reusable
battery section (or second section) 72, which may be coupled together at a
threaded connector
205. It should be appreciated that the connector 205 may be any type of
connector, such as a
snug-fit, detent, clamp, bayonet, clasp, and combinations thereof. The first
section 70 may
include a housing 6 and the second section 72 may include a second housing 6'.
The e-vaping
device 60 includes a mouth-end insert 8.
In at least one example embodiment, the housing 6 and the second housing 6'
may have
a generally cylindrical cross-section. In other example embodiments, the
housings 6, 6' may
have a generally triangular cross-section along one or more of the first
section 70 and the
battery section 72.
FIG. 2 is a cross-sectional view along line II-II of the e-vaping device of
FIG. 1.
In at least one example embodiment, as shown in FIG. 2, the first section 70
may include
a reservoir 22 configured to contain a pre-vapor formulation and a heater 14
that may vaporize
the pre-vapor formulation, which may be drawn from the reservoir 22 by a wick
28. The e-
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vaping device 60 may include the features set forth in U.S. Patent Application
Publication No.
2013/0192623 to Tucker et al. filed January 31, 2013, the entire contents of
which is
incorporated herein by reference thereto.
In at least one example embodiment, the pre-vapor formulation is a material or
combination of materials that may be transformed into a vapor. For example,
the pre-vapor
formulation may be at least one of a liquid, solid, or gel formulation
including, but not limited to,
water, beads, solvents, active ingredients, ethanol, plant extracts, natural
or artificial flavors,
vapor formers such as glycerin and propylene glycol, and combinations thereof.
In at least one example embodiment, the first section 70 may include the
housing 6
extending in a longitudinal direction and an inner tube (or chimney) 62
coaxially positioned
within the housing 6.
At an upstream end portion of the inner tube 62, a nose portion 61 of a gasket
(or seal) 15
may be fitted into the inner tube 62, while at the other end, an outer
perimeter of the gasket 15
may provide a seal with an interior surface of the outer housing 6. The gasket
15 may also
include a central, longitudinal air passage 20, which opens into an interior
of the inner tube 62
that defines a central channel 21. A transverse channel 33 at a backside
portion of the gasket
15 may intersect and communicate with the air passage 20 of the gasket 15.
This transverse
channel 33 assures communication between the air passage 20 and a space 35
defined
between the gasket 15 and a cathode connector piece 37.
In at least one example embodiment, the cathode connector piece 37 may include
a
threaded section for effecting the connection between the first section 70 and
the battery
section 72.
In at least one example embodiment, more than two air inlet ports 44 may be
included in
the housing 6. Alternatively, a single air inlet port 44 may be included in
the outer housing 6.
Such arrangement allows for placement of the air inlet ports 44 close to the
connector 205
without occlusion by the presence of the cathode connector piece 37. This
arrangement may
also reinforce the area of air inlet ports 44 to facilitate precise drilling
of the air inlet ports 44.
In at least one example embodiments, the air inlet ports 44 may be provided in
the
connector 205 instead of in the outer housing 6.
In at least one example embodiment, the at least one air inlet port 44 may be
formed in
the outer housing 6, adjacent the connector 205 to minimize the chance of an
adult vaper's
fingers occluding one of the ports and to control the resistance-to-draw (RTD)
during vaping. In
an example embodiment, the air inlet ports 44 may be machined into the housing
6 with
precision tooling such that their diameters are closely controlled and
replicated from one e-
vaping device 60 to the next during manufacture.
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In at least one example embodiment, the air inlet ports 44 may be sized and
configured
such that the e-vaping device 60 has a RTD in the range of from about 60
millimetres of water
to about 150 millimetres of water.
In at least one example embodiment, a nose portion 93 of a downstream gasket
10 may
be fitted into a downstream end portion 81 of the inner tube 62. An outer
perimeter of the
gasket 10 may provide a substantially tight seal with an interior surface 97
of the housing 6.
The downstream gasket 10 may include a central channel 63 disposed between the
inner
passage 21 of the inner tube 62 and the interior of a mouth-end insert 8,
which may transport
the vapor from the inner passage 21 to the mouth-end insert 8.
In at least one example embodiment, the space defined between the gaskets 10
and 15
and the outer housing 6 and the inner tube 62 may establish the confines of a
reservoir 22. The
reservoir 22 may contain a pre-vapor formulation, and optionally a storage
medium (not shown)
configured to store the pre-vapor formulation therein. The storage medium may
include a
winding of cotton gauze or other fibrous material about the inner tube 62.
In at least one example embodiment, the reservoir 22 may be contained in an
outer
annulus between the inner tube 62 and the housing 6 and between the gaskets 10
and 15.
Therefore, the reservoir 22 may at least partially surround the central inner
passage 21. The
heater 14 may extend transversely across the inner passage 21 between opposing
portions of
the reservoir 22. In some example embodiments, the heater 14 may extend
parallel to a
longitudinal axis of the inner passage 21.
In at least one example embodiment, the reservoir 22 may be sized and
configured to
hold enough pre-vapor formulation such that the e-vaping device 60 may be
configured for
vaping for at least about 200 seconds. Moreover, the e-vaping device 60 may be
configured to
allow each puff to last a maximum of about 5 seconds.
In at least one example embodiment, the storage medium may be a fibrous
material
including at least one of cotton, polyethylene, polyester, rayon and
combinations thereof. The
fibers may have a diameter ranging in size from about 6 microns to about 15
microns (for
example, about 8 microns to about 12 microns or about 9 microns to about 11
microns). The
storage medium may be a sintered, porous or foamed material. Also, the fibers
may be sized to
be irrespirable and may have a cross-section which has a Y-shape, cross shape,
clover shape
or any other suitable shape. In at least one example embodiment, the reservoir
22 may include
a filled tank lacking any storage medium and containing only pre-vapor
formulation.
During vaping, pre-vapor formulation may be transferred from the reservoir 22,
storage
medium, or both, to the proximity of the heater 14 via capillary action of the
wick 28. The wick
28 may include at least a first end portion and a second end portion, which
may extend into
opposite sides of the reservoir 22. The heater 14 may at least partially
surround a central
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portion of the wick 28 such that when the heater 14 is activated, the pre-
vapor formulation in the
central portion of the wick 28 may be vaporized by the heater 14 to form a
vapor.
In at least one example embodiment, the wick 28 may include filaments (or
threads)
having a capacity to draw the pre-vapor formulation. For example, the wick 28
may be a bundle
of glass (or ceramic) filaments, a bundle including a group of windings of
glass filaments, and so
forth, all of which arrangements may be capable of drawing pre-vapor
formulation via capillary
action by interstitial spacings between the filaments. The filaments may be
generally aligned in
a direction perpendicular (transverse) to the longitudinal direction of the e-
vaping device 60. In
at least one example embodiment, the wick 28 may include one to eight filament
strands, each
strand comprising a plurality of glass filaments twisted together. The end
portions of the wick
28 may be flexible and foldable into the confines of the reservoir 22. The
filaments may have a
cross-section that is generally cross-shaped, clover-shaped, Y-shaped, or in
any other suitable
shape.
In at least one example embodiment, the wick 28 may include any suitable
material or
combination of materials. Examples of suitable materials may be, but not
limited to, glass,
ceramic- or graphite-based materials. The wick 28 may have any suitable
capillarity drawing
action to accommodate pre-vapor formulations having different physical
properties such as
density, viscosity, surface tension and vapor pressure. The wick 28 may be non-
conductive.
In at least one example embodiment, the heater 14 may include a wire coil
which at least
partially surrounds the wick 28. The wire may be a metal wire. The heater coil
may extend fully
or partially along the length of the wick 28. The heater coil may further
extend fully or partially
around the circumference of the wick 28. In some example embodiments, the
heater coil 14
may or may not be in contact with the wick 28.
In at least one example embodiment, the heater coil may be formed of any
suitable
electrically resistive materials. Examples of suitable electrically resistive
materials may include,
but not limited to, copper, titanium, zirconium, tantalum and metals from the
platinum group.
Examples of suitable metal alloys include, but not limited to, stainless
steel, nickel, cobalt,
chromium, aluminum-titanium-zirconium, hafnium, niobium, molybdenum, tantalum,
tungsten,
tin, gallium, manganese and iron-containing alloys, and super-alloys based on
nickel, iron,
cobalt, stainless steel. For example, the heater 14 may be formed of nickel
aluminide, a
material with a layer of alumina on the surface, iron aluminide and other
composite materials,
the electrically resistive material may optionally be embedded in,
encapsulated or coated with
an insulating material or vice-versa, depending on the kinetics of energy
transfer and the
external physicochemical properties required. The heater 14 may include at
least one material
selected from the group consisting of stainless steel, copper, copper alloys,
nickel-chromium
alloys, super alloys and combinations thereof. In an example embodiment, the
heater 14 may
be formed of nickel-chromium alloys or iron-chromium alloys. In another
example embodiment,
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the heater 14 may be a ceramic heater having an electrically resistive layer
on an outside
surface thereof.
In at least one example embodiment, the heater 14 may heat pre-vapor
formulation in the
wick 28 by thermal conduction. Alternatively, heat from the heater 14 may be
conducted to the
pre-vapor formulation by means of a heat conductive element or the heater 14
may transfer
heat to the incoming ambient air that is drawn through the e-vaping device 60
during vaping,
which in turn heats the pre-vapor formulation by convection.
It should be appreciated that, instead of using a wick 28, the heater 14 may
include a
porous material which incorporates a resistance heater formed of a material
having a high
electrical resistance capable of generating heat quickly.
In at least one example embodiment, as shown in FIG. 2, the second section 72
of the e-
vaping device 60 may include a puff sensor 16 responsive to air drawn into the
second section
72 via an air inlet port 44a adjacent a free end or tip of the e-vaping device
60. The second
section 72 may also include a battery 1 and a control circuit 200.
Upon completing the connection between the first section 70 and the second
section 72,
the battery 1 may be electrically connectable with the heater 14 of the first
section 70 upon
actuation of the puff sensor 16. Air is drawn primarily into the first section
70 through one or
more air inlets 44, which may be located along the housing or at the connector
205.
The power supply 1 may include a battery arranged in the e-vaping device 60.
The power
supply 1 may be a Lithium-ion battery or one of its variants, for example a
Lithium-ion polymer
battery. Alternatively, the power supply 1 may be a nickel-metal hydride
battery, a nickel
cadmium battery, a lithium-manganese battery, a lithium-cobalt battery or a
fuel cell. The e-
vaping device 60 may be usable by an adult vaper until the energy in the power
supply 1 is
depleted or in the case of lithium polymer battery, a minimum voltage cut-off
level is achieved.
In at least one example embodiment, the power supply 1 may be rechargeable and
may
include circuitry configured to allow the battery to be chargeable by an
external charging device.
To recharge the e-vaping device 60, an USB charger or other suitable charger
assembly may
be used.
Furthermore, the e-vaping device 60 may include the control circuit 200 and
the puff
sensor 16. The puff sensor 16 may be configured to sense an air pressure drop
and initiate
application of voltage from the power supply 1 to the heater 14. The control
circuit 200 may
also include a heater activation light 48 configured to glow when the heater
14 is activated. The
heater activation light 48 may include a light-emitting diode (LED) and may be
at an upstream
end of the e-vaping device 60. Moreover, the heater activation light 48 may be
arranged to be
visible to an adult vaper during vaping. In addition, the heater activation
light 48 may be utilized
for e-vaping system diagnostics or to indicate that recharging is in progress.
The heater
activation light 48 may also be configured such that the adult vaper may
activate, deactivate, or
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activate and deactivate the heater activation light 48 for privacy. The heater
activation light 48
may be on a tip end of the e-vaping device 60 or on a side of the housing 6.
In at least one example embodiment, the at least one air inlet 44a may be
located
adjacent the puff sensor 16, such that the puff sensor 16 may sense air flow
indicative of an
adult vaper taking a puff and activates the power supply 1 and the heater
activation light 48 to
indicate that the heater 14 is working. The heater activation light 48 may be
located at or on the
tip end of the e-vaping device. In other example embodiments, the heater
activation light 48
may be located on a side portion of the housing 6.
In at least one example embodiment, the control circuit 200 may supply power
to the
heater 14 responsive to the puff sensor 16. In one example embodiment, the
control circuit may
include a maximum, time-period limiter. In another example embodiment, the
control circuit 200
may include a manually operable switch for an adult vaper to initiate a puff.
The time-period of
the electric current supply to the heater 14 may be pre-set depending on the
amount of pre-
vapor formulation desired to be vaporized. In yet another example embodiment,
the circuitry
may supply power to the heater 14 as long as the puff sensor 16 detects a
pressure drop.
When activated, the heater 14 may heat a portion of the wick 28 surrounded by
the heater
for less than about 10 seconds.
The inner tube 62 may include a pair of opposing slots, such that the wick 28
and the
leading end 109, 109' of the heater 14 may extend out from the respective
opposing slots. The
provision of the opposing slots in the inner tube 62 may facilitate placement
of the heater 14
and wick 28 into position within the inner tube 62 without impacting edges of
the slots and the
coiled section of the heater 14. Accordingly, edges of the slots may not be
allowed to impact
and alter the coil spacing of the heater 14, which would otherwise create
potential sources of
hotspots.
In at least one example embodiment, the inner tube 62 may have a diameter of
about 4
millimetres and each of the opposing slots may have major and minor dimensions
of about 2
millimetres by about 4 millimetres.
In at least one example embodiment, the first section 70 may be replaceable.
In other
words, once the pre-vapor formulation of the cartridge is depleted, only the
first section 70 may
be replaced. An alternate arrangement may include an example embodiment where
the entire
e-vaping device 60 may be disposed once the reservoir 22 is depleted.
In at least one example embodiment, the e-vaping device 60 may be about 80
millimetres
to about 110 millimetres long and about 7 millimetres to about 8 millimetres
in diameter. For
example, in one example embodiment, the e-vaping device may be about 84
millimetres long
and may have a diameter of about 7.8 millimetres.
In at least one example embodiment, a mouth-end insert 8 may be positioned at
a mouth
end 32 of the first section 70. The mouth-end insert 8 includes at least two
outlets, which may
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be located off-axis from the longitudinal axis of the e-vaping device 60. The
outlets may be
angled outwardly in relation to the longitudinal axis of the e-vaping device
60. The outlets may
be substantially uniformly distributed about the perimeter of the mouth-end
insert 8 so as to
substantially uniformly distribute vapor in an adult vaper's mouth during
vaping and create a
greater perception of fullness in the mouth. Therefore, as the vapor passes
into the adult
vaper's mouth, the vapor may enter the mouth and may move in different
directions so as to
provide a full mouth feel.
In at least one example embodiment, the mouth-end insert 8 may be removable to
allow
for the insertion, removal, or insertion and removal of a roll of material 210
that is formed of a
sheet of material 260 (shown in FIGS. 4 and 5) that is impregnated with,
coated with, or
impregnated with and coated with one or more additives. Once the additives in
the roll of
material 210 have been eluted to the vapor, the roll of material 210 may be
removed. If desired,
an adult vaper may replace the roll of material 210 with a new roll of
material 210. The adult
vaper may alter the flavor profile of the vapor by choosing a roll of material
210 with the desired
additives that provide desired vapor characteristics. Therefore, the adult
vaper may customize
the vaping experience.
In at least one example embodiment, the roll of material 210 may be positioned
between
the heater 14 and the mouth-end insert 8. The roll of material 210 may include
a coating of a
material, may be impregnated with a material, or both. The material may
include at least one of
an additive, one or more carriers, binders, and combinations thereof.
In at least one example embodiment, the additive may include at least one of a
flavorant,
a pH adjusting agent, a vapor former, tobacco material, and nicotine. The
additive may be
included in the roll of material 210 in an amount ranging from about 0.01
percent to about 50
percent by weight based on the weight of the roll of material 210.
In at least one example embodiment, the flavorant may include any suitable
flavor
including menthol, mint flavors, fruit flavors, herb flavors, vegetable
flavors, and the like, or
combinations thereof.
In at least one example embodiment, the vapor former may include polyhydric
alcohols,
such as propylene glycol, triethylene glycol, 1,3-butanediol and glycerin;
esters of polyhydric
alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of
mono-, di- or
polycarboxylic acids, such as at least one of dimethyl dodecanedioate and
dimethyl
tetradecanedioate. Example vapor formers are polyhydric alcohols or mixtures
thereof, such as
propylene glycol, triethylene glycol, 1,3-butanediol and glycerin.
In at least one example embodiment, the pH modifying agent includes at least
one of an
acid or a base. The pH modifying agent is selected to adjust a pH of the vapor
to a desired
level.
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In at least one example embodiment, the tobacco material may include material
from any
member of the genus Nicotiana. In at least one example embodiment, the tobacco
material
includes a blend of two or more different tobacco varieties.
Examples of suitable types of tobacco materials that may be used include flue-
cured
tobacco, Burley tobacco, Dark tobacco, Maryland tobacco, Oriental tobacco,
rare tobacco,
specialty tobacco, and blends thereof. The tobacco material may be provided in
any suitable
form, including tobacco lamina, processed tobacco materials, such as volume
expanded or
puffed tobacco, processed tobacco stems, such as cut-rolled or cut-puffed
stems, reconstituted
tobacco materials, and blends thereof.
In at least one example embodiment, the additive includes nicotine. In at
least one
example embodiment, the pre-vapor formulation does not include nicotine, and
nicotine is
impregnated in the roll of material 210, coated on the roll of material 210,
or both.
The additives may include volatile, heat sensitive additives that are not
easily included in
the pre-vapor formulation, additives that are difficult to store, or both.
Inclusion of such additives
in the roll of material 210 may reduce or prevent undesired chemical reactions
with other
ingredients of the pre-vapor formulation and loss of the additives prior to
vaping.
In at least one example embodiment, the carrier, binder, or both, may include
food-grade
adhesives, polymers, solvents, or combinations thereof.
FIGS. 3A and 3B are perspective views of rolls of material according to at
least one
example embodiment.
In at least one example embodiment, as shown in FIG. 3A, when the sheet of
material 260
(shown in FIG. 4) is rolled to form the roll of material 210, the roll of
material 210 may include
overlapping edges 212, 214 and an opening 216 extending through the roll of
material 210.
During vaping, vapor travels through the opening 216 in the roll of material
210 and the
materials coated, impregnated, or coated and impregnated in the roll of
material 210 are eluted
to the vapor.
In at least one example embodiment, as shown in FIG. 3B, the roll of material
210 may
include a plurality of layers 220 of rolled material. The layers 220 of the
roll of material 210 may
include spaces 222 between each adjacent layer 220, such that the vapor passes
through the
central opening 216, through the channels 222 between the layers 220, or both.
FIG. 4 is a top view of a sheet of material that forms a roll of material
according to at least
one example embodiment.
In at least one example embodiment, as shown in FIG. 4, the roll of material
210 is formed
from a sheet of material 260 that is rollable by an adult vaper. In at least
one example
embodiment, the sheet of material 260 includes at least one of a polymeric
film, paper, and a
film of reconstituted tobacco material. The sheet of material 260 may be
impregnated with at
least one material including at least one additive.
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In at least one example embodiment, the sheet of material 260 comprises a
polymeric
film. The film may be a water soluble film that dissolves when in contact with
moisture, heat
from the vapor, or both. Therefore, over time, the film may dissolve as the
film releases
additives during vaping, may be replaced by another film if desired, or both.
For example, the
film may be a film of microcrystalline cellulose,
hydroxypropylmethylcellulose, pullulan, chitosan,
cellulose derivatives, alginate, pectin, or combinations thereof, including
additives dispersed
therethrough.
In at least one example embodiment, the sheet of material 260 has a length
ranging from
about 10 millimetres to about 50 millimetres and a width ranging from about 10
millimetres to
about 50 millimetres . The sheet of material 260 may be sized such that when
rolled, the roll of
material fits between the gasket 10 and the mouth-end insert 8.
FIG. 5 is a cross-sectional view along line V-V of the material of FIG. 4.
In at least one example embodiment, as shown in FIG. 5, the sheet of material
260 may
include a coating 232 in lieu of or in addition to the impregnated additives.
The coating 232 may
include the same or different additives than the impregnated additives. For
example, the
coating 232 may include pieces of tobacco material adhered to the sheet of
material 260 with
food-grade binders, adhesives, or both. Alternatively, the sheet of material
260 may be formed
of reconstituted tobacco material that is impregnated with flavorants, other
additives, or both.
In at least one example embodiment, the sheet of material 260 has a thickness
of up to
about 150 microns. The coating 232 may also have a thickness of up to about
150 microns.
The coating 232 may be on at least one surface of the sheet of material 260.
FIG. 6 is a cross-sectional view of a flavor capsule impregnated in, coated
on, or
impregnated in and coated on a sheet of material according to at least one
example
embodiment.
In at least one example embodiment, as shown in FIG. 6, the additives may be
encapsulated. The encapsulated additives may include a first outer shell 320
and an inner core
310. Encapsulated additives embedded in the material may refer to different
types of
encapsulation including: 1) a matrix-type of encapsulation in which the flavor
is dispersed within
an encapsulation matric, 2) a core/shell-type encapsulation in which the
flavor is contained
within a core surrounded by an encapsulant material, and 3) an adsorbent
material in which the
flavor has been adsorbed onto, into, or both, (that is, silica gel, activated
carbon, molecular
sieves, and so forth). The encapsulated additives may be available in
different forms such as
powders, spherical particles or other geometries, needle-like or fiber-like
structure, and so forth.
FIG. 7 is a cross-sectional view of a flavor capsule impregnated in, coated
on, or
impregnated in and coated on a sheet of material according to at least one
example
embodiment.
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In at least one example embodiment, as shown in FIG. 7, the additives may be
encapsulated, and the capsules may include the first outer shell 320, a second
outer shell 330,
and the inner core 310.
In at least one example embodiment, the encapsulated additives may be formed
to
release the additive in response to one or more of heat from the vapor,
moisture from the vapor,
or both.
In at least one example embodiment, the first outer shell 320, the second
outer shell, or
both, may be formed of water soluble materials having varying levels of water
solubility so as to
provide controlled release of the additive over a desired period of time. The
first outer shell 320,
the second outer shell 330, or both, may include one or more of gelatin,
pectin, and sodium
alginate. The polymers may be cross-linked with a cross-linking agent, such as
calcium salts
including calcium acetate, calcium chloride, and the like.
In at least one example embodiment, the first outer shell 320, the second
outer shell 330,
or both, may have varying thicknesses so as to release the additives at
different times.
In at least one example embodiment, the encapsulated additives have similar
shells so as
to release the additives from the inner core 310 at the same time. Therefore,
the shells 320, 330
may be formed of substantially the same materials and have substantially the
same
thicknesses.
FIG. 8 is a cross-sectional view of a flavor capsule in the form of an
encapsulated matrix
330. Flavor particles 340 may be dispersed uniformly or non-uniformly in a
matrix 335 of a
food-grade polymer.
FIG. 9A is a perspective view of a kit including a plurality of sheets of
material according
to at least one example embodiment.
In at least one example embodiment, as shown in FIG. 9A, a kit 500 may include
a
plurality of sheets of material 260 as described above. The kit 500 may
include a plurality of the
same types of sheets of material 260 or the kit 500 may include different
types of sheets of
material 260. The sheets of material 260 may be packaged in a hinged-lid pack
600 or other
suitable packaging. The sheets of material 260 may be individually wrapped or
wrapped
according to type of additives included therein to avoid or reduce loss of
volatile additives,
cross-contamination, or both.
In at least one example embodiment, if the kit 500 includes a variety of
different types of
sheets of material 260, each type may be a different color and the color may
indicate the type of
additive, flavor, or both, included in that sheet of material 260.
In at least one example embodiment, as shown in FIG. 9B, the kit 500 may
include a roller
610 that squeezes, scratches, or squeezes and scratches a surface of the
sheets of material
260 prior to rolling so as to mechanically release encapsulated flavors.
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In at least one example embodiment, as shown in FIG. 90, the kit 500 may
include an
inflexible guide 620. The guide 620 may be formed of metal or plastic. The
guide 620 may be
used to assure the resulting rolled material maintains open through-channels
and is consistently
rolled from one sheet or material to the next. The sheets may be available pre-
rolled with the
guide 620 or without the guide 620. In a pre-rolled configuration, the mouth-
end insert may be
pre-attached for convenience and hygiene.
In at least one example embodiment, as shown in Figure 10, a method of
enhancing a
vapor of an electronic vaping device may include rolling a sheet of material
700 to form a rolled
sheet of material and inserting the rolled sheet of material between a heater
and a mouth end of
a cartridge 710. The method may also include removing the mouth-end insert
prior to inserting
the rolled sheet of material.
In at least one example embodiment, an adult vaper may choose to roll two or
more
sheets of material 260 together to provide multiple different additives.
In at least one example embodiment, instead of a roll of material, additives
may be
impregnated in, coated on, or impregnated in and coated on a plug of material,
such as
cellulose acetate. Plugs of material may include longitudinally extending
channels extending
therethrough, surfaces of which may also be coated, impregnated, or coated and
impregnated
with additives.
While a number of example embodiments have been disclosed herein, it should be
understood that other variations may be possible. Such variations are not to
be regarded as a
departure from the scope of the present disclosure, and all such modifications
as would be
obvious to one skilled in the art are intended to be included within the scope
of the following
claims.
